U.S. patent application number 11/621245 was filed with the patent office on 2007-07-26 for system for lining a wellbore casing.
This patent application is currently assigned to Enventure Global Technology, L.L.C.. Invention is credited to Charles Anthony JR. Butterfield, William Patrick Parker.
Application Number | 20070169944 11/621245 |
Document ID | / |
Family ID | 38284409 |
Filed Date | 2007-07-26 |
United States Patent
Application |
20070169944 |
Kind Code |
A1 |
Parker; William Patrick ; et
al. |
July 26, 2007 |
SYSTEM FOR LINING A WELLBORE CASING
Abstract
A system for lining a wellbore casing.
Inventors: |
Parker; William Patrick;
(Katy, TX) ; Butterfield; Charles Anthony JR.;
(Cypress, TX) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET, SUITE 3100
DALLAS
TX
75202
US
|
Assignee: |
Enventure Global Technology,
L.L.C.
Houston
TX
|
Family ID: |
38284409 |
Appl. No.: |
11/621245 |
Filed: |
January 9, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10488664 |
Mar 4, 2004 |
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PCT/US02/25727 |
Aug 14, 2002 |
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11621245 |
Jan 9, 2007 |
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10030593 |
Oct 29, 2002 |
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PCT/US00/18635 |
Jul 7, 2000 |
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11621245 |
Jan 9, 2007 |
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60317985 |
Sep 6, 2001 |
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60318386 |
Sep 10, 2001 |
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60146203 |
Jul 29, 1999 |
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60143039 |
Jul 9, 1999 |
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Current U.S.
Class: |
166/380 ;
166/207 |
Current CPC
Class: |
E21B 43/103 20130101;
E21B 43/105 20130101 |
Class at
Publication: |
166/380 ;
166/207 |
International
Class: |
E21B 23/00 20060101
E21B023/00 |
Claims
1. A system for lining a wellbore casing, comprising: a tubular
support member defining a first passage; a tubular expansion cone
defining a second passage fluidicly coupled to the first passage
coupled to an end of the tubular support member and comprising a
tapered end; a tubular liner coupled to and supported by the
tapered end of the tubular expansion cone; and a shoe defining a
valveable passage coupled to an end of the tubular liner; wherein
the tubular liner comprises an expandable tubular member that
comprises: first and second tubular portions; an intermediate
tubular portion coupled between the first and second tubular
portions; and a sealing member coupled to the exterior surface of
the intermediate tubular portion; wherein the inside diameters of
the first and second tubular portions are greater than the inside
diameter of the intermediate tubular portion; and wherein the
inside diameter of the first tubular portion is greater than the
inside diameter of the second tubular portion.
2. The system of claim 1 wherein the inside diameter of the first
tubular portion is about 5% greater than the inside diameter of the
second tubular portion.
3. The system of claim 1 wherein the wall thicknesses of the first
and second tubular portions are greater than the wall thickness of
the intermediate tubular portion.
4. The system of claim 1 wherein the expandable tubular member
further comprises: a first tubular tapered transitionary portion
coupled between the first tubular portion and the intermediate
tubular portion; and a second tubular tapered transitionary portion
coupled between the second tubular portion and the intermediate
tubular portion; wherein the angles of inclination of the first and
second tapered tubular transitionary portions relative to the
intermediate tubular portion ranges from greater than 0 to about 30
degrees.
5. The system of claim 1 wherein the outside diameter of the
intermediate tubular portion ranges from about 75 percent to about
98 percent of the outside diameters of the second tubular
portion.
6. The system of claim 1 wherein the burst strength of the first
and second tubular portions is substantially equal to the burst
strength of the intermediate tubular portion.
7. The system of claim 1 wherein the ratio of the inside diameter
of the second tubular portion to the interior diameter of the
intermediate tubular portion ranges from greater than 100 to about
120 percent.
8. The system of claim 1 wherein the tapered end of the tubular
expansion cone comprises a plurality of adjacent discrete tapered
sections.
9. The system of claim 8 wherein the angle of attack of the
adjacent discrete tapered sections increases in a continuous manner
from one end of the tubular expansion cone to the opposite end of
the tubular expansion cone.
10. The system of claim 1 wherein the tapered end of the tubular
expansion cone comprises a paraboloid body.
11. The system of claim 10 wherein the angle of attack of the outer
surface of the paraboloid body increases in a continuous manner
from one end of the paraboloid body to the opposite end of the
paraboloid body.
12. The system of claim 1 wherein the tubular liner comprises a
plurality of expandable tubular members and a plurality of other
tubular members, and wherein the other tubular members are
interleaved among the expandable tubular members.
13. A method of lining a wellbore casing, comprising: positioning a
tubular liner within the wellbore casing; and radially expanding
one or more discrete portions of the tubular liner into engagement
with the wellbore casing; wherein the tubular liner comprises an
expandable tubular member that comprises: first and second tubular
portions; an intermediate tubular portion coupled between the first
and second tubular portions; and a sealing member coupled to the
exterior surface of the intermediate tubular portion; wherein the
inside diameters of the first and second tubular portions are
greater than the inside diameter of the intermediate tubular
portion; and wherein the inside diameter of the first tubular
portion is greater than an inside diameter of the second tubular
portion.
14. The method of claim 13 wherein the inside diameter of the first
tubular portion is about 5% greater than an inside diameter of the
second tubular portion.
15. The method of claim 13 wherein a plurality of discrete portions
of the tubular liner are radially expanded into engagement with the
wellbore casing.
16. The method of claim 15 wherein the remaining portions of the
tubular liner are not radially expanded.
17. The method of claim 15 wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
18. The method of claim 13 wherein the tubular liner comprises a
plurality of expandable tubular members, wherein one or more of the
expandable tubular members are radially expanded into engagement
with the wellbore casing, and wherein a plurality of the expandable
tubular members are not radially expanded into engagement with the
well bore casing.
19. A system for lining a wellbore casing, comprising: means for
positioning a tubular liner within the wellbore casing; and means
for radially expanding one or more discrete portions of the tubular
liner into engagement with the wellbore casing; wherein the tubular
liner comprises an expandable tubular member that comprises: first
and second tubular portions; an intermediate tubular portion
coupled between the first and second tubular portions; and a
sealing member coupled to the exterior surface of the intermediate
tubular portion; wherein the inside diameters of the first and
second tubular portions are greater than the inside diameter of the
intermediate tubular portion; and wherein the inside diameter of
the first tubular portion is greater than the inside diameter of
the second tubular portion.
20. The system of claim 19 wherein the inside diameter of the first
tubular portion is about 5% greater than the inside diameter of the
second tubular portion.
21. The system of claim 19 wherein a plurality of discrete portions
of the tubular liner are radially expanded into engagement with the
wellbore casing.
22. The system of claim 21 wherein remaining portions of the
tubular liner are not radially expanded.
23. The system of claim 21 wherein the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner.
24. The system of claim 19 wherein the tubular liner comprises a
plurality of tubular members, wherein one or more of the tubular
members are radially expanded into engagement with the wellbore
casing, and wherein a plurality of the tubular members are not
radially expanded into engagement with the wellbore casing.
25. An apparatus, comprising: a subterranean formation defining a
borehole; a casing positioned in and coupled to the borehole; and a
tubular liner positioned in and coupled to the casing at one or
more discrete locations; wherein the tubular liner comprises a
radially expanded and plastically deformed tubular member that
comprises: first and second tubular portions; an intermediate
tubular portion coupled between the first and second tubular
portions; and a sealing member coupled to the exterior surface of
the intermediate tubular portion that engages the interior surface
of the casing; wherein the intermediate tubular portion is radially
expanded and plastically deformed; wherein the first and second
tubular portions are not radially expanded and plastically
deformed; and wherein the first tubular portion is greater in
diameter than the second tubular portion.
26. The apparatus of claim 25 wherein the inside diameter of the
first tubular portion is about 5% greater than an inside diameter
of the second tubular portion.
27. The system of claim 25 wherein the tubular liner comprises a
plurality of radially expanded and plastically deformed tubular
members.
28. A system for lining a wellbore casing, comprising: a support
member; an expansion device coupled to an end of the support
member; and a tubular liner coupled to the expansion device that
comprises: a first expandable tubular member that comprises: first
and second tubular portions; a first intermediate tubular portion
coupled between the first and second tubular portions; and a first
sealing member coupled to the exterior surface of the first
intermediate tubular portion; wherein the inside diameters of the
first and second tubular portions are greater than the inside
diameter of the intermediate tubular portion; and wherein the
inside diameter of the first tubular portion is greater than an
inside diameter of the second tubular portion; and one or more
second expandable tubular members that each comprise: third and
fourth tubular portions; a second intermediate tubular portion
coupled between the third and fourth tubular portions; and a second
sealing member coupled to the exterior surface of the second
intermediate tubular portion; wherein the inside diameters of the
first, second, third and fourth tubular portions are greater than
the inside diameters of the first and second intermediate tubular
portions.
29. The system of claim 28 wherein the inside diameter of the first
tubular portion is about 5% greater than an inside diameter of the
second tubular portion.
30. The system of claim 28 wherein the wall thicknesses of the
first, second, third and fourth tubular portions are greater than
the wall thicknesses of the first and second intermediate tubular
portions.
31. The system of claim 28 wherein the first expandable tubular
member further comprises: a first tubular tapered transitionary
portion coupled between the first tubular portion and the first
intermediate tubular portion; and a second tubular tapered
transitionary portion coupled between the second tubular portion
and the first intermediate tubular portion; wherein the angles of
inclination of the first and second tapered tubular transitionary
portions relative to the first intermediate tubular portion ranges
from greater than 0 to about 30 degrees.
32. The system of claim 31 wherein each of the second expandable
tubular members further comprise: a third tubular tapered
transitionary portion coupled between the third tubular portion and
the second intermediate tubular portion; and a fourth tubular
tapered transitionary portion coupled between the fourth tubular
portion and the second intermediate tubular portion; wherein the
angles of inclination of the third and fourth tapered tubular
transitionary portions relative to the second intermediate tubular
portion ranges from greater than 0 to about 30 degrees.
33. The system of claim 28 wherein the outside diameters of the
first and second intermediate tubular portions each range from
about 75 percent to about 98 percent of the outside diameters of
the second, third and fourth tubular portions.
34. The system of claim 28 wherein the burst strength of the first,
second, third and fourth tubular portions is substantially equal to
the burst strength of the first and second intermediate tubular
portions.
35. The system of claim 28 wherein the ratio of the inside
diameters of the second, third and fourth tubular portions to the
interior diameters of the first and second intermediate tubular
portions ranges from greater than 100 to about 120 percent.
36. The system of claim 28 wherein the expansion device comprises a
plurality of adjacent discrete tapered sections.
37. The system of claim 36 wherein the angle of attack of the
adjacent discrete tapered sections increases in a continuous manner
from one end of the expansion device to the opposite end of the
expansion device.
38. The system of claim 28 wherein the expansion device comprises
an paraboloid body.
39. The system of claim 38 wherein the angle of attack of the outer
surface of the paraboloid body increases in a continuous manner
from one end of the paraboloid body to the opposite end of the
paraboloid body.
40. A liner for lining a wellbore casing, comprising: a first
tubular portion; a second tubular portion; an intermediate tubular
portion coupled between the first and second tubular portions; and
a sealing member coupled to the exterior surface of the
intermediate tubular portion; wherein the inside diameters of the
first and second tubular portions are greater than the inside
diameter of the intermediate tubular portion; and wherein the
inside diameter of the first tubular portion is greater than the
inside diameter of the second tubular portion.
41. The liner of claim 40 wherein the inside diameter of the first
tubular portion is about 5% greater than the inside diameter of the
second tubular portion.
42. The liner of claim 40 wherein the wall thicknesses of the first
and second tubular portions are greater than the wall thickness of
the intermediate tubular portion.
43. The liner of claim 40 further comprising: a first tubular
tapered transitionary portion coupled between the first tubular
portion and the intermediate tubular portion; and a second tubular
tapered transitionary portion coupled between the second tubular
portion and the intermediate tubular portion; wherein the angles of
inclination of the first and second tapered tubular transitionary
portions relative to the intermediate tubular portion ranges from
greater than 0 to about 30 degrees.
44. The liner of claim 40 wherein the outside diameter of the
intermediate tubular portion ranges from about 75 percent to about
98 percent of the outside diameter of the second tubular
portion.
45. The liner of claim 40 wherein the ratio of the inside diameter
of the second tubular portion to the interior diameter of the
intermediate tubular portion ranges from greater than 100 to about
120 percent.
46. A method of lining a wellbore casing, comprising: positioning a
tubular liner within the wellbore casing, wherein the tubular liner
comprises first and second discrete portions coupled by a
conventional threaded connection; and radially expanding the first
and second discrete portions of the tubular liner, including the
conventional threaded connection, providing a fluid tight seal
between the radially expanded first and second discrete
portions.
47. The method of claim 46 wherein radially expanding the first and
second discrete portions of the tubular liner and the conventional
threaded connection includes radially expanding a diameter of an
inner passage extending through the first and second discrete
portions and the conventional threaded connection up to about
5%.
48. A system for lining a wellbore casing, comprising: means for
positioning a tubular liner within the wellbore casing, wherein the
tubular liner comprises first and second discrete portions coupled
by a conventional threaded connection; and means for radially
expanding the first and second discrete portions of the tubular
liner, including the conventional threaded connection, providing a
fluid tight seal between the radially expanded first and second
discrete portions.
49. The system of claim 48 wherein the radially expanding means
includes is configured to radially expand a diameter of an inner
passage extending through the first and second discrete portions
and the conventional threaded connection up to about 5%.
50. A liner for lining a wellbore casing, comprising: a first
tubular portion; and a second tubular portion; wherein the first
and second tubular portions are coupled by a conventional threaded
connection; wherein the first and second tubular portions and the
conventional threaded connection are radially expanded up to about
5%; and wherein a fluid tight seal is provided between the radially
expanded first and second tubular portions by the radially expanded
conventional threaded connection.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] The present application is a continuation-in-part of U.S
utility patent application Ser. No. 10/488,664. attorney docket
number 25791.67.06, filed on Mar. 4, 2004, which was the National
Stage filing for PCT patent application Ser. No. PCT/US02/25727,
attorney docket number 25791.67.03, filed on Aug. 14, 2002, which
claimed the benefit of the filing dates of 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, the disclosures of which are incorporated herein by
reference.
[0002] The present application is also a continuation-in-part of
U.S. utility patent application Ser. No. 10/030,593, attorney
docket number 25791.25.08, filed on Jan. 8, 2002, which was the
National Stage filing for PCT patent application Ser. No.
PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9,
2000, which claimed the benefit of the filing dates of U.S.
provisional patent application Ser. No. 60/146,203, attorney docket
no. 25791.25, filed on Jul. 29, 1999, and U.S. provisional patent
application Ser. No. 60/143,039, attorney docket no. 25791.26,
filed on Jul. 9, 1999, the disclosures of which are incorporated
herein by reference.
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 No. 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 No. 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 No. 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 No. 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 No. 60/183,546, filed on Feb.
18, 2000, (6) U.S. Pat. No. 6,640,903 which was filed as 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 No. 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 No.
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 No. 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 No. 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
No. 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 No. 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 No. 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,
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12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed
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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,
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Ser. No. 10/303,992, filed on Nov. 22, 2002, attorney docket no.
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(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
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(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
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application Ser. No. 60/259,486, attorney docket no. 25791.52,
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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 No. 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 No. 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
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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,
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patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903
which issued Nov. 4, 2003), which claims priority from provisional
application No. 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, (now U.S. Pat. No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 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, (now U.S. Pat. No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 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, (now U.S. Patent No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 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, (now U.S. Patent No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 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, (now U.S. Patent No. 6,634,431 which issued 10/21/2003),
which is a continuation-in-part application of U.S. patent 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 No.
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, (now U.S. Patent No. 6,634,431
which issued Oct. 21, 2003), 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 No. 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 No. 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 No.
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 No. 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 No. 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 No.
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 No. 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 No. 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 No.
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 No. 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 No.
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 No. 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 No.
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 No. 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 No.
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 No. 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 No. 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 No. 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 No. 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 PCT/US03/24779, 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 No. 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 No. 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, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application No. 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 No.
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, (now U.S. Patent No. 6,634,431 which issued
Oct. 21, 2003), 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 No.
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, (now U.S. Pat. No. 6,640,903
which issued Nov. 4, 2003), which claims priority from provisional
application No. 60/124,042, filed on Mar. 11, 1999, and (122) U.S.
utility patent application Ser. No. 10/784,679, attorney docket no.
25791.318, filed on Feb. 23, 2004, which was a continuation-in-part
of U.S. utility patent application Ser. No. 10/089419, attorney
docket no. 25791.36.03, filed on Sep. 19, 2002, which issued as
U.S. Pat. No. 6,695,012, the disclosures of which are incorporated
herein by reference.
This application is related to the following co-pending
applications: (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 No. 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 No. 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, now U.S. Patent 6,823,937 which
issued Nov. 30, 2004, which claims priority from provisional
application No. 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 No.
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 No.
60/183,546, filed on Feb. 18, 2000, (6) U.S. Pat. No. 6,640,903
which was filed as 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 No. 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 No. 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 No.
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 No. 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 No. 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 No. 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 No. 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, now U.S. Pat. No. 6,695,012 which issued Feb. 24,
2004, 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.
10/322947, 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, now U.S. Pat. No. 6,976,541 which issued Dec. 20, 2005,
attorney docket No. 25791.47.07, 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 No. 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 No.
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 No. 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 No. 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.
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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, now U.S. Pat. No. 6,892,819 which issued May 17, 2005,
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, (now U.S. Pat. No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 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, (now U.S. Pat. No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
No. 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent
application Ser. No. 09/962,471, filed on Sep. 25, 2001, now U.S.
Pat. No. 6,739,392 which issued May 25, 2004, 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, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application No. 60/124,042,
filed on Mar. 11, 1999, (42) U.S. patent application Ser. No.
09/962,467, filed on Sep. 25, 2001, now U.S. Pat. No. 6,725,919
which issued Apr. 27, 2004, 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, (now U.S.
Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims
priority from provisional application No. 60/124,042, filed on Mar.
11, 1999, (43) U.S. patent application Ser. No. 09/962,468, filed
on Sep. 25, 2001, now U.S. Pat. No. 6,758,278 which issued Jul. 6,
2004, 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, (now U.S. Pat. No. 6,640,903
which issued Nov. 4, 2003), which claims priority from provisional
application No. 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, (now U.S. Pat. 6,634,431 which issued Oct.
21, 2003), 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,
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application Ser. No. 10/516,467, now U.S. Pat. No. 6745845 which
issued Jun. 8, 2004, 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, (now U.S. Pat. No. 6,634,431 which
issued Oct. 21, 2003), 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 No. 60/108,558, filed on Nov. 16, 1998, (48) PCT
application US 03/00609, filed on Jan. 9, 2003, attorney docket no.
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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, now U.S. Pat. No. 6,705,395 which issued Mar. 16, 2004,
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 No. 60/121,841, filed on Feb. 26, 1999, (50) U.S.
patent application Ser. No. 10/074,244, attorney docket no.
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issued Oct. 14, 2003, 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,
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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
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priority from provisional application No. 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, now U.S. Pat.
No. 6,631,769 which issued Oct. 14, 2003, 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,
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60/121,841, filed on Feb. 26, 1999, (53) U.S. patent application
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15, 2002, now U.S. Pat. No. 7,063,142 which issued Jun. 20, 2006,
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.
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provisional application No. 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, now U.S. Pat. No. 6,684,947
which issued Feb. 3, 2004, 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,
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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, now U.S. Pat. No. 6,966,370 which issued Nov. 22, 2005,
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.
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provisional application 60/121,841, filed on Feb. 26, 1999, (56)
U.S. patent application Ser. No. 10/078,921, attorney docket no.
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issued May 16, 2006, 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,
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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, now U.S. Pat. No. 7,011,161 which issued Mar. 14, 2006, 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.
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provisional application No. 60/137,998, filed on Jun. 7, 1999, (58)
U.S. patent application Ser. No. 10/079,276, attorney docket no.
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6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
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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, now U.S. Pat. No. 7,048,062 which issued May 23, 2006, 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.
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provisional application No. 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, now U.S. Pat. No. 6,857,473 which
issued Feb. 22, 2005, 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 No. 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 No. 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, now U.S. Pat. No. 7,077,213 which issued Jul. 18, 2006, 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 No. 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, now U.S. Pat. No. 7,036,582 which
issued 5/2/2006, 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 No. 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, now U.S. Pat. No.
7,044,218 which issued May 16, 2006, 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 No. 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 No. 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
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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
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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 No. 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 No. 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, now U.S. Pat. No. 6,823,937 which issued
11/30/2004, which claims priority from provisional application No.
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. patent application Ser. No.
10/418,687, attorney docket no. 25791.228, filed on Apr. 18, 2003,
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patent application Ser. No. 60/450,504, attorney docket no.
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PCT/US2004/06246, attorney docket no. 25791.238.02, filed on Feb.
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(159) U.S. provisional patent application Ser. No. 60/652564,
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attorney
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U.S. Provisional Patent Application No. 60/725181, attorney docket
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U.S. National Stage application Ser. No. 10/568719, attorney docket
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filed on Feb. 17, 2006, (179) U.S. National State patent
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filed on Mar. 3, 2006; (180) U.S. National State patent application
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3, 2006; (181) U.S. National State patent application Ser. No.
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(183) U.S. utility patent application Ser. number 10/938788,
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U.S. utility patent application Ser. No. 10/938225, attorney docket
number 25791.331, filed on Sep. 10, 2004, (185) U.S. utility patent
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filed on Sep. 28, 2004, (186) U.S. utility patent application Ser.
No. 10/952416, attorney docket number 25791.333, filed on 9/28/04,
(187) U.S. utility patent application Ser. No. 10/950749, attorney
docket number 25791.334, filed on Sep. 27, 2004, (188)U.S. utility
patent application Ser. No. 10/950869, attorney docket number
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application Ser. No. 60/761324, attorney docket number 25791.340,
filed on Jan. 23, 2006, (190) U.S. provisional patent application
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U.S. utility patent application Ser. No. 10/522039, attorney docket
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patent application Ser. No. 60/746,813, attorney docket number
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11, 2006; (197) PCT Patent Application No. PCT/US2006/009886,
attorney docket no. 25791.32.02 filed on Mar. 21, 2006; (198) PCT
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(203) U.S. patent application No. 10/770363 filed Feb. 2, 2004,
attorney docket no. 25791.311; (204) U.S. utility patent
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No. 11/070,147, attorney docket no. 25791.351, filed on Mar. 12,
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application Ser. No. 11/074,266, attorney docket No. 25791.358,
filed on Mar. 7, 2005, (213) U.S. provisional patent application
Ser. No. 60/832909, attorney docket no. 25791.407, filed on Jul.
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11/536,302, attorney docket no. 25791.412, filed Sep. 28, 2006,
(215) U.S. utility patent application Ser. No. 11/538228, attorney
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application Ser. No. 11/552,703, filed on Oct. 25, 2006, attorney
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(218) U.S. utility application Ser. No. 11/554288, attorney docket
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filed on Nov. 15, 2006, (220) U.S. provisional application Ser. No.
60/866536, attorney docket no. 25791.237, filed on Nov. 20, 2006,
and (221) U.S. provisional application Ser. No. 60/866543, attorney
docket no. 25791.251, filed on Nov. 20, 2006.
[0004] BACKGROUND
[0005] This invention relates generally to wellbore casings, and in
particular to wellbore casings that are formed using expandable
tubing.
[0006] 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.
[0007] The present invention is directed to overcoming one or more
of the limitations of the existing procedures for forming wellbore
casings.
BRIEF DESCRIPTION OF THE DRAWINGS
[0008] FIG. 1a is a cross sectional illustration of the placement
of an illustrative embodiment of a system for lining a wellbore
casing within a borehole having a preexisting wellbore casing.
[0009] FIG. 1b is a cross sectional illustration of the system of
FIG. 1a during the injection of a fluidic material into the tubular
support member.
[0010] FIG. 1c is a cross sectional illustration of the system of
FIG. 1b during the pressurization of the interior portion of the
shoe after sealing off the valveable fluid passage of the shoe.
[0011] FIG. 1d is a cross sectional illustration of the system of
FIG. 1c during the continued injection of the fluidic material into
the tubular support member.
[0012] FIG. 1e is a cross sectional illustration of the system of
FIG. 1d after the completion of the radial expansion and plastic
deformation of the expandable tubular members.
[0013] FIG. 1f is a cross sectional illustration of the system of
FIG. 1e after machining the bottom central portion of the shoe.
[0014] FIG. 2 is a cross sectional illustration of an illustrative
embodiment of the expandable tubular members of the system of FIG.
1a.
[0015] FIG. 3 is a flow chart illustration of an illustrative
embodiment of a method for manufacturing the expandable tubular
member of FIG. 2.
[0016] FIG. 4a is a cross sectional illustration of an illustrative
embodiment of the upsetting of the ends of a tubular member.
[0017] FIG. 4b is a cross sectional illustration of the expandable
tubular member of FIG. 4a after radially expanding and plastically
deforming the ends of the expandable tubular member.
[0018] FIG. 4c is a cross sectional illustration of the expandable
tubular member of FIG. 4b after forming threaded connections on the
ends of the expandable tubular member.
[0019] FIG. 4d is a cross sectional illustration of the expandable
tubular member of FIG. 4c after coupling sealing members to the
exterior surface of the intermediate unexpanded portion of the
expandable tubular member.
[0020] FIG. 5 is a cross-sectional illustration of an exemplary
embodiment of a tubular expansion cone.
[0021] FIG. 6 is a cross-sectional illustration of an exemplary
embodiment of a tubular expansion cone.
[0022] FIG. 7a is a cross sectional illustration of the placement
of an illustrative embodiment of a system for lining a wellbore
casing within a borehole having a preexisting wellbore casing.
[0023] FIG. 7b is a cross sectional illustration of the system of
FIG. 7a during the injection of a fluidic material into the tubular
support member.
[0024] FIG. 7c is a cross sectional illustration of the system of
FIG. 7b during the pressurization of the interior portion of the
shoe after sealing off the valveable fluid passage of the shoe.
[0025] FIG. 7d is a cross sectional illustration of the system of
FIG. 7c during the continued injection of the fluidic material into
the tubular support member.
[0026] FIG. 7e is a cross sectional illustration of the system of
FIG. 7d after the completion of the radial expansion and plastic
deformation of the expandable tubular members.
[0027] FIG. 7f is a cross sectional illustration of the system of
FIG. 7e after machining the bottom central portion of the shoe.
DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0028] Referring initially to FIG. 1a, the reference numeral 10
refers, in general, to a system for lining a wellbore casing that
includes a tubular support member 12 that defines a passage 12a. A
tubular expansion cone 14 that defines a passage 14a is coupled to
an end of the tubular support member 12. In an exemplary
embodiment, the tubular expansion cone 14 includes a tapered outer
surface 14b for reasons to be described. A pre-expanded end 16a of
a first expandable tubular member 16 that defines a passage 16b is
adapted to mate with and be supported by the tapered outer surface
14b of the tubular expansion cone 14. The first expandable tubular
member 16 further includes an unexpanded intermediate portion 16c,
another pre-expanded end 16d, and a sealing member 16e coupled to
the exterior surface of the unexpanded intermediate portion. In an
exemplary embodiment, the inside and outside diameters of the
pre-expanded ends, 16a and 16d, of the first expandable tubular
member 16 are greater than the inside and outside diameters of the
unexpanded intermediate portion 16c. An end 18a of a shoe 18 that
defines a passage 18b and a valveable passage 18c is coupled to the
pre-expanded end 16a of the first expandable tubular member 16 by a
conventional threaded connection.
[0029] An end 20a of a tubular member 20 that defines a passage 20b
is coupled to the other pre-expanded end 16d of the first
expandable tubular member 16 by a conventional threaded connection.
Another end 20c of the tubular member 20 is coupled to an end 22a
of a tubular member 22 that defines a passage 22b by a conventional
threaded connection. A pre-expanded end 24a of a second expandable
tubular member 24 that defines a passage 24b is coupled to the
other end 22c of the tubular member 22. The second expandable
tubular member 24 further includes an unexpanded intermediate
portion 24c, another pre-expanded end 24d, and a sealing member 24e
coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 24a and 24d, of the second
expandable tubular member 24 are greater than the inside and
outside diameters of the unexpanded intermediate portion 24c.
[0030] An end 26a of a tubular member 26 that defines a passage 26b
is coupled to the other pre-expanded end 24d of the second
expandable tubular member 24 by a conventional threaded connection.
Another end 26c of the tubular member 26 is coupled to an end 28a
of a tubular member 28 that defines a passage 28b by a conventional
threaded connection. A pre-expanded end 30a of a third expandable
tubular member 30 that defines a passage 30b is coupled to the
other end 28c of the tubular member 28. The third expandable
tubular member 30 further includes an unexpanded intermediate
portion 30c, another pre-expanded end 30d, and a sealing member 30e
coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 30a and 30d, of the third
expandable tubular member 30 are greater than the inside and
outside diameters of the unexpanded intermediate portion 30c.
[0031] In an exemplary embodiment, the inside and outside diameters
of the pre-expanded ends, 16a, 16d, 24a, 24d, 30a and 30d, of the
expandable tubular members, 16, 24, and 30, and the tubular members
20, 22, 26, and 28, are substantially equal. In several exemplary
embodiments, the sealing members, 16e, 24e, and 30e, of the
expandable tubular members, 16, 24, and 30, respectively, further
include anchoring elements for engaging the wellbore casing 104. In
several exemplary embodiments, the tubular members, 20, 22, 26, and
28, are conventional tubular members having threaded end
connections suitable for use in an oil or gas well, an underground
pipeline, or as a structural support.
[0032] In an exemplary embodiment, as illustrated in FIG. 1a, the
system 10 is initially positioned in a borehole 100 formed in a
subterranean formation 102 that includes a pre-existing wellbore
casing 104. The borehole 100 may be positioned in any orientation
from vertical to horizontal. Furthermore, the wellbore casing 104
may be, for example, a wellbore casing for an oil or gas well, an
underground pipeline, or a structural support. In an exemplary
embodiment, the upper end of the tubular support member 12 may be
supported in a conventional manner using, for example, a slip
joint, or equivalent device in order to permit upward movement of
the tubular support member and tubular expansion cone 14 relative
to one or more of the expandable tubular members, 16, 24, and 30,
and tubular members, 20, 22, 26, and 28.
[0033] In an exemplary embodiment, as illustrated in FIG. 1b, a
fluidic material 106 is then injected into the system 10, through
the passages, 12a and 14a, of the tubular support member 12 and
tubular expansion cone 14, respectively. The fluidic material 106
then passes into the passages, 18b and 18c, of the shoe 18 into the
borehole 100.
[0034] In an exemplary embodiment, as illustrated in FIG. 1c, a
ball 108, plug or other equivalent device is then introduced into
the injected fluidic material 106. The ball 108 will then pass
through the passages, 12a, 14a, and 18b, of the tubular support
member 12, the tubular expansion cone 14, and the shoe 18,
respectively, and will then be positioned within the valveable
passage 18c of the shoe. In this manner, the valveable passage 18c
of the shoe 18 is closed thereby permitting the passage 18b of the
shoe below the tubular expansion cone 14 to be pressurized by the
continued injection of the fluidic material 106.
[0035] In an exemplary embodiment, as illustrated in FIG. 1d, the
continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the tubular support member 12 and the
tubular expansion cone 14, respectively, pressurizes the passage
18b of the shoe 18 below the tubular expansion cone thereby
radially expanding and plastically deforming the expandable tubular
member 16 off of the tapered external surface 14b of the tubular
expansion cone 14. In particular, the intermediate non pre-expanded
portion 16c of the expandable tubular member 16 is radially
expanded and plastically deformed off of the tapered external
surface 14b of the tubular expansion cone 14. As a result, the
sealing member 16e engages the interior surface of the wellbore
casing 104. Consequently, the radially expanded intermediate
portion 16c of the expandable tubular member 16 is thereby coupled
to the wellbore casing 104. In an exemplary embodiment, the
radially expanded intermediate portion 16c of the expandable
tubular member 16 is also thereby anchored to the wellbore casing
104.
[0036] The continued injection of the fluidic material 106 through
the passages, 1 2a and 14a, of the tubular support member 12 and
the tubular expansion cone 14, respectively, will then displace the
tubular expansion cone 14 upwardly into engagement with the
pre-expanded end 24a of the second expandable tubular member
24.
[0037] In an exemplary embodiment, as illustrated in FIG. 1e, the
continued injection of the fluidic material 106 through the
passages, 12a and 14a, of the tubular support member 12 and tubular
expansion cone 14, respectively, will then pressurize the passages
18b, 16b, 20b and 22b below the tubular expansion cone thereby
radially expanding and plastically deforming the second expandable
tubular member 24 off of the tapered external surface 14b of the
tubular expansion cone 14. In particular, the intermediate non
pre-expanded portion 24c of the second expandable tubular member 24
is radially expanded and plastically deformed off of the tapered
external surface 14b of the tubular expansion cone 14. As a result,
the sealing member 24e engages the interior surface of the wellbore
casing 104. Consequently, the radially expanded intermediate
portion 24c of the second expandable tubular member 24 is thereby
coupled to the wellbore casing 104. In an exemplary embodiment, the
radially expanded intermediate portion 24c of the second expandable
tubular member 24 is also thereby anchored to the wellbore casing
104.
[0038] The continued injection of the fluidic material 106 through
the passages, 12a and 14a, of the tubular support member 12 and the
tubular expansion cone 14, respectively, will then displace the
tubular expansion cone 14 upwardly into engagement with the
pre-expanded end 30a of the third expandable tubular member 30.
[0039] The continued injection of the fluidic material 106 through
the passages, 12a and 14a, of the tubular support member 12 and
tubular expansion cone 14, respectively, will then pressurize the
passages 18b, 16b, 20b, 22b, 24b, 26b, and 28b below the tubular
expansion cone thereby radially expanding and plastically deforming
the third expandable tubular member 30 off of the tapered external
surface 14b of the tubular expansion cone 14. In particular, the
intermediate non pre-expanded portion 30c of the third expandable
tubular member 30 is radially expanded and plastically deformed off
of the tapered external surface 14b of the tubular expansion cone
14. As a result, the sealing member 30e engages the interior
surface of the well bore casing 104. Consequently, the radially
expanded intermediate portion 30c of the third expandable tubular
member 30 is thereby coupled to the wellbore casing 104. In an
exemplary embodiment, the radially expanded intermediate portion
30c of the third expandable tubular member 30 is also thereby
anchored to the wellbore casing 104.
[0040] In an exemplary embodiment, during the injection of the
fluidic material 106 through the passages, 12a and 14a, of the
tubular support member 12 and the tubular expansion cone 14,
respectively, the tubular support member 12 and tubular expansion
cone 14 are displaced upwardly relative to the expandable tubular
members, 16, 24, and 30, and the tubular members, 20, 22, 26, and
28, by applying an upward axial force to the upper end of the
tubular support member.
[0041] After completing the radial expansion and plastic
deformation of the third expandable tubular member 30, the tubular
support member 12 and the tubular expansion cone 14 are removed
from the wellbore 100.
[0042] In an exemplary embodiment, as illustrated in FIG. 1f, the
lower central portion of the shoe 18 is then removed using a
conventional milling device.
[0043] Thus, during the operation of the system 10, the
intermediate non pre-expanded portions, 16c, 24c, and 30c, of the
expandable tubular members, 16, 24, and 30, respectively, are
radially expanded and plastically deformed by the pressurization of
the interior passages, 18a, 16b, 20b, 22b, 24b, 26b, 28b, and 30b,
of the shoe 18, the expandable tubular member 16, the tubular
members, 20 and 22, the expandable tubular member 24, the tubular
members, 26 and 28, and the expandable tubular member 30,
respectively, below the tubular expansion cone 14. As a result, the
sealing members, 16e, 24e, and 30e, are displaced in the radial
direction into engagement with the wellbore casing 104 thereby
coupling the shoe 18, the expandable tubular member 16, the tubular
members, 20 and 22, the expandable tubular member 24, the tubular
members, 26 and 28, and the expandable tubular member 30 to the
wellbore casing. Furthermore, as a result, the expandable
connections between the expandable tubular members, 16, 24, and 30,
the shoe 18, and the tubular members, 20, 22, 26, and 28, do not
have to be expandable connections thereby providing significant
cost savings. Furthermore, in the system 10, the tubular members
20, 22, 26, and 28 are interleaved among the expandable tubular
members, 16, 24, and 30. As a result, because only the intermediate
non pre-expanded portions, 16c, 24c, and 30c, of the expandable
tubular members, 16, 24, and 30, respectively, are radially
expanded and plastically deformed, the tubular members, 20, 22, 26,
and 28 can be conventional tubular members thereby significantly
reducing the cost and complexity of the system 10. Moreover,
because only the intermediate non pre-expanded portions, 16c, 24c,
and 30c, of the expandable tubular members, 16, 24, and 30,
respectively, are radially expanded and plastically deformed, the
number and length of the interleaved tubular members, 20, 22, 26,
and 28 can be much greater than the number and length of the
expandable tubular members. In an exemplary embodiment, the total
length of the intermediate non pre-expanded portions, 16c, 24c, and
30c, of the expandable tubular members, 16, 24, and 30, is
approximately 200 feet, and the total length of the tubular
members, 20, 22, 26, and 28, is approximately 3800 feet.
Consequently, in an exemplary embodiment, a liner having a total
length of approximately 4000 feet is coupled to a wellbore casing
by radially expanding and plastically deforming a total length of
only approximately 200 feet.
[0044] Furthermore, the sealing members 16e, 24e, and 30e, of the
expandable tubular members, 16, 24, and 30, respectively, are used
to couple the expandable tubular members and the tubular members,
20, 22, 26, and 28 to the wellbore casing 104, the radial gap
between the tubular members, the expandable tubular members, and
the wellbore casing 104 may be large enough to effectively
eliminate the possibility of damage to the expandable tubular
members and tubular members during the placement of the system 10
within the wellbore casing.
[0045] In an exemplary embodiment, after the sealing member 16e of
the expandable tubular member 16 has been radially expanded into
engagement with the wellbore casing 104, the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed
by injecting the fluidic material 106 and applying an upward axial
force to the tubular support member 12 and tubular expansion cone
14. In this manner, radial expansion and plastic deformation of the
expandable tubular members, 24 and 30, may be enhanced.
[0046] In an exemplary embodiment, after the sealing member 16e of
the expandable tubular member 16 has been radially expanded into
engagement with the wellbore casing 104, the expandable tubular
members, 24 and 30, are radially expanded and plastically deformed
by only applying an upward axial force to the tubular support
member 12 and tubular expansion cone 14. In this manner, radial
expansion and plastic deformation of the expandable tubular
members, 24 and 30, may be provided without the further continued
injection of the fluidic material 106.
[0047] In an exemplary embodiment, the pre-expanded ends, 16a, 16d,
24a, 24d, 30a, and 30d, of the expandable tubular members, 16, 24,
and 30, respectively, and the tubular members, 20, 22, 26, and 28,
have outside diameters and wall thicknesses of 8.375 inches and
0.350 inches, respectively; prior to the radial expansion, the
intermediate non pre-expanded portions, 16c, 24c, and 30c, of the
expandable tubular members, 16, 24, and 30, respectively, have
outside diameters of 7.625 inches; the tubular members, 20, 22, 26,
and 28, have inside diameters of 7.675 inches; after the radial
expansion, the inside diameters of the intermediate portions, 16c,
24c, and 30c, of the expandable tubular members, 16, 24, and 30,
are equal to 7.675 inches; and the wellbore casing 104 has an
inside diameter of 8.755 inches.
[0048] In an exemplary embodiment, the pre-expanded ends, 16a, 16d,
24a, 24d, 30a, and 30d, of the expandable tubular members, 16, 24,
and 30, respectively, and the tubular members, 20, 22, 26, and 28,
have outside diameters and wall thicknesses of 4.500 inches and
0.250 inches, respectively; prior to the radial expansion, the
intermediate non pre-expanded portions, 16c, 24c, and 30c, of the
expandable tubular members, 16, 24, and 30, respectively, have
outside diameters of 4.000 inches; the tubular members, 20, 22, 26,
and 28, have inside diameters of 4.000 inches; after the radial
expansion, the inside diameters of the intermediate portions, 16c,
24c, and 30c, of the expandable tubular members, 16, 24, and 30,
are equal to 4.000 inches; and the wellbore casing 104 has an
inside diameter of 4.892 inches.
[0049] In an exemplary embodiment, the system 10 is used to form or
repair a wellbore casing, a pipeline, or a structural support.
[0050] Referring now to FIG. 2, an exemplary embodiment of an
expandable tubular member 200 will now be described. The tubular
member 200 defines an interior region 200a and includes a first end
200b including a first threaded connection 200ba, a first tapered
portion 200c, an intermediate portion 200d, a second tapered
portion 200e, and a second end 200f including a second threaded
connection 200fa. The tubular member 200 further preferably
includes an intermediate sealing member 200g that is coupled to the
exterior surface of the intermediate portion 200d.
[0051] In an exemplary embodiment, the tubular member 200 has a
substantially annular cross section. The tubular member 200 may be
fabricated from any number of conventional commercially available
materials such as, for example, Oilfield Country Tubular Goods
(OCTG), 13 chromium steel tubing/casing, or L83, J55, or P110 API
casing.
[0052] In an exemplary embodiment, the interior 200a of the tubular
member 200 has a substantially circular cross section. Furthermore,
in an exemplary embodiment, the interior region 200a of the tubular
member includes a first inside diameter D.sub.1, an intermediate
inside diameter D.sub.INT, and a second inside diameter D.sub.2. In
an exemplary embodiment, the first and second inside diameters,
D.sub.1 and D.sub.2, are substantially equal. In an exemplary
embodiment, the first and second inside diameters, D.sub.1 and
D.sub.2, are greater than the intermediate inside diameter
D.sub.INT.
[0053] The first end 200b of the tubular member 200 is coupled to
the intermediate portion 200d by the first tapered portion 200c,
and the second end 200f of the tubular member is coupled to the
intermediate portion by the second tapered portion 200e. In an
exemplary embodiment, the outside diameters of the first and second
ends, 200b and 200f, of the tubular member 200 is greater than the
outside diameter of the intermediate portion 200d of the tubular
member. The first and second ends, 200b and 200f, of the tubular
member 200 include wall thicknesses, t.sub.1 and t.sub.2,
respectively. In an exemplary embodiment, the outside diameter of
the intermediate portion 200d of the tubular member 200 ranges from
about 75% to 98% of the outside diameters of the first and second
ends, 200a and 200f. The intermediate portion 200d of the tubular
member 200 includes a wall thickness t.sub.INT.
[0054] In an exemplary embodiment, the wall thicknesses t.sub.1 and
t.sub.2 are substantially equal in order to provide substantially
equal burst strength for the first and second ends, 200a and 200f,
of the tubular member 200. In an exemplary embodiment, the wall
thicknesses, t.sub.1 and t.sub.2, are both greater than the wall
thickness t.sub.INT in order to optimally match the burst strength
of the first and second ends, 200a and 200f, of the tubular member
200 with the intermediate portion 200d of the tubular member
200.
[0055] In an exemplary embodiment, the first and second tapered
portions, 200c and 200e, are inclined at an angle, .alpha.,
relative to the longitudinal direction ranging from about 0 to 30
degrees in order to optimally facilitate the radial expansion of
the tubular member 200. In an exemplary embodiment, the first and
second tapered portions, 200c and 200e, provide a smooth transition
between the first and second ends, 200a and 200f, and the
intermediate portion 200d, of the tubular member 200 in order to
minimize stress concentrations.
[0056] The intermediate sealing member 200g is coupled to the outer
surface of the intermediate portion 200d of the tubular member 200.
In an exemplary embodiment, the intermediate sealing member 200g
seals the interface between the intermediate portion 200d of the
tubular member 200 and the interior surface of a wellbore casing
205 after the radial expansion and plastic deformation of the
intermediate portion 200d of the tubular member 200. In an
exemplary embodiment, the intermediate sealing member 200g has a
substantially annular cross section. In an exemplary embodiment,
the outside diameter of the intermediate sealing member 200g is
selected to be less than the outside diameters of the first and
second ends, 200a and 200f, of the tubular member 200 in order to
optimally protect the intermediate sealing member 200g during
placement of the tubular member 200 within the wellbore casings
205. The intermediate sealing member 200g may be fabricated from
any number of conventional commercially available materials such
as, for example, thermoset or thermoplastic polymers. In an
exemplary embodiment, the intermediate sealing member 200g is
fabricated from thermoset polymers in order to optimally seal the
radially expanded intermediate portion 200d of the tubular member
200 with the wellbore casing 205. In several alternative
embodiments, the sealing member 200g includes one or more rigid
anchors for engaging the wellbore casing 205 to thereby anchor the
radially expanded and plastically deformed intermediate portion
200d of the tubular member 200 to the wellbore casing.
[0057] Referring to FIGS. 3, and 4a to 4d, in an exemplary
embodiment, the tubular member 200 is formed by a process 300 that
includes the steps of: (1) upsetting both ends of a tubular member
in step 305; (2) expanding both upset ends of the tubular member in
step 310; (3) stress relieving both expanded upset ends of the
tubular member in step 315; (4) forming threaded connections in
both expanded upset ends of the tubular member in step 320; and (5)
putting a sealing material on the outside diameter of the
non-expanded intermediate portion of the tubular member in step
325.
[0058] As illustrated in FIG. 4a, in step 305, both ends, 400a and
400b, of a tubular member 400 are upset using conventional
upsetting methods. The upset ends, 400a and 400b, of the tubular
member 400 include the wall thicknesses t.sub.1 and t.sub.2. The
intermediate portion 400c of the tubular member 400 includes the
wall thickness t.sub.INT and the interior diameter D.sub.INT. In an
exemplary embodiment, the wall thicknesses t.sub.1 and t.sub.2 are
substantially equal in order to provide burst strength that is
substantially equal along the entire length of the tubular member
400. In an exemplary embodiment, the wall thicknesses t.sub.1 and
t.sub.2 are both greater than the wall thickness t.sub.INT in order
to provide burst strength that is substantially equal along the
entire length of the tubular member 400, and also to optimally
facilitate the formation of threaded connections in the first and
second ends, 400a and 400b.
[0059] As illustrated in FIG. 4b, in steps 310 and 315, both ends,
400a and 400b, of the tubular member 400 are radially expanded
using conventional radial expansion methods, and then both ends,
400a and 400b, of the tubular member are stress relieved. The
radially expanded ends, 400a and 400b, of the tubular member 400
include the interior diameters D.sub.1 and D.sub.2. In an exemplary
embodiment, the interior diameters D.sub.1 and D.sub.2 are
substantially equal in order to provide a burst strength that is
substantially equal. In an exemplary embodiment, the ratio of the
interior diameters D.sub.1 and D.sub.2 to the interior diameter
D.sub.INT ranges from about 100% to 120% in order to faciliate the
subsequent radial expansion of the tubular member 400.
[0060] In a preferred embodiment, the relationship between the wall
thicknesses t.sub.1, t.sub.2, and t.sub.INT of the tubular member
400; the inside diameters D.sub.1, D.sub.2 and D.sub.INT of the
tubular member 400; the inside diameter D.sub.wellbore of the
wellbore casing that the tubular member 400 will be inserted into;
and the outside diameter D.sub.cone of the expansion cone that will
be used to radially expand the tubular member 400 within the
wellbore casing is given by the following expression: Dwellbore - 2
* t 1 .gtoreq. D 1 .gtoreq. 1 t 1 .function. [ ( t 1 - t INT ) * D
cone + t INT * D INT ] ( 1 ) ##EQU1## where t.sub.1=t.sub.2; and
D.sub.1=D.sub.2.
[0061] By satisfying the relationship given in equation (1), the
expansion forces placed upon the tubular member 400 during the
subsequent radial expansion process are substantially equalized.
More generally, the relationship given in equation (1) may be used
to calculate the optimal geometry for the tubular member 400 for
subsequent radial expansion and plastic deformation of the tubular
member 400 for fabricating and/or repairing a wellbore casing, a
pipeline, or a structural support.
[0062] As illustrated in FIG. 4c, in step 320, conventional
threaded connections, 400d and 400e, are formed in both expanded
ends, 400a and 400b, of the tubular member 400. In an exemplary
embodiment, the threaded connections, 400d and 400e, are provided
using conventional processes for forming pin and box type threaded
connections available from Atlas-Bradford.
[0063] As illustrated in FIG. 4d, in step 325, a sealing member
400f is then applied onto the outside diameter of the non-expanded
intermediate portion 400c of the tubular member 400. The sealing
member 400f may be applied to the outside diameter of the
non-expanded intermediate portion 400c of the tubular member 400
using any number of conventional commercially available methods. In
a preferred embodiment, the sealing member 400f is applied to the
outside diameter of the intermediate portion 400c of the tubular
member 400 using commercially available chemical and temperature
resistant adhesive bonding.
[0064] In an exemplary embodiment, the expandable tubular members,
16, 24, and 30, of the system 10 are substantially identical to,
and/or incorporate one or more of the teachings of, the tubular
members 200 and 400.
[0065] Referring to FIG. 5, an exemplary embodiment of tubular
expansion cone 500 for radially expanding the tubular members 16,
24, 30, 200 and 400 will now be described. The expansion cone 500
defines a passage 500a and includes a front end 505, a rear end
510, and a radial expansion section 515.
[0066] In an exemplary embodiment, the radial expansion section 515
includes a first conical outer surface 520 and a second conical
outer surface 525. The first conical outer surface 520 includes an
angle of attack .alpha..sub.1 and the second conical outer surface
525 includes an angle of attack .alpha..sub.2. In an exemplary
embodiment, the angle of attack .alpha..sub.1 is greater than the
angle of attack .alpha..sub.2. In this manner, the first conical
outer surface 520 radially overexpands the intermediate portions,
16c, 24c, 30c, 200d, and 400c, of the tubular members, 16, 24, 30,
200, and 400, and the second conical outer surface 525 radially
overexpands the pre-expanded first and second ends, 16a and 16d,
24a and 24d, 30a and 30d, 200b and 200f, and 400a and 400b, of the
tubular members, 16, 24, 30, 200 and 400. In an exemplary
embodiment, the first conical outer surface 520 includes an angle
of attack .alpha..sub.1 ranging from about 8 to 20 degrees, and the
second conical outer surface 525 includes an angle of attack
.alpha..sub.2 ranging from about 4 to 15 degrees in order to
optimally radially expand and plastically deform the tubular
members, 16, 24, 30, 200 and 400. More generally, the expansion
cone 500 may include 3 or more adjacent conical outer surfaces
having angles of attack that decrease from the front end 505 of the
expansion cone 500 to the rear end 510 of the expansion cone
500.
[0067] Referring to FIG. 6, another exemplary embodiment of a
tubular expansion cone 600 defines a passage 600a and includes a
front end 605, a rear end 610, and a radial expansion section 615.
In an exemplary embodiment, the radial expansion section 615
includes an outer surface having a substantially parabolic outer
profile thereby providing a paraboloid shape. In this manner, the
outer surface of the radial expansion section 615 provides an angle
of attack that constantly decreases from a maximum at the front end
605 of the expansion cone 600 to a minimum at the rear end 610 of
the expansion cone. The parabolic outer profile of the outer
surface of the radial expansion section 615 may be formed using a
plurality of adjacent discrete conical sections and/or using a
continuous curved surface. In this manner, the region of the outer
surface of the radial expansion section 615 adjacent to the front
end 605 of the expansion cone 600 may optimally radially overexpand
the intermediate portions, 16c, 24c, 30c, 200d, and 400c, of the
tubular members, 16, 24, 30, 200, and 400, while the region of the
outer surface of the radial expansion section 615 adjacent to the
rear end 610 of the expansion cone 600 may optimally radially
overexpand the pre-expanded first and second ends, 16a and 16d, 24a
and 24d, 30a and 30d, 200b and 200f, and 400a and 400b, of the
tubular members, 16, 24, 30, 200 and 400. In an exemplary
embodiment, the parabolic profile of the outer surface of the
radial expansion section 615 is selected to provide an angle of
attack that ranges from about 8 to 20 degrees in the vicinity of
the front end 605 of the expansion cone 6800 and an angle of attack
in the vicinity of the rear end 610 of the expansion cone 600 from
about 4 to 15 degrees.
[0068] Referring to FIG. 7a, the reference numeral 710 refers, in
general, to a system for lining a wellbore casing that includes a
tubular support member 712 that defines a passage 712a. A tubular
expansion cone 714 that defines a passage 714a is coupled to an end
of the tubular support member 712. In an exemplary embodiment, the
tubular expansion cone 714 includes a tapered outer surface 714b
for reasons to be described. A pre-expanded end 716a of a first
expandable tubular member 716 that defines a passage 716b is
adapted to mate with and be supported by the tapered outer surface
714b of the tubular expansion cone 714. The first expandable
tubular member 716 further includes an unexpanded intermediate
portion 716c, another pre-expanded end 716d, and a sealing member
716e coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 716a and 716d, of the first
expandable tubular member 716 are greater than the inside and
outside diameters of the unexpanded intermediate portion 716c.
[0069] An end 718a of a shoe 718 that defines a passage 718b and a
valveable passage 718c is coupled to the pre-expanded end 716a of
the first expandable tubular member 716 by a conventional threaded
connection 718d. An end 720a of a tubular member 720 that defines a
passage 720b is coupled to the other pre-expanded end 716d of the
first expandable tubular member 716 by a conventional threaded
connection 720d. Another end 720c of the tubular member 720 is
coupled to an end 722a of a tubular member 722 that defines a
passage 722b by a conventional threaded connection 722d. A
pre-expanded end 724a of a second expandable tubular member 724
that defines a passage 724b is coupled to the other end 722c of the
tubular member 722 by a conventional threaded connection 724f. The
second expandable tubular member 724 further includes an unexpanded
intermediate portion 724c, another pre-expanded end 724d, and a
sealing member 724e coupled to the exterior surface of the
unexpanded intermediate portion. In an exemplary embodiment, the
inside and outside diameters of the pre-expanded ends, 724a and
724d, of the second expandable tubular member 724 are greater than
the inside and outside diameters of the unexpanded intermediate
portion 724c.
[0070] An end 726a of a tubular member 726 that defines a passage
726b is coupled to the other pre-expanded end 724d of the second
expandable tubular member 724 by a conventional threaded connection
726d. Another end 726c of the tubular member 726 is coupled to an
end 728a of a tubular member 728 that defines a passage 728b by a
conventional threaded connection 728d. A pre-expanded end 730a of a
third expandable tubular member 730 that defines a passage 730b is
coupled to the other end 728c of the tubular member 728 by a
conventional threaded connection 730f. The third expandable tubular
member 730 further includes an unexpanded intermediate portion
730c, another pre-expanded end 730d, and a sealing member 730e
coupled to the exterior surface of the unexpanded intermediate
portion. In an exemplary embodiment, the inside and outside
diameters of the pre-expanded ends, 730a and 730d, of the third
expandable tubular member 730 are greater than the inside and
outside diameters of the unexpanded intermediate portion 730c.
[0071] In an exemplary embodiment, the inside and outside diameters
of the pre-expanded ends, 716d, 724a, 724d, 730a and 730d, of the
expandable tubular members, 716, 724, and 730, and the tubular
members 720, 722, 726, and 728, are substantially equal. The
outside diameter of the pre-expanded end 716a of the first
expandable tubular member 716 is greater than the outside diameter
of the pre-expanded end 716d, and the inside diameter of the
pre-expanded end 716a of the first expandable tubular member 716 is
greater than the inside diameter of the pre-expanded end 716d. In
an exemplary embodiment, the outside diameter of the end 716a is
about 5% greater than the outside diameter of the end 716d, and the
inside diameter of the end 716a is about 5% greater than the inside
diameter of the end 716d. In several exemplary embodiments, the
sealing members, 716e, 724e, and 730e, of the expandable tubular
members, 716, 724, and 730, respectively, further include anchoring
elements for engaging the wellbore casing 704. In several exemplary
embodiments, the tubular members, 720, 722, 726, and 728, are
conventional tubular members coupled by conventional threaded end
connections 720d, 722d, 724f, 726d, 728d and 730f that are suitable
for use in an oil or gas well, an underground pipeline, or as a
structural support.
[0072] In an exemplary embodiment, as illustrated in FIG. 7a, the
system 710 is initially positioned in a borehole 700 formed in a
subterranean formation 702 that includes a pre-existing wellbore
casing 704. The borehole 700 may be positioned in any orientation
from vertical to horizontal. Furthermore, the wellbore casing 704
may be, for example, a wellbore casing for an oil or gas well, an
underground pipeline, or a structural support. In an exemplary
embodiment, the upper end of the tubular support member 712 may be
supported in a conventional manner using, for example, a slip
joint, or equivalent device in order to permit upward movement of
the tubular support member and tubular expansion cone 714 relative
to one or more of the expandable tubular members, 716, 724, and
730, and tubular members, 720, 722, 726, and 728.
[0073] In an exemplary embodiment, as illustrated in FIG. 7b, a
fluidic material 706 is then injected into the system 710, through
the passages, 712a and 714a, of the tubular support member 712 and
tubular expansion cone 714, respectively. The fluidic material 706
then passes into the passages, 718b and 718c, of the shoe 718 into
the borehole 700.
[0074] In an exemplary embodiment, as illustrated in FIG. 7c, a
ball 708, plug or other equivalent device is then introduced into
the injected fluidic material 706. The ball 708 will then pass
through the passages, 712a, 714a, and 718b, of the tubular support
member 712, the tubular expansion cone 714, and the shoe 718,
respectively, and will then be positioned within the valveable
passage 718c of the shoe. In this manner, the valveable passage
718c of the shoe 718 is closed thereby permitting the passage 718b
of the shoe below the tubular expansion cone 714 to be pressurized
by the continued injection of the fluidic material 706.
[0075] In an exemplary embodiment, as illustrated in FIG. 7d, the
continued injection of the fluidic material 706 through the
passages, 712a and 714a, of the tubular support member 712 and the
tubular expansion cone 714, respectively, pressurizes the passage
718b of the shoe 718 below the tubular expansion cone thereby
radially expanding and plastically deforming the expandable tubular
member 716 off of the tapered external surface 714b of the tubular
expansion cone 714. In particular, the intermediate non
pre-expanded portion 716c of the expandable tubular member 716 is
radially expanded and plastically deformed off of the tapered
external surface 714b of the tubular expansion cone 714. As a
result, the sealing member 716e engages the interior surface of the
wellbore casing 704. Consequently, the radially expanded
intermediate portion 716c of the expandable tubular member 716 is
thereby coupled to the wellbore casing 704. In an exemplary
embodiment, the radially expanded intermediate portion 716c of the
expandable tubular member 716 is also thereby anchored to the
wellbore casing 704.
[0076] The continued injection of the fluidic material 706 through
the passages, 712a and 714a, of the tubular support member 712 and
the tubular expansion cone 714, respectively, pressurizes the
passages 718b and 716b, of the shoe 718 and the expandable tubular
member 716, respectively, thereby radially expanding and
plastically deforming the tubular member 720 off of the tapered
external surface 714b of the tubular expansion cone 714, including
the conventional threaded connection 720d between the end 716d of
the expandable tubular member 716 and the end 720a of the tubular
member 720. The continued injection of the fluidic material 706
through the passages, 712a and 714a, of the tubular support member
712 and the tubular expansion cone 714, respectively, pressurizes
the passages 718b, 716b and 720b, of the shoe 718, the expandable
tubular member 716 and the tubular member 720, respectively,
thereby radially expanding and plastically deforming the tubular
member 722 off of the tapered external surface 714b of the tubular
expansion cone 714, including the conventional threaded connection
722d between the end 720c of the tubular member 720 and the end
722a of the tubular member 722. The continued injection of the
fluidic material 706 through the passages, 712a and 714a, of the
tubular support member 712 and the tubular expansion cone 714,
respectively, will then displace the tubular expansion cone 714
upwardly to radially expand and plastically deform the pre-expanded
end 724a of the second expandable tubular member 724.
[0077] In an exemplary embodiment, as illustrated in FIG. 7e, the
continued injection of the fluidic material 706 through the
passages, 712a and 714a, of the tubular support member 712 and
tubular expansion cone 714, respectively, will then pressurize the
passages 718b, 716b, 720b and 722b below the tubular expansion cone
thereby radially expanding and plastically deforming the second
expandable tubular member 724 off of the tapered external surface
714b of the tubular expansion cone 714. In particular, the
intermediate non pre-expanded portion 724c of the second expandable
tubular member 724 is radially expanded and plastically deformed
off of the tapered external surface 714b of the tubular expansion
cone 714. As a result, the sealing member 724e engages the interior
surface of the wellbore casing 704. Consequently, the radially
expanded intermediate portion 724c of the second expandable tubular
member 724 is thereby coupled to the wellbore casing 704. In an
exemplary embodiment, the radially expanded intermediate portion
724c of the second expandable tubular member 724 is also thereby
anchored to the wellbore casing 704.
[0078] The continued injection of the fluidic material 706 through
the passages, 712a and 714a, of the tubular support member 712 and
the tubular expansion cone 714, respectively, pressurizes the
passages 718b, 716b, 720b, 722b and 724b of the shoe 718, the
expandable tubular member 716, the tubular member 720, the tubular
member 722 and the expandable tubular member 724, respectively,
thereby radially expanding and plastically deforming the tubular
member 726 off of the tapered external surface 714b of the tubular
expansion cone 714, including the conventional threaded connection
726d between the end 724d of the expandable tubular member 724 and
the end 726a of the tubular member 726. The continued injection of
the fluidic material 706 through the passages, 712a and 714a, of
the tubular support member 712 and the tubular expansion cone 714,
respectively, pressurizes the passages 718b, 716b, 720b, 722b, 724b
and 726b of the shoe 718, the expandable tubular member 716, the
tubular member 720, the tubular member 722, the expandable tubular
member 724 and the tubular member 726, respectively, thereby
radially expanding and plastically deforming the tubular member 728
off of the tapered external surface 714b of the tubular expansion
cone 714, including the conventional threaded connection 728d
between the end 726c of the tubular member 726 and the end 728a of
the tubular member 728. The continued injection of the fluidic
material 706 through the passages, 712a and 714a, of the tubular
support member 712 and the tubular expansion cone 714,
respectively, will then displace the tubular expansion cone 714
upwardly to radially expand and plastically deform the pre-expanded
end 730a of the third expandable tubular member 730.
[0079] The continued injection of the fluidic material 706 through
the passages, 712a and 714a, of the tubular support member 712 and
tubular expansion cone 714, respectively, will then pressurize the
passages 718b, 716b, 720b, 722b, 724b, 726b, and 728b below the
tubular expansion cone 714 thereby radially expanding and
plastically deforming the third expandable tubular member 730 off
of the tapered external surface 714b of the tubular expansion cone
714. In particular, the intermediate non pre-expanded portion 730c
of the third expandable tubular member 730 is radially expanded and
plastically deformed off of the tapered external surface 714b of
the tubular expansion cone 714. As a result, the sealing member
730e engages the interior surface of the wellbore casing 704.
Consequently, the radially expanded intermediate portion 730c of
the third expandable tubular member 730 is thereby coupled to the
wellbore casing 704. In an exemplary embodiment, the radially
expanded intermediate portion 730c of the third expandable tubular
member 730 is also thereby anchored to the wellbore casing 704.
[0080] In an exemplary embodiment, during the injection of the
fluidic material 706 through the passages, 712a and 714a, of the
tubular support member 712 and the tubular expansion cone 714,
respectively, the tubular support member 712 and tubular expansion
cone 714 are displaced upwardly relative to the expandable tubular
members, 716, 724, and 730, and the tubular members, 720, 722, 726,
and 728, by applying an upward axial force to the upper end of the
tubular support member.
[0081] After completing the radial expansion and plastic
deformation of the third expandable tubular member 730, the tubular
support member 712 and the tubular expansion cone 714 are removed
from the wellbore 700.
[0082] In an exemplary embodiment, as illustrated in FIG. 7f, the
lower central portion of the shoe 718 is then removed using a
conventional milling device.
[0083] In an exemplary embodiment, the pre-expanded end 716a of the
expandable tubular member 716 has an outside diameter of about
8.750 inches and a wall thickness of about 0.350 inches; the
pre-expanded ends 716d, 724a, 724d, 730a and 730d of the expandable
tubular members 716, 724 and 730, respectively, and the tubular
members 720, 722, 726 and 728 have outside diameters and wall
thicknesses of about 8.375 inches and about 0.350 inches,
respectively; prior to the radial expansion, the intermediate
pre-expanded portions 716c, 724c and 730c of the expandable tubular
members 716, 724 and 730, respectively, have outside diameters of
about 7.625 inches; prior to the radial expansion, the tubular
members 720, 722, 726 and 728 have inside diameters of about 7.675
inches; after the radial expansion, the inside diameters of the
intermediate portions 716c, 724c and 730c of the expandable tubular
members 716, 724 and 730 and the tubular members 720, 722, 726 and
728 are equal to about 8.050 inches; and the wellbore casing 704
has an inside diameter of about 8.755 inches.
[0084] In an exemplary embodiment, the pre-expanded end 716a of the
expandable tubular member 716 has an outside diameter of about
4.725 inches and a wall thickness of about 0.250 inches; the
pre-expanded ends 716d, 724a, 724d, 730a and 730d of the expandable
tubular members 716, 724 and 730, respectively, and the tubular
members 720, 722, 726 and 728 have outside diameters and wall
thicknesses of about 4.500 inches and about 0.250 inches,
respectively; prior to the radial expansion, the intermediate non
pre-expanded portions 716c, 724c and 730c of the expandable tubular
members 716, 724 and 730, respectively, have outside diameters of
about 4.000 inches; prior to the radial expansion, the tubular
members 720, 722, 726 and 728 have inside diameters of about 4.000
inches; after the radial expansion, the inside diameters of the
intermediate portions 716c, 724c and 730c of the expandable tubular
members 716, 724 and 730 and the tubular members 720, 722, 726 and
728 are equal to about 4.000 inches; and the wellbore casing 704
has an inside diameter of about 4.892 inches.
[0085] In an exemplary embodiment, one or more of the conventional
threaded connections 718d, 720d, 722d, 724f, 726d, 728d and 730f
may be or include, for example, a pin and box connection, including
those having standard American Petroleum Institute (API) pin and
box threads.
[0086] In an exemplary embodiment, the system 710 is used to form
or repair a wellbore casing, a pipeline, or a structural
support.
[0087] In an exemplary embodiment, the tubular expansion cone 714
of the system 710 is substantially identical to the expansion cones
14, 500 or 600, and/or incorporates one or more of the teachings of
the expansion cones 14, 500 and/or 600. However, the outer diameter
of the expansion cone 714 may be about 5% greater than the outside
diameter of the expansion cone 14.
[0088] In several alternative embodiments, a conventional rotary
expansion system such as, for example, those commercially available
from Weatherford International may be substituted for, or used in
combination with the expansion cones 14, 500, 600 and/or 714
above.
[0089] In several alternative embodiments, conventional expansion
systems may be substituted for, or used in combination with the
expansion cones 14, 500, 60 and/or 714 above.
[0090] Experimental testing has shown that the expansion performed
with the system 10 and the system 710 can provide a fluid tight
seal between the conventional threaded connections between the
expandable tubular members and the conventional tubular members for
radial expansion of up to about 5%. This was an unexpected result.
Accordingly, radial expansion and plastic deformation can be
achieved utilizing conventional tubular members and conventional
threaded connections between the conventional tubular members and
the expandable tubular members, while significantly reducing costs
and complexity.
[0091] A system for lining a wellbore casing has been described
that includes a tubular support member defining a first passage, a
tubular expansion cone defining a second passage fluidicly coupled
to the first passage coupled to an end of the tubular support
member and comprising a tapered end, a tubular liner coupled to and
supported by the tapered end of the tubular expansion cone, and a
shoe defining a valveable passage coupled to an end of the tubular
liner, wherein the tubular liner includes one or more expandable
tubular members that each include a tubular body comprising an
intermediate portion and first and second expanded end portions
coupled to opposing ends of the intermediate portion, and a sealing
member coupled to the exterior surface of the intermediate portion,
and one or more other tubular members coupled to the expandable
tubular members, wherein the inside diameters of the other tubular
members are greater than or equal to the outside diameter of the
tubular expansion cone. In an exemplary embodiment, the wall
thicknesses of the first and second expanded end portions are
greater than the wall thickness of the intermediate portion. In an
exemplary embodiment, each expandable tubular member further
includes a first tubular transitionary member coupled between the
first expanded end portion and the intermediate portion, and a
second tubular transitionary member coupled between the second
expanded end portion and the intermediate portion, wherein the
angles of inclination of the first and second tubular transitionary
members relative to the intermediate portion ranges from about 0 to
30 degrees. In an exemplary embodiment, the outside diameter of the
intermediate portion ranges from about 75 percent to about 98
percent of the outside diameters of the first and second expanded
end portions. In an exemplary embodiment, the burst strength of the
first and second expanded end portions is substantially equal to
the burst strength of the intermediate tubular section. In an
exemplary embodiment, the ratio of the inside diameters of the
first and second expanded end portions to the interior diameter of
the intermediate portion ranges from about 100 to 120 percent. In
an exemplary embodiment, the relationship between the wall
thicknesses t.sub.1, t.sub.2, and t.sub.INT of the first expanded
end portion, the second expanded end portion, and the intermediate
portion, respectively, of the expandable tubular members, the
inside diameters D.sub.1, D.sub.2 and D.sub.INT of the first
expanded end portion, the second expanded end portion, and the
intermediate portion, respectively, of the expandable tubular
members, and the inside diameter D.sub.wellbore of the wellbore
casing that the expandable tubular member will be inserted into,
and the outside diameter D.sub.cone of the expansion cone that will
be used to radially expand the expandable tubular member within the
wellbore casing is given by the following expression: Dwellbore - 2
* t 1 .gtoreq. D 1 .gtoreq. 1 t 1 .function. [ ( t 1 - t INT ) * D
cone + t INT * D INT ] ; ##EQU2## wherein t.sub.1=t.sub.2; and
wherein D.sub.1=D.sub.2. In an exemplary embodiment, the tapered
end of the tubular expansion cone includes a plurality of adjacent
discrete tapered sections. In an exemplary embodiment, the angle of
attack of the adjacent discrete tapered sections increases in a
continuous manner from one end of the tubular expansion cone to the
opposite end of the tubular expansion cone. In an exemplary
embodiment, the tapered end of the tubular expansion cone includes
an paraboloid body. In an exemplary embodiment, the angle of attack
of the outer surface of the paraboloid body increases in a
continuous manner from one end of the paraboloid body to the
opposite end of the paraboloid body. In an exemplary embodiment,
the tubular liner includes a plurality of expandable tubular
members, and the other tubular members are interleaved among the
expandable tubular members.
[0092] A method of lining a wellbore casing has also been described
that includes positioning a tubular liner within the wellbore
casing, and radially expanding one or more discrete portions of the
tubular liner into engagement with the wellbore casing. In an
exemplary embodiment, a plurality of discrete portions of the
tubular liner are radially expanded into engagement with the
wellbore casing. In an exemplary embodiment, the remaining portions
of the tubular liner are not radially expanded. In an exemplary
embodiment, the discrete portions of the tubular liner are radially
expanded by injecting a fluidic material into the tubular liner. In
an exemplary embodiment, the tubular liner includes a plurality of
tubular members; and wherein one or more of the tubular members are
radially expanded into engagement with the wellbore casing and one
or more of the tubular members are not radially expanded into
engagement with the wellbore casing. In an exemplary embodiment,
the tubular members that are radially expanded into engagement with
the wellbore casing include a portion that is radially expanded
into engagement with the wellbore casing and a portion that is not
radially expanded into engagement with the wellbore casing. In an
exemplary embodiment, the tubular liner includes one or more
expandable tubular members that each include a tubular body
comprising an intermediate portion and first and second expanded
end portions coupled to opposing ends of the intermediate portion,
and a sealing member coupled to the exterior surface of the
intermediate portion, and one or more other tubular members coupled
to the expandable tubular members, wherein the inside diameters of
the other tubular members are greater than or equal to the maximum
inside diameters of the expandable tubular members. In an exemplary
embodiment, the tubular liner includes a plurality of expandable
tubular members, and the other tubular members are interleaved
among the expandable tubular members.
[0093] A system for lining a wellbore casing has also been
described that includes means for positioning a tubular liner
within the wellbore casing, and means for radially expanding one or
more discrete portions of the tubular liner into engagement with
the wellbore casing. In an exemplary embodiment, a plurality of
discrete portions of the tubular liner are radially expanded into
engagement with the wellbore casing. In an exemplary embodiment,
the remaining portions of the tubular liner are not radially
expanded. In an exemplary embodiment, the discrete portions of the
tubular liner are radially expanded by injecting a fluidic material
into the tubular liner. In an exemplary embodiment, the tubular
liner includes a plurality of tubular members; and wherein one or
more of the tubular members are radially expanded into engagement
with the wellbore casing and one or more of the tubular members are
not radially expanded into engagement with the wellbore casing. In
an exemplary embodiment, the tubular members that are radially
expanded into engagement with the well bore casing comprise a
portion that is radially expanded into engagement with the wellbore
casing and a portion that is not radially expanded into engagement
with the wellbore casing.
[0094] An apparatus has also been described that includes a
subterranean formation defining a borehole, a casing positioned in
and coupled to the borehole, and a tubular liner positioned in and
coupled to the casing at one or more discrete locations. In an
exemplary embodiment, the tubular liner is coupled to the casing at
a plurality of discrete locations. In an exemplary embodiment, the
tubular liner is coupled to the casing by a process that includes
positioning the tubular liner within the casing, and radially
expanding one or more discrete portions of the tubular liner into
engagement with the casing. In an exemplary embodiment, a plurality
of discrete portions of the tubular liner are radially expanded
into engagement with the casing. In an exemplary embodiment, the
remaining portions of the tubular liner are not radially expanded.
In an exemplary embodiment, the discrete portions of the tubular
liner are radially expanded by injecting a fluidic material into
the tubular liner. In an exemplary embodiment, the tubular liner
includes a plurality of tubular members; and wherein one or more of
the tubular members are radially expanded into engagement with the
casing and one or more of the tubular members are not radially
expanded into engagement with the casing. In an exemplary
embodiment, the tubular members that are radially expanded into
engagement with the casing comprise a portion that is radially
expanded into engagement with the casing and a portion that is not
radially expanded into engagement with the casing. In an exemplary
embodiment, the tubular liner includes one or more expandable
tubular members that each include a tubular body comprising an
intermediate portion and first and second expanded end portions
coupled to opposing ends of the intermediate portion, and a sealing
member coupled to the exterior surface of the intermediate portion,
and one or more other tubular members coupled to the expandable
tubular members, wherein the inside diameters of the other tubular
members are greater than or equal to the maximum inside diameters
of the expandable tubular members. In an exemplary embodiment, the
tubular liner includes a plurality of expandable tubular members,
and the other tubular members are interleaved among the expandable
tubular members.
[0095] A system for lining a wellbore casing has been described
that includes a tubular support member defining a first passage; a
tubular expansion cone defining a second passage fluidicly coupled
to the first passage coupled to an end of the tubular support
member and comprising a tapered end; a tubular liner coupled to and
supported by the tapered end of the tubular expansion cone; and a
shoe defining a valveable passage coupled to an end of the tubular
liner; wherein the tubular liner comprises an expandable tubular
member that comprises: first and second tubular portions; an
intermediate tubular portion coupled between the first and second
tubular portions; and a sealing member coupled to the exterior
surface of the intermediate tubular portion; wherein the inside
diameters of the first and second tubular portions are greater than
the inside diameter of the intermediate tubular portion; and
wherein the inside diameter of the first tubular portion is greater
than the inside diameter of the second tubular portion. In an
exemplary embodiment, the inside diameter of the first tubular
portion is about 5% greater than the inside diameter of the second
tubular portion. In an exemplary embodiment, the wall thicknesses
of the first and second tubular portions are greater than the wall
thickness of the intermediate tubular portion. In an exemplary
embodiment, the expandable tubular member further comprises: a
first tubular tapered transitionary portion coupled between the
first tubular portion and the intermediate tubular portion; and a
second tubular tapered transitionary portion coupled between the
second tubular portion and the intermediate tubular portion;
wherein the angles of inclination of the first and second tapered
tubular transitionary portions relative to the intermediate tubular
portion ranges from greater than 0 to about 30 degrees. In an
exemplary embodiment, the outside diameter of the intermediate
tubular portion ranges from about 75 percent to about 98 percent of
the outside diameters of the second tubular portion. In an
exemplary embodiment, the burst strength of the first and second
tubular portions is substantially equal to the burst strength of
the intermediate tubular portion. In an exemplary embodiment, the
ratio of the inside diameter of the second tubular portion to the
interior diameter of the intermediate tubular portion ranges from
greater than 100 to about 120 percent. In an exemplary embodiment,
the tapered end of the tubular expansion cone comprises a plurality
of adjacent discrete tapered sections. In an exemplary embodiment,
the angle of attack of the adjacent discrete tapered sections
increases in a continuous manner from one end of the tubular
expansion cone to the opposite end of the tubular expansion cone.
In an exemplary embodiment, the tapered end of the tubular
expansion cone comprises a paraboloid body. In an exemplary
embodiment, the angle of attack of the outer surface of the
paraboloid body increases in a continuous manner from one end of
the paraboloid body to the opposite end of the paraboloid body. In
an exemplary embodiment, the tubular liner comprises a plurality of
expandable tubular members and a plurality of other tubular
members, and the other tubular members are interleaved among the
expandable tubular members.
[0096] A method of lining a wellbore casing has also been described
that includes positioning a tubular liner within the wellbore
casing; and radially expanding one or more discrete portions of the
tubular liner into engagement with the wellbore casing; wherein the
tubular liner comprises an expandable tubular member that
comprises: first and second tubular portions; an intermediate
tubular portion coupled between the first and second tubular
portions; and a sealing member coupled to the exterior surface of
the intermediate tubular portion; wherein the inside diameters of
the first and second tubular portions are greater than the inside
diameter of the intermediate tubular portion; and wherein the
inside diameter of the first tubular portion is greater than an
inside diameter of the second tubular portion. In an exemplary
embodiment, the inside diameter of the first tubular portion is
about 5% greater than an inside diameter of the second tubular
portion. In an exemplary embodiment, a plurality of discrete
portions of the tubular liner are radially expanded into engagement
with the wellbore casing. In an exemplary embodiment, the remaining
portions of the tubular liner are not radially expanded. In an
exemplary embodiment, the discrete portions of the tubular liner
are radially expanded by injecting a fluidic material into the
tubular liner. In an exemplary embodiment, the tubular liner
comprises a plurality of expandable tubular members, wherein one or
more of the expandable tubular members are radially expanded into
engagement with the wellbore casing, and wherein a plurality of the
expandable tubular members are not radially expanded into
engagement with the well bore casing.
[0097] A system for lining a wellbore casing has also been
described that comprises means for positioning a tubular liner
within the wellbore casing; and means for radially expanding one or
more discrete portions of the tubular liner into engagement with
the wellbore casing; wherein the tubular liner comprises an
expandable tubular member that comprises: first and second tubular
portions; an intermediate tubular portion coupled between the first
and second tubular portions; and a sealing member coupled to the
exterior surface of the intermediate tubular portion; wherein the
inside diameters of the first and second tubular portions are
greater than the inside diameter of the intermediate tubular
portion; and wherein the inside diameter of the first tubular
portion is greater than the inside diameter of the second tubular
portion. In an exemplary embodiment, the inside diameter of the
first tubular portion is about 5% greater than the inside diameter
of the second tubular portion. In an exemplary embodiment, a
plurality of discrete portions of the tubular liner are radially
expanded into engagement with the wellbore casing. In an exemplary
embodiment, remaining portions of the tubular liner are not
radially expanded. In an exemplary embodiment, the discrete
portions of the tubular liner are radially expanded by injecting a
fluidic material into the tubular liner. In an exemplary
embodiment, the tubular liner comprises a plurality of tubular
members, wherein one or more of the tubular members are radially
expanded into engagement with the wellbore casing, and wherein a
plurality of the tubular members are not radially expanded into
engagement with the well bore casing.
[0098] An apparatus has also been described that comprises a
subterranean formation defining a borehole; a casing positioned in
and coupled to the borehole; and a tubular liner positioned in and
coupled to the casing at one or more discrete locations; wherein
the tubular liner comprises a radially expanded and plastically
deformed tubular member that comprises: first and second tubular
portions; an intermediate tubular portion coupled between the first
and second tubular portions; and a sealing member coupled to the
exterior surface of the intermediate tubular portion that engages
the interior surface of the casing; wherein the intermediate
tubular portion is radially expanded and plastically deformed;
wherein the first and second tubular portions are not radially
expanded and plastically deformed; and wherein the first tubular
portion is greater in diameter than the second tubular portion. In
an exemplary embodiment, the inside diameter of the first tubular
portion is about 5% greater than an inside diameter of the second
tubular portion. In an exemplary embodiment, the tubular liner
comprises a plurality of radially expanded and plastically deformed
tubular members.
[0099] A system for lining a wellbore casing has also been
described that comprises a support member; an expansion device
coupled to an end of the support member; and a tubular liner
coupled to the expansion device that comprises: a first expandable
tubular member that comprises: first and second tubular portions; a
first intermediate tubular portion coupled between the first and
second tubular portions; and a first sealing member coupled to the
exterior surface of the first intermediate tubular portion; wherein
the inside diameters of the first and second tubular portions are
greater than the inside diameter of the intermediate tubular
portion; and wherein the inside diameter of the first tubular
portion is greater than an inside diameter of the second tubular
portion; and one or more second expandable tubular members that
each comprise: third and fourth tubular portions; a second
intermediate tubular portion coupled between the third and fourth
tubular portions; and a second sealing member coupled to the
exterior surface of the second intermediate tubular portion;
wherein the inside diameters of the first, second, third and fourth
tubular portions are greater than the inside diameters of the first
and second intermediate tubular portions. In an exemplary
embodiment, the inside diameter of the first tubular portion is
about 5% greater than an inside diameter of the second tubular
portion. In an exemplary embodiment, the wall thicknesses of the
first, second, third and fourth tubular portions are greater than
the wall thicknesses of the first and second intermediate tubular
portions. In an exemplary embodiment, the first expandable tubular
member further comprises: a first tubular tapered transitionary
portion coupled between the first tubular portion and the first
intermediate tubular portion; and a second tubular tapered
transitionary portion coupled between the second tubular portion
and the first intermediate tubular portion; wherein the angles of
inclination of the first and second tapered tubular transitionary
portions relative to the first intermediate tubular portion ranges
from greater than 0 to about 30 degrees. In an exemplary
embodiment, each of the second expandable tubular members further
comprise: a third tubular tapered transitionary portion coupled
between the third tubular portion and the second intermediate
tubular portion; and a fourth tubular tapered transitionary portion
coupled between the fourth tubular portion and the second
intermediate tubular portion; wherein the angles of inclination of
the third and fourth tapered tubular transitionary portions
relative to the second intermediate tubular portion ranges from
greater than 0 to about 30 degrees. In an exemplary embodiment, the
outside diameters of the first and second intermediate tubular
portions each range from about 75 percent to about 98 percent of
the outside diameters of the second, third and fourth tubular
portions. In an exemplary embodiment, the burst strength of the
first, second, third and fourth tubular portions is substantially
equal to the burst strength of the first and second intermediate
tubular portions. In an exemplary embodiment, the ratio of the
inside diameters of the second, third and fourth tubular portions
to the interior diameters of the first and second intermediate
tubular portions ranges from greater than 100 to about 120 percent.
In an exemplary embodiment, the expansion device comprises a
plurality of adjacent discrete tapered sections. In an exemplary
embodiment, the angle of attack of the adjacent discrete tapered
sections increases in a continuous manner from one end of the
expansion device to the opposite end of the expansion device. In an
exemplary embodiment, the expansion device comprises an paraboloid
body. In an exemplary embodiment, the angle of attack of the outer
surface of the paraboloid body increases in a continuous manner
from one end of the paraboloid body to the opposite end of the
paraboloid body.
[0100] A liner for lining a wellbore casing has also been described
that comprises a first tubular portion; a second tubular portion;
an intermediate tubular portion coupled between the first and
second tubular portions; and a sealing member coupled to the
exterior surface of the intermediate tubular portion; wherein the
inside diameters of the first and second tubular portions are
greater than the inside diameter of the intermediate tubular
portion; and wherein the inside diameter of the first tubular
portion is greater than the inside diameter of the second tubular
portion. In an exemplary embodiment, the inside diameter of the
first tubular portion is about 5% greater than the inside diameter
of the second tubular portion. In an exemplary embodiment, the wall
thicknesses of the first and second tubular portions are greater
than the wall thickness of the intermediate tubular portion. In an
exemplary embodiment, the liner further comprises a first tubular
tapered transitionary portion coupled between the first tubular
portion and the intermediate tubular portion; and a second tubular
tapered transitionary portion coupled between the second tubular
portion and the intermediate tubular portion; wherein the angles of
inclination of the first and second tapered tubular transitionary
portions relative to the intermediate tubular portion ranges from
greater than 0 to about 30 degrees. In an exemplary embodiment, the
outside diameter of the intermediate tubular portion ranges from
about 75 percent to about 98 percent of the outside diameter of the
second tubular portion. In an exemplary embodiment, the ratio of
the inside diameter of the second tubular portion to the interior
diameter of the intermediate tubular portion ranges from greater
than 100 to about 120 percent.
[0101] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the system 10 and/or the system 710 may be used to form or
repair a wellbore casing, an underground pipeline, a structural
support, or a tubing. Furthermore, the system 10 and/or the system
710 may include one or more expandable tubular members and one or
more other tubular members. In addition, the system 10 and/or the
system 710 may include a plurality of expandable tubular members,
and the other tubular members may be interleaved among the
expandable tubular members.
[0102] 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.
* * * * *