U.S. patent application number 10/547686 was filed with the patent office on 2006-12-07 for apparatus and method for radially expanding a wellbore casing using and adaptive expansion system.
This patent application is currently assigned to Enventure Golbal Technology. Invention is credited to Scott Costa, Mark Shuster.
Application Number | 20060272826 10/547686 |
Document ID | / |
Family ID | 33029959 |
Filed Date | 2006-12-07 |
United States Patent
Application |
20060272826 |
Kind Code |
A1 |
Shuster; Mark ; et
al. |
December 7, 2006 |
Apparatus and method for radially expanding a wellbore casing using
and adaptive expansion system
Abstract
An apparatus and method for radially expanding a wellbore using
an adaptive expansion system.
Inventors: |
Shuster; Mark; (Houston,
TX) ; Costa; Scott; (Kingwood, TX) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET
SUITE 3100
DALLAS
TX
75202-3789
US
|
Assignee: |
Enventure Golbal Technology
Houston
TX
77084
|
Family ID: |
33029959 |
Appl. No.: |
10/547686 |
Filed: |
March 17, 2004 |
PCT Filed: |
March 17, 2004 |
PCT NO: |
PCT/US04/08030 |
371 Date: |
June 30, 2006 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
60455124 |
Mar 17, 2003 |
|
|
|
Current U.S.
Class: |
166/380 ;
166/207 |
Current CPC
Class: |
E21B 43/105
20130101 |
Class at
Publication: |
166/380 ;
166/207 |
International
Class: |
E21B 23/02 20060101
E21B023/02 |
Claims
1. An apparatus for radially expanding and plastically deforming a
tubular member, comprising: a support member, and an adaptive
expansion device coupled to the support member for radially
expanding and plastically deforming the tubular member, comprising:
a support structure coupled to the support member; one or more
expansion device segments for engaging the tubular member to
thereby radially expand and plastically deform the tubular member;
one or more adjustable spring elements coupled between the support
structure and one or more of the expansion device segments; one or
more adjustable damping elements coupled between the support
structure and one or more of the expansion device segments; and one
or more sensors for sensing operating conditions during the radial
expansion and plastic deformation of the tubular member by the
adaptive expansion device; a controller operably coupled to the
adjustable spring elements, the adjustable damping elements, and
the sensors; and a user interface operably coupled to the
controller for receiving user inputs; wherein the controller is
programmed to controllably adjust a spring rate of one or more of
the adjustable spring elements, and a damping rate of one or more
of the damping elements as a function of the operating conditions
sensed by the sensors and the user inputs.
2. A method of adaptively radially expanding a tubular member
within a wellbore, comprising: inserting an adaptive expansion
device into the tubular member; radially expanding and plastically
deforming the tubular member using the adaptive expansion device;
sensing one or more operating conditions during the radial
expansion and plastic deformation of the tubular member; and as a
function of the sensed operating conditions, controllably adjusting
a spring rate and a damping rate of the adaptive expansion device
during the radial expansion and plastic deformation of the tubular
member.
3. A system for adaptively radially expanding a tubular member
within a wellbore, comprising: means for inserting an adaptive
expansion device into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting a spring rate and a
damping rate of the adaptive expansion device during the radial
expansion and plastic deformation of the tubular member.
4. An apparatus for radially expanding and plastically deforming a
tubular member, comprising: a support member; and an adaptive
expansion device coupled to the support member for radially
expanding and plastically deforming the tubular member, comprising:
a support structure coupled to the support member; one or more
expansion device segments for engaging the tubular member to
thereby radially expand and plastically deform the tubular member;
and one or more sensors for sensing operating conditions during the
radial expansion and plastic deformation of the tubular member by
the adaptive expansion device; and a controller operably coupled to
the expansion device segments and the sensors; wherein the
controller is programmed to controllably adjust a frequency
characteristic of one or more of the expansion device segments as a
function of the operating conditions sensed by the sensors.
5. A method of adaptively radially expanding a tubular member
within a wellbore, comprising: inserting an adaptive expansion
device comprising one or more expansion device segments for
engaging and radially expanding and plastically deforming the
tubular member into the tubular member; radially expanding and
plastically deforming the tubular member using the adaptive
expansion device; sensing one or more operating conditions during
the radial expansion and plastic deformation of the tubular member;
and as a function of the sensed operating conditions, controllably
adjusting a frequency response characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the tubular member.
6. A system for adaptively radially expanding a tubular member
within a wellbore, comprising: means for inserting an adaptive
expansion device comprising one or more expansion device segments
for engaging and radially expanding and plastically deforming the
tubular member into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting a frequency response
characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the tubular
member.
7. An apparatus for radially expanding and plastically deforming
overlapping ends of first and second tubular members, comprising: a
support member; and an adaptive expansion device coupled to the
support member for radially expanding and plastically deforming the
overlapping ends of the tubular members, comprising: a support
structure coupled to the support member; one or more expansion
device segments for engaging the overlapping ends of the tubular
members to thereby radially expand and plastically deform the
overlapping ends of the tubular member; and one or more sensors for
sensing operating conditions during the radial expansion and
plastic deformation of the overlapping ends of the tubular member
by the adaptive expansion device; and a controller operably coupled
to the expansion device segments and the sensors; wherein the
controller is programmed to controllably adjust one or more
operational characteristics of one or more of the expansion device
segments as a function of a sensing of the overlapping ends of the
tubular members by one or more of the sensors.
8. A method of adaptively radially expanding overlapping ends of
tubular members within a wellbore, comprising: inserting an
adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically
deforming the tubular member into the overlapping ends of the
tubular members; radially expanding and plastically deforming the
overlapping ends of the tubular members using the adaptive
expansion device; sensing the overlapping ends of the tubular
members during the radial expansion and plastic deformation of the
overlapping ends of the tubular members; and as a function of the
sensing of the overlapping ends of the tubular members,
controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and
plastic deformation of the overlapping ends of the tubular
members.
9. A system for adaptively radially expanding overlapping ends of
tubular members within a wellbore, comprising: means for inserting
an adaptive expansion device comprising one or more expansion
device segments for engaging and radially expanding and plastically
deforming the tubular member into the overlapping ends of the
tubular members; means for radially expanding and plastically
deforming the overlapping ends of the tubular members using the
adaptive expansion device; means for sensing the overlapping ends
of the tubular members during the radial expansion and plastic
deformation of the overlapping ends of the tubular members; and
means for, as a function of the sensing of the overlapping ends of
the tubular members, controllably adjusting an operational
characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the
overlapping ends of the tubular members.
10. An apparatus for radially expanding and plastically deforming
first and second tubular members coupled to one another by a
threaded connection, comprising: a support member; and an adaptive
expansion device coupled to the support member for radially
expanding and plastically deforming the threaded connection,
comprising: a support structure coupled to the support member; one
or more expansion device segments for engaging the threaded
connection to thereby radially expand and plastically deform the
threaded connection; and one or more sensors for sensing operating
conditions during the radial expansion and plastic deformation of
the threaded connection by the adaptive expansion device; and a
controller operably coupled to the expansion device segments and
the sensors; wherein the controller is programmed to controllably
adjust one or more operational characteristics of one or more of
the expansion device segments as a function of a sensing of the
threaded connection by one or more of the sensors.
11. A method of adaptively radially expanding tubular members
coupled to one another by a threaded connection within a wellbore,
comprising: inserting an adaptive expansion device comprising one
or more expansion device segments for engaging and radially
expanding and plastically deforming the tubular members proximate
the threaded connection; radially expanding and plastically
deforming the threaded connection using the adaptive expansion
device; sensing the threaded connection during the radial expansion
and plastic deformation of the threaded connection; and as a
function of the sensing of the threaded connection, controllably
adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the threaded connection.
12. A system for adaptively radially expanding tubular members
coupled to one another by a threaded connection within a wellbore,
comprising: means for inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular members
proximate the threaded connection; means for radially expanding and
plastically deforming the threaded connection using the adaptive
expansion device; means for sensing the threaded connection during
the radial expansion and plastic deformation of the threaded
connection; and means for, as a function of the sensing of the
threaded connection, controllably adjusting an operational
characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the threaded
connection.
13. An apparatus for radially expanding and plastically deforming a
tubular member within a wellbore that traverses a subterranean
formation, comprising: a support member; and an adaptive expansion
device coupled to the support member for radially expanding and
plastically deforming the tubular member and elastically deforming
the subterranean formation, comprising: a support structure coupled
to the support member; one or more expansion device segments for
engaging the threaded connection to thereby radially expand and
plastically deform the tubular member and elastically deform the
subterranean formation; and one or more sensors for sensing
operating conditions during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of
the subterranean formation; and a controller operably coupled to
the expansion device segments and the sensors; wherein the
controller is programmed to controllably adjust one or more
operational characteristics of one or more of the expansion device
segments as a function of a sensing of the subterranean formation
by one or more of the sensors.
14. A method of adaptively radially expanding a tubular member
within a wellbore that traverses a subterranean formation,
comprising: inserting an adaptive expansion device comprising one
or more expansion device segments for engaging and radially
expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation within the
wellbore; radially expanding and plastically deforming the tubular
member and elastically deforming the subterranean formation using
the adaptive expansion device; sensing the subterranean formation
during the radial expansion and plastic deformation of the tubular
member and the elastic deformation of the subterranean formation;
and as a function of the sensing of the subterranean formation,
controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and
plastic deformation of the tubular member and the elastic
deformation of the subterranean formation.
15. A system for adaptively radially expanding a tubular member
within a wellbore that traverses a subterranean formation,
comprising: means for inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation within the
wellbore; means for radially expanding and plastically deforming
the tubular member and elastically deforming the subterranean
formation using the adaptive expansion device; means for sensing
the subterranean formation during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of
the subterranean formation; and means for, as a function of the
sensing of the subterranean formation, controllably adjusting an
operational characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the
tubular member and the elastic deformation of the subterranean
formation.
16. An apparatus for radially expanding and plastically deforming a
tubular member, comprising: a support member, and an adaptive
expansion device coupled to the support member for radially
expanding and plastically deforming the tubular member, comprising:
a support structure coupled to the support member; and one or more
expansion device segments coupled to the support structure for
engaging the tubular member to thereby radially expand and
plastically deform the tubular member; one or more sensors for
sensing one or more operating conditions during the radial
expansion and plastic deformation of the tubular member; and a
controller operably coupled to the expansion device segments and
the sensors; and wherein the controller is programmed to
controllably adjust one or more of the operational characteristics
of one or more the expansion device segments as a function of the
operating conditions sensed by the sensors.
17. A method of adaptively radially expanding a tubular member
within a wellbore, comprising: inserting an adaptive expansion
device into the tubular member; radially expanding and plastically
deforming the tubular member using the adaptive expansion device;
sensing one or more operating conditions during the radial
expansion and plastic deformation of the tubular member; and as a
function of the sensed operating conditions, controllably adjusting
one or more of the operating characteristics of the adaptive
expansion device during the radial expansion and plastic
deformation of the tubular member.
18. A system for adaptively radially expanding a tubular member
within a wellbore, comprising: means for inserting an adaptive
expansion device into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting one or more of the
operating characteristics of the adaptive expansion device during
the radial expansion and plastic deformation of the tubular
member.
19. The apparatus of claims 1, 4, 7, 10, 13, or 16, wherein one or
more of the expansion device segments comprise: one or more
expansion surfaces; and an actuator coupled to the expansion
surfaces.
20. The apparatus of claim 19, wherein the actuator comprises one
or more degrees of freedom.
21. The apparatus of claim 20, wherein the actuator comprises a
plurality of degrees of freedom.
22. The apparatus of claim 19, wherein the actuator comprises one
or more rotary actuators.
23. The apparatus of claims 1, 4, 7, 10, 13, or 16, wherein one or
more of the expansion device segments comprise: one or more
hydro-forming devices.
24. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially
expanding and plastically deforming the tubular member using the
adaptive expansion device comprises: displacing the adaptive
expansion device relative to the tubular member in the longitudinal
direction.
25. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially
expanding and plastically deforming the tubular member using the
adaptive expansion device comprises: rotating the adaptive
expansion device relative to the tubular member.
26. The method of claims 2, 5, 8, 11, 14, or 17, wherein radially
expanding and plastically deforming the tubular member using the
adaptive expansion device comprises: applying a pressurized fluid
to the interior surface of the tubular member.
27. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means
for radially expanding and plastically deforming the tubular member
using the adaptive expansion device comprises: means for displacing
the adaptive expansion device.
28. The system of claim 27, wherein the means for displacing the
adaptive expansion device comprises one or more degrees of
freedom.
29. The system of claim 27, wherein the means for displacing the
adaptive expansion device comprises a plurality of degrees of
freedom.
30. The system of claims 3, 6, 9, 12, 15, or 18, wherein the means
for radially expanding and plastically deforming the tubular member
using the adaptive expansion device comprises: means for radially
expanding and plastically deforming the tubular member using a
hydro-forming device.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application claims the benefit of the filing
date of U.S. provisional patent application Ser. No. 60/455,124,
attorney docket no. 25791.241, filed on Mar. 17, 2003, the
disclosure of which is incorporated herein by reference.
[0002] The present application is related to the following: (1)
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser.
No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23,
2000, which claims priority from provisional application
60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application
Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb.
10, 2000, which claims priority from provisional application
60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434,
attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which
claims priority from provisional application 60/183,546, filed on
Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468,
attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which
claims priority from provisional application 60/124,042, filed on
Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as
patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (8)
U.S. Pat. No. 6,575,240, which was filed as patent application Ser.
No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640,
which was filed as patent application Ser. No. 09/588,946, attorney
docket no. 25791.17.02, filed on Jun. 7, 2000, which claims
priority from provisional application 60/137,998, filed on Jun. 7,
1999, (10) U.S. patent application Ser. No. 09/981,916, attorney
docket no. 25791.18, filed on Oct. 18, 2001 as a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (11) U.S. Pat. No. 6,604,763, which was filed as application
Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr.
26, 2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application
Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan.
8, 2002, which claims priority from provisional application
60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent
application Ser. No. 60/143,039, attorney docket no. 25791.26,
filed on Jul. 9, 1999, (14) U.S. patent application Ser. No.
10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30,
2002, which claims priority from provisional patent application
Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1,
1999, (15) U.S. provisional patent application Ser. No. 60/154,047,
attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S.
provisional patent application Ser. No. 60/438,828, attorney docket
no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,
which was filed as application Ser. No. 09/679,907, attorney docket
no. 25791.34.02, on Oct. 5, 2000, which claims priority from
provisional patent application Ser. No. 60/159,082, attorney docket
no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application
Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no.
25791.36.03, which claims priority from provisional patent
application Ser. No. 60/159,039, attorney docket no. 25791.36,
filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,
which claims priority from provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
2002, attorney docket no. 25791.38.07, which claims priority from
provisional patent application Ser. No. 60/212,359, attorney docket
no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent
application Ser. No. 60/165,228, attorney docket no. 25791.39,
filed on Nov. 12, 1999, (22) U.S. provisional patent application
Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar.
14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002,
attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent application Ser. No. 60/303,711, attorney docket
no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application
Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001,
(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
provisional patent application Ser. No. 60/262,434, attorney docket
no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application
Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no.
25791.52.06, which claims priority from U.S. provisional patent
application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.
25791.58.02, filed on Aug. 13, 2002, which claims priority from
provisional application 60/318,021, filed on Sep. 7, 2001, attorney
docket no. 25791.58, (36) PCT Application US02/24399, attorney
docket no. 25791.59.02, filed on Aug. 1, 2002, which claims
priority from U.S. provisional patent application Ser. No.
60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001,
(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
patent application Ser. No. 60/326,886, attorney docket no.
25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256,
attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001,
(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
2001, attorney docket no. 25791.62, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (40)
U.S. patent application Ser. No. 09/962,470, filed on Sep. 25,
2001, attorney docket no. 25791.63, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (41)
U.S. patent application Ser. No. 09/962,471, filed on Sep. 25,
2001, attorney docket no. 25791.64, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (42)
U.S. patent application Ser. No. 09/962,467, filed on Sep. 25,
2001, attorney docket no. 25791.65, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (43)
U.S. patent application Ser. No. 09/962,468, filed on Sep. 25,
2001, attorney docket no. 25791.66, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (44)
PCT application US 02/25727, filed on Aug. 14, 2002, attorney
docket no. 25791.67.03, which claims priority from U.S. provisional
patent application Ser. No. 60/317,985, attorney docket no.
25791.67, filed on Sep. 6, 2001, and U.S. provisional patent
application Ser. No. 60/318,386, attorney docket no. 25791.67.02,
filed on Sep. 10, 2001, (45) PCT application US 02/39425, filed on
Dec. 10, 2002, attorney docket no. 25791.68.02, which claims
priority from U.S. provisional patent application Ser. No.
60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001,
(46) U.S. utility patent application Ser. No. 09/969,922, attorney
docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (47) U.S. utility patent application Ser. No. 10/516,467,
attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a
continuation application of U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, which is a continuation-in-part application of U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (48) PCT application US
03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15,
2002, (49) U.S. patent application Ser. No. 10/074,703, attorney
docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (50) U.S. patent application
Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (51) U.S. patent application Ser. No. 10/076,660, attorney
docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (52) U.S. patent application
Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (53) U.S. patent application Ser. No. 10/076,659, attorney
docket no. 25791.78, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (54) U.S. patent application
Ser. No. 10/078,928, attorney docket no. 25791.79, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (55) U.S. patent application Ser. No. 10/078,922, attorney
docket no. 25791.80, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (56) U.S. patent application
Ser. No. 10/078,921, attorney docket no. 25791.81, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (57) U.S. patent application Ser. No. 10/261,928, attorney
docket no. 25791.82, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (58) U.S. patent application
Ser. No. 10/079,276, attorney docket no. 25791.83, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (59) U.S. patent application Ser. No. 10/262,009, attorney
docket no. 25791.84, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (60) U.S. patent application
Ser. No. 10/092,481, attorney docket no. 25791.85, filed on Mar. 7,
2002, which is a divisional of U.S. Pat. No. 6,568,471, which was
filed as patent application Ser. No. 09/512,895, attorney docket
no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (61)
U.S. patent application Ser. No. 10/261,926, attorney docket no.
25791.86, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (62) PCT application US 02/36157, filed on
Nov. 12, 2002, attorney docket no. 25791.87.02, which claims
priority from U.S. provisional patent application Ser. No.
60/338,996, attorney docket no. 25791.87, filed on Nov. 12, 2001,
(63) PCT application US 02/36267, filed on Nov. 12, 2002, attorney
docket no. 25791.88.02, which claims priority from U.S. provisional
patent application Ser. No. 60/339,013, attorney docket no.
25791.88, filed on Nov. 12, 2001, (64) PCT application US 03/11765,
filed on Apr. 16, 2003, attorney docket no. 25791.89.02, which
claims priority from U.S. provisional patent application Ser. No.
60/383,917, attorney docket no. 25791.89, filed on May 29, 2002,
(65) PCT application US 03/15020, filed on May 12, 2003, attorney
docket no. 25791.90.02, which claims priority from U.S. provisional
patent application Ser. No. 60/391,703, attorney docket no.
25791.90, filed on Jun. 26, 2002, (66) PCT application US 02/39418,
filed on Dec. 10, 2002, attorney docket no. 25791.92.02, which
claims priority from U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on
Mar. 4, 2003, attorney docket no. 25791.93.02, which claims
priority from U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(68) U.S. patent application Ser. No. 10/331,718, attorney docket
no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S.
patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
attorney docket no. 25791.37.02, which claims priority from
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (71) U.S. patent application
Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
May 6, 2003, attorney docket no. 25791.104.02, which claims
priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 6, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
docket no. 25791.106.02, which claims priority from U.S.
provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
attorney docket no. 25791.111.02, which claims priority from U.S.
provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application Ser. No. 10/280,356,
attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a
continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
Aug. 8, 2003, attorney docket no. 25791.125.02, which claims
priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
attorney docket no. 25791.126, filed on Dec. 10, 2002, (92) U.S.
provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.128,
filed on Sep. 20, 2002, (94) U.S. provisional patent application
Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep.
20, 2002, (95) U.S. patent application Ser. No. 10/382,325,
attorney docket no. 25791.145, filed on Mar. 5, 2003, which is a
continuation of U.S. Pat. No. 6,557,640, which was filed as patent
application Ser. No. 09/588,946, attorney docket no. 25791.17.02,
filed on Jun. 7, 2000, which claims priority from provisional
application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent
application Ser. No. 10/624,842, attorney docket no. 25791.151,
filed on Jul. 22, 2003, which is a divisional of U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (97) U.S.
provisional patent application Ser. No. 60/431,184, attorney docket
no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional patent
application Ser. No. 60/448,526, attorney docket no. 25791.185,
filed on Feb. 18, 2003, (99) U.S. provisional patent application
Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr.
9, 2003, (100) U.S. provisional patent application Ser. No.
60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S.
provisional patent application Ser. No. 60/442,942, attorney docket
no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional
patent application Ser. No. 60/442,938, attorney docket no.
25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent
application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar.
14, 2003, (106) U.S. provisional patent application Ser. No.
60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S.
provisional patent application Ser. No. 60/455,124, attorney docket
no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional
patent application Ser. No. 60/453,678, attorney docket no.
25791.253, filed on Mar. 11, 2003, (110) U.S. patent application
Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr.
23, 2003, which is a continuation of U.S. patent application Ser.
No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent
application Ser. No. 60/457,965, attorney docket no. 25791.260,
filed on Mar. 27, 2003, (112) U.S. provisional patent application
Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar.
18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent
application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S.
patent application Ser. No. 10/436,467, attorney docket no.
25791.268, filed on May 12, 2003, which is a continuation of U.S.
Pat. No. 6,604,763, which was filed as application Ser. No.
09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 2, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
8, 2003, (117) U.S. provisional patent application Ser. No.
60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 26791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility
patent application Ser. No. 10/418,688, attorney docket no.
25791.257, which was filed on Apr. 18, 2003, as a division of U.S.
utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (122)
PCT patent application Ser. No. PCT/US04______, attorney docket no.
25791.238.02, filed on Feb. 26, 2004, (123) PCT patent application
Ser. No. PCT/US04/______, attorney docket no. 25791.40.02, filed on
Mar. 15, 2004, (124) PCT patent application Ser. No.
PCT/US04/______, attorney docket no. 25791.236.02, filed on Mar.
15, 2004, and (125) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, the disclosures of which are incorporated herein by
reference.
BACKGROUND OF THE INVENTION
[0003] This invention relates generally to oil and gas exploration,
and in particular to forming and repairing wellbore casings to
facilitate oil and gas exploration.
[0004] 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.
[0005] 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
[0006] According to one aspect of the present invention, an
apparatus for radially expanding and plastically deforming a
tubular member is provided that includes a support member; and an
adaptive expansion device coupled to the support member for
radially expanding and plastically deforming the tubular member
that includes a support structure coupled to the support member;
one or more expansion device segments for engaging the tubular
member to thereby radially expand and plastically deform the
tubular member; one or more adjustable spring elements coupled
between the support structure and one or more of the expansion
device segments; one or more adjustable damping elements coupled
between the support structure and one or more of the expansion
device segments; and one or more sensors for sensing operating
conditions during the radial expansion and plastic deformation of
the tubular member by the adaptive expansion device; a controller
operably coupled to the adjustable spring elements, the adjustable
damping elements, and the sensors; and a user interface operably
coupled to the controller for receiving user inputs; wherein the
controller is programmed to controllably adjust a spring rate of
one or more of the adjustable spring elements, and a damping rate
of one or more of the damping elements as a function of the
operating conditions sensed by the sensors and the user inputs.
[0007] According to another aspect of the present invention, a
method of adaptively radially expanding a tubular member within a
wellbore is provided that includes inserting an adaptive expansion
device into the tubular member; radially expanding and plastically
deforming the tubular member using the adaptive expansion device;
sensing one or more operating conditions during the radial
expansion and plastic deformation of the tubular member; and as a
function of the sensed operating conditions, controllably adjusting
a spring rate and a damping rate of the adaptive expansion device
during the radial expansion and plastic deformation of the tubular
member.
[0008] According to another aspect of the present invention, a
system for adaptively radially expanding a tubular member within a
wellbore is provided that includes means for inserting an adaptive
expansion device into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting a spring rate and a
damping rate of the adaptive expansion device during the radial
expansion and plastic deformation of the tubular member.
[0009] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming a
tubular member is provided that includes a support member, and an
adaptive expansion device coupled to the support member for
radially expanding and plastically deforming the tubular member
that includes a support structure coupled to the support member;
one or more expansion device segments for engaging the tubular
member to thereby radially expand and plastically deform the
tubular member; and one or more sensors for sensing operating
conditions during the radial expansion and plastic deformation of
the tubular member by the adaptive expansion device; and a
controller operably coupled to the expansion device segments and
the sensors; wherein the controller is programmed to controllably
adjust a frequency characteristic of one or more of the expansion
device segments as a function of the operating conditions sensed by
the sensors.
[0010] According to another aspect of the present invention, a
method of adaptively radially expanding a tubular member within a
wellbore is provided that includes inserting an adaptive expansion
device comprising one or more expansion device segments for
engaging and radially expanding and plastically deforming the
tubular member into the tubular member, radially expanding and
plastically deforming the tubular member using the adaptive
expansion device; sensing one or more operating conditions during
the radial expansion and plastic deformation of the tubular member;
and as a function of the sensed operating conditions, controllably
adjusting a frequency response characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the tubular member.
[0011] According to another aspect of the present invention, a
system for adaptively radially expanding a tubular member within a
wellbore is provided that includes means for inserting an adaptive
expansion device comprising one or more expansion device segments
for engaging and radially expanding and plastically deforming the
tubular member into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting a frequency response
characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the tubular
member.
[0012] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming
overlapping ends of first and second tubular members is provided
that includes a support member; and an adaptive expansion device
coupled to the support member for radially expanding and
plastically deforming the overlapping ends of the tubular members
that includes a support structure coupled to the support member;
one or more expansion device segments for engaging the overlapping
ends of the tubular members to thereby radially expand and
plastically deform the overlapping ends of the tubular member; and
one or more sensors for sensing operating conditions during the
radial expansion and plastic deformation of the overlapping ends of
the tubular member by the adaptive expansion device; and a
controller operably coupled to the expansion device segments and
the sensors; wherein the controller is programmed to controllably
adjust one or more operational characteristics of one or more of
the expansion device segments as a function of a sensing of the
overlapping ends of the tubular members by one or more of the
sensors.
[0013] According to another aspect of the present invention, a
method of adaptively radially expanding overlapping ends of tubular
members within a wellbore is provided that includes inserting an
adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically
deforming the tubular member into the overlapping ends of the
tubular members; radially expanding and plastically deforming the
overlapping ends of the tubular members using the adaptive
expansion device; sensing the overlapping ends of the tubular
members during the radial expansion and plastic deformation of the
overlapping ends of the tubular members; and as a function of the
sensing of the overlapping ends of the tubular members,
controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and
plastic deformation of the overlapping ends of the tubular
members.
[0014] According to another aspect of the present invention, a
system for adaptively radially expanding overlapping ends of
tubular members within a wellbore is provided that includes means
for inserting an adaptive expansion device comprising one or more
expansion device segments for engaging and radially expanding and
plastically deforming the tubular member into the overlapping ends
of the tubular members; means for radially expanding and
plastically deforming the overlapping ends of the tubular members
using the adaptive expansion device; means for sensing the
overlapping ends of the tubular members during the radial expansion
and plastic deformation of the overlapping ends of the tubular
members; and means for, as a function of the sensing of the
overlapping ends of the tubular members, controllably adjusting an
operational characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the
overlapping ends of the tubular members.
[0015] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming first
and second tubular members coupled to one another by a threaded
connection is provided that includes a support member; and an
adaptive expansion device coupled to the support member for
radially expanding and plastically deforming the threaded
connection that includes a support structure coupled to the support
member; one or more expansion device segments for engaging the
threaded connection to thereby radially expand and plastically
deform the threaded connection; and one or more sensors for sensing
operating conditions during the radial expansion and plastic
deformation of the threaded connection by the adaptive expansion
device; and a controller operably coupled to the expansion device
segments and the sensors; wherein the controller is programmed to
controllably adjust one or more operational characteristics of one
or more of the expansion device segments as a function of a sensing
of the threaded connection by one or more of the sensors.
[0016] According to another aspect of the present invention, a
method of adaptively radially expanding tubular members coupled to
one another by a threaded connection within a wellbore is provided
that includes inserting an adaptive expansion device comprising one
or more expansion device segments for engaging and radially
expanding and plastically deforming the tubular members proximate
the threaded connection; radially expanding and plastically
deforming the threaded connection using the adaptive expansion
device; sensing the threaded connection during the radial expansion
and plastic deformation of the threaded connection; and as a
function of the sensing of the threaded connection, controllably
adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the threaded connection.
[0017] According to another aspect of the present invention, a
system for adaptively radially expanding tubular members coupled to
one another by a threaded connection within a wellbore is provided
that includes means for inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular members
proximate the threaded connection; means for radially expanding and
plastically deforming the threaded connection using the adaptive
expansion device; means for sensing the threaded connection during
the radial expansion and plastic deformation of the threaded
connection; and means for, as a function of the sensing of the
threaded connection, controllably adjusting an operational
characteristic of one or more of the expansion device segments
during the radial expansion and plastic deformation of the threaded
connection.
[0018] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming a
tubular member within a wellbore that traverses a subterranean
formation is provided that includes a support member; and an
adaptive expansion device coupled to the support member for
radially expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation that includes a
support structure coupled to the support member; one or more
expansion device segments for engaging the threaded connection to
thereby radially expand and plastically deform the tubular member
and elastically deform the subterranean formation; and one or more
sensors for sensing operating conditions during the radial
expansion and plastic deformation of the tubular member and the
elastic deformation of the subterranean formation; and a controller
operably coupled to the expansion device segments and the sensors;
wherein the controller is programmed to controllably adjust one or
more operational characteristics of one or more of the expansion
device segments as a function of a sensing of the subterranean
formation by one or more of the sensors.
[0019] According to another aspect of the present invention, a
method of adaptively radially expanding a tubular member within a
wellbore that traverses a subterranean formation is provided that
includes inserting an adaptive expansion device comprising one or
more expansion device segments for engaging and radially expanding
and plastically deforming the tubular member and elastically
deforming the subterranean formation within the wellbore; radially
expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation using the adaptive
expansion device; sensing the subterranean formation during the
radial expansion and plastic deformation of the tubular member and
the elastic deformation of the subterranean formation; and as a
function of the sensing of the subterranean formation, controllably
adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of
the subterranean formation.
[0020] According to another aspect of the present invention, a
system for adaptively radially expanding a tubular member within a
wellbore that traverses a subterranean formation is provided that
includes means for inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation within the
wellbore; means for radially expanding and plastically deforming
the tubular member and elastically deforming the subterranean
formation using the adaptive expansion device; means for sensing
the subterranean formation during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of
the subterranean formation; and means for, as a function of the
sensing of the subterranean formation, controllably adjusting an
operational characteristic of one or more of the expansion device
segments during the radial expansion and plastic deformation of the
tubular member and the elastic deformation of the subterranean
formation.
[0021] According to another aspect of the present invention, an
apparatus for radially expanding and plastically deforming a
tubular member is provided that includes a support member, and an
adaptive expansion device coupled to the support member for
radially expanding and plastically deforming the tubular member
that includes a support structure coupled to the support member;
and one or more expansion device segments coupled to the support
structure for engaging the tubular member to thereby radially
expand and plastically deform the tubular member; one or more
sensors for sensing one or more operating conditions during the
radial expansion and plastic deformation of the tubular member; and
a controller operably coupled to the expansion device segments and
the sensors; and wherein the controller is programmed to
controllably adjust one or more of the operational characteristics
of one or more the expansion device segments as a function of the
operating conditions sensed by the sensors.
[0022] According to another aspect of the present invention, a
method of adaptively radially expanding a tubular member within a
wellbore is provided that includes inserting an adaptive expansion
device into the tubular member; radially expanding and plastically
deforming the tubular member using the adaptive expansion device;
sensing one or more operating conditions during the radial
expansion and plastic deformation of the tubular member; and as a
function of the sensed operating conditions, controllably adjusting
one or more of the operating characteristics of the adaptive
expansion device during the radial expansion and plastic
deformation of the tubular member.
[0023] According to another aspect of the present invention, a
system for adaptively radially expanding a tubular member within a
wellbore is provided that includes means for inserting an adaptive
expansion device into the tubular member; means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; means for sensing one or more operating
conditions during the radial expansion and plastic deformation of
the tubular member; and means for, as a function of the sensed
operating conditions, controllably adjusting one or more of the
operating characteristics of the adaptive expansion device during
the radial expansion and plastic deformation of the tubular
member.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] FIGS. 1a and 1b are fragmentary cross sectional
illustrations of an exemplary embodiment of an adaptive system for
radially expanding a tubular member.
[0025] FIG. 2 is a schematic illustration of an exemplary
embodiment of the adaptive expansion device of the system of FIGS.
1a and 1b.
[0026] FIGS. 3a-3c are fragmentary cross sectional illustrations of
exemplary embodiments of the operation of the adaptive system of
FIGS. 1a and 1b.
DETAILED DESCRIPTION OF HE PREFERRED EMBODIMENTS
[0027] Referring to FIGS. 1a, 1b, and 2, an adaptive system 10 for
radially expanding a tubular member includes a support member 12
and an adaptive expansion device 14. In several exemplary
embodiments, the system 10 may be used to radially expand and
plastically deform a tubular member 16 by displacing the expansion
device 14 in the longitudinal direction and/or by rotating the
expansion device relative to the tubular member.
[0028] In an exemplary embodiment, the adaptive expansion device 14
includes one or more expansion device segments 18 for engaging, and
thereby radially expanding and plastically deforming the tubular
member 16, that are coupled to an expansion device support
structure 20 by one or more conventional adjustable spring elements
22 and one or more conventional adjustable damping elements 24. In
several exemplary embodiments, the adjustable spring elements 22
and/or the adjustable damping elements 24 are be provided as
disclosed in one or more of the following: 1) U.S. Pat. No.
6,431,284, 2) U.S. Pat. No. 6,390,956, 3) U.S. Pat. No. 6,296,533,
4) U.S. Pat. No. 6,237,889, 5) U.S. Pat. No. 6,220,089, 6) U.S.
Pat. No. 6,159,289, 7) U.S. Pat. No. 6,105,988, 8) U.S. Pat. No.
6,065,741, 9) U.S. Pat. No. 6,062,324, 10) U.S. Pat. No. 6,035,954,
11) U.S. Pat. No. 5,947,458, 12) U.S. Pat. No. 5,875,567, 13) U.S.
Pat. No. 5,713,088, 14) U.S. Pat. No. 5,603,574, 15) U.S. Pat. No.
5,364,565, 16) U.S. Pat. No. 5,531,522, 17) U.S. Pat. No.
5,464,197, 18) U.S. Pat. No. 5,421,655, 19) U.S. Pat. No.
5,201,392, 20) U.S. Pat. No. 5,169,129, 21) U.S. Pat. No.
5,005,820, 22) U.S. Pat. No. 4,984,632, 23) U.S. Pat. No.
4,862,995, 24) U.S. Pat. No. 4,789,343, 25) U.S. Pat. No.
4,657,280, 26) U.S. Pat. No. 4,624,477, 27) U.S. Pat. No.
4,575,058, 28) U.S. Pat. No. 4,566,717, 29) U.S. Pat. No.
4,509,403, 30) U.S. Pat. No. 4,277,045, and/or 31) U.S. Pat. No.
4,071,104, the disclosures of which are incorporated herein by
reference.
[0029] In several exemplary embodiments, the expansion device
segments 18 include, for example, segments of a conventional
expansion cone and/or conventional roller expansion elements and/or
conventional hydro-forming elements. The expansion device support
structure 20 is also coupled to the support member 12. The
adjustable spring and damping elements, 22 and 24, are also
operably coupled to a controller 26, and one or more sensors 28 are
also operably coupled to the controller 26 for reasons to be
described. A user interface 28 may also be provided that is
operably coupled to the controller 26. In several exemplary
embodiments, the controller 26 includes analog, digital,
electronic, and/or hydraulic control elements that may or may not
be positioned within the adaptive expansion device 14. In several
alternative embodiments, the user interface 28 may include a
conventional keyboard input device and/or a conventional display
device and/or a conventional communication channel for linking the
user interface to the controller 26.
[0030] In an exemplary embodiment, during the operation of the
system 10, the controller 26 is programmed to adjust the spring
rate of the adjustable spring elements 22 and/or the damping rate
of the adjustable damping elements 24 as a function of one or more
operating conditions that are sensed by the sensors 28. In several
exemplary embodiments, the sensed operating conditions may include
the reaction forces of the tubular member 16, the operating
pressure of fluidic materials within the system 10 and/or the
tubular member, the rotational speed of the system, the
longitudinal speed of the system, and/or one or more user defined
inputs to the controller 26 provided via the user interface 28.
[0031] In an exemplary embodiment, at least one of the sensors 28
includes a conventional strain gauge that senses the reaction force
of the tubular member 16 during the radial expansion and plastic
deformation of the tubular member by the system 10. In an exemplary
embodiment, increases in the sensed reaction force causes the
controller 26 to increase or decrease the spring rate of one or
more of the adjustable spring elements 22 thereby increasing or
decreasing the stiffness of the corresponding expansion device
segments 18. In this manner, the forces applied to the tubular
member 16 may be increased or decreased for example, to provide
increased or decreased radial expansion forces as a function of the
sensed reaction forces.
[0032] In an exemplary embodiment, at least one of the sensors 28
includes a conventional pressure sensor that senses the operating
pressures of fluidic materials within the system 10 and/or the
tubular member 16 during the radial expansion and plastic
deformation of the tubular member by the system 10. In an exemplary
embodiment, the value of the sensed operating pressure causes the
controller 26 to increase or decrease the spring rate of one or
more of the adjustable spring elements 22 thereby increasing or
decreasing the stiffness of the corresponding expansion device
segments 18. In this manner, the forces applied to the tubular
member 16 may be increased or decreased for example, to provide
increased or decreased radial expansion forces as a function of the
sensed operating pressures.
[0033] In an exemplary embodiment, the controller 26 is programmed
to adaptively adjust the spring rates of one or more of the
adjustable spring elements 22 and/or the damping rate of one or
more of the adjustable damping elements 24 to control the frequency
response of one or more of the corresponding expansion device
segments to provide, for example, an underdamped, a critically
damped, or an overdamped frequency response. In this manner, the
system 10 can provide an adaptive expansion system having user
defined operational characteristics that may vary as a function of
one or more sensed operating conditions.
[0034] Referring to FIG. 3a, in an exemplary embodiment, the system
10 is used to radially expand and plastically deform the
overlapping ends of tubular members, 16 and 30. In an exemplary
embodiment, during the radial expansion and plastic deformation of
the overlapping ends of the tubular members, 16 and 30, the
reaction forces of the overlapping ends of the tubular members, 16
and 30, are sensed by one or more of the sensors 28, and, if the
sensed reaction forces increase, the spring rates of one or more of
the adjustable spring elements 22 of the adaptive expansion device
14 are increased to thereby increase the radial expansion forces
applied to the overlapping ends of the tubular members. In this
manner, the system 10 can controllably adjust the radial expansion
forces applied to overlapping tubulars thereby enhancing the radial
expansion process. In an alternative embodiment, the location of
the overlapped ends of the tubular members, 16 and 30, may be input
into the controller 26 using the user interface 28 to control the
initiation of the adjustment of the spring rates of the adjustable
spring elements 22 in combination with, or in the alternative to,
the sensing of the reaction forces described above.
[0035] Referring to FIG. 3b, in an exemplary embodiment, the system
10 is used to radially expand and plastically deform a tubular
member 16 that includes first and second tubular members, 16a and
16b, coupled to one another by a threaded connection 32. In an
exemplary embodiment, during the radial expansion and plastic
deformation of the threaded connection 32, the reaction forces of
the threaded connection are sensed by one or more of the sensors
28, and, the spring rates and/or the damping rate of one or more of
the adjustable spring elements 22 and/or adjustable damping
elements 24 of the adaptive expansion device 14 are adjusted to
thereby minimize damage to the integrity of the threaded connection
during the radial expansion process. For example, the spring rates
one or more of the adjustable spring elements 22 may be reduced to
minimize damage to the integrity of the threaded connection 32
during the radial expansion process and/or the damping rates of one
or more of the adjustable damping elements 24 may be increased to
minimize shock loading of the threaded connection during the radial
expansion process. In an alternative embodiment, the location of
the threaded connection 32 may be input into the controller 26
using the user interface 28 to control the initiation of the
adjustment of the spring rates and/or damping rates of the
adjustable spring elements 22 and/or damping elements 24 in
combination with, or in the alternative to, the sensing of the
reaction forces described above.
[0036] Referring to FIG. 3c, in an exemplary embodiment, the system
10 is used to radially expand and elastically deform a subterranean
formation 34 during the radial expansion and plastic deformation of
the tubular member 16. In an exemplary embodiment, during the
radial expansion and plastic deformation of the tubular member 16
against the subterranean formation 34, the reaction forces of the
formation 34 are sensed by one or more of the sensors 28, and the
spring rates of one or more of the adjustable spring elements 22 of
the adaptive expansion device 14 are increased to thereby increase
the radial expansion forces applied to the formation. In this
manner, the system 10 can controllably adjust the radial expansion
forces applied to the formation 34 surrounding the tubular member
16 during the radial expansion and plastic deformation of the
tubular member. In an alternative embodiment, the location of the
formation 34 may be input into the controller 26 using the user
interface 28 to control the initiation of the adjustment of the
spring rates of the adjustable spring elements 22 in combination
with, or in the alternative to, the sensing of the reaction forces
described above.
[0037] In several alternative embodiments, the exemplary
embodiments of the present disclosure are implemented using the
methods and/or apparatus disclosed one or more of the following:
(1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent
application Ser. No. 09/454,139, attorney docket no. 25791.03.02,
filed on Dec. 3, 1999, which claims priority from provisional
application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent
application Ser. No. 09/510,913, attorney docket no. 25791.7.02,
filed on Feb. 23, 2000, which claims priority from provisional
application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application
Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar.
10, 2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471,
which was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, which claims priority from provisional
application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No.
6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (10) U.S. patent application Ser. No.
09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as
a continuation-in-part application of U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent
application Ser. No. 10/030,593, attorney docket no. 25791.25.08,
filed on Jan. 8, 2002, which claims priority from provisional
application 60/146,203, filed on Jul. 29, 1999, (13) U.S.
provisional patent application Ser. No. 60/143,039, attorney docket
no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application
Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr.
30, 2002, which claims priority from provisional patent application
Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1,
1999, (15) U.S. provisional patent application Ser. No. 60/154,047,
attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S.
provisional patent application Ser. No. 60/438,828, attorney docket
no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875,
which was filed as application Ser. No. 09/679,907, attorney docket
no. 25791.34.02, on Oct. 5, 2000, which claims priority from
provisional patent application Ser. No. 60/159,082, attorney docket
no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application
Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no.
25791.36.03, which claims priority from provisional patent
application Ser. No. 60/159,039, attorney docket no. 25791.36,
filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02,
which claims priority from provisional patent application Ser. No.
60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999,
(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
2002, attorney docket no. 25791.38.07, which claims priority from
provisional patent application Ser. No. 60/212,359, attorney docket
no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent
application Ser. No. 60/165,228, attorney docket no. 25791.39,
filed on Nov. 12, 1999, (22) U.S. provisional patent application
Ser. No. 60/455,051, attorney docket no. 25791.40, filed on Mar.
14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002,
attorney docket no. 25791.44.02, which claims priority from U.S.
provisional patent application Ser. No. 60/303,711, attorney docket
no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application
Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001,
(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
provisional patent application Ser. No. 60/262,434, attorney docket
no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application
Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no.
25791.52.06, which claims priority from U.S. provisional patent
application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.
25791.58.02, filed on Aug. 13, 2002, which claims priority from
provisional application 60/318,021, filed on Sep. 7, 2001, attorney
docket no. 25791.58, (36) PCT Application US02/24399, attorney
docket no. 25791.59.02, filed on Aug. 1, 2002, which claims
priority from U.S. provisional patent application Ser. No.
60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001,
(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
patent application Ser. No. 60/326,886, attorney docket no.
25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256,
attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001,
(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
2001, attorney docket no. 25791.62, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (40)
U.S. patent application Ser. No. 09/962,470, filed on 9/25/01,
attorney docket no. 25791.63, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent
application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney
docket no. 25791.64, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent
application Ser. No. 09/962,467, filed on Sep. 25, 2001, attorney
docket no. 25791.65, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent
application Ser. No. 09/962,468, filed on Sep. 25, 2001, attorney
docket no. 25791.66, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (44) PCT
application US 02/25727, filed on Aug. 14, 2002, attorney docket
no. 25791.67.03, which claims priority from U.S. provisional patent
application Ser. No. 60/317,985, attorney docket no. 25791.67,
filed on Sep. 6, 2001, and U.S. provisional patent application Ser.
No. 60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10,
2001, (45) PCT application US 02/39425, filed on Dec. 10, 2002,
attorney docket no. 25791.68.02, which claims priority from U.S.
provisional patent application Ser. No. 60/343,674, attorney docket
no. 25791.68, filed on Dec. 27, 2001, (46) U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (47) U.S. utility
patent application Ser. No. 10/516,467, attorney docket no.
25791.70, filed on Dec. 10, 2001, which is a continuation
application of U.S. utility patent application Ser. No. 09/969,922,
attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (48) PCT application US 03/00609, filed on Jan. 9, 2003,
attorney docket no. 25791.71.02, which claims priority from U.S.
provisional patent application Ser. No. 60/357,372, attorney docket
no. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application
Ser. No. 10/074,703, attorney docket no. 25791.74, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (50) U.S. patent application Ser. No. 10/074,244, attorney
docket no. 25791.75, filed on Feb. 2, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (51) U.S. patent application
Ser. No. 10/076,660, attorney docket no. 25791.76, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (52) U.S. patent application Ser. No. 10/076,661, attorney
docket no. 25791.77, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (53) U.S. patent application
Ser. No. 10/076,659, attorney docket no. 25791.78, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (54) U.S. patent application Ser. No. 10/078,928, attorney
docket no. 25791.79, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (55) U.S. patent application
Ser. No. 10/078,922, attorney docket no. 25791.80, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (56) U.S. patent application Ser. No. 10/078,921, attorney
docket no. 25791.81, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (57) U.S. patent application
Ser. No. 10/261,928, attorney docket no. 25791.82, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (58)
U.S. patent application Ser. No. 10/079,276, attorney docket no.
25791.83, filed on Feb. 20, 2002, which is a divisional of U.S.
Pat. No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (59) U.S. patent application
Ser. No. 10/262,009, attorney docket no. 25791.84, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (60)
U.S. patent application Ser. No. 10/092,481, attorney docket no.
25791.85, filed on Mar. 7, 2002, which is a divisional of U.S. Pat.
No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application
Ser. No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (62) PCT
application US 02/36157, filed on Nov. 12, 2002, attorney docket
no. 25791.87.02, which claims priority from U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (63) PCT application US 02/36267, filed on
Nov. 12, 2002, attorney docket no. 25791.88.02, which claims
priority from U.S. provisional patent application Ser. No.
60/339,013, attorney docket no. 25791.88, filed on Nov. 12, 2001,
(64) PCT application US 03/11765, filed on Apr. 16, 2003, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional
patent application Ser. No. 60/383,917, attorney docket no.
25791.89, filed on May 29, 2002, (65) PCT application US 03/15020,
filed on May 12, 2003, attorney docket no. 25791.90.02, which
claims priority from U.S. provisional patent application Ser. No.
60/391,703, attorney docket no. 25791.90, filed on Jun. 26, 2002,
(66) PCT application US 02/39418, filed on Dec. 10, 2002, attorney
docket no.
25791.92.02, which claims priority from U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, (67) PCT application US 03/06544, filed on
Mar. 4, 2003, attorney docket no. 25791.93.02, which claims
priority from U.S. provisional patent application Ser. No.
60/372,048, attorney docket no. 25791.93, filed on Apr. 12, 2002,
(68) U.S. patent application Ser. No. 10/331,718, attorney docket
no. 25791.94, filed on Dec. 30, 2002, which is a divisional U.S.
patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
attorney docket no. 25791.37.02, which claims priority from
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (71) U.S. patent application
Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
May 6, 2003, attorney docket no. 25791.104.02, which claims
priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 16, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
docket no. 25791.106.02, which claims priority from U.S.
provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
attorney docket no. 25791.111.02, which claims priority from U.S.
provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application Ser. No. 10/280,356,
attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a
continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
Aug. 8, 2003, attorney docket no. 25791.125.02, which claims
priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
attorney docket no. 25791.126, filed on Dec. 10, 2002, (
92) U.S. provisional patent application Ser. No. 60/412,196,
attorney docket no. 25791.127, filed on Sep. 20, 2002, (93) U.S.
provisional patent application Ser. No. 60/412,187, attorney docket
no. 25791.128, filed on Sep. 20, 2002, (94) U.S. provisional patent
application Ser. No. 60/412,371, attorney docket no. 25791.129,
filed on Sep. 20, 2002, (95) U.S. patent application Ser. No.
10/382,325, attorney docket no. 25791.145, filed on Mar. 5, 2003,
which is a continuation of U.S. Pat. No. 6,557,640, which was filed
as patent application Ser. No. 09/588,946, attorney docket no.
25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (96)
U.S. patent application Ser. No. 10/624,842, attorney docket no.
25791.151, filed on Jul. 22, 2003, which is a divisional of U.S.
patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (97)
U.S. provisional patent application Ser. No. 60/431,184, attorney
docket no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional
patent application Ser. No. 60/448,526, attorney docket no.
25791.185, filed on Feb. 18, 2003, (99) U.S. provisional patent
application Ser. No. 60/461,539, attorney docket no. 25791.186,
filed on Apr. 9, 2003, (100) U.S. provisional patent application
Ser. No. 60/462,750, attorney docket no. 25791.193, filed on Apr.
14, 2003, (101) U.S. provisional patent application Ser. No.
60/436,106, attorney docket no. 25791.200, filed on Dec. 23, 2002,
(102) U.S. provisional patent application Ser. No. 60/442,942,
attorney docket no. 25791.213, filed on Jan. 27, 2003, (103) U.S.
provisional patent application Ser. No. 60/442,938, attorney docket
no. 25791.225, filed on Jan. 27, 2003, (104) U.S. provisional
patent application Ser. No. 60/418,687, attorney docket no.
25791.228, filed on Apr. 18, 2003, (105) U.S. provisional patent
application Ser. No. 60/454,896, attorney docket no. 25791.236,
filed on Mar. 14, 2003, (106) U.S. provisional patent application
Ser. No. 60/450,504, attorney docket no. 25791.238, filed on Feb.
26, 2003, (107) U.S. provisional patent application Ser. No.
60/451,152, attorney docket no. 25791.239, filed on Mar. 9, 2003,
(108) U.S. provisional patent application Ser. No. 60/455,124,
attorney docket no. 25791.241, filed on Mar. 17, 2003, (109) U.S.
provisional patent application Ser. No. 60/453,678, attorney docket
no. 25791.253, filed on Mar. 11, 2003, (110) U.S. patent
application Ser. No. 10/421,682, attorney docket no. 25791.256,
filed on Apr. 23, 2003, which is a continuation of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (111) U.S.
provisional patent application Ser. No. 60/457,965, attorney docket
no. 25791.260, filed on Mar. 27, 2003, (112) U.S. provisional
patent application Ser. No. 60/455,718, attorney docket no.
25791.262, filed on Mar. 18, 2003, (113) U.S. Pat. No. 6,550,821,
which was filed as patent application Ser. No. 09/811,734, filed on
Mar. 19, 2001, (114) U.S. patent application Ser. No. 10/436,467,
attorney docket no. 25791.268, filed on May 12, 2003, which is a
continuation of U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (115) U.S.
provisional patent application Ser. No. 60/459,776, attorney docket
no. 25791.270, filed on Apr. 2, 2003, (116) U.S. provisional patent
application Ser. No. 60/461,094, attorney docket no. 25791.272,
filed on Apr. 8, 2003, (117) U.S. provisional patent application
Ser. No. 60/461,038, attorney docket no. 25791.273, filed on Apr.
7, 2003, (118) U.S. provisional patent application Ser. No.
60/463,586, attorney docket no. 25791.277, filed on Apr. 17, 2003,
(119) U.S. provisional patent application Ser. No. 60/472,240,
attorney docket no. 25791.286, filed on May 20, 2003, (120) U.S.
patent application Ser. No. 10/619,285, attorney docket no.
25791.292, filed on Jul. 14, 2003, which is a continuation-in-part
of U.S. utility patent application Ser. No. 09/969,922, attorney
docket no. 25791.69, filed on Oct. 3, 2001, which is a
continuation-in-part application of U.S. Pat. No. 6,328,113, which
was filed as U.S. patent application Ser. No. 09/440,338, attorney
docket number 25791.9.02, filed on Nov. 15, 1999, which claims
priority from provisional application 60/108,558, filed on Nov. 16,
1998, (121) U.S. utility patent application Ser. No. 10/418,688,
attorney docket no. 25791.257, which was filed on Apr. 18, 2003, as
a division of U.S. utility patent application Ser. No. 09/523,468,
attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which
claims priority from provisional application 60/124,042, filed on
Mar. 11, 1999, (122) PCT patent application Ser. No.
PCT/US04/______, attorney docket no. 25791.238.02, filed on Feb.
26, 2004, (123) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.40.02, filed on Mar.
15, 2004 ______, (124) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.236.02, filed on Mar.
15, 2004, and (125) PCT patent application serial number
PCT/US04/______, attorney docket number 25791.253.02, filed on Mar.
11, 2004, (125) conventional rotary expansion tools such as, for
example, as described in U.S. 6,457,532 and/or WO 02/081863 A1, or
any one of the commercially available rotary expansion tools
available from Weatherford International, Inc., and/or (126)
conventional hydro-forming methods and tools, the disclosures of
which are incorporated herein by reference.
[0038] More generally, the operational characteristics of the
adaptive expansion device 14 may be determined as a function of
empirical data regarding the tubular member 16 determined during a
radial expansion testing procedure. For example, if a certain
spring rate and/or damping rate, or range and/or variation in
spring rate and/or damping rate, for one or more of the adjustable
spring elements 22 and/or one or more of the adjustable damping
elements 24 provide enhanced operational performance of the tubular
member 16, before, during or after, a radial expansion and plastic
deformation of the tubular member, then the preferred spring rate
and/or damping rate, or the range and/or variation in the spring
rate and/or damping rate, for one or more of the adjustable spring
elements 22 and/or one or more of the adjustable damping elements
24 may be programmed into the controller 26 to thereby provide
enhanced radial expansion and plastic deformation of the tubular
member using the adaptive expansion device 14.
[0039] An apparatus for radially expanding and plastically
deforming a tubular member has been described that includes a
support member; and an adaptive expansion device coupled to the
support member for radially expanding and plastically deforming the
tubular member that includes a support structure coupled to the
support member; one or more expansion device segments for engaging
the tubular member to thereby radially expand and plastically
deform the tubular member; one or more adjustable spring elements
coupled between the support structure and one or more of the
expansion device segments; one or more adjustable damping elements
coupled between the support structure and one or more of the
expansion device segments; and one or more sensors for sensing
operating conditions during the radial expansion and plastic
deformation of the tubular member by the adaptive expansion device;
a controller operably coupled to the adjustable spring elements,
the adjustable damping elements, and the sensors; and a user
interface operably coupled to the controller for receiving user
inputs; wherein the controller is programmed to controllably adjust
a spring rate of one or more of the adjustable spring elements, and
a damping rate of one or more of the damping elements as a function
of the operating conditions sensed by the sensors and the user
inputs.
[0040] A method of adaptively radially expanding a tubular member
within a wellbore has been described that includes inserting an
adaptive expansion device into the tubular member; radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; sensing one or more operating conditions
during the radial expansion and plastic deformation of the tubular
member; and as a function of the sensed operating conditions,
controllably adjusting a spring rate and a damping rate of the
adaptive expansion device during the radial expansion and plastic
deformation of the tubular member.
[0041] A system for adaptively radially expanding a tubular member
within a wellbore has been described that includes means for
inserting an adaptive expansion device into the tubular member;
means for radially expanding and plastically deforming the tubular
member using the adaptive expansion device; means for sensing one
or more operating conditions during the radial expansion and
plastic deformation of the tubular member; and means for, as a
function of the sensed operating conditions, controllably adjusting
a spring rate and a damping rate of the adaptive expansion device
during the radial expansion and plastic deformation of the tubular
member.
[0042] An apparatus for radially expanding and plastically
deforming a tubular member has been described that includes a
support member; and an adaptive expansion device coupled to the
support member for radially expanding and plastically deforming the
tubular member that includes a support structure coupled to the
support member; one or more expansion device segments for engaging
the tubular member to thereby radially expand and plastically
deform the tubular member; and one or more sensors for sensing
operating conditions during the radial expansion and plastic
deformation of the tubular member by the adaptive expansion device;
and a controller operably coupled to the expansion device segments
and the sensors; wherein the controller is programmed to
controllably adjust a frequency characteristic of one or more of
the expansion device segments as a function of the operating
conditions sensed by the sensors.
[0043] A method of adaptively radially expanding a tubular member
within a wellbore has been described that includes inserting an
adaptive expansion device comprising one or more expansion device
segments for engaging and radially expanding and plastically
deforming the tubular member into the tubular member; radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; sensing one or more operating conditions
during the radial expansion and plastic deformation of the tubular
member; and as a function of the sensed operating conditions,
controllably adjusting a frequency response characteristic of one
or more of the expansion device segments during the radial
expansion and plastic deformation of the tubular member.
[0044] A system for adaptively radially expanding a tubular member
within a wellbore has been described that includes means for
inserting an adaptive expansion device comprising one or more
expansion device segments for engaging and radially expanding and
plastically deforming the tubular member into the tubular member,
means for radially expanding and plastically deforming the tubular
member using the adaptive expansion device; means for sensing one
or more operating conditions during the radial expansion and
plastic deformation of the tubular member; and means for, as a
function of the sensed operating conditions, controllably adjusting
a frequency response characteristic of one or more of the expansion
device segments during the radial expansion and plastic deformation
of the tubular member.
[0045] An apparatus for radially expanding and plastically
deforming overlapping ends of first and second tubular members has
been described that includes a support member; and an adaptive
expansion device coupled to the support member for radially
expanding and plastically deforming the overlapping ends of the
tubular members that includes a support structure coupled to the
support member; one or more expansion device segments for engaging
the overlapping ends of the tubular members to thereby radially
expand and plastically deform the overlapping ends of the tubular
member; and one or more sensors for sensing operating conditions
during the radial expansion and plastic deformation of the
overlapping ends of the tubular member by the adaptive expansion
device; and a controller operably coupled to the expansion device
segments and the sensors; wherein the controller is programmed to
controllably adjust one or more operational characteristics of one
or more of the expansion device segments as a function of a sensing
of the overlapping ends of the tubular members by one or more of
the sensors.
[0046] A method of adaptively radially expanding overlapping ends
of tubular members within a wellbore has been described that
includes inserting an adaptive expansion device comprising one or
more expansion device segments for engaging and radially expanding
and plastically deforming the tubular member into the overlapping
ends of the tubular members; radially expanding and plastically
deforming the overlapping ends of the tubular members using the
adaptive expansion device; sensing the overlapping ends of the
tubular members during the radial expansion and plastic deformation
of the overlapping ends of the tubular members; and as a function
of the sensing of the overlapping ends of the tubular members,
controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and
plastic deformation of the overlapping ends of the tubular
members.
[0047] A system for adaptively radially expanding overlapping ends
of tubular members within a wellbore has been described that
includes means for inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular member
into the overlapping ends of the tubular members; means for
radially expanding and plastically deforming the overlapping ends
of the tubular members using the adaptive expansion device; means
for sensing the overlapping ends of the tubular members during the
radial expansion and plastic deformation of the overlapping ends of
the tubular members; and means for, as a function of the sensing of
the overlapping ends of the tubular members, controllably adjusting
an operational characteristic of one or more of the expansion
device segments during the radial expansion and plastic deformation
of the overlapping ends of the tubular members.
[0048] An apparatus for radially expanding and plastically
deforming first and second tubular members coupled to one another
by a threaded connection has been described that includes a support
member; and an adaptive expansion device coupled to the support
member for radially expanding and plastically deforming the
threaded connection that includes a support structure coupled to
the support member; one or more expansion device segments for
engaging the threaded connection to thereby radially expand and
plastically deform the threaded connection; and one or more sensors
for sensing operating conditions during the radial expansion and
plastic deformation of the threaded connection by the adaptive
expansion device; and a controller operably coupled to the
expansion device segments and the sensors; wherein the controller
is programmed to controllably adjust one or more operational
characteristics of one or more of the expansion device segments as
a function of a sensing of the threaded connection by one or more
of the sensors.
[0049] A method of adaptively radially expanding tubular members
coupled to one another by a threaded connection within a wellbore
has been described that includes inserting an adaptive expansion
device comprising one or more expansion device segments for
engaging and radially expanding and plastically deforming the
tubular members proximate the threaded connection; radially
expanding and plastically deforming the threaded connection using
the adaptive expansion device; sensing the threaded connection
during the radial expansion and plastic deformation of the threaded
connection; and as a function of the sensing of the threaded
connection, controllably adjusting an operational characteristic of
one or more of the expansion device segments during the radial
expansion and plastic deformation of the threaded connection.
[0050] A system for adaptively radially expanding tubular members
coupled to one another by a threaded connection within a wellbore
has been described that includes means for inserting an adaptive
expansion device comprising one or more expansion device segments
for engaging and radially expanding and plastically deforming the
tubular members proximate the threaded connection; means for
radially expanding and plastically deforming the threaded
connection using the adaptive expansion device; means for sensing
the threaded connection during the radial expansion and plastic
deformation of the threaded connection; and means for, as a
function of the sensing of the threaded connection, controllably
adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the threaded connection.
[0051] An apparatus for radially expanding and plastically
deforming a tubular member within a wellbore that traverses a
subterranean formation has been described that includes a support
member; and an adaptive expansion device coupled to the support
member for radially expanding and plastically deforming the tubular
member and elastically deforming the subterranean formation that
includes a support structure coupled to the support member; one or
more expansion device segments for engaging the threaded connection
to thereby radially expand and plastically deform the tubular
member and elastically deform the subterranean formation; and one
or more sensors for sensing operating conditions during the radial
expansion and plastic deformation of the tubular member and the
elastic deformation of the subterranean formation; and a controller
operably coupled to the expansion device segments and the sensors;
wherein the controller is programmed to controllably adjust one or
more operational characteristics of one or more of the expansion
device segments as a function of a sensing of the subterranean
formation by one or more of the sensors.
[0052] A method of adaptively radially expanding a tubular member
within a wellbore that traverses a subterranean formation has been
described that includes inserting an adaptive expansion device
comprising one or more expansion device segments for engaging and
radially expanding and plastically deforming the tubular member and
elastically deforming the subterranean formation within the
wellbore; radially expanding and plastically deforming the tubular
member and elastically deforming the subterranean formation using
the adaptive expansion device; sensing the subterranean formation
during the radial expansion and plastic deformation of the tubular
member and the elastic deformation of the subterranean formation;
and as a function of the sensing of the subterranean formation,
controllably adjusting an operational characteristic of one or more
of the expansion device segments during the radial expansion and
plastic deformation of the tubular member and the elastic
deformation of the subterranean formation.
[0053] A system for adaptively radially expanding a tubular member
within a wellbore that traverses a subterranean formation has been
described that includes means for inserting an adaptive expansion
device comprising one or more expansion device segments for
engaging and radially expanding and plastically deforming the
tubular member and elastically deforming the subterranean formation
within the wellbore; means for radially expanding and plastically
deforming the tubular member and elastically deforming the
subterranean formation using the adaptive expansion device; means
for sensing the subterranean formation during the radial expansion
and plastic deformation of the tubular member and the elastic
deformation of the subterranean formation; and means for, as a
function of the sensing of the subterranean formation, controllably
adjusting an operational characteristic of one or more of the
expansion device segments during the radial expansion and plastic
deformation of the tubular member and the elastic deformation of
the subterranean formation.
[0054] An apparatus for radially expanding and plastically
deforming a tubular member has been described that includes a
support member; and an adaptive expansion device coupled to the
support member for radially expanding and plastically deforming the
tubular member that includes a support structure coupled to the
support member; and one or more expansion device segments coupled
to the support structure for engaging the tubular member to thereby
radially expand and plastically deform the tubular member; one or
more sensors for sensing one or more operating conditions during
the radial expansion and plastic deformation of the tubular member;
and a controller operably coupled to the expansion device segments
and the sensors; and wherein the controller is programmed to
controllably adjust one or more of the operational characteristics
of one or more the expansion device segments as a function of the
operating conditions sensed by the sensors.
[0055] A method of adaptively radially expanding a tubular member
within a wellbore has been described that includes inserting an
adaptive expansion device into the tubular member; radially
expanding and plastically deforming the tubular member using the
adaptive expansion device; sensing one or more operating conditions
during the radial expansion and plastic deformation of the tubular
member; and as a function of the sensed operating conditions,
controllably adjusting one or more of the operating characteristics
of the adaptive expansion device during the radial expansion and
plastic deformation of the tubular member.
[0056] A system for adaptively radially expanding a tubular member
within a wellbore has been described that includes means for
inserting an adaptive expansion device into the tubular member;
means for radially expanding and plastically deforming the tubular
member using the adaptive expansion device; means for sensing one
or more operating conditions during the radial expansion and
plastic deformation of the tubular member; and means for, as a
function of the sensed operating conditions, controllably adjusting
one or more of the operating characteristics of the adaptive
expansion device during the radial expansion and plastic
deformation of the tubular member.
[0057] In several exemplary embodiments, one or more of the
expansion device segments includes one or more expansion surfaces;
and an actuator coupled to the expansion surfaces. In an exemplary
embodiment, the actuator includes one or more degrees of freedom.
In an exemplary embodiment, the actuator includes a plurality of
degrees of freedom. In an exemplary embodiment, the actuator
includes one or more rotary actuators. In an exemplary embodiment,
one or more of the expansion device segments include one or more
hydro-forming devices.
[0058] In several exemplary embodiments, radially expanding and
plastically deforming the tubular member using the adaptive
expansion device includes displacing the adaptive expansion device
relative to the tubular member in the longitudinal direction. In
several exemplary embodiments, radially expanding and plastically
deforming the tubular member using the adaptive expansion device
includes rotating the adaptive expansion device relative to the
tubular member. In an exemplary embodiment, radially expanding and
plastically deforming the tubular member using the adaptive
expansion device includes applying a pressurized fluid to the
interior surface of the tubular member. In several exemplary
embodiments, the means for radially expanding and plastically
deforming the tubular member using the adaptive expansion device
includes means for displacing the adaptive expansion device. In
several exemplary embodiments, the means for displacing the
adaptive expansion device includes one or more degrees of freedom.
In several exemplary embodiments, the means for displacing the
adaptive expansion device includes a plurality of degrees of
freedom. In several exemplary embodiments, the means for radially
expanding and plastically deforming the tubular member using the
adaptive expansion device includes means for radially expanding and
plastically deforming the tubular member using a hydro-forming
device.
[0059] 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, one or more of the tubular members, 16 and
30, may be slotted, perforated, or otherwise include one or more
radial passages. In addition, the adaptive expansion device 14 may
be displaced in the longitudinal direction and/or rotated relative
to the tubular member 16 during the radial expansion and plastic
deformation of the tubular member.
[0060] 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.
* * * * *