U.S. patent application number 10/571086 was filed with the patent office on 2007-09-06 for expandable tubular.
This patent application is currently assigned to Eventure Global Technology, LLC. Invention is credited to Scott Costa, Malcolm Gray, Grigoriy Grinberg, Alla Petlyuk, Matt Shade, Mark Shuster.
Application Number | 20070205001 10/571086 |
Document ID | / |
Family ID | 34279824 |
Filed Date | 2007-09-06 |
United States Patent
Application |
20070205001 |
Kind Code |
A1 |
Shuster; Mark ; et
al. |
September 6, 2007 |
Expandable Tubular
Abstract
A system for reducing the coefficient of friction between an
expansion device and the tubular member during radial
expansion.
Inventors: |
Shuster; Mark; (Houston,
TX) ; Gray; Malcolm; (Houston, TX) ; Grinberg;
Grigoriy; (Sylvania, OH) ; Costa; Scott;
(Katy, TX) ; Shade; Matt; (Plymouth, MI) ;
Petlyuk; Alla; (West Chester, PA) |
Correspondence
Address: |
HAYNES AND BOONE, LLP
901 MAIN STREET, SUITE 3100
DALLAS
TX
75202
US
|
Assignee: |
Eventure Global Technology,
LLC
Houston
US
77079
|
Family ID: |
34279824 |
Appl. No.: |
10/571086 |
Filed: |
September 7, 2004 |
PCT Filed: |
September 7, 2004 |
PCT NO: |
PCT/US04/28889 |
371 Date: |
November 7, 2006 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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60500435 |
Sep 5, 2003 |
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60585370 |
Jul 2, 2004 |
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60600679 |
Aug 11, 2004 |
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Current U.S.
Class: |
166/380 ;
166/207; 166/244.1; 184/6; 420/43; 420/91; 508/110; 73/87 |
Current CPC
Class: |
B21D 39/04 20130101;
E21B 43/105 20130101; E21B 43/00 20130101; E21B 43/103 20130101;
Y10T 29/4994 20150115; E21B 43/14 20130101; E21B 43/108 20130101;
E21B 43/106 20130101; E21B 43/305 20130101; B21D 39/20 20130101;
E21B 43/084 20130101; E21B 29/10 20130101 |
Class at
Publication: |
166/380 ;
166/207; 166/244.1; 184/006; 420/043; 420/091; 508/110;
073/087 |
International
Class: |
E21B 43/10 20060101
E21B043/10 |
Claims
1. A method of forming a tubular liner within a preexisting
structure, comprising: positioning a tubular assembly within the
preexisting structure; and radially expanding and plastically
deforming the tubular assembly within the preexisting structure;
wherein, prior to the radial expansion and plastic deformation of
the tubular assembly, a predetermined portion of the tubular
assembly has a lower yield point than another portion of the
tubular assembly.
2. An expandable tubular member comprising a steel alloy comprising
by weight percentage, the following: 0.065 to 18% C, 0.006 to 1.44%
Mn, 0.006 to 0.02% P, 0.001 to 0.004% S, 0.24 to 0.45% Si, up to
0.16% Cu, 0.01 to 9.1% Ni, and 0.02 to 18.7% Cr.
3. An expandable tubular member, wherein the yield point of the
expandable tubular member is at most about 46.9 to 61.7 ksi prior
to a radial expansion and plastic deformation; and wherein the
yield point of the expandable tubular member is at least about 65.9
to 74.4 ksi after the radial expansion and plastic deformation.
4. An expandable tubular member, wherein a yield point of the
expandable tubular member after a radial expansion and plastic
deformation is at least about 5.8 to 40% greater than the yield
point of the expandable tubular member prior to the radial
expansion and plastic deformation.
5. An expandable tubular member, wherein anisotropy of the
expandable tubular member, prior to the radial expansion and
plastic deformation, ranges from about 1.04 to at least about
1.92.
6. An expandable tubular member, wherein the expandability
coefficient of the expandable tubular member, prior to the radial
expansion and plastic deformation, is greater than 0.12.
7. An expandable tubular member, wherein the expandability
coefficient of the expandable tubular member is greater than the
expandability coefficient of another portion of the expandable
tubular member.
8. An expandable tubular member, wherein the tubular member has a
higher ductility and a lower yield point prior to a radial
expansion and plastic deformation than after the radial expansion
and plastic deformation.
9. A method of radially expanding and plastically deforming a
tubular assembly comprising a first tubular member coupled to a
second tubular member, comprising: radially expanding and
plastically deforming the tubular assembly within a preexisting
structure; and using less power to radially expand each unit length
of the first tubular member than to radially expand each unit
length of the second tubular member.
10. A method of manufacturing a tubular member, comprising:
processing a tubular member until the tubular member is
characterized by one or more intermediate characteristics;
positioning the tubular member within a preexisting structure; and
processing the tubular member within the preexisting structure
until the tubular member is characterized one or more final
characteristics.
11. An apparatus, comprising: an expandable tubular assembly; and
an expansion device coupled to the expandable tubular assembly;
wherein a predetermined portion of the expandable tubular assembly
has a lower yield point than another portion of the expandable
tubular assembly.
12. An expandable tubular member, wherein a yield point of the
expandable tubular member after a radial expansion and plastic
deformation is at least about 5.8% greater than the yield point of
the expandable tubular member prior to the radial expansion and
plastic deformation.
13. A method of determining the expandability of a selected tubular
member, comprising: determining an anisotropy value for the
selected tubular member; determining a strain hardening value for
the selected tubular member; and multiplying the anisotropy value
times the strain hardening value to generate an expandability value
for the selected tubular member.
14. A method of radially expanding and plastically deforming
tubular members, comprising: selecting a tubular member;
determining an anisotropy value for the selected tubular member;
determining a strain hardening value for the selected tubular
member; multiplying the anisotropy value times the strain hardening
value to generate an expandability value for the selected tubular
member; and if the anisotropy value is greater than 0.12, then
radially expanding and plastically deforming the selected tubular
member.
15. A radially expandable tubular member apparatus comprising: a
first tubular member; a second tubular member engaged with the
first tubular member forming a joint; and a sleeve overlapping and
coupling the first and second tubular members at the joint;
wherein, prior to a radial expansion and plastic deformation of the
apparatus, a predetermined portion of the apparatus has a lower
yield point than another portion of the apparatus.
16. A method of joining radially expandable tubular members
comprising: providing a first tubular member; engaging a second
tubular member with the first tubular member to form a joint;
providing a sleeve; mounting the sleeve for overlapping and
coupling the first and second tubular members at the joint; wherein
the first tubular member, the second tubular member, and the sleeve
define a tubular assembly; and radially expanding and plastically
deforming the tubular assembly; wherein, prior to the radial
expansion and plastic deformation, a predetermined portion of the
tubular assembly has a lower yield point than another portion of
the tubular assembly.
17. An expandable tubular member, wherein, if the carbon content of
the tubular member is less than or equal to 0.12 percent, then the
carbon equivalent value for the tubular member is less than 0.21;
and wherein, if the carbon content of the tubular member is greater
than 0.12 percent, then the carbon equivalent value for the tubular
member is less than 0.36.
18. A method of selecting tubular members for radial expansion and
plastic deformation, comprising: selecting a tubular member from a
collection of tubular member; determining a carbon content of the
selected tubular member; determining a carbon equivalent value for
the selected tubular member; if the carbon content of the selected
tubular member is less than or equal to 0.12 percent and the carbon
equivalent value for the selected tubular member is less than 0.21,
then determining that the selected tubular member is suitable for
radial expansion and plastic deformation; and if the carbon content
of the selected tubular member is greater than 0.12 percent and the
carbon equivalent value for the selected tubular member is less
than 0.36, then determining that the selected tubular member is
suitable for radial expansion and plastic deformation.
19. An expandable tubular member, comprising: a tubular body;
wherein a yield point of an inner tubular portion of the tubular
body is less than a yield point of an outer tubular portion of the
tubular body.
20. A method of manufacturing an expandable tubular member,
comprising: providing a tubular member; heat treating the tubular
member; and quenching the tubular member; wherein following the
quenching, the tubular member comprises a microstructure comprising
a hard phase structure and a soft phase structure.
21. A system for radially expanding and plastically deforming a
tubular member, comprising: an expansion device positioned in the
tubular member; and wherein the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08.
22. A method of radially expanding and plastically deforming a
tubular member, comprising: positioning an expansion device having
a first tapered end and a second end at least partially within the
tubular member; displacing the expansion device relative to the
tubular member to radially expand and plastically deform the
tubular member; and wherein the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08.
23. A lubricant for injecting in an interface between a tubular
member and an expansion device, comprising, by weight percentage:
64.25% to 90.89% canola oil; 0.02% to 0.05% tolyltriazole; 0.5% to
1.0% aminic antioxidant; 0.5% to 2.0% phenolic antioxidant; 4% to
12% sulfurized natural oil or sulferized lard oil; 4% to 12%
phosphate ester; 0.4% to 1.5% phosphoric acid; 0.08% to 1.5%
styrene hydrocarbon polymer; 0.1% to 0.5% alkyl ester copolymer;
0.01% to 0.2% silicon based antifoam agent; and 1% to 5% carbozylic
acid soap.
24. An expansion device for radially expanding and plastically
deforming the tubular member, comprising: one or more expansion
surfaces on the expansion device for engaging the interior surface
of the tubular member during the radial expansion and plastic
deformation of the tubular member; and a lubrication device
operably coupled to the expansion surface for injecting lubricant
into an interface between the expansion surface and the tubular
member during the radial expansion and plastic deformation of the
tubular member when a predetermined pressure for lubrication is
reached.
25. An expansion device for radially expanding and plastically
deforming a tubular member, comprising: a tapered portion with an
outer surface; internal flow passage in the tapered portion; and at
least one circumferential groove having a first edge and a second
edge with a predetermined sliding angle on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the sliding angle is less than or
equal to 30 degrees.
26. A method for radially expanding and plastically deforming the
tubular member, comprising: positioning an expansion device having
one or more expansion surfaces in the interior surface of the
tubular member; displacing the expansion device relative to the
tubular member to radially expand and plastically deform the
tubular member; and operating a lubrication device to inject
lubricant into an interface between the expansion surface and the
tubular member when a predetermined lubricant pressure is
reached.
27. A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than 0.08, comprising: altering at least one of the elements
selected from the group consisting of: expansion device geometry,
expansion device composition, expansion device surface roughness,
expansion device texture, expansion device coating, lubricant
composition, lubricant environmental issues, lubricant frictional
modifiers, tubular member roughness, and tubular member
coating.
1046. A lubrication system for lubricating an interface between a
first element and a second element, comprising: a vaporizer
proximate to the interface for vaporizing a lubricant to inject the
lubricant in the interface.
28. A lubrication system f a first element and a second element,
comprising: a vaporizer proximate to the interface for vaporizing a
lubricant to inject the lubricant in the interface.
29. A method for lubricating an interface between a first element
and a second element, comprising: vaporizing a lubricant proximate
to the interface to inject the lubricant in the interface.
30. A system for radially expanding and plastically deforming a
tubular member, comprising: an expansion device positioned in the
tubular member; and wherein the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08 and wherein lubricant is
stored in a reservoir with a magnetic coil in the expansion device
and is injected through at least a portion of the expansion device
between the tubular member and the expansion device when current
runs through the magnetic coil.
31. A system for radially expanding and plastically deforming a
tubular member, comprising: an expansion device positioned in the
tubular member; and wherein the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08 and wherein lubricant is
stored in a reservoir and injected through at least a portion of
the expansion device between the tubular member and the expansion
device when vaporized.
32. A method of radially expanding and plastically deforming a
tubular member, comprising: positioning an expansion device having
a first tapered end and a second end at least partially within the
tubular member; displacing the expansion device relative to the
tubular member to radially expand and plastically deform the
tubular member; and injecting a lubricant stored in a reservoir
with a magnetic coil in the expansion device through at least a
portion of the expansion device between the tubular member and the
expansion device when current runs through the magnetic coil, and
wherein the coefficient of friction between the expansion device
and the tubular member during radial expansion and plastic
deformation is less than 0.08.
33. A method of radially expanding and plastically deforming a
tubular member, comprising: positioning an expansion device having
a first tapered end and a second end at least partially within the
tubular member; displacing the expansion device relative to the
tubular member to radially expand and plastically deform the
tubular member; and vaporizing a lubricant stored in a reservoir in
the expansion device and injecting it through at least a portion of
the expansion device between the tubular member and the expansion
device, and wherein the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08.
34. A lubricant delivery assembly for radially expanding and
plastically deforming a tubular member, comprising: an expansion
device having a tapered portion with an outer surface, at least one
reservoir for housing a lubricant, at least one circumferential
groove on the outer surface fluidicly connected to the reservoir;
and a lubricant injection mechanism to force lubricant into the at
least one circumferential groove while radially expanding and
plastically deforming the tubular member when a predetermined
lubricant pressure is reached.
35. A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than 0.08, comprising: altering at least one of the elements
selected from the group consisting of: expansion device geometry,
expansion device composition, expansion device surface roughness,
expansion device texture, expansion device coating, lubricant
composition, lubricant environmental issues, lubricant frictional
modifiers, tubular member roughness, and tubular member
coating.
36. A system for radially expanding and plastically deforming a
tubular member having a non-uniform wall thickness, comprising: an
expansion device having one or more expansion surfaces and a
tapered portion having a tapered faceted polygonal outer expansion
surface in the interior surface of the tubular member.
37. A method of radially expanding and plastically deforming a
tubular member having a non-uniform wall thickness, comprising:
positioning an expansion device having one or more expansion
surfaces and a tapered portion having a tapered faceted polygonal
outer expansion surface in the interior surface of the tubular
member; and displacing the expansion device relative to the tubular
member to radially expand and plastically deform the tubular
member.
38. A method of increasing a collapse strength of a tubular member
after a radial expansion and plastic deformation of the tubular
member using an expansion device, comprising: reducing a
coefficient of friction between the tubular member and the
expansion device during the radial expansion and plastic
deformation of the tubular member; and reducing a ratio of a
diameter of the tubular member to a wall thickness.
39. A system for radially expanding and plastically deforming a
tubular member, comprising: a tubular member; and an expansion
device positioned within the tubular member; wherein the
coefficient of friction between the tubular member and the
expansion device is less than 0.075; and wherein the ratio of the
diameter of the tubular member to a wall thickness of the tubular
member is less than 21.6.
40. A method of radially expanding and plastically deforming a
tubular member using an expansion device, comprising: quenching and
tempering the tubular member; positioning the tubular member within
a preexisting structure; and radially expanding and plastically
deforming the tubular member.
41. A radially expandable and plastically deformable tubular
member, comprising: a yield strength ranging from about 40.0 ksi to
100.0 ksi; a ratio of the yield strength to a tensile strength of
the tubular member ranging from about 0.40 to 0.86; elongation of
the tubular member prior to failure ranging from about 14.8% to
35.0%: a width reduction of the tubular member prior to failure
ranging from about 30% to a width thickness reduction of the
tubular member prior to failure ranges from about 30.0% to 45%; and
an anisotropy of the tubular member ranges from about 0.65 to
1.50.
42. A method of manufacturing a tubular member, comprising:
fabricating a tubular member having intermediate properties;
positioning the tubular member within a preexisting structure;
radially expanding and plastically deforming the tubular member
within the preexisting structure; and baking the tubular member
within the preexisting structure to convert one or more of the
intermediate properties to final properties.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is the U.S. National Stage application for
PCT application serial no. PCT/US2004/028889, attorney docket no.
25791.307.02, filed on Sep. 7, 2004, which claimed the benefit of
the filing dates of: (1) U.S. provisional patent application Ser.
No. 60/600,679, attorney docket no 25791.194, filed on Aug. 11,
2004, (2) U.S. provisional patent application Ser. No. 60/585,370,
attorney docket no 25791.299, filed on Jul. 2, 2004, and (3) U.S.
provisional patent application Ser. No. 60/500,435, attorney docket
no 25791.304, filed on Sep. 5, 2003, the disclosures of which are
incorporated herein by reference.
[0002] The application is a continuation-in-part of U.S. utility
patent application Ser. No. 10/528,498, attorney docket no.
25791.118.08, filed on Mar. 18, 2005, which was the National Stage
for PCT application serial no. PCT/US03/025667, attorney docket no.
25791.118.02, filed on Aug. 18, 2003, which claimed the benefit of
the filing date of U.S. provisional patent application Ser. No.
60/412,653, attorney docket 25791.118, filed on Sep. 20, 2002, the
disclosures of which are incorporated herein by reference.
[0003] This application is related to the following co-pending
applications: (1) U.S. National State patent application Ser. No.
______, attorney docket no. 25791.304.10, filed on Mar. 2, 2006;
(2) U.S. National State patent application Ser. No. ______,
attorney docket no. 25791.305.05, filed on ______; (3) U.S.
National State patent application Ser. No. ______, attorney docket
no. 25791.306.04, filed on ______; and (4) U.S. National State
patent application Ser. No. ______, attorney docket no.
25791.308.07, filed on ______, 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 60/111,293, filed on Dec. 7, 1998, (2) U.S.
patent application Ser. No. 09/510,913, attorney docket no.
25791.7.02, filed on Feb. 23, 2000, which claims priority from
provisional application 60/121,702, filed on Feb. 25, 1999, (3)
U.S. patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (4)
U.S. Pat. No. 6,328,113, which was filed as U.S. patent application
Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on
Nov. 15, 1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. 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 60/124,042, filed on
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patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (8)
U.S. Pat. No. 6,575,240, which was filed as patent application Ser.
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2000, which claims priority from provisional application
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which was filed as patent application Ser. No. 09/588,946, attorney
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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
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26, 2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application
Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan.
8, 2002, which claims priority from provisional application
60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent
application Ser. No. 60/143,039, attorney docket no. 25791.26,
filed on Jul. 9, 1999, (14) U.S. patent application Ser. No.
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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.
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(20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22,
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(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
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filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
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(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
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which claims priority from provisional application 60/111,293,
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filed as patent application Ser. No. 09/852,026, filed on May 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
claims priority from provisional application 60/111,293, filed on
Dec. 7, 1998, (35) PCT Application US02/25608, attorney docket no.
25791.58.02, filed on Aug. 13, 2002, which claims priority from
provisional application 60/318,021, filed on Sep. 7, 2001, attorney
docket no. 25791.58, (36) PCT Application US02/24399, attorney
docket no. 25791.59.02, filed on Aug. 1, 2002, which claims
priority from U.S. provisional patent application Ser. No.
60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001,
(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
patent application Ser. No. 60/326,886, attorney docket no.
25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256,
attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
claims priority from U.S. provisional patent application Ser. No.
60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001,
(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
2001, attorney docket no. 25791.62, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903
which issued Nov. 4, 2003), which claims priority from provisional
application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent
application Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney
docket no. 25791.63, which is a divisional of U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued
Nov. 4, 2003), which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (41) U.S. patent application
Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney docket no.
25791.64, which is a divisional of U.S. patent application Ser. No.
09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application 60/124,042,
filed on Mar. 11, 1999, (42) U.S. patent application Ser. No.
09/962,467, filed on Sep. 25, 2001, attorney docket no. 25791.65,
which is a divisional of U.S. patent application Ser. No.
09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application 60/124,042,
filed on Mar. 11, 1999, (43) U.S. patent application Ser. No.
09/962,468, filed on Sep. 25, 2001, attorney docket no. 25791.66,
which is a divisional of U.S. patent application Ser. No.
09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application 60/124,042,
filed on Mar. 11, 1999, (44) PCT application US 02/25727, filed on
Aug. 14, 2002, attorney docket no. 25791.67.03, which claims
priority from U.S. provisional patent application Ser. No.
60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001,
and U.S. provisional patent application Ser. No. 60/318,386,
attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (45) PCT
application US 02/39425, filed on Dec. 10, 2002, attorney docket
no. 25791.68.02, which claims priority from U.S. provisional patent
application Ser. No. 60/343,674, attorney docket no. 25791.68,
filed on Dec. 27, 2001, (46) U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, (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
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. 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 60/108,558, filed on Nov. 16, 1998, (48) PCT
application US 03/00609, filed on Jan. 9, 2003, attorney docket no.
25791.71.02, which claims priority from U.S. provisional patent
application Ser. No. 60/357,372, attorney docket no. 25791.71,
filed on Feb. 15, 2002, (49) U.S. patent application Ser. No.
10/074,703, attorney docket no. 25791.74, filed on Feb. 12, 2002,
which is a divisional of U.S. Pat. No. 6,568,471, which was filed
as patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
provisional application 60/121,841, filed on Feb. 26, 1999, (50)
U.S. patent application Ser. No. 10/074,244, attorney docket no.
25791.75, filed on Feb. 12, 2002, which is a divisional of U.S.
Pat. No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (51) U.S. patent application
Ser. No. 10/076,660, attorney docket no. 25791.76, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (52) U.S. patent application Ser. No. 10/076,661, attorney
docket no. 25791.77, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (53) U.S. patent application
Ser. No. 10/076,659, attorney docket no. 25791.78, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (54) U.S. patent application Ser. No. 10/078,928, attorney
docket no. 25791.79, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (55) U.S. patent application
Ser. No. 10/078,922, attorney docket no. 25791.80, filed on Feb.
20, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (56) U.S. patent application Ser. No. 10/078,921, attorney
docket no. 25791.81, filed on Feb. 20, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (57) U.S. patent application
Ser. No. 10/261,928, attorney docket no. 25791.82, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (58)
U.S. patent application Ser. No. 10/079,276, attorney docket no.
25791.83, filed on Feb. 20, 2002, which is a divisional of U.S.
Pat. No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (59) U.S. patent application
Ser. No. 10/262,009, attorney docket no. 25791.84, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (60)
U.S. patent application Ser. No. 10/092,481, attorney docket no.
25791.85, filed on Mar. 7, 2002, which is a divisional of U.S. Pat.
No. 6,568,471, which was filed as patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (61) U.S. patent application
Ser. No. 10/261,926, attorney docket no. 25791.86, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (62) PCT
application US 02/36157, filed on Nov. 12, 2002, attorney docket
no. 25791.87.02, which claims priority from U.S. provisional patent
application Ser. No. 60/338,996, attorney docket no. 25791.87,
filed on Nov. 12, 2001, (63) PCT application US 02/36267, filed on
Nov. 12, 2002, attorney docket no. 25791.88.02, which claims
priority from U.S. provisional patent application Ser. No.
60/339,013, attorney docket no. 25791.88, filed on Nov. 12, 2001,
(64) PCT application US 03/11765, filed on Apr. 16, 2003, attorney
docket no. 25791.89.02, which claims priority from U.S. provisional
patent application Ser. No. 60/383,917, attorney
docket no. 25791.89, filed on May 29, 2002, (65) PCT application US
03/15020, filed on May 12, 2003, attorney docket no. 25791.90.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/391,703, attorney docket no. 25791.90, filed on Jun. 26,
2002, (66) PCT application US 02/39418, filed on Dec. 10, 2002,
attorney docket no. 25791.92.02, which claims priority from U.S.
provisional patent application Ser. No. 60/346,309, attorney docket
no. 25791.92, filed on Jan. 7, 2002, (67) PCT application US
03/06544, filed on Mar. 4, 2003, attorney docket no. 25791.93.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/372,048, attorney docket no. 25791.93, filed on Apr. 12,
2002, (68) U.S. patent application Ser. No. 10/331,718, attorney
docket no. 25791.94, filed on Dec. 30, 2002, which is a divisional
U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000,
attorney docket no. 25791.37.02, which claims priority from
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (69) PCT application US
03/04837, filed on Feb. 29, 2003, attorney docket no. 25791.95.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/363,829, attorney docket no. 25791.95, filed on Mar. 13,
2002, (70) U.S. patent application Ser. No. 10/261,927, attorney
docket no. 25791.97, filed on Oct. 1, 2002, which is a divisional
of U.S. Pat. No. 6,557,640, which was filed as patent application
Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun.
7, 2000, which claims priority from provisional application
60/137,998, filed on Jun. 7, 1999, (71) U.S. patent application
Ser. No. 10/262,008, attorney docket no. 25791.98, filed on Oct. 1,
2002, which is a divisional of U.S. Pat. No. 6,557,640, which was
filed as patent application Ser. No. 09/588,946, attorney docket
no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from
provisional application 60/137,998, filed on Jun. 7, 1999, (72)
U.S. patent application Ser. No. 10/261,925, attorney docket no.
25791.99, filed on Oct. 1, 2002, which is a divisional of U.S. Pat.
No. 6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (73) U.S. patent application Ser. No.
10/199,524, attorney docket no. 25791.100, filed on Jul. 19, 2002,
which is a continuation of U.S. Pat. No. 6,497,289, which was filed
as U.S. patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, which claims priority from
provisional application 60/111,293, filed on Dec. 7, 1998, (74) PCT
application US 03/10144, filed on Mar. 28, 2003, attorney docket
no. 25791.101.02, which claims priority from U.S. provisional
patent application Ser. No. 60/372,632, attorney docket no.
25791.101, filed on Apr. 15, 2002, (75) U.S. provisional patent
application Ser. No. 60/412,542, attorney docket no. 25791.102,
filed on Sep. 20, 2002, (76) PCT application US 03/14153, filed on
May 6, 2003, attorney docket no. 25791.104.02, which claims
priority from U.S. provisional patent application Ser. No.
60/380,147, attorney docket no. 25791.104, filed on May 6, 2002,
(77) PCT application US 03/19993, filed on Jun. 24, 2003, attorney
docket no. 25791.106.02, which claims priority from U.S.
provisional patent application Ser. No. 60/397,284, attorney docket
no. 25791.106, filed on Jul. 19, 2002, (78) PCT application US
03/13787, filed on May 5, 2003, attorney docket no. 25791.107.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/387,486, attorney docket no. 25791.107, filed on Jun. 10,
2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
attorney docket no. 25791.108.02, which claims priority from U.S.
provisional patent application Ser. No. 60/387,961, attorney docket
no. 25791.108, filed on Jun. 12, 2002, (80) PCT application US
03/20694, filed on Jul. 1, 2003, attorney docket no. 25791.110.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/398,061, attorney docket no. 25791.110, filed on Jul. 24,
2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
attorney docket no. 25791.111.02, which claims priority from U.S.
provisional patent application Ser. No. 60/399,240, attorney docket
no. 25791.111, filed on Jul. 29, 2002, (82) U.S. provisional patent
application Ser. No. 60/412,487, attorney docket no. 25791.112,
filed on Sep. 20, 2002, (83) U.S. provisional patent application
Ser. No. 60/412,488, attorney docket no. 25791.114, filed on Sep.
20, 2002, (84) U.S. patent application Ser. No. 10/280,356,
attorney docket no. 25791.115, filed on Oct. 25, 2002, which is a
continuation of U.S. Pat. No. 6,470,966, which was filed as patent
application Ser. No. 09/850,093, filed on May 7, 2001, attorney
docket no. 25791.55, as a divisional application of U.S. Pat. No.
6,497,289, which was filed as U.S. patent application Ser. No.
09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999,
which claims priority from provisional application 60/111,293,
filed on Dec. 7, 1998, (85) U.S. provisional patent application
Ser. No. 60/412,177, attorney docket no. 25791.117, filed on Sep.
20, 2002, (86) U.S. provisional patent application Ser. No.
60/412,653, attorney docket no. 25791.118, filed on Sep. 20, 2002,
(87) U.S. provisional patent application Ser. No. 60/405,610,
attorney docket no. 25791.119, filed on Aug. 23, 2002, (88) U.S.
provisional patent application Ser. No. 60/405,394, attorney docket
no. 25791.120, filed on Aug. 23, 2002, (89) U.S. provisional patent
application Ser. No. 60/412,544, attorney docket no. 25791.121,
filed on Sep. 20, 2002, (90) PCT application US 03/24779, filed on
Aug. 8, 2003, attorney docket no. 25791.125.02, which claims
priority from U.S. provisional patent application Ser. No.
60/407,442, attorney docket no. 25791.125, filed on Aug. 30, 2002,
(91) U.S. provisional patent application Ser. No. 60/423,363,
attorney docket no. 25791.126, filed on Dec. 10, 2002, (92) U.S.
provisional patent application Ser. No. 60/412,196, attorney docket
no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
application Ser. No. 60/412,187, attorney docket no. 25791.128,
filed on Sep. 20, 2002, (94) U.S. provisional patent application
Ser. No. 60/412,371, attorney docket no. 25791.129, filed on Sep.
20, 2002, (95) U.S. patent application Ser. No. 10/382,325,
attorney docket no. 25791.145, filed on Mar. 5, 2003, which is a
continuation of U.S. Pat. No. 6,557,640, which was filed as patent
application Ser. No. 09/588,946, attorney docket no. 25791.17.02,
filed on Jun. 7, 2000, which claims priority from provisional
application 60/137,998, filed on Jun. 7, 1999, (96) U.S. patent
application Ser. No. 10/624,842, attorney docket no. 25791.151,
filed on Jul. 22, 2003, which is a divisional of U.S. patent
application Ser. No. 09/502,350, attorney docket no. 25791.8.02,
filed on Feb. 10, 2000, which claims priority from provisional
application 60/119,611, filed on Feb. 11, 1999, (97) U.S.
provisional patent application Ser. No. 60/431,184, attorney docket
no. 25791.157, filed on Dec. 5, 2002, (98) U.S. provisional patent
application Ser. No. 60/448,526, attorney docket no. 25791.185,
filed on Feb. 18, 2003, (99) U.S. provisional patent application
Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr.
9, 2003, (100) U.S. provisional patent application Ser. No.
60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S.
provisional patent application Ser. No. 60/442,942, attorney docket
no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional
patent application Ser. No. 60/442,938, attorney docket no.
25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent
application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar.
14, 2003, (106) U.S. provisional patent application Ser. No.
60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S.
provisional patent application Ser. No. 60/455,124, attorney docket
no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional
patent application Ser. No. 60/453,678, attorney docket no.
25791.253, filed on Mar. 11, 2003, (110) U.S. patent application
Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr.
23, 2003, which is a continuation of U.S. patent application Ser.
No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003),
which claims priority from provisional application 60/124,042,
filed on Mar. 11, 1999, (111) U.S. provisional patent application
Ser. No. 60/457,965, attorney docket no. 25791.260, filed on Mar.
27, 2003, (112) U.S. provisional patent application Ser. No.
60/455,718, attorney docket no. 25791.262, filed on Mar. 18, 2003,
(113) U.S. Pat. No. 6,550,821, which was filed as patent
application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S.
patent application Ser. No. 10/436,467, attorney docket no.
25791.268, filed on May 12, 2003, which is a continuation of U.S.
Pat. No. 6,604,763, which was filed as application Ser. No.
09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 2, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
8, 2003, (117) U.S. provisional patent application Ser. No.
60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, (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
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 60/124,042, filed on Mar. 11, 1999; (122) PCT patent
application serial no. PCT/US2004/06246, attorney docket no.
25791.238.02, filed on Feb. 26, 2004; (123) PCT patent application
serial number PCT/US2004/08170, attorney docket number 25791.40.02,
filed on Mar. 15, 2004; (124) PCT patent application serial number
PCT/US2004/08171, attorney docket number 25791.236.02, filed on
Mar. 15, 2004; (125) PCT patent application serial number
PCT/US2004/08073, attorney docket number 25791.262.02, filed on
Mar. 18, 2004; (126) PCT patent application serial number
PCT/US2004/07711, attorney docket number 25791.253.02, filed on
Mar. 11, 2004; (127) PCT patent application serial number
PCT/US2004/029025, attorney docket number 25791.260.02, filed on
Mar. 26, 2004; (128) PCT patent application serial number
PCT/US2004/010317, attorney docket number 25791.270.02, filed on
Apr. 2, 2004; (129) PCT patent application serial number
PCT/US2004/010712, attorney docket number 25791.272.02, filed on
Apr. 6, 2004; (130) PCT patent application serial number
PCT/US2004/010762, attorney docket number 25791.273.02, filed on
Apr. 6, 2004; (131) PCT patent application serial number
PCT/US2004/011973, attorney docket number 25791.277.02, filed on
Apr. 15, 2004; (132) U.S. provisional patent application Ser. No.
60/495,056, attorney docket number 25791.301, filed on Aug. 14,
2003; (133) U.S. provisional patent application Ser. No.
60/600,679, attorney docket number 25791.194, filed on Aug. 11,
2004; (134) PCT patent application serial number PCT/US2005/027318,
attorney docket number 25791.329.02, filed on Jul. 29, 2005; (135)
PCT patent application serial number PCT/US2005/028936, attorney
docket number 25791.338.02, filed on Aug. 12, 2005; (136) PCT
patent application serial number PCT/US2005/028669, attorney docket
number 25791.194.02, filed on Aug. 11, 2005; (137) PCT patent
application serial number PCT/US2005/028453, attorney docket number
25791.371, filed on Aug. 11, 2005; (138) PCT patent application
serial number PCT/US2005/028641, attorney docket number 25791.372,
filed on Aug. 11, 2005; (139) PCT patent application serial number
PCT/US2005/028819, attorney docket number 25791.373, filed on Aug.
11, 2005; (140) PCT patent application serial number
PCT/US2005/028446, attorney docket number 25791.374, filed on Aug.
11, 2005; (141) PCT patent application serial number
PCT/US2005/028642, attorney docket number 25791.375, filed on Aug.
11, 2005; (142) PCT patent application serial number
PCT/US2005/028451, attorney docket number 25791.376, filed on Aug.
11, 2005, and (143). PCT patent application serial number
PCT/US2005/028473, attorney docket number 25791.377, filed on Aug.
11, 2005, (144) U.S. utility patent application Ser. No.
10/546,082, attorney docket number 25791.378, filed on Aug. 16,
2005, (145) U.S. utility patent application Ser. No. 10/546,076,
attorney docket number 25791.379, filed on Aug. 16, 2005, (146)
U.S. utility patent application Ser. No. 10/545,936, attorney
docket number 25791.380, filed on Aug. 16, 2005, (147) U.S. utility
patent application Ser. No. 10/546,079, attorney docket number
25791.381, filed on Aug. 16, 2005 (148) U.S. utility patent
application Ser. No. 10/545,941, attorney docket number 25791.382,
filed on Aug. 16, 2005, (149) U.S. utility patent application Ser.
No. 546078, attorney docket number 25791.383, filed on Aug. 16,
2005, filed on Aug. 11, 2005, (150) U.S. utility patent application
Ser. No. 10/545,941, attorney docket number 25791.185.05, filed on
Aug. 16, 2005, (151) U.S. utility patent application Ser. No.
11/249,967, attorney docket number 25791.384, filed on Oct. 13,
2005, (152) U.S. provisional patent application Ser. No.
60/734,302, attorney docket number 25791.24, filed on Nov. 7, 2005,
(153) U.S. provisional patent application Ser. No. 60/725,181,
attorney docket number 25791.184, filed on Oct. 11, 2005, (154) PCT
patent application serial number PCT/US2005/023391, attorney docket
number 25791.299.02 filed Jun. 29, 2005 which claims priority from
U.S. provisional patent application Ser. No. 60/585,370, attorney
docket number 25791.299, filed on Jul. 2, 2004, (155) U.S.
provisional patent application Ser. No. 60/721,579, attorney docket
number 25791.327, filed on Sep. 28, 2005, (156) U.S. provisional
patent application Ser. No. 60/717,391, attorney docket number
25791.214, filed on Sep. 15, 2005, (157) U.S. provisional patent
application Ser. No. 60/702,935, attorney docket number 25791.133,
filed on Jul. 27, 2005, (158) U.S. provisional patent application
Ser. No. 60/663,913, attorney docket number 25791.32, filed on Mar.
21, 2005, (159) U.S. provisional patent application Ser. No.
60/652,564, attorney docket number 25791.348, filed on Feb. 14,
2005, (160) U.S. provisional patent application Ser. No.
60/645,840, attorney docket number 25791.324, filed on Jan. 21,
2005, (161) PCT patent application serial number PCT/US2005/______,
attorney docket number 25791.326.02, filed on Nov. 29, 2005 which
claims priority from U.S. provisional patent application Ser. No.
60/631,703, attorney docket number 25791.326, filed on Nov. 30,
2004, (162) U.S. provisional patent application Ser. No. ______,
attorney docket number 25791.339, filed on Dec. 22, 2005, (163)
U.S. National Stage application Ser. No. 10/548,934, attorney
docket no. 25791.253.05, filed on Sep. 12, 2005; (164) U.S.
National Stage application Ser. No. 10/549,410, attorney docket no.
25791.262.05, filed on Sep. 13, 2005; (165) U.S. Provisional Patent
Application No. 60/717,391, attorney docket no. 25791.214 filed on
Sep. 15, 2005; (166) U.S. National Stage application Ser. No.
10/550,906, attorney docket no. 25791.260.06, filed on Sep. 27,
2005; (167) U.S. National Stage application Ser. No. 10/551,880,
attorney docket no. 25791.270.06, filed on Sep. 30, 2005; (168)
U.S. National Stage application Ser. No. 10/552,253, attorney
docket no. 25791.273.06, filed on Oct. 4, 2005; (169) U.S. National
Stage application Ser. No. 10/552,790, attorney docket no.
25791.272.06, filed on Oct. 11, 2005; (170) U.S. Provisional Patent
Application No. 60/725,181, attorney docket no. 25791.184 filed on
Oct. 11, 2005; (171) U.S. National Stage application Ser. No.
10/553,094, attorney docket no. 25791.193.03, filed on Oct. 13,
2005; (172) U.S. National Stage
application Ser. No. 10/553,566, attorney docket no. 25791.277.06,
filed on Oct. 17, 2005; (173) PCT Patent Application No.
PCT/US2006/______, attorney docket no. 25791.324.02 filed on Jan.
20, 2006, and (174) PCT Patent Application No. PCT/US2006/______,
attorney docket no. 25791.348.02 filed on Feb. 9, 2006; (175) U.S.
Utility patent application Ser. No. ______, attorney docket no.
25791.386, filed on Feb. 17, 2006, (176) U.S. National Stage
application Ser. No. ______, attorney docket no. 25791.301.06,
filed on ______, (177) U.S. National Stage application Ser. No.
______, attorney docket no. 25791.137.04, filed on ______, (178)
U.S. National Stage application Ser. No. ______, attorney docket
no. 25791.215.06, (179) U.S. National State patent application Ser.
No. ______, attorney docket no. 25791.305.05, filed on ______;
(180) U.S. National State patent application Ser. No. ______,
attorney docket no. 25791.306.04, filed on ______; (181) U.S.
National State patent application Ser. No. ______, attorney docket
no. 25791.307.04, filed on ______; and (182) U.S. National State
patent application Ser. No.______, attorney docket no.
25791.308.07, filed on ______, the disclosures of which are
incorporated herein by reference.
[0004] BACKGROUND OF THE INVENTION
[0005] This invention relates generally to oil and gas exploration,
and in particular to forming and repairing wellbore casings to
facilitate oil and gas exploration.
BRIEF DESCRIPTION OF THE DRAWINGS
[0006] FIG. 1 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0007] FIG. 2 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 1 after positioning an expansion
device within the expandable tubular member.
[0008] FIG. 3 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 2 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform a portion of the expandable tubular member.
[0009] FIG. 4 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 3 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform another portion of the expandable tubular
member.
[0010] FIG. 5 is a graphical illustration of exemplary embodiments
of the stress/strain curves for several portions of the expandable
tubular member of FIGS. 1-4.
[0011] FIG. 6 is a graphical illustration of the an exemplary
embodiment of the yield strength vs. ductility curve for at least a
portion of the expandable tubular member of FIGS. 1-4.
[0012] FIG. 7 is a fragmentary cross sectional illustration of an
embodiment of a series of overlapping expandable tubular
members.
[0013] FIG. 8 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0014] FIG. 9 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 8 after positioning an expansion
device within the expandable tubular member.
[0015] FIG. 10 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 9 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform a portion of the expandable tubular member.
[0016] FIG. 11 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 10 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform another portion of the expandable tubular
member.
[0017] FIG. 12 is a graphical illustration of exemplary embodiments
of the stress/strain curves for several portions of the expandable
tubular member of FIGS. 8-11.
[0018] FIG. 13 is a graphical illustration of an exemplary
embodiment of the yield strength vs. ductility curve for at least a
portion of the expandable tubular member of FIGS. 8-11.
[0019] FIG. 14 is a fragmentary cross sectional view of an
exemplary embodiment of an expandable tubular member positioned
within a preexisting structure.
[0020] FIG. 15 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 14 after positioning an expansion
device within the expandable tubular member.
[0021] FIG. 16 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 15 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform a portion of the expandable tubular member.
[0022] FIG. 17 is a fragmentary cross sectional view of the
expandable tubular member of FIG. 16 after operating the expansion
device within the expandable tubular member to radially expand and
plastically deform another portion of the expandable tubular
member.
[0023] FIG. 18 is a flow chart illustration of an exemplary
embodiment of a method of processing an expandable tubular
member.
[0024] FIG. 19 is a graphical illustration of the an exemplary
embodiment of the yield strength vs. ductility curve for at least a
portion of the expandable tubular member during the operation of
the method of FIG. 18.
[0025] FIG. 20 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0026] FIG. 21 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0027] FIG. 22 is a fragmentary cross-sectional view illustrating
an embodiment of the radial expansion and plastic deformation of a
portion of a first tubular member having an internally threaded
connection at an end portion, an embodiment of a tubular sleeve
supported by the end portion of the first tubular member, and a
second tubular member having an externally threaded portion coupled
to the internally threaded portion of the first tubular member and
engaged by a flange of the sleeve. The sleeve includes the flange
at one end for increasing axial compression loading.
[0028] FIG. 23 is a fragmentary cross-sectional view illustrating
an embodiment of the radial expansion and plastic deformation of a
portion of a first tubular member having an internally threaded
connection at an end portion, a second tubular member having an
externally threaded portion coupled to the internally threaded
portion of the first tubular member, and an embodiment of a tubular
sleeve supported by the end portion of both tubular members. The
sleeve includes flanges at opposite ends for increasing axial
tension loading.
[0029] FIG. 24 is a fragmentary cross-sectional illustration of the
radial expansion and plastic deformation of a portion of a first
tubular member having an internally threaded connection at an end
portion, a second tubular member having an externally threaded
portion coupled to the internally threaded portion of the first
tubular member, and an embodiment of a tubular sleeve supported by
the end portion of both tubular members. The sleeve includes
flanges at opposite ends for increasing axial compression/tension
loading.
[0030] FIG. 25 is a fragmentary cross-sectional illustration of the
radial expansion and plastic deformation of a portion of a first
tubular member having an internally threaded connection at an end
portion, a second tubular member having an externally threaded
portion coupled to the internally threaded portion of the first
tubular member, and an embodiment of a tubular sleeve supported by
the end portion of both tubular members. The sleeve includes
flanges at opposite ends having sacrificial material thereon.
[0031] FIG. 26 is a fragmentary cross-sectional illustration of the
radial expansion and plastic deformation of a portion of a first
tubular member having an internally threaded connection at an end
portion, a second tubular member having an externally threaded
portion coupled to the internally threaded portion of the first
tubular member, and an embodiment of a tubular sleeve supported by
the end portion of both tubular members. The sleeve includes a thin
walled cylinder of sacrificial material.
[0032] FIG. 27 is a fragmentary cross-sectional illustration of the
radial expansion and plastic deformation of a portion of a first
tubular member having an internally threaded connection at an end
portion, a second tubular member having an externally threaded
portion coupled to the internally threaded portion of the first
tubular member, and an embodiment of a tubular sleeve supported by
the end portion of both tubular members. The sleeve includes a
variable thickness along the length thereof.
[0033] FIG. 28 is a fragmentary cross-sectional illustration of the
radial expansion and plastic deformation of a portion of a first
tubular member having an internally threaded connection at an end
portion, a second tubular member having an externally threaded
portion coupled to the internally threaded portion of the first
tubular member, and an embodiment of a tubular sleeve supported by
the end portion of both tubular members. The sleeve includes a
member coiled onto grooves formed in the sleeve for varying the
sleeve thickness.
[0034] FIG. 29 is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable connection.
[0035] FIGS. 30a-30c are fragmentary cross-sectional illustrations
of exemplary embodiments of expandable connections.
[0036] FIG. 31 is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable connection.
[0037] FIGS. 32a and 32b are fragmentary cross-sectional
illustrations of the formation of an exemplary embodiment of an
expandable connection.
[0038] FIG. 33 is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable connection.
[0039] FIGS. 34a, 34b and 34c are fragmentary cross-sectional
illustrations of an exemplary embodiment of an expandable
connection.
[0040] FIG. 35a is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable tubular member.
[0041] FIG. 35b is a graphical illustration of an exemplary
embodiment of the variation in the yield point for the expandable
tubular member of FIG. 35a.
[0042] FIG. 36a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0043] FIG. 36b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0044] FIG. 36c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0045] FIG. 37a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0046] FIG. 37b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0047] FIG. 37c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0048] FIG. 38a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0049] FIG. 38b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0050] FIG. 38c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0051] FIG. 39a is an illustration of exemplary tribological
elements in a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0052] FIG. 39b is a fragmentary cross-sectional illustration of
the lubrication of the interface between an expansion cone and a
tubular member during the radial expansion process.
[0053] FIG. 40 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0054] FIG. 41 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0055] FIG. 42 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0056] FIG. 43 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0057] FIG. 44 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0058] FIG. 45 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0059] FIG. 46 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0060] FIG. 47 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0061] FIG. 48 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0062] FIG. 49 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0063] FIG. 50 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0064] FIG. 51 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0065] FIG. 52 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0066] FIG. 53 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0067] FIG. 54 is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0068] FIG. 55 is a cross-sectional illustration of a
circumferential groove suitable for use with the expansion cones of
FIGS. 40-54.
[0069] FIG. 56 is an illustration of the groove of FIG. 55.
[0070] FIG. 57 is an illustration of an alternate embodiment of the
circumferential grove of the expansion cones of FIGS. 40-57.
[0071] FIG. 58a is an elevational view of an embodiment of an
expansion cone including a system for lubricating the interface
between the expansion cone and a tubular member during the radial
expansion and plastic deformation of the tubular member utilizing a
groove designed in accordance with FIG. 57.
[0072] FIG. 58b is a top view of the expansion cone of FIG.
58a.
[0073] FIG. 58c is an enlarged section of the expansion cone of
FIG. 58a.
[0074] FIG. 59a is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0075] FIG. 59b is a top view of the expansion cone of FIG.
59a.
[0076] FIG. 60a is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone having a tapered faceted polygonal outer expansion
surface and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0077] FIG. 60b is a top view of the expansion cone in FIG.
60a.
[0078] FIG. 60c is a fragmentary cross-sectional illustration of
the expansion cone in FIG. 60a in a tubular member.
[0079] FIGS. 61a and 61b are cross-sectional illustrations of an
alternate embodiment of tubular member and an expansion cone
including a system for lubricating the interface between the
expansion cone having a tapered faceted polygonal outer expansion
surface and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0080] FIGS. 61c and 61d are cross-sectional illustrations of an
alternate embodiment of an expansion cone including a system for
lubricating the interface between the expansion cone having a
tapered faceted polygonal outer expansion surface and a tubular
member during the radial expansion and plastic deformation of the
tubular member.
[0081] FIG. 61e is cross-sectional illustrations of an alternate
embodiment of an expansion cone including a system for lubricating
the interface between the expansion cone having a tapered faceted
polygonal outer expansion surface and a tubular member having
non-uniform wall thickness during the radial expansion and plastic
deformation of the tubular member.
[0082] FIG. 62a, 62b, and 62c are an illustrations of an alternate
embodiment of an expansion cone including a system for lubricating
the interface between the expansion cone having a tapered faceted
polygonal outer expansion surface and a tubular member during the
radial expansion and plastic deformation of the tubular member.
[0083] FIG. 62d, 62e, and 62f are an illustrations of an alternate
embodiment of an expansion cone including a system for lubricating
the interface between the expansion cone having a tapered faceted
polygonal outer expansion surface and a tubular member during the
radial expansion and plastic deformation of the tubular member.
[0084] FIG. 63 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0085] FIG. 64 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0086] FIG. 65 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0087] FIG. 66 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0088] FIG. 67 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0089] FIG. 68 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0090] FIG. 69 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0091] FIG. 70 is a cross-sectional illustration of an embodiment
of a system for lubricating the interface between the expansion
cone and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0092] FIGS. 71a, 71b, 71c, 71d and 71e are graphical illustrations
of example expansion cone materials characteristics.
[0093] FIG. 72 is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0094] FIG. 73a is a fragmentary cross-sectional illustration of
example frictional forces in a system including an expansion cone
and a tubular member during the radial expansion and plastic
deformation of the tubular member.
[0095] FIG. 73b is a fragmentary cross-sectional illustration of an
example components in a system including an expansion cone and a
tubular member during the radial expansion and plastic deformation
of the tubular member that contribute to the frictional forces.
[0096] FIGS. 73c and 73d are fragmentary cross-sectional
illustrations of example expansion cone surface roughness and
texture characteristics in a system including an expansion cone and
a tubular member during the radial expansion and plastic
deformation of the tubular member that contribute to the frictional
forces.
[0097] FIG. 74 is a graphical illustration of a coefficient of
friction versus expansion force in an exemplary system for radially
expanding a tubular member.
[0098] FIG. 75 is a graphical logarithmic illustration of the
coefficient of friction versus expansion force (in pounds per
square inch) in an exemplary system for radially expanding a
tubular member.
[0099] FIG. 76 is a graphical logarithmic illustration of the
coefficient of friction versus expansion force (in pounds) in an
exemplary system for radially expanding a tubular member.
[0100] FIG. 77 is a graphical illustration of the expansion forces
in an exemplary system for radially expanding a tubular member over
time.
[0101] FIG. 78 is a graphical illustration the range of
coefficients of friction for exemplary systems for radially
expanding a tubular member.
[0102] FIGS. 79a and 79b are photo-micrograph illustrations of the
microstructure of an exemplary embodiments of expansion cones.
[0103] FIGS. 80a and 80b are photo-micrograph illustrations of the
microstructure of the exemplary embodiments of expansion cones
shown in FIGS. 79a and 79b, respectively.
[0104] FIGS. 81a and 81b are graphical illustrations of the
x-profile of the exemplary embodiments of expansion cones shown in
FIGS. 79a and 79b, respectively.
[0105] FIGS. 82a and 82b are graphical illustrations of the bearing
ratio of the exemplary embodiments of expansion cones shown in
FIGS. 79a and 79b, respectively.
[0106] FIGS. 83a and 83b are photo-micrograph illustrations of the
microstructure of an exemplary embodiments of expansion cones.
[0107] FIGS. 84a and 84b are photo-micrograph illustrations of the
microstructure of the exemplary embodiments of expansion cones
shown in FIGS. 83a and 83b, respectively.
[0108] FIGS. 85a and 85b are graphical illustrations of the
x-profile of the exemplary embodiments of expansion cones shown in
FIGS. 83a and 83b, respectively.
[0109] FIGS. 86a and 86b are graphical illustrations of the bearing
ratio of the exemplary embodiments of expansion cones shown in
FIGS. 83a and 83b, respectively.
[0110] FIG. 87 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0111] FIG. 88 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0112] FIG. 89 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0113] FIG. 90 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0114] FIG. 91 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0115] FIG. 92 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0116] FIG. 93 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0117] FIG. 94 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0118] FIG. 95 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0119] FIG. 96 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0120] FIG. 97 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0121] FIG. 98 is a graphical illustration ranges of expansion
forces associated with exemplary systems for radially expanding a
tubular member.
[0122] FIG. 99a is an illustration of an embodiment of an expansion
cone including a system for lubricating the interface between the
expansion cone and a tubular member during the radial expansion and
plastic deformation of the tubular member.
[0123] FIG. 99b are photo-micrograph illustrations of the
microstructure of an exemplary embodiments of expansion cones.
[0124] FIG. 99c is an illustration of an embodiment of a system for
lubricating the interface between the expansion cone and a tubular
member during the radial expansion and plastic deformation of the
tubular member.
[0125] FIG. 100 is a schematic fragmentary cross-sectional view
along a plane along and through the central axis of a tubular
member that is tested to failure with axial opposed forces.
[0126] FIG. 101 is a stress-strain curve representing values for
stress and strain that may be plotted for solid specimen
sample.
[0127] FIG. 102 is a schematically depiction of a stress strain
curve representing values from an exemplary test on a tubular
member.
[0128] FIG. 103 is a graphical illustration of an exemplary
experimental embodiment.
[0129] FIG. 104 is a graphical illustration of an exemplary
experimental embodiment.
[0130] FIG. 105 is a flow chart illustration of an exemplary
embodiment of a method of processing tubular members.
[0131] FIG. 106 is a graphical illustration of an exemplary
embodiment of a method of processing tubular members.
[0132] FIG. 107 is a graphical illustration of an exemplary
embodiment of a method of processing tubular members.
[0133] FIG. 108 is a graphical illustration of an exemplary
embodiment of a method of processing tubular members.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0134] Referring initially to FIG. 1, an exemplary embodiment of an
expandable tubular assembly 10 includes a first expandable tubular
member 12 coupled to a second expandable tubular member 14. In
several exemplary embodiments, the ends of the first and second
expandable tubular members, 12 and 14, are coupled using, for
example, a conventional mechanical coupling, a welded connection, a
brazed connection, a threaded connection, and/or an interference
fit connection. In an exemplary embodiment, the first expandable
tubular member 12 has a plastic yield point YP.sub.1, and the
second expandable tubular member 14 has a plastic yield point
YP.sub.2. In an exemplary embodiment, the expandable tubular
assembly 10 is positioned within a preexisting structure such as,
for example, a wellbore 16 that traverses a subterranean formation
18.
[0135] As illustrated in FIG. 2, an expansion device 20 may then be
positioned within the second expandable tubular member 14. In
several exemplary embodiments, the expansion device 20 may include,
for example, one or more of the following conventional expansion
devices: a) an expansion cone; b) a rotary expansion device; c) a
hydroforming expansion device; d) an impulsive force expansion
device; d) any one of the expansion devices commercially available
from, or disclosed in any of the published patent applications or
issued patents, of Weatherford International, Baker Hughes,
Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or
Enventure Global Technology L.L.C. In several exemplary
embodiments, the expansion device 20 is positioned within the
second expandable tubular member 14 before, during, or after the
placement of the expandable tubular assembly 10 within the
preexisting structure 16.
[0136] As illustrated in FIG. 3, the expansion device 20 may then
be operated to radially expand and plastically deform at least a
portion of the second expandable tubular member 14 to form a
bell-shaped section.
[0137] As illustrated in FIG. 4, the expansion device 20 may then
be operated to radially expand and plastically deform the remaining
portion of the second expandable tubular member 14 and at least a
portion of the first expandable tubular member 12.
[0138] In an exemplary embodiment, at least a portion of at least a
portion of at least one of the first and second expandable tubular
members, 12 and 14, are radially expanded into intimate contact
with the interior surface of the preexisting structure 16.
[0139] In an exemplary embodiment, as illustrated in FIG. 5, the
plastic yield point YP.sub.1 is greater than the plastic yield
point YP.sub.2. In this manner, in an exemplary embodiment, the
amount of power and/or energy required to radially expand the
second expandable tubular member 14 is less than the amount of
power and/or energy required to radially expand the first
expandable tubular member 12.
[0140] In an exemplary embodiment, as illustrated in FIG. 6, the
first expandable tubular member 12 and/or the second expandable
tubular member 14 have a ductility D.sub.PE and a yield strength
YS.sub.PE prior to radial expansion and plastic deformation, and a
ductility D.sub.AE and a yield strength YS.sub.AE after radial
expansion and plastic deformation. In an exemplary embodiment,
D.sub.PE is greater than D.sub.AE, and YS.sub.AE is greater than
YS.sub.PE. In this manner, the first expandable tubular member 12
and/or the second expandable tubular member 14 are transformed
during the radial expansion and plastic deformation process.
Furthermore, in this manner, in an exemplary embodiment, the amount
of power and/or energy required to radially expand each unit length
of the first and/or second expandable tubular members, 12 and 14,
is reduced. Furthermore, because the YS.sub.AE is greater than
YS.sub.PE, the collapse strength of the first expandable tubular
member 12 and/or the second expandable tubular member 14 is
increased after the radial expansion and plastic deformation
process.
[0141] In an exemplary embodiment, as illustrated in FIG. 7,
following the completion of the radial expansion and plastic
deformation of the expandable tubular assembly 10 described above
with reference to FIGS. 1-4, at least a portion of the second
expandable tubular member 14 has an inside diameter that is greater
than at least the inside diameter of the first expandable tubular
member 12. In this manner a bell-shaped section is formed using at
least a portion of the second expandable tubular member 14. Another
expandable tubular assembly 22 that includes a first expandable
tubular member 24 and a second expandable tubular member 26 may
then be positioned in overlapping relation to the first expandable
tubular assembly 10 and radially expanded and plastically deformed
using the methods described above with reference to FIGS. 1-4.
Furthermore, following the completion of the radial expansion and
plastic deformation of the expandable tubular assembly 20, in an
exemplary embodiment, at least a portion of the second expandable
tubular member 26 has an inside diameter that is greater than at
least the inside diameter of the first expandable tubular member
24. In this manner a bell-shaped section is formed using at least a
portion of the second expandable tubular member 26. Furthermore, in
this manner, a mono-diameter tubular assembly is formed that
defines an internal passage 28 having a substantially constant
cross-sectional area and/or inside diameter.
[0142] Referring to FIG. 8, an exemplary embodiment of an
expandable tubular assembly 100 includes a first expandable tubular
member 102 coupled to a tubular coupling 104. The tubular coupling
104 is coupled to a tubular coupling 106. The tubular coupling 106
is coupled to a second expandable tubular member 108. In several
exemplary embodiments, the tubular couplings, 104 and 106, provide
a tubular coupling assembly for coupling the first and second
expandable tubular members, 102 and 108, together that may include,
for example, a conventional mechanical coupling, a welded
connection, a brazed connection, a threaded connection, and/or an
interference fit connection. In an exemplary embodiment, the first
and second expandable tubular members 12 have a plastic yield point
YP.sub.1, and the tubular couplings, 104 and 106, have a plastic
yield point YP.sub.2. In an exemplary embodiment, the expandable
tubular assembly 100 is positioned within a preexisting structure
such as, for example, a wellbore 110 that traverses a subterranean
formation 112.
[0143] As illustrated in FIG. 9, an expansion device 114 may then
be positioned within the second expandable tubular member 108. In
several exemplary embodiments, the expansion device 114 may
include, for example, one or more of the following conventional
expansion devices: a) an expansion cone; b) a rotary expansion
device; c) a hydroforming expansion device; d) an impulsive force
expansion device; d) any one of the expansion devices commercially
available from, or disclosed in any of the published patent
applications or issued patents, of Weatherford International, Baker
Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger,
and/or Enventure Global Technology L.L.C. In several exemplary
embodiments, the expansion device 114 is positioned within the
second expandable tubular member 108 before, during, or after the
placement of the expandable tubular assembly 100 within the
preexisting structure 110.
[0144] As illustrated in FIG. 10, the expansion device 114 may then
be operated to radially expand and plastically deform at least a
portion of the second expandable tubular member 108 to form a
bell-shaped section.
[0145] As illustrated in FIG. 11, the expansion device 114 may then
be operated to radially expand and plastically deform the remaining
portion of the second expandable tubular member 108, the tubular
couplings, 104 and 106, and at least a portion of the first
expandable tubular member 102.
[0146] In an exemplary embodiment, at least a portion of at least a
portion of at least one of the first and second expandable tubular
members, 102 and 108, are radially expanded into intimate contact
with the interior surface of the preexisting structure 110.
[0147] In an exemplary embodiment, as illustrated in FIG. 12, the
plastic yield point YP.sub.1 is less than the plastic yield point
YP.sub.2. In this manner, in an exemplary embodiment, the amount of
power and/or energy required to radially expand each unit length of
the first and second expandable tubular members, 102 and 108, is
less than the amount of power and/or energy required to radially
expand each unit length of the tubular couplings, 104 and 106.
[0148] In an exemplary embodiment, as illustrated in FIG. 13, the
first expandable tubular member 12 and/or the second expandable
tubular member 14 have a ductility D.sub.PE and a yield strength
YS.sub.PE prior to radial expansion and plastic deformation, and a
ductility D.sub.AE and a yield strength YS.sub.AE after radial
expansion and plastic deformation. In an exemplary embodiment,
D.sub.PE is greater than D.sub.AE, and YS.sub.AE is greater than
YS.sub.PE. In this manner, the first expandable tubular member 12
and/or the second expandable tubular member 14 are transformed
during the radial expansion and plastic deformation process.
Furthermore, in this manner, in an exemplary embodiment, the amount
of power and/or energy required to radially expand each unit length
of the first and/or second expandable tubular members, 12 and 14,
is reduced. Furthermore, because the YS.sub.AE is greater than
YS.sub.PE, the collapse strength of the first expandable tubular
member 12 and/or the second expandable tubular member 14 is
increased after the radial expansion and plastic deformation
process.
[0149] Referring to FIG. 14, an exemplary embodiment of an
expandable tubular assembly 200 includes a first expandable tubular
member 202 coupled to a second expandable tubular member 204 that
defines radial openings 204a, 204b, 204c, and 204d. In several
exemplary embodiments, the ends of the first and second expandable
tubular members, 202 and 204, are coupled using, for example, a
conventional mechanical coupling, a welded connection, a brazed
connection, a threaded connection, and/or an interference fit
connection. In an exemplary embodiment, one or more of the radial
openings, 204a, 204b, 204c, and 204d, have circular, oval, square,
and/or irregular cross sections and/or include portions that extend
to and interrupt either end of the second expandable tubular member
204. In an exemplary embodiment, the expandable tubular assembly
200 is positioned within a preexisting structure such as, for
example, a wellbore 206 that traverses a subterranean formation
208.
[0150] As illustrated in FIG. 15, an expansion device 210 may then
be positioned within the second expandable tubular member 204. In
several exemplary embodiments, the expansion device 210 may
include, for example, one or more of the following conventional
expansion devices: a) an expansion cone; b) a rotary expansion
device; c) a hydroforming expansion device; d) an impulsive force
expansion device; d) any one of the expansion devices commercially
available from, or disclosed in any of the published patent
applications or issued patents, of Weatherford International, Baker
Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger,
and/or Enventure Global Technology L.L.C. In several exemplary
embodiments, the expansion device 210 is positioned within the
second expandable tubular member 204 before, during, or after the
placement of the expandable tubular assembly 200 within the
preexisting structure 206.
[0151] As illustrated in FIG. 16, the expansion device 210 may then
be operated to radially expand and plastically deform at least a
portion of the second expandable tubular member 204 to form a
bell-shaped section.
[0152] As illustrated in FIG. 16, the expansion device 20 may then
be operated to radially expand and plastically deform the remaining
portion of the second expandable tubular member 204 and at least a
portion of the first expandable tubular member 202.
[0153] In an exemplary embodiment, the anisotropy ratio AR for the
first and second expandable tubular members is defined by the
following equation: a.
AR=ln(WT.sub.f/WT.sub.o)/ln(D.sub.f/D.sub.o); (1) [0154] b. where
AR=anisotropy ratio; [0155] c. where WT.sub.f=final wall thickness
of the expandable tubular member following the radial expansion and
plastic deformation of the expandable tubular member; [0156] d.
where WT.sub.i=initial wall thickness of the expandable tubular
member prior to the radial expansion and plastic deformation of the
expandable tubular member; [0157] e. where D.sub.f=final inside
diameter of the expandable tubular member following the radial
expansion and plastic deformation of the expandable tubular member;
and [0158] f. where D.sub.i=initial inside diameter of the
expandable tubular member prior to the radial expansion and plastic
deformation of the expandable tubular member.
[0159] In an exemplary embodiment, the anisotropy ratio AR for the
first and/or second expandable tubular members, 204 and 204, is
greater than 1.
[0160] In an exemplary experimental embodiment, the second
expandable tubular member 204 had an anisotropy ratio AR greater
than 1, and the radial expansion and plastic deformation of the
second expandable tubular member did not result in any of the
openings, 204a, 204b, 204c, and 204d, splitting or otherwise
fracturing the remaining portions of the second expandable tubular
member. This was an unexpected result.
[0161] Referring to FIG. 18, in an exemplary embodiment, one or
more of the expandable tubular members, 12, 14, 24, 26, 102, 104,
106, 108, 202 and/or 204 are processed using a method 300 in which
a tubular member in an initial state is thermo-mechanically
processed in step 302. In an exemplary embodiment, the
thermo-mechanical processing 302 includes one or more heat treating
and/or mechanical forming processes. As a result, of the
thermo-mechanical processing 302, the tubular member is transformed
to an intermediate state. The tubular member is then further
thermo-mechanically processed in step 304. In an exemplary
embodiment, the thermo-mechanical processing 304 includes one or
more heat treating and/or mechanical forming processes. As a
result, of the thermo-mechanical processing 304, the tubular member
is transformed to a final state.
[0162] In an exemplary embodiment, as illustrated in FIG. 19,
during the operation of the method 300, the tubular member has a
ductility D.sub.PE and a yield strength YS.sub.PE prior to the
final thermo-mechanical processing in step 304, and a ductility
D.sub.AE and a yield strength YS.sub.AE after final
thermo-mechanical processing. In an exemplary embodiment, D.sub.PE
is greater than D.sub.AE, and YS.sub.AE is greater than YS.sub.PE.
In this manner, the amount of energy and/or power required to
transform the tubular member, using mechanical forming processes,
during the final thermo-mechanical processing in step 304 is
reduced. Furthermore, in this manner, because the YS.sub.AE is
greater than YS.sub.PE, the collapse strength of the tubular member
is increased after the final thermo-mechanical processing in step
304.
[0163] In an exemplary embodiment, one or more of the expandable
tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or
204, have the following characteristics: TABLE-US-00001
Characteristic Value Tensile Strength 60 to 120 ksi Yield Strength
50 to 100 ksi Y/T Ratio Maximum of 50/85% Elongation During Radial
Expansion and Minimum of 35% Plastic Deformation Width Reduction
During Radial Expansion Minimum of 40% and Plastic Deformation Wall
Thickness Reduction During Radial Minimum of 30% Expansion and
Plastic Deformation Anisotropy Minimum of 1.5 Minimum Absorbed
Energy at -4 F. (-20 C.) in 80 ft-lb the Longitudinal Direction
Minimum Absorbed Energy at -4 F. (-20 C.) in 60 ft-lb the
Transverse Direction Minimum Absorbed Energy at -4 F. (-20 C.) 60
ft-lb Transverse To A Weld Area Flare Expansion Testing Minimum of
75% Without A Failure Increase in Yield Strength Due To Radial
Greater than 5.4% Expansion and Plastic Deformation
[0164] In an exemplary embodiment, one or more of the expandable
tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or
204, are characterized by an expandability coefficient f: i.
f=r.times.n (2) [0165] where f=expandability coefficient; [0166] 1.
r=anisotropy coefficient; and [0167] 2. n=strain hardening
exponent.
[0168] In an exemplary embodiment, the anisotropy coefficient for
one or more of the expandable tubular members, 12, 14, 24, 26, 102,
104, 106, 108, 202 and/or 204 is greater than 1. In an exemplary
embodiment, the strain hardening exponent for one or more of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202
and/or 204 is greater than 0.12. In an exemplary embodiment, the
expandability coefficient for one or more of the expandable tubular
members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is
greater than 0.12.
[0169] In an exemplary embodiment, a tubular member having a higher
expandability coefficient requires less power and/or energy to
radially expand and plastically deform each unit length than a
tubular member having a lower expandability coefficient. In an
exemplary embodiment, a tubular member having a higher
expandability coefficient requires less power and/or energy per
unit length to radially expand and plastically deform than a
tubular member having a lower expandability coefficient.
[0170] In several exemplary experimental embodiments, one or more
of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204, are steel alloys having one of the following
compositions: TABLE-US-00002 Steel Element and Percentage By Weight
Alloy C Mn P S Si Cu Ni Cr A 0.065 1.44 0.01 0.002 0.24 0.01 0.01
0.02 B 0.18 1.28 0.017 0.004 0.29 0.01 0.01 0.03 C 0.08 0.82 0.006
0.003 0.30 0.16 0.05 0.05 D 0.02 1.31 0.02 0.001 0.45 -- 9.1
18.7
[0171] In exemplary experimental embodiment, as illustrated in FIG.
20, a sample of an expandable tubular member composed of Alloy A
exhibited a yield point before radial expansion and plastic
deformation YP.sub.BE, a yield point after radial expansion and
plastic deformation of about 16% YP.sub.AE16%, and a yield point
after radial expansion and plastic deformation of about 24%
YP.sub.AE24%. In an exemplary experimental embodiment,
YP.sub.AE24%>YP.sub.AE16%>YP.sub.BE. Furthermore, in an
exemplary experimental embodiment, the ductility of the sample of
the expandable tubular member composed of Alloy A also exhibited a
higher ductility prior to radial expansion and plastic deformation
than after radial expansion and plastic deformation. These were
unexpected results.
[0172] In an exemplary experimental embodiment, a sample of an
expandable tubular member composed of Alloy A exhibited the
following tensile characteristics before and after radial expansion
and plastic deformation: TABLE-US-00003 Yield Wall Point Yield
Width Thickness ksi Ratio Elongation % Reduction % Reduction %
Anisotropy Before 46.9 0.69 53 -52 55 0.93 Radial Expansion and
Plastic Deformation After 16% 65.9 0.83 17 42 51 0.78 Radial
Expansion After 24% 68.5 0.83 5 44 54 0.76 Radial Expansion %
Increase 40% for 16% radial expansion 46% for 24% radial
expansion
[0173] In exemplary experimental embodiment, as illustrated in FIG.
21, a sample of an expandable tubular member composed of Alloy B
exhibited a yield point before radial expansion and plastic
deformation YP.sub.BE, a yield point after radial expansion and
plastic deformation of about 16% YP.sub.AE16%, and a yield point
after radial expansion and plastic deformation of about 24%
YP.sub.AE24%. In an exemplary embodiment,
YP.sub.AE24%>YP.sub.AE16%>YP.sub.BE. Furthermore, in an
exemplary experimental embodiment, the ductility of the sample of
the expandable tubular member composed of Alloy B also exhibited a
higher ductility prior to radial expansion and plastic deformation
than after radial expansion and plastic deformation. These were
unexpected results.
[0174] In an exemplary experimental embodiment, a sample of an
expandable tubular member composed of Alloy B exhibited the
following tensile characteristics before and after radial expansion
and plastic deformation: TABLE-US-00004 Yield Wall Point Yield
Width Thickness ksi Ratio Elongation % Reduction % Reduction %
Anisotropy Before 57.8 0.71 44 43 46 0.93 Radial Expansion and
Plastic Deformation After 16% 74.4 0.84 16 38 42 0.87 Radial
Expansion After 24% 79.8 0.86 20 36 42 0.81 Radial Expansion %
Increase 28.7% increase for 16% radial expansion 38% increase for
24% radial expansion
[0175] In an exemplary experimental embodiment, samples of
expandable tubulars composed of Alloys A, B, C, and D exhibited the
following tensile characteristics prior to radial expansion and
plastic deformation: TABLE-US-00005 Elon- Absorbed Steel Yield
Yield gation Energy Expandability Alloy ksi Ratio % Anisotropy
ft-lb Coefficient A 47.6 0.71 44 1.48 145 B 57.8 0.71 44 1.04 62.2
C 61.7 0.80 39 1.92 268 D 48 0.55 56 1.34 --
[0176] In an exemplary embodiment, one or more of the expandable
tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
have a strain hardening exponent greater than 0.12, and a yield
ratio is less than 0.85.
[0177] In an exemplary embodiment, the carbon equivalent C.sub.e,
for tubular members having a carbon content (by weight percentage)
less than or equal to 0.12%, is given by the following expression:
C.sub.e=C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15 (3)
[0178] where C.sub.e=carbon equivalent value;
[0179] b. C=carbon percentage by weight;
[0180] c. Mn=manganese percentage by weight;
[0181] d. Cr=chromium percentage by weight;
[0182] e. Mo=molybdenum percentage by weight;
[0183] f. V=vanadium percentage by weight;
[0184] g. Ti=titanium percentage by weight;
[0185] h. Nb=niobium percentage by weight;
[0186] i. Ni=nickel percentage by weight; and
[0187] j. Cu=copper percentage by weight.
[0188] In an exemplary embodiment, the carbon equivalent value
C.sub.e, for tubular members having a carbon content less than or
equal to 0.12% (by weight), for one or more of the expandable
tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204
is less than 0.21.
[0189] In an exemplary embodiment, the carbon equivalent C.sub.e,
for tubular members having more than 0.12% carbon content (by
weight), is given by the following expression:
C.sub.e=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B (4) [0190] where
C.sub.e=carbon equivalent value;
[0191] k. C=carbon percentage by weight;
[0192] l. Si=silicon percentage by weight;
[0193] m. Mn=manganese percentage by weight;
[0194] n. Cu=copper percentage by weight;
[0195] o. Cr=chromium percentage by weight;
[0196] p. Ni=nickel percentage by weight;
[0197] q. Mo=molybdenum percentage by weight;
[0198] r. V=vanadium percentage by weight; and
[0199] s. B=boron percentage by weight.
[0200] In an exemplary embodiment, the carbon equivalent value
C.sub.e, for tubular members having greater than 0.12% carbon
content (by weight), for one or more of the expandable tubular
members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less
than 0.36.
[0201] Referring to FIG. 22 in an exemplary embodiment, a first
tubular member 2210 includes an internally threaded connection 2212
at an end portion 2214. A first end of a tubular sleeve 2216 that
includes an internal flange 2218 having a tapered portion 2220, and
a second end that includes a tapered portion 2222, is then mounted
upon and receives the end portion 2214 of the first tubular member
2210. In an exemplary embodiment, the end portion 2214 of the first
tubular member 2210 abuts one side of the internal flange 2218 of
the tubular sleeve 2216, and the internal diameter of the internal
flange 2218 of the tubular sleeve 2216 is substantially equal to or
greater than the maximum internal diameter of the internally
threaded connection 2212 of the end portion 2214 of the first
tubular member 2210. An externally threaded connection 2224 of an
end portion 2226 of a second tubular member 2228 having an annular
recess 2230 is then positioned within the tubular sleeve 2216 and
threadably coupled to the internally threaded connection 2212 of
the end portion 2214 of the first tubular member 2210. In an
exemplary embodiment, the internal flange 2218 of the tubular
sleeve 2216 mates with and is received within the annular recess
2230 of the end portion 2226 of the second tubular member 2228.
Thus, the tubular sleeve 2216 is coupled to and surrounds the
external surfaces of the first and second tubular members, 2210 and
2228.
[0202] The internally threaded connection 2212 of the end portion
2214 of the first tubular member 2210 is a box connection, and the
externally threaded connection 2224 of the end portion 2226 of the
second tubular member 2228 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2216 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members, 2210 and 2228. In this
manner, during the threaded coupling of the first and second
tubular members, 2210 and 2228, fluidic materials within the first
and second tubular members may be vented from the tubular
members.
[0203] As illustrated in FIG. 22, the first and second tubular
members, 2210 and 2228, and the tubular sleeve 2216 may be
positioned within another structure 2232 such as, for example, a
cased or uncased wellbore, and radially expanded and plastically
deformed, for example, by displacing and/or rotating a conventional
expansion device 2234 within and/or through the interiors of the
first and second tubular members. The tapered portions, 2220 and
2222, of the tubular sleeve 2216 facilitate the insertion and
movement of the first and second tubular members within and through
the structure 2232, and the movement of the expansion device 2234
through the interiors of the first and second tubular members, 2210
and 2228, may be, for example, from top to bottom or from bottom to
top.
[0204] During the radial expansion and plastic deformation of the
first and second tubular members, 2210 and 2228, the tubular sleeve
2216 is also radially expanded and plastically deformed. As a
result, the tubular sleeve 2216 may be maintained in
circumferential tension and the end portions, 2214 and 2226, of the
first and second tubular members, 2210 and 2228, may be maintained
in circumferential compression.
[0205] Sleeve 2216 increases the axial compression loading of the
connection between tubular members 2210 and 2228 before and after
expansion by the expansion device 2234. Sleeve 2216 may, for
example, be secured to tubular members 2210 and 2228 by a heat
shrink fit.
[0206] In several alternative embodiments, the first and second
tubular members, 2210 and 2228, are radially expanded and
plastically deformed using other conventional methods for radially
expanding and plastically deforming tubular members such as, for
example, internal pressurization, hydroforming, and/or roller
expansion devices and/or any one or combination of the conventional
commercially available expansion products and services available
from Baker Hughes, Weatherford International, and/or Enventure
Global Technology L.L.C.
[0207] The use of the tubular sleeve 2216 during (a) the coupling
of the first tubular member 2210 to the second tubular member 2228,
(b) the placement of the first and second tubular members in the
structure 2232, and (c) the radial expansion and plastic
deformation of the first and second tubular members provides a
number of significant benefits. For example, the tubular sleeve
2216 protects the exterior surfaces of the end portions, 2214 and
2226, of the first and second tubular members, 2210 and 2228,
during handling and insertion of the tubular members within the
structure 2232. In this manner, damage to the exterior surfaces of
the end portions, 2214 and 2226, of the first and second tubular
members, 2210 and 2228, is avoided that could otherwise result in
stress concentrations that could cause a catastrophic failure
during subsequent radial expansion operations. Furthermore, the
tubular sleeve 2216 provides an alignment guide that facilitates
the insertion and threaded coupling of the second tubular member
2228 to the first tubular member 2210. In this manner, misalignment
that could result in damage to the threaded connections, 2212 and
2224, of the first and second tubular members, 2210 and 2228, may
be avoided. In addition, during the relative rotation of the second
tubular member with respect to the first tubular member, required
during the threaded coupling of the first and second tubular
members, the tubular sleeve 2216 provides an indication of to what
degree the first and second tubular members are threadably coupled.
For example, if the tubular sleeve 2216 can be easily rotated, that
would indicate that the first and second tubular members, 2210 and
2228, are not fully threadably coupled and in intimate contact with
the internal flange 2218 of the tubular sleeve. Furthermore, the
tubular sleeve 2216 may prevent crack propagation during the radial
expansion and plastic deformation of the first and second tubular
members, 2210 and 2228. In this manner, failure modes such as, for
example, longitudinal cracks in the end portions, 2214 and 2226, of
the first and second tubular members may be limited in severity or
eliminated all together. In addition, after completing the radial
expansion and plastic deformation of the first and second tubular
members, 2210 and 2228, the tubular sleeve 2216 may provide a fluid
tight metal-to-metal seal between interior surface of the tubular
sleeve 2216 and the exterior surfaces of the end portions, 2214 and
2226, of the first and second tubular members. In this manner,
fluidic materials are prevented from passing through the threaded
connections, 2212 and 2224, of the first and second tubular
members, 2210 and 2228, into the annulus between the first and
second tubular members and the structure 2232. Furthermore,
because, following the radial expansion and plastic deformation of
the first and second tubular members, 2210 and 2228, the tubular
sleeve 2216 may be maintained in circumferential tension and the
end portions, 2214 and 2226, of the first and second tubular
members, 2210 and 2228, may be maintained in circumferential
compression, axial loads and/or torque loads may be transmitted
through the tubular sleeve.
[0208] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2210 and 2228, and the
tubular sleeve 2216 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0209] Referring to FIG. 23, in an exemplary embodiment, a first
tubular member 210 includes an internally threaded connection 2312
at an end portion 2314. A first end of a tubular sleeve 2316
includes an internal flange 2318 and a tapered portion 2320. A
second end of the sleeve 2316 includes an internal flange 2321 and
a tapered portion 2322. An externally threaded connection 2324 of
an end portion 2326 of a second tubular member 2328 having an
annular recess 2330, is then positioned within the tubular sleeve
2316 and threadably coupled to the internally threaded connection
2312 of the end portion 2314 of the first tubular member 2310. The
internal flange 2318 of the sleeve 2316 mates with and is received
within the annular recess 2330.
[0210] The first tubular member 2310 includes a recess 2331. The
internal flange 2321 mates with and is received within the annular
recess 2331. Thus, the sleeve 2316 is coupled to and surrounds the
external surfaces of the first and second tubular members 2310 and
2328.
[0211] The internally threaded connection 2312 of the end portion
2314 of the first tubular member 2310 is a box connection, and the
externally threaded connection 2324 of the end portion 2326 of the
second tubular member 2328 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2316 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members 2310 and 2328. In this manner,
during the threaded coupling of the first and second tubular
members 2310 and 2328, fluidic materials within the first and
second tubular members may be vented from the tubular members.
[0212] As illustrated in FIG. 23, the first and second tubular
members 2310 and 2328, and the tubular sleeve 2316 may then be
positioned within another structure 2332 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device 2334
through and/or within the interiors of the first and second tubular
members. The tapered portions 2320 and 2322, of the tubular sleeve
2316 facilitates the insertion and movement of the first and second
tubular members within and through the structure 2332, and the
displacement of the expansion device 2334 through the interiors of
the first and second tubular members 2310 and 2328, may be from top
to bottom or from bottom to top.
[0213] During the radial expansion and plastic deformation of the
first and second tubular members 2310 and 2328, the tubular sleeve
2316 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2316 may be
maintained in circumferential tension and the end portions 2314 and
2326, of the first and second tubular members 2310 and 2328, may be
maintained in circumferential compression.
[0214] Sleeve 2316 increases the axial tension loading of the
connection between tubular members 2310 and 2328 before and after
expansion by the expansion device 2334. Sleeve 2316 may be secured
to tubular members 2310 and 2328 by a heat shrink fit.
[0215] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2310 and 2328, and the
tubular sleeve 2316 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0216] Referring to FIG. 24, in an exemplary embodiment, a first
tubular member 2410 includes an internally threaded connection 2412
at an end portion 2414. A first end of a tubular sleeve 2416
includes an internal flange 2418 and a tapered portion 2420. A
second end of the sleeve 2416 includes an internal flange 2421 and
a tapered portion 2422. An externally threaded connection 2424 of
an end portion 2426 of a second tubular member 2428 having an
annular recess 2430, is then positioned within the tubular sleeve
2416 and threadably coupled to the internally threaded connection
2412 of the end portion 2414 of the first tubular member 2410. The
internal flange 2418 of the sleeve 2416 mates with and is received
within the annular recess 2430. The first tubular member 2410
includes a recess 2431. The internal flange 2421 mates with and is
received within the annular recess 2431. Thus, the sleeve 2416 is
coupled to and surrounds the external surfaces of the first and
second tubular members 2410 and 2428.
[0217] The internally threaded connection 2412 of the end portion
2414 of the first tubular member 2410 is a box connection, and the
externally threaded connection 2424 of the end portion 2426 of the
second tubular member 2428 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2416 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members 2410 and 2428. In this manner,
during the threaded coupling of the first and second tubular
members 2410 and 2428, fluidic materials within the first and
second tubular members may be vented from the tubular members.
[0218] As illustrated in FIG. 24, the first and second tubular
members 2410 and 2428, and the tubular sleeve 2416 may then be
positioned within another structure 2432 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device 2434
through and/or within the interiors of the first and second tubular
members. The tapered portions 2420 and 2422, of the tubular sleeve
2416 facilitate the insertion and movement of the first and second
tubular members within and through the structure 2432, and the
displacement of the expansion device 2434 through the interiors of
the first and second tubular members, 2410 and 2428, may be from
top to bottom or from bottom to top.
[0219] During the radial expansion and plastic deformation of the
first and second tubular members, 2410 and 2428, the tubular sleeve
2416 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2416 may be
maintained in circumferential tension and the end portions, 2414
and 2426, of the first and second tubular members, 2410 and 2428,
may be maintained in circumferential compression.
[0220] The sleeve 2416 increases the axial compression and tension
loading of the connection between tubular members 2410 and 2428
before and after expansion by expansion device 2424. Sleeve 2416
may be secured to tubular members 2410 and 2428 by a heat shrink
fit.
[0221] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2410 and 2428, and the
tubular sleeve 2416 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0222] Referring to FIG. 25, in an exemplary embodiment, a first
tubular member 2510 includes an internally threaded connection 2512
at an end portion 2514. A first end of a tubular sleeve 2516
includes an internal flange 2518 and a relief 2520. A second end of
the sleeve 2516 includes an internal flange 2521 and a relief 2522.
An externally threaded connection 2524 of an end portion 2526 of a
second tubular member 2528 having an annular recess 2530, is then
positioned within the tubular sleeve 2516 and threadably coupled to
the internally threaded connection 2512 of the end portion 2514 of
the first tubular member 2510. The internal flange 2518 of the
sleeve 2516 mates with and is received within the annular recess
2530. The first tubular member 2510 includes a recess 2531. The
internal flange 2521 mates with and is received within the annular
recess 2531. Thus, the sleeve 2516 is coupled to and surrounds the
external surfaces of the first and second tubular members 2510 and
2528.
[0223] The internally threaded connection 2512 of the end portion
2514 of the first tubular member 2510 is a box connection, and the
externally threaded connection 2524 of the end portion 2526 of the
second tubular member 2528 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2516 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members 2510 and 2528. In this manner,
during the threaded coupling of the first and second tubular
members 2510 and 2528, fluidic materials within the first and
second tubular members may be vented from the tubular members.
[0224] As illustrated in FIG. 25, the first and second tubular
members 2510 and 2528, and the tubular sleeve 2516 may then be
positioned within another structure 2532 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device 2534
through and/or within the interiors of the first and second tubular
members. The reliefs 2520 and 2522 are each filled with a
sacrificial material 2540 including a tapered surface 2542 and
2544, respectively. The material 2540 may be a metal or a
synthetic, and is provided to facilitate the insertion and movement
of the first and second tubular members 2510 and 2528, through the
structure 2532. The displacement of the expansion device 2534
through the interiors of the first and second tubular members 2510
and 2528, may, for example, be from top to bottom or from bottom to
top.
[0225] During the radial expansion and plastic deformation of the
first and second tubular members 2510 and 2528, the tubular sleeve
2516 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2516 may be
maintained in circumferential tension and the end portions 2514 and
2526, of the first and second tubular members, 2510 and 2528, may
be maintained in circumferential compression.
[0226] The addition of the sacrificial material 2540, provided on
sleeve 2516, avoids stress risers on the sleeve 2516 and the
tubular member 2510. The tapered surfaces 2542 and 2544 are
intended to wear or even become damaged, thus incurring such wear
or damage which would otherwise be borne by sleeve 2516. Sleeve
2516 may be secured to tubular members 2510 and 2528 by a heat
shrink fit.
[0227] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2510 and 2528, and the
tubular sleeve 2516 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0228] Referring to FIG. 26, in an exemplary embodiment, a first
tubular member 2610 includes an internally threaded connection 2612
at an end portion 2614. A first end of a tubular sleeve 2616
includes an internal flange 2618 and a tapered portion 2620. A
second end of the sleeve 2616 includes an internal flange 2621 and
a tapered portion 2622. An externally threaded connection 2624 of
an end portion 2626 of a second tubular member 2628 having an
annular recess 2630, is then positioned within the tubular sleeve
2616 and threadably coupled to the internally threaded connection
2612 of the end portion 2614 of the first tubular member 2610. The
internal flange 2618 of the sleeve 2616 mates with and is received
within the annular recess 2630.
[0229] The first tubular member 2610 includes a recess 2631. The
internal flange 2621 mates with and is received within the annular
recess 2631. Thus, the sleeve 2616 is coupled to and surrounds the
external surfaces of the first and second tubular members 2610 and
2628.
[0230] The internally threaded connection 2612 of the end portion
2614 of the first tubular member 2610 is a box connection, and the
externally threaded connection 2624 of the end portion 2626 of the
second tubular member 2628 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2616 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members 2610 and 2628. In this manner,
during the threaded coupling of the first and second tubular
members 2610 and 2628, fluidic materials within the first and
second tubular members may be vented from the tubular members.
[0231] As illustrated in FIG. 26, the first and second tubular
members 2610 and 2628, and the tubular sleeve 2616 may then be
positioned within another structure 2632 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device 2634
through and/or within the interiors of the first and second tubular
members. The tapered portions 2620 and 2622, of the tubular sleeve
2616 facilitates the insertion and movement of the first and second
tubular members within and through the structure 2632, and the
displacement of the expansion device 2634 through the interiors of
the first and second tubular members 2610 and 2628, may, for
example, be from top to bottom or from bottom to top.
[0232] During the radial expansion and plastic deformation of the
first and second tubular members 2610 and 2628, the tubular sleeve
2616 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2616 may be
maintained in circumferential tension and the end portions 2614 and
2626, of the first and second tubular members 2610 and 2628, may be
maintained in circumferential compression.
[0233] Sleeve 2616 is covered by a thin walled cylinder of
sacrificial material 2640. Spaces 2623 and 2624, adjacent tapered
portions 2620 and 2622, respectively, are also filled with an
excess of the sacrificial material 2640. The material may be a
metal or a synthetic, and is provided to facilitate the insertion
and movement of the first and second tubular members 2610 and 2628,
through the structure 2632.
[0234] The addition of the sacrificial material 2640, provided on
sleeve 2616, avoids stress risers on the sleeve 2616 and the
tubular member 2610. The excess of the sacrificial material 2640
adjacent tapered portions 2620 and 2622 are intended to wear or
even become damaged, thus incurring such wear or damage which would
otherwise be borne by sleeve 2616. Sleeve 2616 may be secured to
tubular members 2610 and 2628 by a heat shrink fit.
[0235] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2610 and 2628, and the
tubular sleeve 2616 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0236] Referring to FIG. 27, in an exemplary embodiment, a first
tubular member 2710 includes an internally threaded connection 2712
at an end portion 2714. A first end of a tubular sleeve 2716
includes an internal flange 2718 and a tapered portion 2720. A
second end of the sleeve 2716 includes an internal flange 2721 and
a tapered portion 2722. An externally threaded connection 2724 of
an end portion 2726 of a second tubular member 2728 having an
annular recess 2730, is then positioned within the tubular sleeve
2716 and threadably coupled to the internally threaded connection
2712 of the end portion 2714 of the first tubular member 2710. The
internal flange 2718 of the sleeve 2716 mates with and is received
within the annular recess 2730.
[0237] The first tubular member 2710 includes a recess 2731. The
internal flange 2721 mates with and is received within the annular
recess 2731. Thus, the sleeve 2716 is coupled to and surrounds the
external surfaces of the first and second tubular members 2710 and
2728.
[0238] The internally threaded connection 2712 of the end portion
2714 of the first tubular member 2710 is a box connection, and the
externally threaded connection 2724 of the end portion 2726 of the
second tubular member 2728 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2716 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members 2710 and 2728. In this manner,
during the threaded coupling of the first and second tubular
members 2710 and 2728, fluidic materials within the first and
second tubular members may be vented from the tubular members.
[0239] As illustrated in FIG. 27, the first and second tubular
members 2710 and 2728, and the tubular sleeve 2716 may then be
positioned within another structure 2732 such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device 2734
through and/or within the interiors of the first and second tubular
members. The tapered portions 2720 and 2722, of the tubular sleeve
2716 facilitates the insertion and movement of the first and second
tubular members within and through the structure 2732, and the
displacement of the expansion device 2734 through the interiors of
the first and second tubular members 2710 and 2728, may be from top
to bottom or from bottom to top.
[0240] During the radial expansion and plastic deformation of the
first and second tubular members 2710 and 2728, the tubular sleeve
2716 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2716 may be
maintained in circumferential tension and the end portions 2714 and
2726, of the first and second tubular members 2710 and 2728, may be
maintained in circumferential compression.
[0241] Sleeve 2716 has a variable thickness due to one or more
reduced thickness portions 2790 and/or increased thickness portions
2792.
[0242] Varying the thickness of sleeve 2716 provides the ability to
control or induce stresses at selected positions along the length
of sleeve 2716 and the end portions 2724 and 2726. Sleeve 2716 may
be secured to tubular members 2710 and 2728 by a heat shrink
fit.
[0243] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2710 and 2728, and the
tubular sleeve 2716 have one or more of the material properties of
one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204.
[0244] Referring to FIG. 28, in an alternative embodiment, instead
of varying the thickness of sleeve 2716, the same result described
above with reference to FIG. 27, may be achieved by adding a member
2740 which may be coiled onto the grooves 2739 formed in sleeve
2716, thus varying the thickness along the length of sleeve
2716.
[0245] Referring to FIG. 29, in an exemplary embodiment, a first
tubular member 2910 includes an internally threaded connection 2912
and an internal annular recess 2914 at an end portion 2916. A first
end of a tubular sleeve 2918 includes an internal flange 2920, and
a second end of the sleeve 2916 mates with and receives the end
portion 2916 of the first tubular member 2910. An externally
threaded connection 2922 of an end portion 2924 of a second tubular
member 2926 having an annular recess 2928, is then positioned
within the tubular sleeve 2918 and threadably coupled to the
internally threaded connection 2912 of the end portion 2916 of the
first tubular member 2910. The internal flange 2920 of the sleeve
2918 mates with and is received within the annular recess 2928. A
sealing element 2930 is received within the internal annular recess
2914 of the end portion 2916 of the first tubular member 2910.
[0246] The internally threaded connection 2912 of the end portion
2916 of the first tubular member 2910 is a box connection, and the
externally threaded connection 2922 of the end portion 2924 of the
second tubular member 2926 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 2918 is at
least approximately 0.020'' greater than the outside diameters of
the first tubular member 2910. In this manner, during the threaded
coupling of the first and second tubular members 2910 and 2926,
fluidic materials within the first and second tubular members may
be vented from the tubular members.
[0247] The first and second tubular members 2910 and 2926, and the
tubular sleeve 2918 may be positioned within another structure such
as, for example, a wellbore, and radially expanded and plastically
deformed, for example, by displacing and/or rotating an expansion
device through and/or within the interiors of the first and second
tubular members.
[0248] During the radial expansion and plastic deformation of the
first and second tubular members 2910 and 2926, the tubular sleeve
2918 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 2918 may be
maintained in circumferential tension and the end portions 2916 and
2924, of the first and second tubular members 2910 and 2926,
respectively, may be maintained in circumferential compression.
[0249] In an exemplary embodiment, before, during, and after the
radial expansion and plastic deformation of the first and second
tubular members 2910 and 2926, and the tubular sleeve 2918, the
sealing element 2930 seals the interface between the first and
second tubular members. In an exemplary embodiment, during and
after the radial expansion and plastic deformation of the first and
second tubular members 2910 and 2926, and the tubular sleeve 2918,
a metal to metal seal is formed between at least one of: the first
and second tubular members 2910 and 2926, the first tubular member
and the tubular sleeve 2918, and/or the second tubular member and
the tubular sleeve. In an exemplary embodiment, the metal to metal
seal is both fluid tight and gas tight.
[0250] In several exemplary embodiments, one or more portions of
the first and second tubular members, 2910 and 2926, the tubular
sleeve 2918, and the sealing element 2930 have one or more of the
material properties of one or more of the tubular members 12, 14,
24, 26, 102, 104, 106, 108, 202 and/or 204.
[0251] Referring to FIG. 30a, in an exemplary embodiment, a first
tubular member 3010 includes internally threaded connections 3012a
and 3012b, spaced apart by a cylindrical internal surface 3014, at
an end portion 3016. Externally threaded connections 3018a and
3018b, spaced apart by a cylindrical external surface 3020, of an
end portion 3022 of a second tubular member 3024 are threadably
coupled to the internally threaded connections, 3012a and 3012b,
respectively, of the end portion 3016 of the first tubular member
3010. A sealing element 3026 is received within an annulus defined
between the internal cylindrical surface 3014 of the first tubular
member 3010 and the external cylindrical surface 3020 of the second
tubular member 3024.
[0252] The internally threaded connections, 3012a and 3012b, of the
end portion 3016 of the first tubular member 3010 are box
connections, and the externally threaded connections, 3018a and
3018b, of the end portion 3022 of the second tubular member 3024
are pin connections. In an exemplary embodiment, the sealing
element 3026 is an elastomeric and/or metallic sealing element.
[0253] The first and second tubular members 3010 and 3024 may be
positioned within another structure such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device through
and/or within the interiors of the first and second tubular
members.
[0254] In an exemplary embodiment, before, during, and after the
radial expansion and plastic deformation of the first and second
tubular members 3010 and 3024, the sealing element 3026 seals the
interface between the first and second tubular members. In an
exemplary embodiment, before, during and/or after the radial
expansion and plastic deformation of the first and second tubular
members 3010 and 3024, a metal to metal seal is formed between at
least one of: the first and second tubular members 3010 and 3024,
the first tubular member and the sealing element 3026, and/or the
second tubular member and the sealing element. In an exemplary
embodiment, the metal to metal seal is both fluid tight and gas
tight.
[0255] In an alternative embodiment, the sealing element 3026 is
omitted, and during and/or after the radial expansion and plastic
deformation of the first and second tubular members 3010 and 3024,
a metal to metal seal is formed between the first and second
tubular members.
[0256] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3010 and 3024, the sealing
element 3026 have one or more of the material properties of one or
more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202
and/or 204.
[0257] Referring to FIG. 30b, in an exemplary embodiment, a first
tubular member 3030 includes internally threaded connections 3032a
and 3032b, spaced apart by an undulating approximately cylindrical
internal surface 3034, at an end portion 3036. Externally threaded
connections 3038a and 3038b, spaced apart by a cylindrical external
surface 3040, of an end portion 3042 of a second tubular member
3044 are threadably coupled to the internally threaded connections,
3032a and 3032b, respectively, of the end portion 3036 of the first
tubular member 3030. A sealing element 3046 is received within an
annulus defined between the undulating approximately cylindrical
internal surface 3034 of the first tubular member 3030 and the
external cylindrical surface 3040 of the second tubular member
3044.
[0258] The internally threaded connections, 3032a and 3032b, of the
end portion 3036 of the first tubular member 3030 are box
connections, and the externally threaded connections, 3038a and
3038b, of the end portion 3042 of the second tubular member 3044
are pin connections. In an exemplary embodiment, the sealing
element 3046 is an elastomeric and/or metallic sealing element.
[0259] The first and second tubular members 3030 and 3044 may be
positioned within another structure such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device through
and/or within the interiors of the first and second tubular
members.
[0260] In an exemplary embodiment, before, during, and after the
radial expansion and plastic deformation of the first and second
tubular members 3030 and 3044, the sealing element 3046 seals the
interface between the first and second tubular members. In an
exemplary embodiment, before, during and/or after the radial
expansion and plastic deformation of the first and second tubular
members 3030 and 3044, a metal to metal seal is formed between at
least one of: the first and second tubular members 3030 and 3044,
the first tubular member and the sealing element 3046, and/or the
second tubular member and the sealing element. In an exemplary
embodiment, the metal to metal seal is both fluid tight and gas
tight.
[0261] In an alternative embodiment, the sealing element 3046 is
omitted, and during and/or after the radial expansion and plastic
deformation of the first and second tubular members 3030 and 3044,
a metal to metal seal is formed between the first and second
tubular members.
[0262] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3030 and 3044, the sealing
element 3046 have one or more of the material properties of one or
more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202
and/or 204.
[0263] Referring to FIG. 30c, in an exemplary embodiment, a first
tubular member 3050 includes internally threaded connections 3052a
and 3052b, spaced apart by a cylindrical internal surface 3054
including one or more square grooves 3056, at an end portion 3058.
Externally threaded connections 3060a and 3060b, spaced apart by a
cylindrical external surface 3062 including one or more square
grooves 3064, of an end portion 3066 of a second tubular member
3068 are threadably coupled to the internally threaded connections,
3052a and 3052b, respectively, of the end portion 3058 of the first
tubular member 3050. A sealing element 3070 is received within an
annulus defined between the cylindrical internal surface 3054 of
the first tubular member 3050 and the external cylindrical surface
3062 of the second tubular member 3068.
[0264] The internally threaded connections, 3052a and 3052b, of the
end portion 3058 of the first tubular member 3050 are box
connections, and the externally threaded connections, 3060a and
3060b, of the end portion 3066 of the second tubular member 3068
are pin connections. In an exemplary embodiment, the sealing
element 3070 is an elastomeric and/or metallic sealing element.
[0265] The first and second tubular members 3050 and 3068 may be
positioned within another structure such as, for example, a
wellbore, and radially expanded and plastically deformed, for
example, by displacing and/or rotating an expansion device through
and/or within the interiors of the first and second tubular
members.
[0266] In an exemplary embodiment, before, during, and after the
radial expansion and plastic deformation of the first and second
tubular members 3050 and 3068, the sealing element 3070 seals the
interface between the first and second tubular members. In an
exemplary embodiment, before, during and/or after the radial
expansion and plastic deformation of the first and second tubular
members, 3050 and 3068, a metal to metal seal is formed between at
least one of: the first and second tubular members, the first
tubular member and the sealing element 3070, and/or the second
tubular member and the sealing element. In an exemplary embodiment,
the metal to metal seal is both fluid tight and gas tight.
[0267] In an alternative embodiment, the sealing element 3070 is
omitted, and during and/or after the radial expansion and plastic
deformation of the first and second tubular members 950 and 968, a
metal to metal seal is formed between the first and second tubular
members.
[0268] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3050 and 3068, the sealing
element 3070 have one or more of the material properties of one or
more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202
and/or 204.
[0269] Referring to FIG. 31, in an exemplary embodiment, a first
tubular member 3110 includes internally threaded connections, 3112a
and 3112b, spaced apart by a non-threaded internal surface 3114, at
an end portion 3116. Externally threaded connections, 3118a and
3118b, spaced apart by a non-threaded external surface 3120, of an
end portion 3122 of a second tubular member 3124 are threadably
coupled to the internally threaded connections, 3112a and 3112b,
respectively, of the end portion 3122 of the first tubular member
3124.
[0270] First, second, and/or third tubular sleeves, 3126, 3128, and
3130, are coupled the external surface of the first tubular member
3110 in opposing relation to the threaded connection formed by the
internal and external threads, 3112a and 3118a, the interface
between the non-threaded surfaces, 3114 and 3120, and the threaded
connection formed by the internal and external threads, 3112b and
3118b, respectively.
[0271] The internally threaded connections, 3112a and 3112b, of the
end portion 3116 of the first tubular member 3110 are box
connections, and the externally threaded connections, 3118a and
3118b, of the end portion 3122 of the second tubular member 3124
are pin connections.
[0272] The first and second tubular members 3110 and 3124, and the
tubular sleeves 3126, 3128, and/or 3130, may then be positioned
within another structure 3132 such as, for example, a wellbore, and
radially expanded and plastically deformed, for example, by
displacing and/or rotating an expansion device 3134 through and/or
within the interiors of the first and second tubular members.
[0273] During the radial expansion and plastic deformation of the
first and second tubular members 3110 and 3124, the tubular sleeves
3126, 3128 and/or 3130 are also radially expanded and plastically
deformed. In an exemplary embodiment, as a result, the tubular
sleeves 3126, 3128, and/or 3130 are maintained in circumferential
tension and the end portions 3116 and 3122, of the first and second
tubular members 3110 and 3124, may be maintained in circumferential
compression.
[0274] The sleeves 3126, 3128, and/or 3130 may, for example, be
secured to the first tubular member 3110 by a heat shrink fit.
[0275] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3110 and 3124, and the
sleeves, 3126, 3128, and 3130, have one or more of the material
properties of one or more of the tubular members 12, 14, 24, 26,
102, 104, 106, 108, 202 and/or 204.
[0276] Referring to FIG. 32a, in an exemplary embodiment, a first
tubular member 3210 includes an internally threaded connection 3212
at an end portion 3214. An externally threaded connection 3216 of
an end portion 3218 of a second tubular member 3220 are threadably
coupled to the internally threaded connection 3212 of the end
portion 3214 of the first tubular member 3210.
[0277] The internally threaded connection 3212 of the end portion
3214 of the first tubular member 3210 is a box connection, and the
externally threaded connection 3216 of the end portion 3218 of the
second tubular member 3220 is a pin connection.
[0278] A tubular sleeve 3222 including internal flanges 3224 and
3226 is positioned proximate and surrounding the end portion 3214
of the first tubular member 3210. As illustrated in FIG. 32b, the
tubular sleeve 3222 is then forced into engagement with the
external surface of the end portion 3214 of the first tubular
member 3210 in a conventional manner. As a result, the end
portions, 3214 and 3218, of the first and second tubular members,
3210 and 3220, are upset in an undulating fashion.
[0279] The first and second tubular members 3210 and 3220, and the
tubular sleeve 3222, may then be positioned within another
structure such as, for example, a wellbore, and radially expanded
and plastically deformed, for example, by displacing and/or
rotating an expansion device through and/or within the interiors of
the first and second tubular members.
[0280] During the radial expansion and plastic deformation of the
first and second tubular members 3210 and 3220, the tubular sleeve
3222 is also radially expanded and plastically deformed. In an
exemplary embodiment, as a result, the tubular sleeve 3222 is
maintained in circumferential tension and the end portions 3214 and
3218, of the first and second tubular members 3210 and 3220, may be
maintained in circumferential compression.
[0281] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3210 and 3220, and the sleeve
3222 have one or more of the material properties of one or more of
the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or
204.
[0282] Referring to FIG. 33, in an exemplary embodiment, a first
tubular member 3310 includes an internally threaded connection 3312
and an annular projection 3314 at an end portion 3316.
[0283] A first end of a tubular sleeve 3318 that includes an
internal flange 3320 having a tapered portion 3322 and an annular
recess 3324 for receiving the annular projection 3314 of the first
tubular member 3310, and a second end that includes a tapered
portion 3326, is then mounted upon and receives the end portion
3316 of the first tubular member 3310.
[0284] In an exemplary embodiment, the end portion 3316 of the
first tubular member 3310 abuts one side of the internal flange
3320 of the tubular sleeve 3318 and the annular projection 3314 of
the end portion of the first tubular member mates with and is
received within the annular recess 3324 of the internal flange of
the tubular sleeve, and the internal diameter of the internal
flange 3320 of the tubular sleeve 3318 is substantially equal to or
greater than the maximum internal diameter of the internally
threaded connection 3312 of the end portion 3316 of the first
tubular member 3310. An externally threaded connection 3326 of an
end portion 3328 of a second tubular member 3330 having an annular
recess 3332 is then positioned within the tubular sleeve 3318 and
threadably coupled to the internally threaded connection 3312 of
the end portion 3316 of the first tubular member 3310. In an
exemplary embodiment, the internal flange 3332 of the tubular
sleeve 3318 mates with and is received within the annular recess
3332 of the end portion 3328 of the second tubular member 3330.
Thus, the tubular sleeve 3318 is coupled to and surrounds the
external surfaces of the first and second tubular members, 3310 and
3328.
[0285] The internally threaded connection 3312 of the end portion
3316 of the first tubular member 3310 is a box connection, and the
externally threaded connection 3326 of the end portion 3328 of the
second tubular member 3330 is a pin connection. In an exemplary
embodiment, the internal diameter of the tubular sleeve 3318 is at
least approximately 0.020'' greater than the outside diameters of
the first and second tubular members, 3310 and 3330. In this
manner, during the threaded coupling of the first and second
tubular members, 3310 and 3330, fluidic materials within the first
and second tubular members may be vented from the tubular
members.
[0286] As illustrated in FIG. 33, the first and second tubular
members, 3310 and 3330, and the tubular sleeve 3318 may be
positioned within another structure 3334 such as, for example, a
cased or uncased wellbore, and radially expanded and plastically
deformed, for example, by displacing and/or rotating a conventional
expansion device 3336 within and/or through the interiors of the
first and second tubular members. The tapered portions, 3322 and
3326, of the tubular sleeve 3318 facilitate the insertion and
movement of the first and second tubular members within and through
the structure 3334, and the movement of the expansion device 3336
through the interiors of the first and second tubular members, 3310
and 3330, may, for example, be from top to bottom or from bottom to
top.
[0287] During the radial expansion and plastic deformation of the
first and second tubular members, 3310 and 3330, the tubular sleeve
3318 is also radially expanded and plastically deformed. As a
result, the tubular sleeve 3318 may be maintained in
circumferential tension and the end portions, 3316 and 3328, of the
first and second tubular members, 3310 and 3330, may be maintained
in circumferential compression.
[0288] Sleeve 3316 increases the axial compression loading of the
connection between tubular members 3310 and 3330 before and after
expansion by the expansion device 3336. Sleeve 3316 may be secured
to tubular members 3310 and 3330, for example, by a heat shrink
fit.
[0289] In several alternative embodiments, the first and second
tubular members, 3310 and 3330, are radially expanded and
plastically deformed using other conventional methods for radially
expanding and plastically deforming tubular members such as, for
example, internal pressurization, hydroforming, and/or roller
expansion devices and/or any one or combination of the conventional
commercially available expansion products and services available
from Baker Hughes, Weatherford International, and/or Enventure
Global Technology L.L.C.
[0290] The use of the tubular sleeve 3318 during (a) the coupling
of the first tubular member 3310 to the second tubular member 3330,
(b) the placement of the first and second tubular members in the
structure 3334, and (c) the radial expansion and plastic
deformation of the first and second tubular members provides a
number of significant benefits. For example, the tubular sleeve
3318 protects the exterior surfaces of the end portions, 3316 and
3328, of the first and second tubular members, 3310 and 3330,
during handling and insertion of the tubular members within the
structure 3334. In this manner, damage to the exterior surfaces of
the end portions, 3316 and 3328, of the first and second tubular
members, 3310 and 3330, is avoided that could otherwise result in
stress concentrations that could cause a catastrophic failure
during subsequent radial expansion operations. Furthermore, the
tubular sleeve 3318 provides an alignment guide that facilitates
the insertion and threaded coupling of the second tubular member
3330 to the first tubular member 3310. In this manner, misalignment
that could result in damage to the threaded connections, 3312 and
3326, of the first and second tubular members, 3310 and 3330, may
be avoided. In addition, during the relative rotation of the second
tubular member with respect to the first tubular member, required
during the threaded coupling of the first and second tubular
members, the tubular sleeve 3318 provides an indication of to what
degree the first and second tubular members are threadably coupled.
For example, if the tubular sleeve 3318 can be easily rotated, that
would indicate that the first and second tubular members, 3310 and
3330, are not fully threadably coupled and in intimate contact with
the internal flange 3320 of the tubular sleeve. Furthermore, the
tubular sleeve 3318 may prevent crack propagation during the radial
expansion and plastic deformation of the first and second tubular
members, 3310 and 3330. In this manner, failure modes such as, for
example, longitudinal cracks in the end portions, 3316 and 3328, of
the first and second tubular members may be limited in severity or
eliminated all together. In addition, after completing the radial
expansion and plastic deformation of the first and second tubular
members, 3310 and 3330, the tubular sleeve 3318 may provide a fluid
tight metal-to-metal seal between interior surface of the tubular
sleeve 3318 and the exterior surfaces of the end portions, 3316 and
3328, of the first and second tubular members. In this manner,
fluidic materials are prevented from passing through the threaded
connections, 3312 and 3326, of the first and second tubular
members, 3310 and 3330, into the annulus between the first and
second tubular members and the structure 3334. Furthermore,
because, following the radial expansion and plastic deformation of
the first and second tubular members, 3310 and 3330, the tubular
sleeve 3318 may be maintained in circumferential tension and the
end portions, 3316 and 3328, of the first and second tubular
members, 3310 and 3330, may be maintained in circumferential
compression, axial loads and/or torque loads may be transmitted
through the tubular sleeve.
[0291] In several exemplary embodiments, one or more portions of
the first and second tubular members, 3310 and 3330, and the sleeve
3318 have one or more of the material properties of one or more of
the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or
204.
[0292] Referring to FIGS. 34a, 34b, and 34c, in an exemplary
embodiment, a first tubular member 3410 includes an internally
threaded connection 1312 and one or more external grooves 3414 at
an end portion 3416.
[0293] A first end of a tubular sleeve 3418 that includes an
internal flange 3420 and a tapered portion 3422, a second end that
includes a tapered portion 3424, and an intermediate portion that
includes one or more longitudinally aligned openings 3426, is then
mounted upon and receives the end portion 3416 of the first tubular
member 3410.
[0294] In an exemplary embodiment, the end portion 3416 of the
first tubular member 3410 abuts one side of the internal flange
3420 of the tubular sleeve 3418, and the internal diameter of the
internal flange 3420 of the tubular sleeve 3416 is substantially
equal to or greater than the maximum internal diameter of the
internally threaded connection 3412 of the end portion 3416 of the
first tubular member 3410. An externally threaded connection 3428
of an end portion 3430 of a second tubular member 3432 that
includes one or more internal grooves 3434 is then positioned
within the tubular sleeve 3418 and threadably coupled to the
internally threaded connection 3412 of the end portion 3416 of the
first tubular member 3410. In an exemplary embodiment, the internal
flange 3420 of the tubular sleeve 3418 mates with and is received
within an annular recess 3436 defined in the end portion 3430 of
the second tubular member 3432. Thus, the tubular sleeve 3418 is
coupled to and surrounds the external surfaces of the first and
second tubular members, 3410 and 3432.
[0295] The first and second tubular members, 3410 and 3432, and the
tubular sleeve 3418 may be positioned within another structure such
as, for example, a cased or uncased wellbore, and radially expanded
and plastically deformed, for example, by displacing and/or
rotating a conventional expansion device within and/or through the
interiors of the first and second tubular members. The tapered
portions, 3422 and 3424, of the tubular sleeve 3418 facilitate the
insertion and movement of the first and second tubular members
within and through the structure, and the movement of the expansion
device through the interiors of the first and second tubular
members, 3410 and 3432, may be from top to bottom or from bottom to
top.
[0296] During the radial expansion and plastic deformation of the
first and second tubular members, 3410 and 3432, the tubular sleeve
3418 is also radially expanded and plastically deformed. As a
result, the tubular sleeve 3418 may be maintained in
circumferential tension and the end portions, 3416 and 3430, of the
first and second tubular members, 3410 and 3432, may be maintained
in circumferential compression.
[0297] Sleeve 3416 increases the axial compression loading of the
connection between tubular members 3410 and 3432 before and after
expansion by the expansion device. The sleeve 3418 may be secured
to tubular members 3410 and 3432, for example, by a heat shrink
fit.
[0298] During the radial expansion and plastic deformation of the
first and second tubular members, 3410 and 3432, the grooves 3414
and/or 3434 and/or the openings 3426 provide stress concentrations
that in turn apply added stress forces to the mating threads of the
threaded connections, 3412 and 3428. As a result, during and after
the radial expansion and plastic deformation of the first and
second tubular members, 3410 and 3432, the mating threads of the
threaded connections, 3412 and 3428, are maintained in metal to
metal contact thereby providing a fluid and gas tight connection.
In an exemplary embodiment, the orientations of the grooves 3414
and/or 3434 and the openings 3426 are orthogonal to one another. In
an exemplary embodiment, the grooves 3414 and/or 3434 are helical
grooves.
[0299] In several alternative embodiments, the first and second
tubular members, 3410 and 3432, are radially expanded and
plastically deformed using other conventional methods for radially
expanding and plastically deforming tubular members such as, for
example, internal pressurization, hydroforming, and/or roller
expansion devices and/or any one or combination of the conventional
commercially available expansion products and services available
from Baker Hughes, Weatherford International, and/or Enventure
Global Technology L.L.C.
[0300] The use of the tubular sleeve 3418 during (a) the coupling
of the first tubular member 3410 to the second tubular member 3432,
(b) the placement of the first and second tubular members in the
structure, and (c) the radial expansion and plastic deformation of
the first and second tubular members provides a number of
significant benefits. For example, the tubular sleeve 3418 protects
the exterior surfaces of the end portions, 3416 and 3430, of the
first and second tubular members, 3410 and 3432, during handling
and insertion of the tubular members within the structure. In this
manner, damage to the exterior surfaces of the end portions, 3416
and 3430, of the first and second tubular members, 3410 and 3432,
is avoided that could otherwise result in stress concentrations
that could cause a catastrophic failure during subsequent radial
expansion operations. Furthermore, the tubular sleeve 3418 provides
an alignment guide that facilitates the insertion and threaded
coupling of the second tubular member 3432 to the first tubular
member 3410. In this manner, misalignment that could result in
damage to the threaded connections, 3412 and 3428, of the first and
second tubular members, 3410 and 3432, may be avoided. In addition,
during the relative rotation of the second tubular member with
respect to the first tubular member, required during the threaded
coupling of the first and second tubular members, the tubular
sleeve 3416 provides an indication of to what degree the first and
second tubular members are threadably coupled. For example, if the
tubular sleeve 3418 can be easily rotated, that would indicate that
the first and second tubular members, 3410 and 3432, are not fully
threadably coupled and in intimate contact with the internal flange
3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418
may prevent crack propagation during the radial expansion and
plastic deformation of the first and second tubular members, 3410
and 3432. In this manner, failure modes such as, for example,
longitudinal cracks in the end portions, 3416 and 3430, of the
first and second tubular members may be limited in severity or
eliminated all together. In addition, after completing the radial
expansion and plastic deformation of the first and second tubular
members, 3410 and 3432, the tubular sleeve 3418 may provide a fluid
and gas tight metal-to-metal seal between interior surface of the
tubular sleeve 3418 and the exterior surfaces of the end portions,
3416 and 3430, of the first and second tubular members. In this
manner, fluidic materials are prevented from passing through the
threaded connections, 3412 and 3430, of the first and second
tubular members, 3410 and 3432, into the annulus between the first
and second tubular members and the structure. Furthermore, because,
following the radial expansion and plastic deformation of the first
and second tubular members, 3410 and 3432, the tubular sleeve 3418
may be maintained in circumferential tension and the end portions,
3416 and 3430, of the first and second tubular members, 3410 and
3432, may be maintained in circumferential compression, axial loads
and/or torque loads may be transmitted through the tubular
sleeve.
[0301] In several exemplary embodiments, the first and second
tubular members described above with reference to FIGS. 1 to 34c
are radially expanded and plastically deformed using the expansion
device in a conventional manner and/or using one or more of the
methods and apparatus disclosed in one or more of the following:
The present application is related to the following: (1) U.S.
patent application Ser. No. 09/454,139, attorney docket no.
25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application
Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb.
23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney
docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent
application Ser. No. 09/440,338, attorney docket no. 25791.9.02,
filed on Nov. 15, 1999, (5) U.S. patent application Ser. No.
09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, (6) U.S. patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, (8) U.S. patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
(9) U.S. patent application Ser. No. 09/559,122, attorney docket
no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent
application serial no. PCT/US00/18635, attorney docket no.
25791.25.02, filed on Jul. 9, 2000, (11) U.S. provisional patent
application Ser. No. 60/162,671, attorney docket no. 25791.27,
filed on Nov. 1, 1999, (12) U.S. provisional patent application
Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep.
16, 1999, (13) U.S. provisional patent application Ser. No.
60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999,
(14) U.S. provisional patent application Ser. No. 60/159,039,
attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S.
provisional patent application Ser. No. 60/159,033, attorney docket
no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent
application Ser. No. 60/212,359, attorney docket no. 25791.38,
filed on Jun. 19, 2000, (17) U.S. provisional patent application
Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov.
12, 1999, (18) U.S. provisional patent application Ser. No.
60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000,
(19) U.S. provisional patent application Ser. No. 60/221,645,
attorney docket no. 25791.46, filed on Jul. 28, 2000, (20) U.S.
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (21) U.S. provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (22) U.S. provisional patent application
Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb.
20, 2001, (23) U.S. provisional patent application Ser. No.
60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001,
(24) U.S. provisional patent application Ser. No. 60/259,486,
attorney docket no. 25791.52, filed on Jan. 3, 2001, (25) U.S.
provisional patent application Ser. No. 60/303,740, attorney docket
no. 25791.61, filed on Jul. 6, 2001, (26) U.S. provisional patent
application Ser. No. 60/313,453, attorney docket no. 25791.59,
filed on Aug. 20, 2001, (27) U.S. provisional patent application
Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6,
2001, (28) U.S. provisional patent application Ser. No.
60/3318,386, attorney docket no. 25791.67.02, filed on Sep. 10,
2001, (29) U.S. utility patent application Ser. No. 09/969,922,
attorney docket no. 25791.69, filed on Oct. 3, 2001, (30) U.S.
utility patent application Ser. No. 10/016,467, attorney docket no.
25791.70, filed on Dec. 10, 2001, (31) U.S. provisional patent
application Ser. No. 60/343,674, attorney docket no. 25791.68,
filed on Dec. 27, 2001; and (32) U.S. provisional patent
application Ser. No. 60/346,309, attorney docket no. 25791.92,
filed on Jan. 7, 2002, the disclosures of which are incorporated
herein by reference.
[0302] Referring to FIG. 35a an exemplary embodiment of an
expandable tubular member 3500 includes a first tubular region 3502
and a second tubular portion 3504. In an exemplary embodiment, the
material properties of the first and second tubular regions, 3502
and 3504, are different. In an exemplary embodiment, the yield
points of the first and second tubular regions, 3502 and 3504, are
different. In an exemplary embodiment, the yield point of the first
tubular region 3502 is less than the yield point of the second
tubular region 3504. In several exemplary embodiments, one or more
of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106,
108, 202 and/or 204 incorporate the tubular member 3500.
[0303] Referring to FIG. 35b, in an exemplary embodiment, the yield
point within the first and second tubular regions, 3502a and 3502b,
of the expandable tubular member 3502 vary as a function of the
radial position within the expandable tubular member. In an
exemplary embodiment, the yield point increases as a function of
the radial position within the expandable tubular member 3502. In
an exemplary embodiment, the relationship between the yield point
and the radial position within the expandable tubular member 3502
is a linear relationship. In an exemplary embodiment, the
relationship between the yield point and the radial position within
the expandable tubular member 3502 is a non-linear relationship. In
an exemplary embodiment, the yield point increases at different
rates within the first and second tubular regions, 3502a and 3502b,
as a function of the radial position within the expandable tubular
member 3502. In an exemplary embodiment, the functional
relationship, and value, of the yield points within the first and
second tubular regions, 3502a and 3502b, of the expandable tubular
member 3502 are modified by the radial expansion and plastic
deformation of the expandable tubular member.
[0304] In several exemplary embodiments, one or more of the
expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108,
202, 204 and/or 3502, prior to a radial expansion and plastic
deformation, include a microstructure that is a combination of a
hard phase, such as martensite, a soft phase, such as ferrite, and
a transitionary phase, such as retained austentite. In this manner,
the hard phase provides high strength, the soft phase provides
ductility, and the transitionary phase transitions to a hard phase,
such as martensite, during a radial expansion and plastic
deformation. Furthermore, in this manner, the yield point of the
tubular member increases as a result of the radial expansion and
plastic deformation. Further, in this manner, the tubular member is
ductile, prior to the radial expansion and plastic deformation,
thereby facilitating the radial expansion and plastic deformation.
In an exemplary embodiment, the composition of a dual-phase
expandable tubular member includes (weight percentages): about 0.1%
C, 1.2% Mn, and 0.3% Si.
[0305] In an exemplary experimental embodiment, as illustrated in
FIGS. 36a-36c, one or more of the expandable tubular members, 12,
14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed
in accordance with a method 3600, in which, in step 3602, an
expandable tubular member 3602a is provided that is a steel alloy
having following material composition (by weight percentage):
0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01%
Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an
exemplary experimental embodiment, the expandable tubular member
3602a provided in step 3602 has a yield strength of 45 ksi, and a
tensile strength of 69 ksi.
[0306] In an exemplary experimental embodiment, as illustrated in
FIG. 36b, in step 3602, the expandable tubular member 3602a
includes a microstructure that includes martensite, pearlite, and
V, Ni, and/or Ti carbides.
[0307] In an exemplary embodiment, the expandable tubular member
3602a is then heated at a temperature of 790.degree. C. for about
10 minutes in step 3604.
[0308] In an exemplary embodiment, the expandable tubular member
3602a is then quenched in water in step 3606.
[0309] In an exemplary experimental embodiment, as illustrated in
FIG. 36c, following the completion of step 3606, the expandable
tubular member 3602a includes a microstructure that includes new
ferrite, grain pearlite, martensite, and ferrite. In an exemplary
experimental embodiment, following the completion of step 3606, the
expandable tubular member 3602a has a yield strength of 67 ksi, and
a tensile strength of 95 ksi.
[0310] In an exemplary embodiment, the expandable tubular member
3602a is then radially expanded and plastically deformed using one
or more of the methods and apparatus described above. In an
exemplary embodiment, following the radial expansion and plastic
deformation of the expandable tubular member 3602a, the yield
strength of the expandable tubular member is about 95 ksi.
[0311] In an exemplary experimental embodiment, as illustrated in
FIGS. 37a-37c, one or more of the expandable tubular members, 12,
14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed
in accordance with a method 3700, in which, in step 3702, an
expandable tubular member 3702a is provided that is a steel alloy
having following material composition (by weight percentage): 0.18%
C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni,
0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an
exemplary experimental embodiment, the expandable tubular member
3702a provided in step 3702 has a yield strength of 60 ksi, and a
tensile strength of 80 ksi.
[0312] In an exemplary experimental embodiment, as illustrated in
FIG. 37b, in step 3702, the expandable tubular member 3702a
includes a microstructure that includes pearlite and pearlite
striation.
[0313] In an exemplary embodiment, the expandable tubular member
3702a is then heated at a temperature of 790.degree. C. for about
10 minutes in step 3704.
[0314] In an exemplary embodiment, the expandable tubular member
3702a is then quenched in water in step 3706.
[0315] In an exemplary experimental embodiment, as illustrated in
FIG. 37c, following the completion of step 3706, the expandable
tubular member 3702a includes a microstructure that includes
ferrite, martensite, and bainite. In an exemplary experimental
embodiment, following the completion of step 3706, the expandable
tubular member 3702a has a yield strength of 82 ksi, and a tensile
strength of 130 ksi.
[0316] In an exemplary embodiment, the expandable tubular member
3702a is then radially expanded and plastically deformed using one
or more of the methods and apparatus described above. In an
exemplary embodiment, following the radial expansion and plastic
deformation of the expandable tubular member 3702a, the yield
strength of the expandable tubular member is about 130 ksi.
[0317] In an exemplary experimental embodiment, as illustrated in
FIGS. 38a-38c, one or more of the expandable tubular members, 12,
14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502 are processed
in accordance with a method 3800, in which, in step 3802, an
expandable tubular member 3802a is provided that is a steel alloy
having following material composition (by weight percentage): 0.08%
C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni,
0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti. In an
exemplary experimental embodiment, the expandable tubular member
3802a provided in step 3802 has a yield strength of 56 ksi, and a
tensile strength of 75 ksi.
[0318] In an exemplary experimental embodiment, as illustrated in
FIG. 38b, in step 3802, the expandable tubular member 3802a
includes a microstructure that includes grain pearlite,
widmanstatten martensite and carbides of V, Ni, and/or Ti.
[0319] In an exemplary embodiment, the expandable tubular member
3802a is then heated at a temperature of 790.degree. C. for about
10 minutes in step 3804.
[0320] In an exemplary embodiment, the expandable tubular member
3802a is then quenched in water in step 3806.
[0321] In an exemplary experimental embodiment, as illustrated in
FIG. 38c, following the completion of step 3806, the expandable
tubular member 3802a includes a microstructure that includes
bainite, pearlite, and new ferrite. In an exemplary experimental
embodiment, following the completion of step 3806, the expandable
tubular member 3802a has a yield strength of 60 ksi, and a tensile
strength of 97 ksi.
[0322] In an exemplary embodiment, the expandable tubular member
3802a is then radially expanded and plastically deformed using one
or more of the methods and apparatus described above. In an
exemplary embodiment, following the radial expansion and plastic
deformation of the expandable tubular member 3802a, the yield
strength of the expandable tubular member is about 97 ksi.
[0323] Referring to FIG. 39a, an example tribological elements in a
system 4000 for reducing the friction between an expansion cone and
a tubular member during the expansion process, will now be
described. In a system for reducing the friction between an
expansion cone and a tubular member during the expansion process,
there may be at least three elements contributing to friction; an
expansion device 4002, a lubricant 4004, and a tubular member 4006.
Elements in the expansion device 4002 that may contribute to
friction comprise the following: composition 4008; geometry 4010;
surface roughness 4012; texture; 4014 and coating 4016. Elements in
the lubricant 4004 that may contribute to friction comprise the
following: composition 4018; environmental issues 4020; and
friction modifiers. Element in the tubular member 4006 that may
contribute to friction comprise the following: inside diameter
roughness 4022; and coating 4024. Each element may be adjusted in
the manner described below to reduce the friction between an
expansion cone and a tubular member during the expansion
process.
[0324] Referring to FIG. 39b, in an exemplary embodiment, during
the radial expansion process, an expansion cone 5000 radially
expands a tubular member 5005 by moving in an axial direction 5010
relative to the tubular member 5005. The interface between the
outer surface 5010 of the tapered portion 5015 of the expansion
cone 5000 and the inner surface 5020 of the tubular member 5005
includes a leading edge portion 5025 and a trailing edge portion
5030.
[0325] During the radial expansion process, the leading edge
portion 5025 may be lubricated by the presence of lubricating
fluids provided ahead of the expansion cone 5000. However, because
the radial clearance between the expansion cone 5000 and the
tubular member 5005 in the trailing edge portion 5030 during the
radial expansion process is typically extremely small, and the
operating contact pressures between the tubular member 5005 and the
expansion cone 5000 are extremely high, the quantity of lubricating
fluid provided to the trailing edge portion 5030 is typically
greatly reduced. In typical radial expansion operations, this
reduction in lubrication in the trailing edge portion 5030
increases the forces required to radially expand the tubular member
5005.
Surface Structure of the Expansion Cone
[0326] Referring to FIG. 40, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 40, an expansion cone 5100, having a front end
5100a and a rear end 5100b, includes a tapered portion 5105 having
an outer surface 3110, one or more circumferential grooves 5115a
and 5115b, and one more internal flow passages 5120a and 5120b.
[0327] In an exemplary embodiment, the circumferential grooves 5115
are fluidicly coupled to the internal flow passages 5120. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5100a of the expansion
cone 5100 into the circumferential grooves 5115 from a lubricant
source, such as, for example, from reservoir 5122 utilizing pump
5124. Thus, the trailing edge portion of the interface between the
expansion cone 5100 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member.
[0328] In an exemplary embodiment, the expansion cone 5100 includes
a plurality of circumferential grooves 5115. In an exemplary
embodiment, the expansion cone 5100 includes circumferential
grooves 5115 concentrated about the axial midpoint of the tapered
portion 5105 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5100 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 5115 are equally spaced
along the trailing edge portion of the expansion cone 5100 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 5100 and a tubular member
during the radial expansion process.
[0329] In an exemplary embodiment, the expansion cone 5100 includes
a plurality of flow passages 5120 coupled to each of the
circumferential grooves 5115. In an exemplary embodiment, the cross
sectional area of the circumferential grooves 5115 is greater than
the cross sectional area of the flow passage 5120 in order to
minimize resistance to fluid flow.
[0330] Referring to FIG. 41, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 41, an expansion cone 5200,
having a front end 5200a and a rear end 5200b, includes a tapered
portion 5205 having an outer surface 5210, one or more
circumferential grooves 5215a and 5215b, and one or more axial
grooves 5220a and 5220b.
[0331] In an exemplary embodiment, the circumferential grooves 5215
are fluidicly coupled to the axial groves 5220. In this manner,
during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5200a of the expansion
cone 5200 into the circumferential grooves 5215. Thus, the trailing
edge portion of the interface between the expansion cone 5200 and a
tubular member is provided with an increased supply of lubricant,
thereby reducing the amount of force required to radially expand
the tubular member. In an exemplary embodiment, the axial grooves
5220 are provided with lubricating fluid using a supply of
lubricating fluid positioned proximate the front end 5200a of the
expansion cone 5200. In an exemplary embodiment, the
circumferential grooves 3215 are concentrated about the axial
midpoint of the tapered portion 5205 of the expansion cone 5200 in
order to provide lubrication to the trailing edge portion of the
interface between the expansion cone 5200 and a tubular member
during the radial expansion process. In an exemplary embodiment,
the circumferential grooves 5215 are equally spaced along the
trailing edge portion of the expansion cone 5200 in order to
provide lubrication to the trailing edge portion of the interface
between the expansion cone 5200 and a tubular member during the
radial expansion process.
[0332] In an exemplary embodiment, the expansion cone 5200 includes
a plurality of circumferential grooves 5215. In an exemplary
embodiment, the expansion cone 5200 includes a plurality of axial
grooves 5220 coupled to each of the circumferential grooves 5215.
In an exemplary embodiment, the cross sectional area of the
circumferential grooves 5215 is greater than the cross sectional
area of the axial grooves 5220 in order to minimize resistance to
fluid flow. In an exemplary embodiment, the axial groves 5220 are
spaced apart in the circumferential direction by at least about 3
inches in order to provide lubrication during the radial expansion
process.
[0333] Referring to FIG. 42, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 42, an expansion cone 5300,
having a front end 5300a and a rear end 5300b, includes a tapered
portion 5305 having an outer surface 5310, one or more
circumferential grooves 5315a and 5315b, and one or more internal
flow passages 5320a and 5320b.
[0334] In an exemplary embodiment, the circumferential grooves 5315
are fluidicly coupled to the internal flow passages 5320. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the areas in front of the front 5300a and/or
behind the rear 5300b of the expansion cone 5300 into the
circumferential grooves 5315. Thus, the trailing edge portion of
the interface between the expansion cone 5300 and a tubular member
is provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand the tubular member.
Furthermore, the lubricating fluids also pass to the area in front
of the expansion cone. In this manner, the area adjacent to the
front 5300a of the expansion cone 5300 is cleaned of foreign
materials. In an exemplary embodiment, the lubricating fluids are
injected into the internal flow passages 5320 by pressurizing the
area behind the rear 5300b of the expansion cone 5300 during the
radial expansion process.
[0335] In an exemplary embodiment, the expansion cone 5300 includes
a plurality of circumferential grooves 5315. In an exemplary
embodiment, the expansion cone 5300 includes circumferential
grooves 5315 that are concentrated about the axial midpoint of the
tapered portion 5305 in order to provide lubrication to the
trailing edge portion of the interface between the expansion cone
5300 and a tubular member during the radial expansion process. In
an exemplary embodiment, the circumferential grooves 5315 are
equally spaced along the trailing edge portion of the expansion
cone 5300 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5300 and a
tubular member during the radial expansion process.
[0336] In an exemplary embodiment, the expansion cone 5300 includes
a plurality of flow passages 5320 coupled to each of the
circumferential grooves 5315. In an exemplary embodiment, the flow
passages 5320 fluidicly coupled the front end 5300a and the rear
end 5300b of the expansion cone 5300. In an exemplary embodiment,
the cross sectional area of the circumferential grooves 5315 is
greater than the cross-sectional area of the flow passages 5320 in
order to minimize resistance to fluid flow.
[0337] Referring to FIG. 43, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 43, an expansion cone 5400, having a front end
5400a and a rear end 5400b, includes a tapered portion 5405 having
an outer surface 5410, one or more circumferential grooves 5415a
and 5415b, and one or more axial grooves 5420a and 5420b.
[0338] In an exemplary embodiment, the circumferential grooves 5415
are fluidicly coupled to the axial grooves 5420. In this manner,
during the radial expansion process, lubricating fluids are
transmitted from the areas in front of the front 5400a and/or
behind the rear 5400b of the expansion cone 5400 into the
circumferential grooves 5415. Thus, the trailing edge portion of
the interface between the expansion cone 5400 and a tubular member
is provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand the tubular member.
Furthermore, In an exemplary embodiment, pressurized lubricating
fluids pass from the fluid passages 5420 to the area in front of
the front 5400a of the expansion cone 5400. In this manner, the
area adjacent to the front 5400a of the expansion cone 5400 is
cleaned of foreign materials. In an exemplary embodiment, the
lubricating fluids are injected into the internal flow passages
5420 by pressurizing the area behind the rear 5400b expansion cone
5400 during the radial expansion process.
[0339] In an exemplary embodiment, the expansion cone 5400 includes
a plurality of circumferential grooves 5415. In an exemplary
embodiment, the expansion cone 5400 includes circumferential
grooves 5415 that are concentrated about the axial midpoint of the
tapered portion 5405 in order to provide lubrication to the
trailing edge portion of the interface between the expansion cone
5400 and a tubular member during the radial expansion process. In
an exemplary embodiment, the circumferential grooves 5415 are
equally spaced along the trailing edge portion of the expansion
cone 5400 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5400 and a
tubular member during the radial expansion process.
[0340] In an exemplary embodiment, the expansion cone 5400 includes
a plurality of axial grooves 5420 coupled to each of the
circumferential grooves 5415. In an exemplary embodiment, the axial
grooves 5420 fluidicly coupled the front end and the rear end of
the expansion cone 5400. In an exemplary embodiment, the cross
sectional area of the circumferential grooves 5415 is greater than
the cross sectional area of the axial grooves 5420 in order to
minimize resistance to fluid flow. In an exemplary embodiment, the
axial grooves 5420 are spaced apart in the circumferential
direction by at least about 3 inches in order to provide
lubrication during the radial expansion process.
[0341] Referring to FIG. 44, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 44, an expansion cone 5500,
having a front end 5500a and a rear end 5500b, includes a tapered
portion 5505 having an outer surface 5510, one or more
circumferential grooves 5515a and 5515b, and one or more axial
grooves 5520a and 5520b.
[0342] In an exemplary embodiment, the circumferential grooves 5515
are fluidicly coupled to the axial grooves 5520. In this manner,
during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5500a of the expansion
cone 5500 into the circumferential grooves 5515. Thus, the trailing
edge portion of the interface between the expansion cone 5500 and a
tubular member is provided with an increased supply of lubricant,
thereby reducing the amount of force required to radially expand
the tubular member. In an exemplary embodiment, the lubricating
fluids are injected into the axial grooves 5520 using a fluid
conduit that is coupled to the tapered end 3205 of the expansion
cone 3200.
[0343] In an exemplary embodiment, the expansion cone 5500 includes
a plurality of circumferential grooves 5515. In an exemplary
embodiment, the expansion cone 5500 includes circumferential
grooves 5515 that are concentrated about the axial midpoint of the
tapered portion 5505 in order to provide lubrication to the
trailing edge portion of the interface between the expansion cone
5500 and a tubular member during the radial expansion process. In
an exemplary embodiment, the circumferential grooves 5515 are
equally spaced along the trailing edge portion of the expansion
cone 5500 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5500 and a
tubular member during the radial expansion process.
[0344] In an exemplary embodiment, the expansion cone 5500 includes
a plurality of axial grooves 5520 coupled to each of the
circumferential grooves 5515. In an exemplary embodiment, the axial
grooves 5520 intersect each of the circumferential groves 5515 at
an acute angle. In an exemplary embodiment, the cross sectional
area of the circumferential grooves 5515 is greater than the cross
sectional area of the axial grooves 5520. In an exemplary
embodiment, the axial grooves 5520 are spaced apart in the
circumferential direction by at least about 3 inches in order to
provide lubrication during the radial expansion process. In an
exemplary embodiment, the axial grooves 5520 intersect the
longitudinal axis of the expansion cone 5500 at a larger angle than
the angle of attack of the tapered portion 5505 in order to provide
lubrication during the radial expansion process.
[0345] Referring to FIG. 45, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 45, an expansion cone 5600,
having a front end 5600a and a rear end 5600b, includes a tapered
portion 5605 having an outer surface 5610, a spiral circumferential
groove 5615, and one or more internal flow passages 5620.
[0346] In an exemplary embodiment, the circumferential groove 5615
is fluidicly coupled to the internal flow passage 5620. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5600a of the expansion
cone 5600 into the circumferential groove 5615, such as, for
example, from reservoir 5622 utilizing pump 5624. Thus, the
trailing edge portion of the interface between the expansion cone
5600 and a tubular member is provided with an increased supply of
lubricant, thereby reducing the amount of force required to
radially expand the tubular member. In an exemplary embodiment, the
lubricating fluids are injected into the internal flow passage 5620
using a fluid conduit that is coupled to the tapered end 5605 of
the expansion cone 5600.
[0347] In an exemplary embodiment, the expansion cone 5600 includes
a plurality of spiral circumferential grooves 5615. In an exemplary
embodiment, the expansion cone 5600 includes circumferential
grooves 5615 that are concentrated about the axial midpoint of the
tapered portion 5605 in order to provide lubrication to the
trailing edge portion of the interface between the expansion cone
5600 and a tubular member during the radial expansion process. In
an exemplary embodiment, the circumferential grooves 5615 are
equally spaced along the trailing edge portion of the expansion
cone 5600 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5600 and a
tubular member during the radial expansion process.
[0348] In an exemplary embodiment, the expansion cone 5600 includes
a plurality of flow passages 5620 coupled to each of the
circumferential grooves 5615. In an exemplary embodiment, the cross
sectional area of the circumferential groove 5615 is greater than
the cross sectional area of the flow passage 5620 in order to
minimize resistance to fluid flow.
[0349] Referring to FIG. 46, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 46, an expansion cone 5700,
having a front end 5700a and a rear end 5700b, includes a tapered
portion 5705 having an outer surface 5710, a spiral circumferential
groove 5715, and one or more axial grooves 5720a, 5720b and
5720c.
[0350] In an exemplary embodiment, the circumferential groove 5715
is fluidicly coupled to the axial grooves 5720. In this manner,
during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5700a of the expansion
cone 5700 into the circumferential groove 5715. Thus, the trailing
edge portion of the interface between the expansion cone 5700 and a
tubular member is provided with an increased supply of lubricant,
thereby reducing the amount of force required to radially expand
the tubular member. In an exemplary embodiment, the lubricating
fluids are injected into the axial grooves 5720 using a fluid
conduit that is coupled to the tapered end 5705 of the expansion
cone 5700.
[0351] In an exemplary embodiment, the expansion cone 5700 includes
a plurality of spiral circumferential grooves 5715. In an exemplary
embodiment, the expansion cone 5700 includes circumferential
grooves 5715 concentrated about the axial midpoint of the tapered
portion 5705 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5700 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 5715 are equally spaced
along the trailing edge portion of the expansion cone 5700 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 5700 and a tubular member
during the radial expansion process.
[0352] In an exemplary embodiment, the expansion cone 5700 includes
a plurality of axial grooves 5720 coupled to each of the
circumferential grooves 5715. In an exemplary embodiment, the axial
grooves 5720 intersect the circumferential grooves 5715 in a
perpendicular manner. In an exemplary embodiment, the cross
sectional area of the circumferential groove 5715 is greater than
the cross sectional area of the axial grooves 5720 in order to
minimize resistance to fluid flow. In an exemplary embodiment, the
circumferential spacing of the axial grooves is greater than about
3 inches in order to provide lubrication during the radial
expansion process. In an exemplary embodiment, the axial grooves
5720 intersect the longitudinal axis of the expansion cone at an
angle greater than the angle of attack of the tapered portion 5705
in order to provide lubrication during the radial expansion
process.
[0353] Referring to FIG. 47, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 47, an expansion cone 5800, having a front end
5800a and a rear end 5800b, includes a tapered portion 5805 having
an outer surface 5810, a circumferential groove 5815, a first axial
groove 5820, and one or more second axial grooves 5825a, 5825b,
5825c and 5825d.
[0354] In an exemplary embodiment, the circumferential groove 5815
is fluidicly coupled to the axial grooves 5820 and 5825. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area behind the back 5800b of the expansion
cone 5800 into the circumferential groove 5815. Thus, the trailing
edge portion of the interface between the expansion cone 5800 and a
tubular member is provided with an increased supply of lubricant,
thereby reducing the amount of force required to radially expand
the tubular member. In an exemplary embodiment, the lubricating
fluids are injected into the first axial groove 5820 by
pressurizing the region behind the back 5800b of the expansion cone
5800. In an exemplary embodiment, the lubricant is further
transmitted into the second axial grooves 5825 where the lubricant
preferably cleans foreign materials from the tapered portion 5805
of the expansion cone 5800.
[0355] In an exemplary embodiment, the expansion cone 5800 includes
a plurality of circumferential grooves 5815. In an exemplary
embodiment, the expansion cone 5800 includes circumferential
grooves 5815 concentrated about the axial midpoint of the tapered
portion 5805 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5800 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 5815 are equally spaced
along the trailing edge portion of the expansion cone 5800 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 5800 and a tubular member
during the radial expansion process.
[0356] In an exemplary embodiment, the expansion cone 5800 includes
a plurality of first axial grooves 5820 coupled to each of the
circumferential grooves 5815. In an exemplary embodiment, the first
axial grooves 5820 extend from the back 5800b of the expansion cone
5800 and intersect the circumferential groove 5815. In an exemplary
embodiment, the first axial groove 5820 intersects the
circumferential groove 5815 in a perpendicular manner. In an
exemplary embodiment, the cross sectional area of the
circumferential groove 5815 is greater than the cross sectional
area of the first axial groove 5820 in order to minimize resistance
to fluid flow. In an exemplary embodiment, the circumferential
spacing of the first axial grooves 5820 is greater than about 3
inches in order to provide lubrication during the radial expansion
process.
[0357] In an exemplary embodiment, the expansion cone 5800 includes
a plurality of second axial grooves 5825 coupled to each of the
circumferential grooves 5815. In an exemplary embodiment, the
second axial grooves 5825 extend from the front 5800a of the
expansion cone 5800 and intersect the circumferential groove 5815.
In an exemplary embodiment, the second axial grooves 5825 intersect
the circumferential groove 5815 in a perpendicular manner. In an
exemplary embodiment, the cross sectional area of the
circumferential groove 5815 is greater than the cross sectional
area of the second axial grooves 5825 in order to minimize
resistance to fluid flow. In an exemplary embodiment, the
circumferential spacing of the second axial grooves 5825 is greater
than about 3 inches in order to provide lubrication during the
radial expansion process. In an exemplary embodiment, the second
axial grooves 5825 intersect the longitudinal axis of the expansion
cone 5800 at an angle greater than the angle of attack of the
tapered portion 5805 in order to provide lubrication during the
radial expansion process.
[0358] Referring to FIG. 48, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 48, an expansion cone 5900, having a front end
5900a and a rear end 5900b, includes a tapered portion 5905 having
an outer surface 5910, one or more circumferential grooves 5915a
and 5915b, one or more radial passageways 5916 and one more
internal flow passages 5920.
[0359] In an exemplary embodiment, the circumferential groove 5915a
is fluidicly coupled to the internal flow passages 5920. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 5900a of the expansion
cone 5900 into the circumferential grooves 5915, such as, for
example, from reservoir 5922 utilizing pump 5924. Thus, the
trailing edge portion of the interface between the expansion cone
5900 and a tubular member is provided with an increased supply of
lubricant, thereby reducing the amount of force required to
radially expand the tubular member.
[0360] In an exemplary embodiment, the expansion cone 5900 includes
a plurality of circumferential grooves 5915a. In an exemplary
embodiment, the expansion cone 5900 includes circumferential
grooves 5915a concentrated about the axial midpoint of the tapered
portion 5905 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 5900 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 5915 are equally spaced
along the trailing edge portion of the expansion cone 5900 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 5900 and a tubular member
during the radial expansion process.
[0361] In an exemplary embodiment, the expansion cone 5900 includes
a plurality of flow passages coupled to each of the circumferential
grooves 5915a. In another embodiment, circumferential groove 5915b,
which is not fluidicly coupled to the internal flow passages, may
also be included.
[0362] Referring to FIG. 49, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 49, an expansion cone 6000, having a front end
6000a and a rear end 6000b, includes a tapered portion 6005 having
an outer surface 6010, one or more circumferential grooves 6015,
one or more radial passageways 6016 and one or more internal flow
passages 6020.
[0363] In an exemplary embodiment, the circumferential grooves 6015
are fluidicly coupled to the internal flow passages 6020. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 6000a of the expansion
cone 6000 into the circumferential grooves 6015, such as, for
example, from reservoir 6022 utilizing pump 6024. Thus, the
trailing edge portion of the interface between the expansion cone
6000 and a tubular member is provided with an increased supply of
lubricant, thereby reducing the amount of force required to
radially expand the tubular member.
[0364] In an exemplary embodiment, the expansion cone 6000 includes
a plurality of circumferential grooves 6015. In an exemplary
embodiment, the expansion cone 6000 includes circumferential
grooves 6015 concentrated about the axial midpoint of the tapered
portion 6005 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 6000 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 6015 are equally spaced
along the trailing edge portion of the expansion cone 6000 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 6000 and a tubular member
during the radial expansion process.
[0365] In an exemplary embodiment, the expansion cone 6000 includes
a plurality of flow passages coupled to each of the circumferential
grooves 6015.
[0366] Referring to FIG. 50, an embodiment of a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 50, an expansion cone 6100, having a front end
6100a and a rear end 6100b, includes a tapered portion 6105 having
an outer surface 6110, one or more circumferential grooves 6115a
and 6115b, one or more radial passageways 6116 and one more
internal flow passages 6120.
[0367] In an exemplary embodiment, the circumferential groove 6115a
is fluidicly coupled to the internal flow passages 6120. In this
manner, during the radial expansion process, lubricating fluids are
transmitted from the area ahead of the front 6100a of the expansion
cone 6100 into the circumferential grooves 6115, such as, for
example, from reservoir 6122 utilizing pump 6124. Thus, the
trailing edge portion of the interface between the expansion cone
6100 and a tubular member is provided with an increased supply of
lubricant, thereby reducing the amount of force required to
radially expand the tubular member.
[0368] In an exemplary embodiment, the expansion cone 6100 includes
a plurality of circumferential grooves 6115a. In an exemplary
embodiment, the expansion cone 6100 includes circumferential
grooves 6115a concentrated about the axial midpoint of the tapered
portion 6105 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 6100 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 6115a are equally spaced
along the trailing edge portion of the expansion cone 6100 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 6100 and a tubular member
during the radial expansion process.
[0369] In an exemplary embodiment, the expansion cone 6100 includes
a plurality of flow passages coupled to each of the circumferential
grooves 6115a. Alternatively, circumferential groove 6115b, which
is not fluidicly coupled to the internal flow passages, may also be
included.
[0370] Referring to FIG. 51, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 51, an expansion cone 6200,
having a front end 6200a and a rear end 6200b, includes a tapered
portion 6205 having an outer surface 6210, circumferential grooves
6215 arranged in a helical crisscrossing pattern, one or more
radial passageways 6216 and one or more internal flow passages
6220.
[0371] In an exemplary embodiment, the circumferential grooves 6215
are fluidicly coupled to each other and to the internal flow
passages 6220. In this manner, during the radial expansion process,
lubricating fluids are transmitted from the area ahead of the front
6200a of the expansion cone 6200 into the circumferential grooves
6215, such as, for example, from reservoir 6222 utilizing pump
6224. Thus, the trailing edge portion of the interface between the
expansion cone 6200 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member.
[0372] In an exemplary embodiment, the expansion cone 6200 includes
a plurality of circumferential grooves 6215 arranged in a pinecone
design. In an exemplary embodiment, the expansion cone 6200
includes circumferential grooves 6215 concentrated about the axial
midpoint of the tapered portion 6205 in order to provide
lubrication to the trailing edge portion of the interface between
the expansion cone 6200 and a tubular member during the radial
expansion process. In an exemplary embodiment, the circumferential
grooves 6215 are equally spaced along the trailing edge portion of
the expansion cone 6200 in order to provide lubrication to the
trailing edge portion of the interface between the expansion cone
6200 and a tubular member during the radial expansion process.
[0373] Referring to FIG. 52, an alternate exemplary embodiment of
the system for lubricating the interface between an expansion cone
and a tubular member during the expansion process shown in FIG. 51
will now be described. As illustrated in FIG. 52, an expansion cone
6200, having a front end 6200a and a rear end 6200b, includes a
tapered portion 6205 having an outer surface 6210, circumferential
grooves 6215 arranged in a helical crisscrossing pattern over the
entire outer surface 6210, one or more radial passageways 6216 and
one or more internal flow passages 6220.
[0374] In an exemplary embodiment, the circumferential grooves 6218
are fluidicly coupled to each other and to the internal flow
passages 6220. In this manner, during the radial expansion process,
lubricating fluids are transmitted from the area ahead of the front
6200a of the expansion cone 6200 into the circumferential grooves
6218, such as, for example, from reservoir 6222 utilizing pump
6224. Thus, the trailing edge portion of the interface between the
expansion cone 6200 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member.
[0375] In an exemplary embodiment, a second circumferential groove
6226 is fluidicly coupled to the circumferential grooves 6218.
[0376] Referring to FIG. 53, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 53, an expansion cone 6300,
having a front end 6300a and a rear end 6300b, includes a tapered
portion 6305 having an outer surface 6310, circumferential grooves
6315 arranged in a helical crisscrossing pattern, one or more
radial passageways 6316 and one or more internal flow passages
6320.
[0377] In an exemplary embodiment, the circumferential grooves 6315
are fluidicly coupled to each other and one more internal flow
passages 6320. In this manner, during the radial expansion process,
lubricating fluids are transmitted from the area ahead of the front
6300a of the expansion cone 6300 into the circumferential grooves
6315, such as, for example, from reservoir 6322 utilizing pump
6324. Thus, the trailing edge portion of the interface between the
expansion cone 6300 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member. In an exemplary
embodiment, the lubricating fluids are injected into the axial
grooves 6320 using a fluid conduit that is coupled to the tapered
end 6305 of the expansion cone 6300.
[0378] In an exemplary embodiment, the expansion cone 6300 includes
a plurality of spiral circumferential grooves 6315. In an exemplary
embodiment, the expansion cone 6300 includes circumferential
grooves 6315 concentrated about the axial midpoint of the tapered
portion 6305 in order to provide lubrication to the trailing edge
portion of the interface between the expansion cone 6300 and a
tubular member during the radial expansion process. In an exemplary
embodiment, the circumferential grooves 6315 are equally spaced
along the trailing edge portion of the expansion cone 6300 in order
to provide lubrication to the trailing edge portion of the
interface between the expansion cone 6300 and a tubular member
during the radial expansion process. In an exemplary embodiment,
the axial grooves 6320 intersect each other in a perpendicular
manner.
[0379] Referring to FIG. 54, an alternate exemplary embodiment of
the a system for lubricating the interface between an expansion
cone and a tubular member during the expansion process shown in
FIG. 53 will now be described. As illustrated in FIG. 54, an
expansion cone 6300, having a front end 6300a and a rear end 6300b,
includes a tapered portion 6305 having an outer surface 6310,
circumferential grooves 6315 arranged in a helical crisscrossing
pattern over the substantially all of the outer surface 6310, one
or more radial passageways 6316 and one more internal flow passages
6320.
[0380] In an exemplary embodiment, the circumferential grooves 6318
are fluidicly coupled to each other and to the internal flow
passages 6320. In this manner, during the radial expansion process,
lubricating fluids are transmitted from the area ahead of the front
6300a of the expansion cone 6300 into the circumferential grooves
6318, such as, for example, from reservoir 6322 utilizing pump
6324. Thus, the trailing edge portion of the interface between the
expansion cone 6300 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member.
[0381] In an exemplary embodiment, a second circumferential groove
6326 is fluidicly coupled to the circumferential grooves 6318.
[0382] Referring to FIG. 55, in an exemplary embodiment,
circumferential groove 6415 may be utilized on the outer surfaces
5101, 5210, 5310, 5410, 5510, 5610, 5710, 5810, 5910, 6010, 6110,
6210, and 6310 in one or more of expansion cones 5100, 5200, 5300,
5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, and 6300.
Furthermore, it may be implemented in any expansion device
including one or more expansion surfaces. In an exemplary
embodiment, circumferential groove 6415 is positioned in tapered
portion 6405 with first edge 6430 on outer surface 6410a having a
first radius of curvature and second edge 6434 on outer surface
6410b having a second radius of curvature. The radius on the
trailing edge 6434 may be much larger than the radius on the
leading edge 6430 to assist lubricant delivery.
[0383] Referring to FIG. 56, in an exemplary embodiment, outer
surfaces 6410a and 6410b of tapered portion 6405 are tapered at
angle .beta.. The angle that is generated by radius of curvature of
second edge 6434 and the tubular member is the sliding angle, which
may be important for adequate delivery of lubricant. If the sliding
angle is too large or too small, then the trailing edge may act as
a wiper, which may remove lubricant form the working area. The
radius of curvature of second edge 6434 and the sliding angle are
at least dependent on the lubricant viscosity, pipe diameter and
friction between the expansion cone and the tubular member. Each
cone surface channel design may be empirically design by testing
cones in stages to determine the optimum friction-reducing
configuration.
[0384] In an exemplary embodiment, outer surfaces 6410a and 6410b
of tapered portion 6405 are tapered at angle .beta.. In an
exemplary embodiment, the angle .beta. may range from 8.5 degrees
to 12.5 degrees, such as, for example, 10 degrees. The width 6442
of circumferential groove 6415 may be as small as possible to
maximize the area of outer surfaces 6410a and 6410b in contact with
the inner surface of the tubular member for radial expansion. In an
exemplary embodiment, the radius of curvature 6446 of second edge
6434, which may be defined as the perpendicular to the tangent 6448
at the point where vertical projection line 6450 intersects second
edge 6434, may be positioned relative to the bottom of
circumferential groove at angle .alpha., the sliding angle. In an
exemplary embodiment, angle .alpha. may be less than or equal to 30
degrees, such as, for example 10 degrees, causing lubricant in the
circumferential groove 6415 to be drawn efficiently on to the inner
surface of the tubular member during radial expansion.
[0385] Referring to FIG. 57, In an exemplary embodiment,
circumferential groove 6518 may be achieved by indenting a portion
of the expansion cone on the tapered portion 6505a thereby creating
a lip 6515 between tapered portion 6505a and second tapered portion
6505b. In an exemplary embodiment, tapered portions, 6505a and
6505b, are at the same angle .beta.. Width y of circumferential
groove 6518 from lip 6515 to the location where taper portion 6505b
is at the same angle .beta. tapered portion 6505a may be wide
enough to supply sufficient lubricant to the tubular member,
thereby reducing the amount of force required to radially expand
the tubular member. Vertical portion 6520 in tapered portion 6505a
having width x exists to reduce the mechanical stress at corner
6552 due to corner loading. The vertical portion 6520 is not
critical to the operation of the circumferential groove 6518 and
hence the width x of the vertical portion 6520 is not critical.
However, width x of vertical portion 6520 may be small enough to
maximize the amount of contact between the expansion cone and the
tubular member during radial expansion, yet large enough to reduce
the mechanical stress at corner 6552. In determining the width x of
the vertical portion 6520 and width y of the circumferential groove
6518 under lip 6515, the following factors may be addressed: the
size of the expansion cone; the viscosity of the lubricant; and the
lubrication injection pressure. Width y of the circumferential
groove 6518 may be as small possible to maximize the area of outer
surfaces, 6510a and 6510b, in contact with the surface of the
tubular member for radial expansion.
[0386] Referring to FIGS. 58a, 58b and 58c, an exemplary embodiment
of a system for lubricating the interface between an expansion cone
and a tubular member during the expansion process shown will now be
described. As illustrated in FIGS. 58a, 58b and 58c, expansion cone
6600, having a front end 6600a and a rear end 6600b, includes a
tapered portions 6605a and 6605b and lip 6615.
[0387] In an exemplary embodiment, the circumferential groove 6618
under lip 6615 is fluidicly coupled to the internal flow passages
6660 through port 6662. In this manner, during the radial expansion
process, lubricating fluids are transmitted from the area ahead of
the front end 6600a of the expansion cone 6600 under lip 6615.
Thus, the trailing edge portion of the interface between the
expansion cone 6600 and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member.
[0388] In an exemplary embodiment, exemplary relative dimensions of
the elements of FIGS. 58a, 58b and 58c are as follows:
[0389] 1. taper angle .beta. of tapered portions 6605a and
6605b--10 degrees;
[0390] 2. width x--0.125;
[0391] 3. radius of curvature of the top edge 6670--0.500;
[0392] 4. radius of curvature of the first edge 6650--0.02;
[0393] 5. width of the circumferential groove 6618 under lip
6615--0.020-0.060;
[0394] 6. height of the cone 6672--1.887;
[0395] 7. height 6682 of the expansion cone beneath the tapered
portion 6605b--0.895;
[0396] 8. diameter 6678 of the cone at front end 6600a--1.380.
[0397] 9. diameter 6676 of the cone at rear end 6600b--1.656;
and
[0398] 10. depth 6680 of the vertical portion between the top and
first edges--0.015.
[0399] Referring to FIGS. 59a and 59b, another exemplary embodiment
of a system for lubricating the interface between an expansion cone
and a tubular member during the expansion process will now be
described. As illustrated in FIGS. 59a and 59b, an expansion cone
6700, having a front end 6700a and a rear end 6700b, includes a
tapered portion 6705 having an outer surface 6710, internal flow
passage 6730 and one or more axial grooves 6720.
[0400] In an exemplary embodiment, during the radial expansion
process, the axial grooves 6720 may be fluidicly coupled to the
area ahead of the front end 6700a of the expansion cone 6700 to
receive lubricant. Thus, the trailing edge portion of the interface
between the expansion cone and a tubular member is provided with an
increased supply of lubricant, thereby reducing the amount of force
required to radially expand the tubular member. In an exemplary
embodiment, the axial grooves 6720 are provided with lubricating
fluid using a supply of lubricating fluid positioned proximate the
front end 6700a of the expansion cone 6700.
[0401] In an exemplary embodiment, example relative dimensions of
the elements of in FIGS. 59a and 59b are as follows:
[0402] 1. taper angle .beta. of tapered portion 6605--10
degrees;
[0403] 2. channel 6720 depth--0.020;
[0404] 3. channel 6720 diameter--0.040;
[0405] 4. radius of curvature of the bottom of taper portion
6705--0.500;
[0406] 5. number of axial grooves 6720--8;
[0407] 6. height of the expansion cone 6700--1.678;
[0408] 7. height of the expansion cone 6700 beneath the tapered
portion 6705--0.895;
[0409] 8. diameter 6778 of the expansion cone 6700 at front end
6600a--1.380; and
[0410] 9. diameter 6776 of the expansion cone 6700 at rear end
6600b--1.656.
[0411] Referring to FIGS. 60a, 60b and 60c, another exemplary
embodiment of a system for lubricating the interface between an
expansion cone and a tubular member during the expansion process
will now be described. As illustrated in FIGS. 60a, 60b and 60c, an
expansion cone 6800, having a front end 6800a and a rear end 6800b,
includes a tapered portion 6805 having an outer surface 6810, which
includes a tapered faceted polygonal outer expansion surface 6802.
Tapered faceted polygonal outer expansion surface 6802 includes
circumferential spaced apart contact points 6810 that may be in
contact with the inside surface of a tubular member during radial
expansion and recesses 6912. When expansion cone circumferential
spaced apart contact points 6810 are in contact with a tubular
member 6820, the recesses 6812 combine with the inside surface of
the tubular member to form lubricant gaps 6822 between the tubular
member, circumferential spaced apart contact points 6810 and
recesses 6812. The lubricant gaps may act as a high-pressure
lubrication channel. Internal passageway 6804 is fluidicly
connected to radial ports 6806, which may supply lubricant to
lubricant gaps.
[0412] Referring to FIGS. 61a, 61b, 61c, 61d and 61e another
exemplary embodiment of a system shown in for lubricating the
interface between an expansion cone having tapered faceted
polygonal outer expansion surface and a tubular member during the
expansion process will now be described. As illustrated in FIGS.
61a and 61b, an expansion cone 6900, includes circumferential
spaced apart contact points 6910, recesses 6912 around the
perimeter of the expansion cone, internal passage 6930 for drilling
fluid, internal passages 6914 for lubricating fluids, and radial
passageways 6916.
[0413] FIGS. 61c and 61d illustrate expansion cone 6900 in contact
with tubular member 6920 at circumferential spaced apart contact
points 6910 around the perimeter of expansion cone 6900. Lubricant
gaps 6922 exist between recesses 6912 and tubular member 6920 and
are fluidicly coupled to internal passages 6914 to act as a
high-pressure lubrication channels to increased supply of
lubricant, thereby reducing the amount of force required to
radially expand tubular member 6920. Lubricant gaps 6922 provide
additional high-pressure lubrication channels, which may assist in
lubricating the tubular member where needed most, at the high load
contact edge.
[0414] Referring to FIG. 61e, an expansion cone having a tapered
faceted polygonal outer expansion surface with contact points, such
as, for example, circumferential spaced apart contact points 6910
and 6910, may compensate for non-uniform wall thickness tubular
member 6940, by applying localized higher loads at the polygon
contact points. In an exemplary embodiment of expansion cone 6900
having tapered faceted polygonal outer expansion surface in contact
with tubular member 6940 having a non-uniform wall thickness is
shown. The high load circumferential spaced apart contact points
may radially expand and plastically deform the thick wall areas T2
as well as the thin wall areas T1, instead of taking the path of
least resistance, which may assist in maintaining a proportional
wall thickness during the radial expansion and plastic deformation
process.
[0415] The number of circumferential spaced apart contact points,
6810 and 6910, having width (W) around the circumference of an
expansion cone may vary for different sizes of expandable tubular
members. Several factors may be considered when determining the
appropriate number contact points, 6810 and 6910, such as, for
example, the coefficient of friction between the expansion cone and
the expandable tubular member, pipe quality, and data from
lubrication tests. For the ideal tubular member with uniform
thickness, the number of circumferential spaced apart contact
points may be infinity. Thus, the dimensions of the final design of
an expansion cone may ultimately be refined by performing an
empirical study.
[0416] In an exemplary embodiment, the following equations may be
used to make a preliminary calculation of the optimum number of
circumferential spaced apart contact points, 6810 and 6910, on an
expansion cone, 6800 and 6900, having a tapered faceted polygonal
outer expansion surface for expanding an expandable tubular member
having an original inside diameter of 4.77'' to an inside diameter
of 5.68'' utilizing an expansion cone, including a lubricant gap
depth of 0.06'': R=(D.sub.1+D.sub.exp)/2=(4.77-5.68)/2=0.42; (5)
Sin(.alpha./2)=1-(H/R)=1-(0.06/0.42); (6) .alpha./2=12.3.degree.;
(7) .alpha.=24.6; (8)
N=360.degree./.alpha.=360.degree./24.6.degree.=15; (9) where,
[0417] D.sub.1=Original tubular member inside diameter;
[0418] D.sub.exp=Expanded tubular member inside diameter;
[0419] H=Gap between gap surface and tubular member inside
diameter;
[0420] R=Radius of polygon at midpoint of expansion cone;
[0421] .alpha.=Angle between circumferential spaced apart contact
points of polygon; and
[0422] N=Number of polygon flat surfaces.
[0423] Accordingly, the theoretical number (N) of circumferential
spaced apart contact points, 6810 and 6910, on an expansion cone
having a tapered faceted polygonal outer expansion surface is 15,
but the actual number that may result from an empirical analysis
may depend on tubular member quality, coefficient of friction, and
data from lubrication tests. In an exemplary embodiment, a range
for the actual number (N) of circumferential spaced apart contact
points necessary to expand an expandable tubular member having an
original inside diameter of 4.77'' to an inside diameter of 5.68''
I.D. may range from 12-15.
[0424] Referring to FIGS. 62a, 62b and 62c, another exemplary
embodiment of the system shown in FIGS. 60a and 60b for lubricating
the interface between an expansion cone having tapered faceted
polygonal outer expansion surface and a tubular member during the
expansion process will now be described. As illustrated in FIG.
62a, an expansion cone 7000, having a front end 7000a and a rear
end 7000b, includes a tapered portion 7005, contact surfaces 7010,
recesses 7012, internal passage 7030 for drilling fluid, internal
passages 7014 for lubricating fluids, and radial passageways 7016.
The width 7020 of contact surfaces 7010 of expansion cone 7000 may
be constant for the length of the cone, resulting in trapezoidal
shaped lubricant gap 7022 between each contact surface 7010. The
following equations may be used for calculating the width (W) 7020
of the contact surface: W=[2R sin(.alpha./2)]/K; (10) R=(D1+D2)/4;
(11) .alpha.=360 degrees/N; (12) where:
[0425] W=Width of contact point;
[0426] D1=initial tubular member diameter;
[0427] D2=expanded diameter;
[0428] N=Number of polygon flat surfaces; and
[0429] K=System friction coefficient that must be determined.
In an exemplary embodiment, K is between 3 to 5 for an expandable
tubular member having an original inside diameter of 4.77'' and an
expanded inside diameter of 5.68'' may range from 12-15. In an
exemplary embodiment, K is 4.2.
[0430] Referring now to FIG. 62d, 62e and 62f another exemplary
embodiment of the system shown in FIGS. 60a, 60b and 61 for
lubricating the interface between an expansion cone having tapered
faceted polygonal outer expansion surface and a tubular member
during the expansion process will now be described. As illustrated
in FIG. 62b, an expansion cone 7100, having a front end 7100a and a
rear end 7100b, includes a tapered portion 7105, contact surfaces
7110, recesses 7112, internal passage 7130 for drilling fluid,
internal passages 7114 for lubricating fluids, and radial
passageways 7116. The width 7120 of contact surfaces 7110 of
expansion cone 7100 may vary the length of the cone. In an
exemplary embodiment, width 7120 of contact surfaces 7110 may be
larger at the front end 7100a W1 and become smaller toward the rear
end 7100b W2.
[0431] In several exemplary embodiments, tapered faceted polygonal
outer expansion surface of an expansion cone may be implemented in
any expansion cone, including one or more of expansion cones 5100,
5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200,
6300 and 6600. Furthermore, it may be implemented in any expansion
device including one or more expansion surfaces.
[0432] The angle of the tapered portion of each expansion cone, the
cone angle, in the system for lubricating the interface between an
expansion cone and a tubular member during the expansion process,
including the tapered portions in expansion cones 5100, 5200, 5300,
5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600,
6700, 6800, 6900, 7000 and 7100, may be dependant on the amount of
friction between the tapered portion of the expansion cone and the
inside diameter of the tubular member. In an exemplary experimental
embodiment, a cone angle of 8.5.degree. to 12.5.degree. was shown
to be sufficient to expand an expandable tubular member having an
original inside diameter of 4.77'' to an inside diameter of 5.68''.
The optimum cone angle may be determined after testing the
lubricant system to determine the exact coefficient of friction. A
cone angle greater than 10.degree. may be required to minimize the
effect of thinning the tubular member wall during expansion and may
potentially reduce failures related to collapsing.
[0433] In several exemplary embodiments, one or more of the
expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800,
5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100
may or may not have internal passages. In another embodiment, a
plurality of inserts having internal flow passages may be provided
in the expansion cone internal flow passages, The internal flow
passages of each insert may vary in size. In this manner, a
expansion cone flow passage may be machined to a standard size, and
the lubricant supply may be varied by using different inserts
having different sized internal flow passages. Each insert may
include a filter for filtering particles and other foreign
materials from the lubricant that passes into the flow passage. In
this manner, the foreign materials are prevented from clogging the
flow passage and other flow passages.
Lubricant Delivery System
[0434] Regardless of the type of expansion device used in the
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process, including, for
example, expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700,
5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000
and 7100, lubricants utilized in the systems may be provided to the
system in various manners. In an exemplary embodiment, lubricating
fluids are provided to the internal flow passages or axial groove
in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800,
5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100
using a supply of lubricating fluids provided adjacent to the front
end 5100a, 5200a, 5300a, 5400a, 5500a, 5600a, 5700a, 5800a, 5900a,
6000a, 6100a, 6200a, 6300a, 6600a, 6700a, 6800a, 6900a, 7000a and
7100a, of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600,
5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900,
7000 and 7100. In another exemplary embodiment, lubricating fluids
may provided to the internal flow passages or axial groove in
expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800,
5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100
using a supply of lubricating fluids provided adjacent to the rear
end 5100a, 5200a, 5300a, 5400a, 5500a, 5600a, 5700a, 5800a, 5900a,
6000a, 6100a, 6200a, 6300a, 6600a, 6700a, 6800a, 6900a, 7000a and
7100a, of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600,
5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900,
7000 and 7100. Alternatively, the lubricating fluids may be
injected into any internal flow passages in expansion cones 5100,
5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200,
6300, 6600, 6700, 6800, 6900, 7000 and 7100 using a fluid conduit
that is fluidicly coupled to the tapered ends of the expansion
cones expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700,
5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000
and 7100.
[0435] Referring to FIG. 63, an embodiment of a system 7200 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 63, an expansion cone 7202 includes a body 7204
that defines a centrally positioned longitudinal passage 7206, an
internal annular recess 7208, an external annular recess 7210,
longitudinal passages, 7212a and 7212b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7214a and 7214b, fluidicly coupled to the external annular recess,
radial passages, 7216a, 7216b, and 7216c, fluidicly coupled to the
longitudinal passage 7214a, and radial passages, 7218a, 7218b, and
7218c, fluidicly coupled to the longitudinal passage 7214b, and
includes a front end face 7220, a rear end face 7222, and a tapered
external expansion surface 7224 including spaced apart external
grooves, 7224a, 7224b, and 7224c, that are fluidicly coupled to the
radial passages, 7214a, 7216a, 7214b, 7216b, 7214c, and 7216c,
respectively. Spring-biased check valves, 7226a and 7226b, are
received within, mate with, and are operably coupled to, the
longitudinal passages, 7214a and 7214b, respectively, for
controlling the flow of fluidic materials therethrough. A tubular
member 7228 that defines a longitudinal passage 7228a and radial
passages, 7228b and 7228c, that are fluidicly coupled to the
internal annular recess 7208 of the expansion cone 7202 is received
within, mates with, and is coupled to the centrally positioned
longitudinal passage 7206 of the expansion cone.
[0436] In an exemplary embodiment, during operation of the system
7200, the expansion cone 7202 is positioned within, and displaced
relative to, an expandable tubular member 7230 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7202 is displaced
relative to the expandable tubular member 7230 by injecting a
pressurized fluidic material 7232 into and through the passage
7228a of the tubular member 7228. As a result, the expansion cone
7202 is displaced in a direction 7233 relative to the expandable
tubular member 7230. In an exemplary embodiment, the fluidic
material 7232 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7202 and the
expandable tubular member 7230 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7232 is conveyed through the radial passages, 7228b and 7228c, of
the tubular member 7228 into a annular chamber 7234 defined between
the internal annular recess 7208 of the expansion cone 7202 and the
tubular member 7228. If the operating pressure of the fluidic
material 7232 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7226a and 7226b, the fluidic material is then conveyed through the
longitudinal passages, 7212a and 7212b, into an annular chamber
7236 defined between the external annular recess 7210 of the
expansion cone 7202 and the expandable tubular member 7230. The
pressurized fluidic material 7232 is then conveyed into the
external grooves, 7224a, 7224b, and 7224c, through the longitudinal
passages, 7214a and 7214b, and the radial passages, 7216a, 7216b,
7216c, 7218a, 7218b, and 7218c, into the interface between the
expansion cone 7202 and the expandable tubular member 7230.
[0437] In an exemplary embodiment, the rate of injection of the
fluidic material 7232 into the external grooves, 7224a, 7224b, and
7224c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7226a and 7226b. In this manner, during the radial
expansion process, the fluidic material 7232 may be controllably
injected and metered into the interface between the tapered
external expansion surface 7224 of the expansion cone 7202 and the
expandable tubular member 7230 continuously during the radial
expansion and plastic deformation of the tubular member. In an
exemplary embodiment, the fluidic material 7232 may be injected
into the external grooves, 7224a, 7224b, and 7224c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7224 of
the expansion cone 7202 and the expandable tubular member 7230 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0438] In an alternate embodiment, the spring-biased check valves,
7226a and 7226b, may be omitted, and/or used in combination with
other types of flow metering devices such as, for example, passive
flow control devices, active flow control devices, fixed orifices,
and/or variable orifices.
[0439] Referring to FIG. 64, an embodiment of a system 7300 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 64, an expansion cone 7302 includes a body 7304
that defines a centrally positioned longitudinal passage 7306, an
internal annular recess 7308, longitudinal passages, 7314a and
7314b, fluidicly coupled to the internal annular recess 7308,
radial passages, 7316a, 7316b, and 7316c, fluidicly coupled to the
longitudinal passage 7314a, and radial passages, 7318a, 7318b, and
7318c, fluidicly coupled to the longitudinal passage 7314b, and
includes a front end face 7320, a rear end face 7322, and a tapered
external expansion surface 7324 including spaced apart external
grooves, 7324a, 7324b, and 7324c, that are fluidicly coupled to the
radial passages, 7314a, 7316a, 7314b, 7316b, 7314c, and 7316c,
respectively. A tubular member 7328 that defines a longitudinal
passage 7328a and radial passages, 7328b and 7328c, that are
fluidicly coupled to the internal annular recess 7308 of the
expansion cone 7302, is received within, mates with, and is coupled
to the centrally positioned longitudinal passage 7306 of the
expansion cone. A tubular piston 7340 defines a passageway 7340a
that receives, mates with and is slidably coupled to the tubular
member 7328 and is received within, mates with and is slidably
coupled to internal annular recess 7332, of the expansion cone.
[0440] In an exemplary embodiment, during operation of the system
7300, the expansion cone 7302 is positioned within, and displaced
relative to, an expandable tubular member 7330 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7302 is displaced
relative to the expandable tubular member 7330 by injecting a
pressurized fluidic material 7332 into and through the passage
7328a of the tubular member 7328. As a result, the expansion cone
7302 is displaced in a direction 7333 relative to the expandable
tubular member 7330. In an exemplary embodiment, the fluidic
material 7332 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7302 and the
expandable tubular member 7330 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7332 is conveyed through the radial passages, 7328b and 7328c, of
the tubular member 7328, into an annular chamber 7336 defined
between the external annular recess 7310 of the expansion cone 7302
and the expandable tubular member 7330 above tubular piston 7340.
In an exemplary embodiment, a second fluidic material 7344 may be
housed in the annular chamber 7336 below tubular piston 7342. In an
exemplary embodiment, the second fluidic material 7344 includes one
or more lubricant materials suitable for lubricating the interface
between the expansion cone 7302 and the expandable tubular member
7330 during the radial expansion process. If the operating pressure
of the fluidic material 7332 exceeds a predetermined value, which
may vary as a function of the operating characteristics the tubular
piston 7340, the fluidic material 7344 is then conveyed through the
radial passages, 7328b and 7328c, into an annular chamber 7336
defined between the external annular recess 7310 of the expansion
cone 7302 and the expandable tubular member 7330. In particular, if
the operating pressure of the fluidic material 7332 exceeds a
predetermined value, the tubular piston 7340 is displaced within
the annular chamber 7336 thereby pumping the pressurized fluidic
material 7344 into the external grooves, 7324a, 7324b, and 7324c,
through the longitudinal passages, 7314a and 7314b, and the radial
passages, 7316a, 7316b, 7316c, 7318a, 7318b, and 7318c, into the
interface between the expansion cone 7302 and the expandable
tubular member 7330.
[0441] In an exemplary embodiment, the rate of injection of the
fluidic material 7344 into the external grooves, 7324a, 7324b, and
7324c, depends on the operating pressure of the fluidic material
7232 and the operating characteristics of the tubular piston 7340.
The tubular piston 7340 pumps second fluidic material 7344 when the
input pressure of the fluidic material 7332 exceeds a predetermined
pressure limit, which may be a factor of diameter of the tubular
member 7330 the length of the tubular member 7330 and the desired
amount of lubricant to be dispensed. In this manner, during the
radial expansion process, the fluidic material 7344 may be
controllably injected and pumped into the interface between the
tapered external expansion surface 7324 of the expansion cone 7302
and the expandable tubular member 7330 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7332 may be injected
into the external grooves, 7324a, 7324b, and 7324c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7324 of
the expansion cone 7302 and the expandable tubular member 7330 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0442] In an exemplary embodiment, the second fluidic material 7344
in the annular chamber 7336 below tubular piston 7340 may be
preloaded into expansion cone 7300 prior to being used to expand
tubular member 7330. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7300.
[0443] Referring to FIG. 65, an embodiment of a system 7400 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 65, an expansion cone 7402 includes a body 7404
that defines a centrally positioned longitudinal passage 7406, an
internal annular recess 7408, an external annular recess 7410,
longitudinal passages, 7412a and 7412b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7414a and 7414b, fluidicly coupled to the external annular recess,
radial passages, 7416a, 7416b, and 7416c, fluidicly coupled to the
longitudinal passage 7414a, and radial passages, 7418a, 7418b, and
7418c, fluidicly coupled to the longitudinal passage 7414b, and
includes a front end face 7420, a rear end face 7422, and a tapered
external expansion surface 7424 including spaced apart external
grooves, 7424a, 7424b, and 7424c, that are fluidicly coupled to the
radial passages, 7414a, 7416a, 7414b, 7416b, 7414c, and 7416c,
respectively. Spring-biased check valves, 7426a and 7426b, are
received within, mate with, and are operably coupled to, the
longitudinal passages, 7414a and 7414b, respectively, for
controlling the flow of fluidic materials therethrough. A tubular
member 7428 that defines a longitudinal passage 7428a and radial
passages, 7428b and 7428c, that are fluidicly coupled to the
internal annular recess 7408 of the expansion cone 7402 is received
within, mates with, and is coupled to the centrally positioned
longitudinal passage 7406 of the expansion cone. A tubular piston
7440 defines a passageway 7440a that receives, mates with and is
slidably coupled to the tubular member 7428 and is received within,
mates with and is slidably coupled to internal annular recess 7432
of the expansion cone 7400.
[0444] In an exemplary embodiment, during operation of the system
7400, the expansion cone 7402 is positioned within, and displaced
relative to, an expandable tubular member 7430 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7402 is displaced
relative to the expandable tubular member 7430 by injecting a
pressurized fluidic material 7432 into and through the passage
7428a of the tubular member 7428. As a result, the expansion cone
7402 is displaced in a direction 7433 relative to the expandable
tubular member 7430. In an exemplary embodiment, the fluidic
material 7432 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7402 and the
expandable tubular member 7430 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7432 is conveyed through the radial passages, 7428b and 7428c, of
the tubular member 7428 into a annular chamber 7434 defined between
the internal annular recess 7408 of the expansion cone 7402 and the
tubular member 7428. In an exemplary embodiment, a second fluidic
material 7444 may be housed in the annular chamber 7434 below
tubular piston 7442 and in an annular chamber 7436 defined between
the external annular recess 7410 of the expansion cone 7402 and the
expandable tubular member 7430. In an exemplary embodiment, the
fluidic material 7444 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
7402 and the expandable tubular member 7430 during the radial
expansion process. If the operating pressure of the fluidic
material 7432 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7426a and 7426b, and tubular piston 7440, the tubular piston is
displaced within annular chamber 7434, thereby pumping the second
fluidic material through the longitudinal passages, 7412a and
7412b, into the annular chamber 7436. The pressurized fluidic
material 7444 is then conveyed into the external grooves, 7424a,
7424b, and 7424c, through the longitudinal passages, 7414a and
7414b, and the radial passages, 7416a, 7416b, 7416c, 7418a, 7418b,
and 7418c, into the interface between the expansion cone 7402 and
the expandable tubular member 7430.
[0445] In an exemplary embodiment, the rate of injection of the
fluidic material 7444 into the external grooves, 7424a, 7424b, and
7424c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7426a and 7426b, and tubular piston 7440. In this manner,
during the radial expansion process, the fluidic material 7444 may
be controllably injected and metered into the interface between the
tapered external expansion surface 7424 of the expansion cone 7402
and the expandable tubular member 7430 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7444 may be injected
into the external grooves, 7424a, 7424b, and 7424c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7424 of
the expansion cone 7402 and the expandable tubular member 7430 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0446] In an embodiment, valves 7426a and 7426b, permits lubricant
flow when the input pressure of the fluidic material 7432 exceeds a
predetermined pressure limit, which may be a factor of diameter of
the tubular member, the length of the tubular member and the
desired amount of lubricant to be dispensed. In an embodiment,
tubular piston 7440 pumps the fluidic material 7444 into the
annular chamber 7736, based on the input pressure of the fluidic
material 7432, such as, for example, when the input pressure of the
fluidic material 7444 exceeds a predetermined pressure limit, which
may be a factor of diameter of the tubular member 7430, the length
of the tubular member 7430 and the desired amount of lubricant to
be injected.
[0447] In an exemplary embodiment, the second fluidic material 7444
in annular chambers, 7434 and 7436 below tubular piston 7440 may be
preloaded into expansion cone 7400 prior to being used to expand
tubular member 7402. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7400.
[0448] In an alternate embodiment, the tubular piston 7440 and
spring-biased check valves, 7426a and 7426b, may be omitted, and/or
used in combination with other types of flow metering devices such
as, for example, passive flow control devices, active flow control
devices, fixed orifices, and/or variable orifices.
[0449] Referring to FIG. 66, an embodiment of a system 7500 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 66, an expansion cone 7502 includes a body 7504
that defines a centrally positioned longitudinal passage 7506, an
internal annular recess 7508, an external annular recess 7510,
longitudinal passages, 7512a and 7512b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7514a and 7514b, fluidicly coupled to the external annular recess,
radial passages, 7516a, 7516b, and 7516c, fluidicly coupled to the
longitudinal passage 7514a, and radial passages, 7518a, 7518b, and
7518c, fluidicly coupled to the longitudinal passage 7514b, and
includes a front end face 7520, a rear end face 7522, and a tapered
external expansion surface 7524 including spaced apart external
grooves, 7524a, 7524b, and 7524c, that are fluidicly coupled to the
radial passages, 7514a, 7516a, 7514b, 7516b, 7514c, and 7516c,
respectively. Spring-biased check valves, 7526a and 7526b, are
received within, mate with, and are operably coupled to, the
longitudinal passages, 7514a and 7514b, respectively, for
controlling the flow of fluidic materials therethrough. A tubular
member 7528 that defines a longitudinal passage 7528a and radial
passages, 7528b and 7528c, that are fluidicly coupled to the
internal annular recess 7508 of the expansion cone 7502 is received
within, mates with, and is coupled to the centrally positioned
longitudinal passage 7506 of the expansion cone. A conventional
pressure enhancer 7550 is received within, mates with and is
slidably coupled to external annular recess 7510, of the expansion
cone.
[0450] In an exemplary embodiment, during operation of the system
7500, the expansion cone 7502 is positioned within, and displaced
relative to, an expandable tubular member 7530 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7502 is displaced
relative to the expandable tubular member 7530 by injecting a
pressurized fluidic material 7532 into and through the passage
7528a of the tubular member 7528. As a result, the expansion cone
7502 is displaced in a direction 7533 relative to the expandable
tubular member 7530. In an exemplary embodiment, the fluidic
material 7532 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7502 and the
expandable tubular member 7530 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7532 is conveyed through the radial passages, 7528b and 7528c, of
the tubular member 7528 into a annular chamber 7534 defined between
the internal annular recess 7508 of the expansion cone 7502 and the
tubular member 7528. The pressure enhancer 7550 increases the
pressure on the fluidic material. If the operating pressure of the
fluidic material 7532 exceeds a predetermined value, which will
vary as a function of the operating characteristics of the check
valves, 7526a and 7526b, the fluidic material is then conveyed
through the longitudinal passages, 7512a and 7512b, into an annular
chamber 7536 defined between the external annular recess 7510 of
the expansion cone 7502 and the expandable tubular member 7530. The
pressurized fluidic material 7532 is then conveyed into the
external grooves, 7524a, 7524b, and 7524c, through the longitudinal
passages, 7514a and 7514b, and the radial passages, 7516a, 7516b,
7516c, 7518a, 7518b, and 7518c, into the interface between the
expansion cone 7502 and the expandable tubular member 7530.
[0451] In an exemplary embodiment, the rate of injection of the
fluidic material 7532 into the external grooves, 7524a, 7524b, and
7524c, depends on the operating pressure of the fluidic material
and the operating characteristics of the pressure enhancer 7550 and
of the spring-biased check valves, 7526a and 7526b. In this manner,
during the radial expansion process, the fluidic material 7532 may
be controllably injected and metered into the interface between the
tapered external expansion surface 7524 of the expansion cone 7502
and the expandable tubular member 7530 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7532 may be injected
into the external grooves, 7524a, 7524b, and 7524c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7524 of
the expansion cone 7502 and the expandable tubular member 7530 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0452] In an alternate embodiment, the spring-biased check valves,
7526a and 7526b, may be omitted, and/or used in combination with
other types of flow metering devices such as, for example, passive
flow control devices, active flow control devices, fixed orifices,
and/or variable orifices. In an alternate embodiment, the pressure
enhancer 7550, which any type of pressure enhancing device, such
as, for example, a piston or a diaphragm, may be omitted, and/or
used in combination with other types of flow enhancing devices or
pressure increasing devices, such as, for example, passive flow
control devices, active flow control devices, fixed orifices,
and/or variable orifices, such as, for example, a high-pressure
lubricator.
[0453] Referring to FIG. 67, an embodiment of a system 7600 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 67, an expansion cone 7602 includes a body 7604
that defines a centrally positioned longitudinal passage 7606, an
internal annular recess 7608, an external annular recess 7610,
longitudinal passages, 7612a and 7612b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7614a and 7614b, fluidicly coupled to the external annular recess,
radial passages, 7616a, 7616b, and 7616c, fluidicly coupled to the
longitudinal passage 7614a, and radial passages, 7618a, 7618b, and
7618c, fluidicly coupled to the longitudinal passage 7614b, and
includes a front end face 7620, a rear end face 7622, and a tapered
external expansion surface 7624 including spaced apart external
grooves, 7624a, 7624b, and 7624c, that are fluidicly coupled to the
radial passages, 7614a, 7616a, 7614b, 7616b, 7614c, and 7616c,
respectively. Spring-biased check valves, 7626a and 7626b, are
received within, mate with, and are operably coupled to, the
longitudinal passages, 7614a and 7614b, respectively, for
controlling the flow of fluidic materials therethrough. A tubular
member 7628 that defines a longitudinal passage 7628a and radial
passages, 7628b and 7628c, that are fluidicly coupled to the
internal annular recess 7608 of the expansion cone 7602 is received
within, mates with, and is coupled to the centrally positioned
longitudinal passage 7606 of the expansion cone. A tubular piston
7640 defines a passageway 7642 that receives, mates with and is
slidably coupled to the tubular member 7628 and is received within,
mates with and is slidably coupled to internal annular recess 7632,
of the expansion cone. A conventional pressure enhancer 7650 is
received within, mates with and is slidably coupled to external
annular recess 7610, of the expansion cone 7630.
[0454] In an exemplary embodiment, during operation of the system
7600, the expansion cone 7602 is positioned within, and displaced
relative to, an expandable tubular member 7630 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7602 is displaced
relative to the expandable tubular member 7630 by injecting a
pressurized fluidic material 7632 into and through the passage
7628a of the tubular member 7628. As a result, the expansion cone
7602 is displaced in a direction 7633 relative to the expandable
tubular member 7630. In an exemplary embodiment, the fluidic
material 7632 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7602 and the
expandable tubular member 7630 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7632 is conveyed through the radial passages, 7628b and 7628c, of
the tubular member 7628 into a annular chamber 7634 defined between
the internal annular recess 7608 of the expansion cone 7602 and the
tubular member 7628. In an exemplary embodiment, a second fluidic
material 7644 may be housed in the annular chamber 7634 below
tubular piston 7642 and in an annular chamber 7636 defined between
the external annular recess 7610 of the expansion cone 7602 and the
expandable tubular member 7630. In an exemplary embodiment, the
fluidic material 7644 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
7602 and the expandable tubular member 7630 during the radial
expansion process. If the operating pressure of the fluidic
material 7632 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7626a and 7626b, and tubular piston 7640, the tubular piston is
displaced within annular chamber 7634, thereby pumping the second
fluidic material through the longitudinal passages, 7612a and
7612b, into the annular chamber 7636. The pressure enhancer 7650
increases the pressure on the second fluidic material 7644. The
pressurized fluidic material 7644 is then conveyed into the
external grooves, 7624a, 7624b, and 7624c, through the longitudinal
passages, 7614a and 7614b, and the radial passages, 7616a, 7616b,
7616c, 7618a, 7618b, and 7618c, into the interface between the
expansion cone 7602 and the expandable tubular member 7630.
[0455] In an exemplary embodiment, the rate of injection of the
fluidic material 7644 into the external grooves, 7624a, 7624b, and
7624c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7626a and 7626b, tubular piston 7640 and pressure enhancer
7650. In this manner, during the radial expansion process, the
fluidic material 7644 may be controllably injected and metered into
the interface between the tapered external expansion surface 7624
of the expansion cone 7602 and the expandable tubular member 7630
continuously during the radial expansion and plastic deformation of
the tubular member. In an exemplary embodiment, the fluidic
material 7644 may be injected into the external grooves, 7624a,
7624b, and 7624c only when required, or as desired. Thus, the
trailing edge portion of the interface between the tapered external
expansion surface 7624 of the expansion cone 7602 and the
expandable tubular member 7630 may be provided with an increased
supply of lubricant, thereby reducing the amount of force required
to radially expand and plastically deform the expandable tubular
member.
[0456] In an embodiment, valves 7626a and 7626b, permits lubricant
flow when the input pressure of the fluidic material 7632 exceeds a
predetermined pressure limit, which may be a factor of diameter of
the tubular member, the length of the tubular member and the
desired amount of lubricant to be dispensed. In an embodiment,
tubular piston 7640 pumps the fluidic material 7644 into the
annular chamber 7636, based on the input pressure of the fluidic
material 7632, such as, for example, when the input pressure of the
fluidic material 7644 exceeds a predetermined pressure limit, which
may be a factor of diameter of the tubular member 7630, the length
of the tubular member 7630 and the desired amount of lubricant to
be injected.
[0457] In an exemplary embodiment, the second fluidic material 7644
in an annular chamber 7636 below tubular piston 7640 may be
preloaded into expansion cone 7600 prior to being used to expand
tubular member 7602. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7600.
[0458] In an alternate embodiment, the tubular piston 7640 and
spring-biased check valves, 7626a and 7626b, may be omitted, and/or
used in combination with other types of flow metering devices such
as, for example, passive flow control devices, active flow control
devices, fixed orifices, and/or variable orifices. In an alternate
embodiment, the pressure enhancer 7550, which any type of pressure
enhancing device, such as, for example, a piston or a diaphragm,
may be omitted, and/or used in combination with other types of flow
enhancing devices or pressure increasing devices, such as, for
example, passive flow control devices, active flow control devices,
fixed orifices, and/or variable orifices, such as, for example, a
high-pressure lubricator.
[0459] Referring to FIG. 68, an embodiment of a system 7700 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 68, an expansion cone 7702 includes a body 7704
that defines a centrally positioned longitudinal passage 7706, an
internal annular recess 7708, an internal annular recess 7709, an
external annular recess 7710, longitudinal passages, 7712a and
7712b, fluidicly coupled between the internal and external annular
recesses, longitudinal passages, 7714a and 7714b, fluidicly coupled
to the external annular recess, radial passages, 7716a, 7716b, and
7716c, fluidicly coupled to the longitudinal passage 7714a, and
radial passages, 7718a, 7718b, and 7718c, fluidicly coupled to the
longitudinal passage 7714b, and includes a front end face 7720, a
rear end face 7722, and a tapered external expansion surface 7724
including spaced apart external grooves, 7724a, 7724b, and 7724c,
that are fluidicly coupled to the radial passages, 7714a, 7716a,
7714b, 7716b, 7714c, and 7716c, respectively. Spring-biased check
valves, 7726a and 7726b, are received within, mate with, and are
operably coupled to, the longitudinal passages, 7714a and 7714b,
respectively, for controlling the flow of fluidic materials
therethrough. A tubular member 7728 that defines a longitudinal
passage 7728a and radial passages, 7728b and 7728c, that are
fluidicly coupled to the internal annular recess 7708 of the
expansion cone 7702 is received within, mates with, and is coupled
to the centrally positioned longitudinal passage 7706 of the
expansion cone. A tubular piston 7740 defines a passageway 7740a
that receives, mates with and is slidably coupled to the tubular
member 7728 and is received within, mates with and is slidably
coupled to internal annular recess 7732, of the expansion cone. A
capacitor bank 7750 is received within the internal annular chamber
7709 and is electrically coupled to power source 7760 through
connectors 7756. Electrodes 7754a and 7754b are received within
external annular recess 7732 and are electrically coupled to
capacitor bank 7750 through connectors 7758.
[0460] In an exemplary embodiment, during operation of the system
7700, the expansion cone 7702 is positioned within, and displaced
relative to, an expandable tubular member 7730 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7702 is displaced
relative to the expandable tubular member 7730 by injecting a
pressurized fluidic material 7732 into and through the passage
7728a of the tubular member 7728. As a result, the expansion cone
7702 is displaced in a direction 7733 relative to the expandable
tubular member 7730. In an exemplary embodiment, the fluidic
material 7732 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7702 and the
expandable tubular member 7730 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7732 is conveyed through the radial passages, 7728b and 7728c, of
the tubular member 7728 into a annular chamber 7734 defined between
the internal annular recess 7708 of the expansion cone 7702 and the
tubular member 7728. In an exemplary embodiment, a second fluidic
material 7744 may be housed in the annular chamber 7734 below
tubular piston 7742 and in an annular chamber 7736 defined between
the external annular recess 7710 of the expansion cone 7702 and the
expandable tubular member 7730. In an exemplary embodiment, the
fluidic material 7744 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
7702 and the expandable tubular member 7730 during the radial
expansion process. If the operating pressure of the fluidic
material 7732 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7726a and 7726b, and tubular piston 7740, the tubular piston is
displaced within annular chamber 7734, thereby pumping the second
fluidic material through the longitudinal passages, 7712a and
7712b, into the annular chamber 7736. The pressurized fluidic
material 7744 is then conveyed into the external grooves, 7724a,
7724b, and 7724c, through the longitudinal passages, 7714a and
7714b, and the radial passages, 7716a, 7716b, 7716c, 7718a, 7718b,
and 7718c, into the interface between the expansion cone 7702 and
the expandable tubular member 7730. In an embodiment, the pressure
on the fluidic material 7744 in annular recess 7736 may be
increased by the introduction of an electric pulse into the fluidic
material 7744 through electrodes, 7754a and 7754b by the
discharging the capacitor bank 7750 to trigger a high-pressure
gaseous expansion within the lubricant in external annular recess
7732 by means of an electric discharge.
[0461] In an exemplary embodiment, the rate of injection of the
fluidic material 7744 into the external grooves, 7724a, 7724b, and
7724c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7726a and 7726b, and tubular piston 7740. In this manner,
during the radial expansion process, the fluidic material 7744 may
be controllably injected and metered into the interface between the
tapered external expansion surface 7724 of the expansion cone 7702
and the expandable tubular member 7730 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7744 may be injected
into the external grooves, 7724a, 7724b, and 7724c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7724 of
the expansion cone 7702 and the expandable tubular member 7730 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0462] In an embodiment, valves 7726a and 7726b, permits lubricant
flow when the input pressure of the fluidic material 7732 exceeds a
predetermined pressure limit, which may be a factor of diameter of
the tubular member, the length of the tubular member and the
desired amount of lubricant to be dispensed. In an embodiment,
tubular piston 7740 pumps the fluidic material 7744 into the
annular chamber 7736, based on the input pressure of the fluidic
material 7732, such as, for example, when the input pressure of the
fluidic material 7744 exceeds a predetermined pressure limit, which
may be a factor of diameter of the tubular member 7730, the length
of the tubular member 7730 and the desired amount of lubricant to
be injected.
[0463] In an exemplary embodiment, the second fluidic material 7744
in an annular chamber 7736 below tubular piston 7740 may be
preloaded into expansion cone 7700 prior to being used to expand
tubular member 7702. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7700.
[0464] In an alternate embodiment, the tubular piston 7740 and
spring-biased check valves, 7726a and 7726b, may be omitted, and/or
used in combination with other types of flow metering devices such
as, for example, passive flow control devices, active flow control
devices, fixed orifices, and/or variable orifices.
[0465] In an exemplary embodiment, the introduction of electrodes
7754a and 7754b that are electrically coupled via connectors 7758
to bank of capacitor 7750 to trigger a high-pressure gaseous
expansion within an enclosed volume of lubricant in annular chamber
7736 when bank of capacitors 7750 discharge, which in turn, may
increase the lubricant pressure. The discharge expansion may create
a pressure impulse allowing more lubricant to flow between the
expansion cone 7700 and tubular member 7730, thereby reducing the
friction. The expansion may create a pressure impulse in annular
recess 7736 of approximately 15 ksi, allowing more lubricant to
flow between expansion cone 7700 and tubular member 7702 and
thereby reducing the friction, which may reduce the working
pressure behind the expansion cone 7700.
[0466] A discharge may occur between electrodes 7754a and 7754b in
the lubricant stored in external annular recess 7732 that acts as a
dielectric when capacitor bank 7750 discharge current through
connectors 7756 to electrodes 7754a and 7754b. When the lubricant
dielectric between the electrodes 7754a and 7754b breaks down, a
high temperature arc is created which vaporizes some of the
dielectric. Due to the incompressibility of fluids, the
vaporization may create a pulse of pressure, which complements the
existing fluid pressure.
[0467] The following three properties may be considered when
determining the properties of a system for lubricating the
interface between an expansion cone and a tubular member
implementing a mechanism to trigger a high-pressure gaseous
expansion: thermodynamic properties, electric properties, and
deformation properties of the tubular member during the expansion
process.
[0468] Regarding thermodynamic properties, due to the non-ideal
nature of a vaporized dielectric medium, the following equations
may be utilized to determining the properties of a system for
lubricating the interface between expansion cone 7700 and a tubular
member 7702 during the expansion process implementing a mechanism
to trigger a high-pressure gaseous expansion. Van der Waals
equation may be manipulated to express pressure as a function of
the ratio of dielectric medium density, average molar mass, and the
dielectric's boiling point as follows: [ P + a .function. ( n V ) 2
] .times. ( V - nb ) = nRT ##EQU1## where:
[0469] P--Pressure [psi]
[0470] V--Volume of Vaporized Lubricant
[0471] T--Temperature [K]
[0472] n--Moles of Lubricant [mols]
[0473] R--1.206 [L-psi/K-mol]
[0474] a--Experimental Proportionality Constant
[0475] b--Experimental Constant Relating to Molecular Volume P = RT
b ( M .rho. ) - b - a .function. ( .rho. M ) 2 ##EQU2## where:
[0476] P--Pressure [psi]
[0477] Tb--Lubricant's Boiling Point [.degree. K]
[0478] M--Av. Lubricant Molar Mass
[0479] .rho.--Lubricant Density
[0480] R--1.206 [L-psi/K-mol]
[0481] a--Experimental Proportionality Constant
[0482] b--Experimental Constant Relating to Molecular Volume
[0483] Since the volume of the external annular recess 7732 is not
well defined, the following constraints may be used. It is assumed
that the vaporization takes place at about the boiling point of the
dielectric, because the addition of the heat of vaporization does
not change the temperature. However, increases beyond this
temperature may have no negative effect on vaporization.
Furthermore, there is no common direct mathematic relationship
between the discharge energy and the pressure created by the
vaporization. Molar mass of the dielectric may need to be
calculated experimentally or mathematically if all the components
of the dielectric medium are known. The constants `a` and `b` may
be experimentally determined or may be available in engineering
tables based on the choice of lubricant.
[0484] The effective discharge energy (E.sub.effective) of back of
capacitor 7750 should be greater than the energy required to
vaporize `m` grams of the lubricant as exhibited in the following
equation:
E.sub.effective=1/2k.sub.iCV.sub.b.sup.2>mL.sub.v+mL.sub.sT (13)
T=T.sub.b-T.sub.i[K] (14) where:
[0485] E.sub.eff--Effective Lubricant Energy [J]
[0486] k.sub.e--Energy Efficiency Factor
[0487] C--Capacitance
[0488] V.sub.b--Breakdown Voltage
[0489] m--Mass of Vaporized Lubricant
[0490] L.sub.v--Heat of Vaporization [J/gm]
[0491] L.sub.s--Specific Heat [J/gm-K]
[0492] T.sub.b--Lubricant's Boiling Point [K]
[0493] T.sub.i--Dielectric Initial Temperature [K]
T-T.sub.b-T.sub.i[K]
[0494] The effective discharge energy (E.sub.effective) of back of
capacitor 7750 is proportionately related to the calculated
discharge energy of back of capacitor 7750 by an experimentally
determined an "energy efficiency factor". The mass `m` of vaporized
lubricant will depend on the geometry of the electrodes and of the
discharge volume.
[0495] Regarding electric properties, the discharge of electricity
takes place when the potential across the electrodes equals the
breakdown voltage. Breakdown voltage for two electrodes 7754a and
7754b can be calculated from the lubricant's dielectric strength
using the following equations: V.sub.b=dE.sub.ds (15) where:
[0496] V.sub.b--Breakdown Voltage
[0497] d--Distance Between Electrodes [mm]
[0498] E.sub.ds--Dielectric Strength [kV/mm]
In general, oils have high dielectric strengths, on the order of
about 10-50 kV/mm. In an exemplary embodiment, a dielectric
strength on the low end of that range may be desired.
[0499] An expression for the relation between current and total
resistance is as follows: V b = IR > 2 .times. m .function. ( L
v + L s .times. T ) k e .times. C ( 16 ) ##EQU3## where:
[0500] V.sub.b--Breakdown Voltage
[0501] l--Line Current
[0502] m--Mass of Vaporized Dielectric
[0503] R--System Resistance
[0504] L.sub.v--Heat of Vaporization [J/gm]
[0505] L.sub.s--Specific Heat [J/gm-K]
[0506] T--T.sub.b-T.sub.i[K]
[0507] k.sub.e--Energy Efficiency Factor
[0508] C--Capacitance R=R.sub.internal+R.sub.design+Z.sub.line (17)
where:
[0509] R--System Resistance
[0510] R.sub.int.--Internal Resistance
[0511] R.sub.design--Design Resistance
[0512] Z.sub.line--Line Impedance
[0513] The resistance consists of several components, internal
resistance of bank of capacitors 7752, resistance added by the
designer, and line impedance. Line impedance may play an important
role since the system will not be in steady state and may need to
be determined empirically.
[0514] The equation for the effective discharge energy
E.sub.effective of bank of capacitors 7752 suggests that minimizing
the specific heat and the heat of vaporization may result in lower
required discharge energy. Synthetic oils, which generally have
higher heats of vaporization, generally have film strengths
exceeding 3000 psi. Mineral-based oils have film strengths of about
400 psi. However, neither synthetic oils nor mineral based oils may
be sufficient for the expected pressures of 10 ksi-15 ksi. It seems
that a hard lubricant with a higher tolerance for pressure, such as
graphite or molybdenum disulfide, may work better. However, the
heat of vaporization of a hard lubricant may be significantly
higher than that of a liquid lubricant. Also, the electrodes 7754a
and 7754b and the surrounding liquid dielectric may be insulated to
prevent any permanent dielectric breakdown in such a hard
lubricants. The use of a system for lubricating the interface
between an expansion cone and a tubular member during the expansion
process implementing a mechanism to trigger a high-pressure gaseous
expansion may be also advantageous because it allows more
flexibility in the choice of the dielectric medium.
[0515] An important aspect of the a system for lubricating the
interface between an expansion cone and a tubular member during the
expansion process implementing a mechanism to trigger a
high-pressure gaseous expansion design is the frequency of the
discharges. Assuming, for the purpose of analysis that the
breakdown voltage across the electrodes 7754a and 7754b is reached
at around t=RC sec, frequency can be easily expressed by the
following equation: .lamda. = 1 RC ( 18 ) ##EQU4## where:
[0516] R--System Resistance
[0517] .lamda.--Discharge Frequency [Hz]
[0518] C--Capacitance
Estimating that the frequency of the discharges will be at least 3
Hz, the lifetime rating of the capacitor bank 7750 should be as
high.
[0519] Since the expansion cone may be used at considerable depths,
it is desirable that capacitor bank 7750 be located as close to the
electrodes 7754a and 7754b as possible. In one embodiment, it is
anticipated that any commercial capacitor for high-power pulsing
applications that uses charging voltages in the tens of kV, can
retain several kJ of energy, and is able to deliver current on the
order of 100 kA may be used in capacitor bank 7750. In addition,
the selected capacitor should be able to tolerate significant
voltage reversal. In an exemplary embodiment, high power
capacitors, such as those manufactured by Passoni Villa that have
built in switches, may be used to achieve more control of the
discharge frequency.
[0520] In an exemplary embodiment, the following of manufacturers
may supply capacitors suitable for capacitor bank 7750, include the
following:
[0521] Passoni Villa (www.passoni-villa.com (Capacitors));
[0522] Aerovox (www.aerovox.com (Capacitors));
[0523] Richardson Electronics (www.industrial.rell.com
(Ignitrons));
[0524] Darrah Electric (www.darrahelectric.com (Power
Semiconductors));
[0525] Magnet-Physik (www.magnet-physik.de (EMF Forming)) and
[0526] Magneform (www.magneform.com (EMF Forming)).
In an exemplary embodiment, capacitor bank 7750 may include one
capacitor or a plurality of capacitors.
[0527] In an exemplary embodiment, a solid-state amplifier located
near the capacitor bank 7750 may be utilized instead of a
high-voltage transformer due to size considerations. Example
manufacturers of such devices are as follows:
[0528] Richardson Electronics (www.industrial.rell.com
(Ignitrons));
[0529] Darrah Electric (www.darrahelectric.com (Power
Semiconductors));
[0530] Magnet-Physik (www.magnet-physik.de (EMF Forming)); and
[0531] Magneform (www.magneform.com (EMF Forming)).
[0532] Regarding the expandable tubular member deformation
characteristics, the work done on tubular member 7702 by the
shockwave created by the electric discharge may be constrained to
be less than the amount of work required to deform the tube. The
work done on the tubular member 7702 can be calculated using the
tubular member 7702 material properties and its cylindrical
geometry. The expression for specific work of deformation is as
follows: a s = B 1 + m m .times. E ( 1 + m m ) ( 19 ) ##EQU5##
where:
[0533] a.sub.s--Specific Work of Deformation
[0534] E--Deformation Intensity
[0535] B, m.sub.m--Mechanical characteristics of tubular member
7702
[0536] The constant m.sub.m, true strain, is defined the following
equation: m m = e n = ln .function. ( 1 + .DELTA.ln l 0 ) ( 20 )
##EQU6## where:
[0537] m.sub.m--True Strain
[0538] .DELTA.l.sub.n/l.sub.0--Elongation
In an exemplary embodiment, .DELTA.l.sub.n/l.sub.0 is the
elongation of tubular member 7702, such as for example, in the case
of En-80 steel, with .DELTA.l.sub.n/l.sub.0=0.20,
m.sub.m=0.182.
[0539] The mechanical constant B is defined by the following
equation. B = E m m e n m m .times. .sigma. b .times. .times. where
.times. : .times. .times. E - r r 0 - 1 .times. .times. m m - True
.times. .times. Strain .times. .times. e n - e n = m m .times.
.times. .sigma. b - Yield .times. .times. Strength ( 21 )
##EQU7##
[0540] For a cylindrical geometry such as that of tubular member
7702, E is defined the following equation: E = r r 0 - 1 ( 22 )
##EQU8## where:
[0541] E--Deformation Intensity
[0542] r.sub.0--Original Radius
[0543] r--Final Radius
The radius referred to is the inner radius of the tubular member
7702.
[0544] The total work of deformation is a function of the specific
work of deformation and the volume of the tubular member 7702
material deformed. The work done by the discharge on the tubular
member must be no greater than the work required to expand the
tubular member 7702 to its final radius and is defined as follows:
W.sub.D<a.sub.sV.sub.w (23) where:
[0545] a.sub.s--Specific Work of Deformation
[0546] V.sub.w--Volume of Deformed Material
[0547] W.sub.D--Work Due to Discharge
[0548] An expression relating the maximum amount of work may be
constructed by assuming a discharge volume of axial length .beta.,
and an outer radius r.sub.0 (the outer radius being equal to the
inner radius of the unexpanded tubular member 7702). The final
outer radius will be designated by r. The equation defining the
volume of deformed material, V.sub.w, is as follows:
V.sub.w=2.beta.(r.sup.2-r.sub.0.sup.2) (24) where:
[0549] .beta.--Axial Length of Discharge Volume
[0550] r--Final Radius
[0551] r.sub.0--Original Radius
[0552] V.sub.w--Volume of Deformed Material
[0553] In an exemplary embodiment, using the equations specified
above for a tubular member 7702 that expands from a 4.77'' inside
diameter to a 5.68'' inside diameter, hypothetically the
deformation intensity (E) is 0.191, assuming that the axial length
of discharge volume (.beta.) is 0.04 m and produces a volume of
deformation material (V.sub.w) of 0.005809 m.sup.3 and true strain
(m.sub.m) of 0.182. Note that the yield strength (.sigma..sub.b)
range for En-80 steel tubes is approximately 48.26.times.10.sup.7
N/m.sup.2 (70 ksi) to 65.50.times.10.sup.7 N/m.sup.2 (95 ksi) and
mechanical constant (B) is found to range from 48.69.times.10.sup.7
N/m.sup.2 to 66.08.times.10.sup.7 N/m.sup.2. Therefore, the
specific work (a.sub.s) of deformation ranges from
5.82.times.10.sup.7 N/m.sup.2 to 7.90.times.10.sup.7 N/m.sup.2. For
this particular volume and radial expansion, the amount of work
required to expand the tubular member 7702 is on the order of 460
kJ to 340 kJ. Hence, the work done on the tubular member 7702 due
to the discharge may not exceed 340 kJ. However, the expected
energy of the discharge is far lower. The pressure produced by the
discharge may also be limited. The yield strength of En-80 steel is
70-95 ksi. The pressure produced by the discharge can therefore not
exceed 70 ksi. Again, the expected maximum pressure due to the
discharge will be approximately 15 ksi. However, should the stated
constraints be exceeded, the results would be unpredictable, and
control over the process could be lost.
[0554] In an exemplary embodiment, an apparatus for testing a
system for lubricating the interface between an expansion cone and
a tubular member implementing a mechanism to trigger a
high-pressure gaseous expansion during the expansion process may
consider the following: (1) the determination of the specific
capacitances of capacitor bank 7750, system resistances and
impedances, and voltage required at power source 7760 for
implementation may be found experimentally; and (2) the process
values for a given lubricant may be determined by utilizing a
discharge volume with piezoelectric sensors. Piezoelectric sensors
are small, may withstand extremely high pressures, and produce
electric outputs that are easily digitized and quantified for
analysis. There are also several possible ways to regulate the
power at power source 7760 in a testing apparatus, including for
example, regulation of system resistance using potentiometers as an
effective way to regulate the discharge power. The capacitor bank
7750 may also be designed to enable quick removal or addition of
capacitors. A digital oscilloscope may be connected to the
transmission line via a voltage divider to monitor system voltage.
Finally, the current may be measured with a Rogowski coil, which
uses the Hall effect to measure high currents.
[0555] Referring to FIG. 69, an embodiment of a system 7800 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 69, an expansion cone 7802 includes a body 7804
that defines a centrally positioned longitudinal passage 7806, an
internal annular recess 7808, an external annular recess 7810,
longitudinal passages, 7812a and 7812b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7814a and 7814b, fluidicly coupled to the external annular recess,
radial passages, 7816a, 7816b, and 7816c, fluidicly coupled to the
longitudinal passage 7814a, and radial passages, 7818a, 7818b, and
7818c, fluidicly coupled to the longitudinal passage 7814b, and
includes a front end face 7820, a rear end face 7822, and a tapered
external expansion surface 7824 including spaced apart external
grooves, 7824a, 7824b, and 7824c, that are fluidicly coupled to the
radial passages, 7814a, 7816a, 7814b, 7816b, 7814c, and 7816c,
respectively. Spring-biased check valves, 7826a and 7826b, are
received within, mate with, and are operably coupled to, the
longitudinal passages, 7814a and 7814b, respectively, for
controlling the flow of fluidic materials therethrough. A tubular
member 7828 that defines a longitudinal passage 7828a and radial
passages, 7828b and 7828c, that are fluidicly coupled to the
internal annular recess 7808 of the expansion cone 7802 is received
within, mates with, and is coupled to the centrally positioned
longitudinal passage 7806 of the expansion cone. A tubular piston
7840 defines a passageway 7840a that receives, mates with and is
slidably coupled to the tubular member 7828 and is received within,
mates with and is slidably coupled to internal annular recess 7732,
of the expansion cone. A magnetic coil 7854 is received within
external annular recess 7752 and is electrically coupled to power
source 7860 via connectors, 7756a and 7756b.
[0556] In an exemplary embodiment, during operation of the system
7800, the expansion cone 7802 is positioned within, and displaced
relative to, an expandable tubular member 7830 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7802 is displaced
relative to the expandable tubular member 7830 by injecting a
pressurized fluidic material 7832 into and through the passage
7828a of the tubular member 7828. As a result, the expansion cone
7802 is displaced in a direction 7833 relative to the expandable
tubular member 7830. In an exemplary embodiment, the fluidic
material 7832 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7802 and the
expandable tubular member 7830 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7832 is conveyed through the radial passages, 7828b and 7828c, of
the tubular member 7828 into a annular chamber 7834 defined between
the internal annular recess 7808 of the expansion cone 7802 and the
tubular member 7828. In an exemplary embodiment, a second fluidic
material 7844 may be housed in the annular chamber 7834 below
tubular piston 7842 and in an annular chamber 7836 defined between
the external annular recess 7810 of the expansion cone 7802 and the
expandable tubular member 7830. In an exemplary embodiment, the
fluidic material 7844 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
7802 and the expandable tubular member 7830 during the radial
expansion process. If the operating pressure of the fluidic
material 7832 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7826a and 7826b, and tubular piston 7840, the tubular piston is
displaced within annular chamber 7834, thereby pumping the second
fluidic material through the longitudinal passages, 7812a and
7812b, into the annular chamber 7836. The pressurized fluidic
material 7844 is then conveyed into the external grooves, 7824a,
7824b, and 7824c, through the longitudinal passages, 7814a and
7814b, and the radial passages, 7816a, 7816b, 7816c, 7818a, 7818b,
and 7818c, into the interface between the expansion cone 7802 and
the expandable tubular member 7830. In an embodiment, magnetic coil
7854 may trigger a high-pressure impulse in volume of fluidic
material in annular recess 7836 from a magnetic field created in
magnetic coil 7854 and thereby increase the pressure in the fluidic
material. The pressurized fluidic material 7844 is then conveyed
into the external grooves, 7824a, 7824b, and 7824c, through the
longitudinal passages, 7814a and 7814b, and the radial passages,
7816a, 7816b, 7816c, 7818a, 7818b, and 7818c, into the interface
between the expansion cone 7802 and the expandable tubular member
7830.
[0557] In an exemplary embodiment, the rate of injection of the
fluidic material 7844 into the external grooves, 7824a, 7824b, and
7824c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7826a and 7826b, and tubular piston 7840. In this manner,
during the radial expansion process, the fluidic material 7844 may
be controllably injected and metered into the interface between the
tapered external expansion surface 7824 of the expansion cone 7802
and the expandable tubular member 7830 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7844 may be injected
into the external grooves, 7824a, 7824b, and 7824c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7824 of
the expansion cone 7802 and the expandable tubular member 7830 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0558] In an embodiment, valves 7826a and 7826b, permits lubricant
flow when the input pressure of the fluidic material 7832 exceeds a
predetermined pressure limit, which may be a factor of diameter of
the tubular member, the length of the tubular member and the
desired amount of lubricant to be dispensed. In an embodiment,
tubular piston 7840 pumps the fluidic material 7844 into the
annular chamber 7836, based on the input pressure of the fluidic
material 7832, such as, for example, when the input pressure of the
fluidic material 7844 exceeds a predetermined pressure limit, which
may be a factor of diameter of the tubular member 7830, the length
of the tubular member 7830 and the desired amount of lubricant to
be injected.
[0559] In an exemplary embodiment, the second fluidic material 7844
in an annular chamber 7836 below tubular piston 7840 may be
preloaded into expansion cone 7800 prior to being used to expand
tubular member 7802. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7800.
[0560] In an alternate embodiment, the tubular piston 7840 and
spring-biased check valves, 7826a and 7826b, may be omitted, and/or
used in combination with other types of flow metering devices such
as, for example, passive flow control devices, active flow control
devices, fixed orifices, and/or variable orifices.
[0561] In an exemplary embodiment, magnetic coil 7854 triggers a
high-pressure impulse in the lubricant in annular recess 7836 by
means of a magnetic field created by in magnetic coil 7854 when
current is generated by power source 7860 and run through magnetic
coil 7854. In an exemplary embodiment, when current generated by
power source 7860 is run through magnetic coil 7854 via cables
7856a and 7856b in the fluidic materials 7844 in annular chamber
7836, a magnetic field is generated around the magnetic coils 7854
that may trigger a high-pressure gaseous expansion within an
enclosed volume of fluidic materials 7844 by means of force/impulse
from a strong magnetic field. The expansion may create a pressure,
allowing more lubricant to flow between the expansion cone 7800 and
the tubular member 7830 and thereby reducing the friction and
working pressure behind the expansion cone 7800. In an exemplary
embodiment, cables, 7856a and 7856b may be used to provide power to
the magnetic coils 7854 that may generate the magnetic field.
[0562] Referring to FIG. 70, an embodiment of a system 7900 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 70, an expansion cone 7902 includes a body 7904
that defines a centrally positioned longitudinal passage 7906, an
internal annular recess 7908, an external annular recess 7910,
longitudinal passages, 7912a and 7912b, fluidicly coupled between
the internal and external annular recesses, longitudinal passages,
7914a and 7914b, fluidicly coupled to the external annular recess,
radial passages, 7916a, 7916b, and 7916c, fluidicly coupled to the
longitudinal passage 7914a, radial passages, 7917a and 7917b,
fluidicly coupled to the longitudinal passage 7906 and radial
passage 7928c and 7928d, and includes a front end face 7920, a rear
end face 7922, and a tapered external expansion surface 7924
including spaced apart external grooves, 7924a, 7924b, and 7924c,
that are fluidicly coupled to the radial passages, 7914a, 7916a,
7914b, 7916b, 7914c, and 7916c, respectively. Spring-biased check
valves, 7926a and 7926b, are received within, mate with, and are
operably coupled to, the longitudinal passages, 7914a and 7914b,
respectively, for controlling the flow of fluidic materials
therethrough. A tubular member 7928 that defines a longitudinal
passage 7928a and radial passages, 7928b and 7928c, that are
fluidicly coupled to the internal annular recess 7908 of the
expansion cone 7902 is received within, mates with, and is coupled
to the centrally positioned longitudinal passage 7906 of the
expansion cone. A tubular piston 7940 defines a passageway 7940a
that receives, mates with and is slidably coupled to the tubular
member 7928 and is received within, mates with and is slidably
coupled to internal annular recess 7932, of the expansion cone.
[0563] In an exemplary embodiment, during operation of the system
7900, the expansion cone 7902 is positioned within, and displaced
relative to, an expandable tubular member 7930 thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 7902 is displaced
relative to the expandable tubular member 7930 by injecting a
pressurized fluidic material 7932 into and through the passage
7928a of the tubular member 7928. As a result, the expansion cone
7902 is displaced in a direction 7933 relative to the expandable
tubular member 7930. In an exemplary embodiment, the fluidic
material 7932 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 7902 and the
expandable tubular member 7930 during the radial expansion process.
In particular, in an exemplary embodiment, the fluidic material
7932 is conveyed through the radial passages, 7928b and 7928c, of
the tubular member 7928 into a annular chamber 7934 defined between
the internal annular recess 7908 of the expansion cone 7902 and the
tubular member 7928. In an exemplary embodiment, a second fluidic
material 7944 may be housed in the annular chamber 7934 below
tubular piston 7942 and in an annular chamber 7936 defined between
the external annular recess 7910 of the expansion cone 7902 and the
expandable tubular member 7930. In an exemplary embodiment, the
fluidic material 7944 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
7902 and the expandable tubular member 7930 during the radial
expansion process. If the operating pressure of the fluidic
material 7932 exceeds a predetermined value, which will vary as a
function of the operating characteristics of the check valves,
7926a and 7926b, and tubular piston 7940, the tubular piston is
displaced within annular chamber 7937, thereby pumping the second
fluidic material through the longitudinal passages, 7912a and
7912b, into the annular chamber 7936. The pressurized fluidic
material 7944 is then conveyed into the external grooves, 7924a,
7924b, and 7924c, through the longitudinal passages, 7914a and
7914b, and the radial passages, 7916a, 7916b, 7916c, 7918a, 7918b,
and 7918c, into the interface between the expansion cone 7902 and
the expandable tubular member 7930. Similarly, in an exemplary
embodiment, the fluidic material 7932 is conveyed through the
radial passages, 7928d and 7928e, of the tubular member 7928 and
through radial passages, 7917a and 7917b, into a passageway 7952
defined between the expansion cone 7902 and the tubular member
7930.
[0564] In an exemplary embodiment, the rate of injection of the
fluidic material 7944 into the external grooves, 7924a, 7924b, and
7924c, depends on the operating pressure of the fluidic material
and the operating characteristics of the spring-biased check
valves, 7926a and 7926b, and tubular piston 7940. In this manner,
during the radial expansion process, the fluidic material 7944 may
be controllably injected and metered into the interface between the
tapered external expansion surface 7924 of the expansion cone 7902
and the expandable tubular member 7930 continuously during the
radial expansion and plastic deformation of the tubular member. In
an exemplary embodiment, the fluidic material 7944 may be injected
into the external grooves, 7924a, 7924b, and 7924c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 7924 of
the expansion cone 7902 and the expandable tubular member 7930 may
be provided with an increased supply of lubricant, thereby reducing
the amount of force required to radially expand and plastically
deform the expandable tubular member.
[0565] The rate of injection of fluidic material 7932 into
passageway 7952 between expansion cone 7900 and tubular member 7902
depends on the input pressure of the fluidic material 7932. Since,
the rate of injection of the second fluidic material 7944 into the
external grooves, 7924a, 7924b, and 7924c, depends on the operating
pressure of the fluidic material and the operating characteristics
of the spring-biased check valves, 7926a and 7926b, and tubular
piston 7940, the delivery of the fluidic material 7930 into
passageway 7952 may be at a different pressure than the pressure of
the fluidic material 7932 injected into passageway 7952 between
expansion cone 7900 and tubular member 7902.
[0566] In an embodiment, valves 7926a and 7926b, permits lubricant
flow when the input pressure of the fluidic material 7932 exceeds a
predetermined pressure limit, which may be a factor of diameter of
the tubular member, the length of the tubular member and the
desired amount of lubricant to be dispensed. In an embodiment,
tubular piston 7940 pumps the fluidic material 7944 into the
annular chamber 7936, based on the input pressure of the fluidic
material 7932, such as, for example, when the input pressure of the
fluidic material 7944 exceeds a predetermined pressure limit, which
may be a factor of diameter of the tubular member 7930, the length
of the tubular member 7930 and the desired amount of lubricant to
be injected.
[0567] In an exemplary embodiment, the second fluidic material 7944
in an annular chamber 7936 below tubular piston 7940 may be
preloaded into expansion cone 7900 prior to being used to expand
tubular member 7902. Alternatively, the lubricant may be
replenished by a lubrication source located in a remote location
from expansion cone 7900.
[0568] In an alternate embodiment, the tubular piston 7940 and
spring-biased check valves, 7926a and 7926b, may be omitted, and/or
used in combination with other types of flow metering devices such
as, for example, passive flow control devices, active flow control
devices, fixed orifices, and/or variable orifices.
[0569] It is understood that variations may be made in the
foregoing expansion lubricant delivery systems without departing
from the scope of the invention. For example, the teachings of the
present illustrative embodiments may be used to vary the expansion
cone size, shape, and external and internal structure. Furthermore,
the elements and teachings of the various illustrative embodiments
may be combined in whole or in part in some or all of the
illustrative embodiments. In addition, one or more of the elements
and teachings of the various illustrative embodiments may be
omitted, at least in part, and/or combined, at least in part, with
one or more of the other elements and teachings of the various
illustrative embodiments.
[0570] For example, In an exemplary embodiment, valve may not be
used in the expansion cone. In another exemplary embodiment only
one or a plurality of lubricant reservoirs may be utilized in the
expansion cone.
Lubricants
[0571] When selecting a lubricant for a system for lubricating the
interface between an expansion cone and a tubular member during the
expansion process, the lubricant may be any media that may assist
in reducing the friction between the expansion cone and a tubular
member, including any fluidic material. Several factors may be
considered, including the coefficient of friction between the
expansion cone and tubular member, the size and complexity of the
expansion cone, and the lubricant injection pressure, length of the
tubular member and the amount of lubricant to be dispersed. The
lubricant may include wet lubricants and/or solid lubricants. It is
expected that the lubricant typically need to withstand at least
5000 psi of pressure.
[0572] In an exemplary embodiment, the lubricants for a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process may include, conventional
commercial lubricants (natural and synthetic), working hydraulic
fluid mud currently used in expandable tubular systems, and working
hydraulic fluid mud blended with solid lubricants to improve
lubricity. In an exemplary embodiment, a lithium based
(non-synthetic) multipurpose grease combined with a solid lubricant
may be used as the lubricant. In an exemplary embodiment, a grease
lubricant for this application may be composed of a solid lubricant
in a moderately high temperature resistant thickener. In an
exemplary embodiment, the lubricant may have at least 10% Graphite
or 10% Molybdenum Disulfide in a thickener with a dropping point
above 350-400F. In an exemplary embodiment, two lubricants, which
meet the requirements state above, and their respective suppliers,
are as follows: TABLE-US-00006 Lubricant Name Manufacturer
Composition Supplier 339-S Graphite Dixon Lube 30% Dixon Lubricants
and Grease Graphite Specialty Products, Asbury, New Jersey #3HT
Moli- Bemol 15% The Rose Mill Grease Molybdenum Company, East
Harford, Connecticut
[0573] Exemplary embodiments of lubricants that may be used in a
system for lubricating the interface between an expansion cone and
a tubular member may consist of the following component in the
weight percentages indicated: TABLE-US-00007 Weight Component
Percentage Characteristic Example 1 64.25-90.89% Base oil A natural
triglyceride oil which is, such as for example, fish, animal or
vegetable triglyceride oil, or mixtures thereof. The triglyceride
oil is a vegetable triglyceride oil, such as for example, sunflower
seed oil, soybean oil, rapeseed oil canola oil, palm nut oil, palm
oil, olive oil, rapeseed oil, canola oil, linseed oil, ground nut
oil, soybean oil, cottonseed oil, sunflower seed oil, pumpkin seed
oil, coconut oil, corn oil, castor oil, walnut oil and mixtures
thereof. A natural or synthetic oil, which may be an ester wherein
unsaturation as above triglycerides. The ester may be formed by a
transesterification reaction of suitable monobasic and/or dibasic
organic acids with primary, secondary or tertiary alcohols. An
example of such a naturally occurring ester is jojoba oil and such
a synthetic ester is lauryl oleate. The ester mentioned above may
be formed by the reaction of unsaturated acids with polyhydric
alcohols, such as for example, neopentyl glycol,
trimethylolylethane, trimethylolpropane or pentaerythritol.
Examples of such a reaction product are pentaerythritol monooleate,
dioleate, trioleate, and the like. Example commercially available
products are as follows: Canola oil from Cargil Inc(Agri-Pure 60,
Agri-Pure-85) or Lambent (Oleocal 102); and Sunflower oil (Lubrizol
7631) 2 0.02-0.05% Metal Triazol and benzotriazol derivatives, such
as for deactivator example, tolyltriazol. Example commercially
available products are as follows: Tolyltriazole, from PMC Inc
(Cobratec TT-100); and 1H-Benzotriazole-1-Methanamine,
N-N-bis(2-ethylhexyl)-methyl, from Ciba-Geigy Corp (Reomet 39) 3
0.5-3.0% Antioxidants Aromatic amine antioxidants and/or hindered
phenolic antioxidants antioxidants, such as for example, 2,6-bis
(tert butyl-4-methylphenol, BHT). Example commercially available
products are as follows: Octylated, Butylated Diphenylamine
Antioxidant from Ciba-Geigy Corp (Irganox L 57); 2,6-bis
(1,1-dimethylethyl)-4-methyl- Phenol, from PMC, Inc (BHT); and
Benzenepropanoic acid, 3,5-bis (1,1- demethylethyl)-4-hydroxy-,
thiodi-2,1-ethanediyl ester, from Ciba-Geigy Corp (Irganox 1035); 4
4-12% Sulfurized Sulfurized vegetable or animal fatty oils, with
natural oils sulfur content 9%-21%, such as for example
13.5%-17.5%. Example commercially available products are as
follows: Sulfurized vegetable oils from Rhein Chemie Corporation
(Additin RC-2515); and Sulfurized Lard Oil from Ferro Corporation
(HSL). 5 4-12% Phosphate Phosphoric acid esters with ethoxylated
fatty ester (C12-C15) alcohols, preferably mixture of phosphoric
acid ester with ethoxylated lauryl alcohol and phosphoric acid
ester with ethoxylated tridecyl alcohol. Example commercially
available products are as follows: Phosphoric acid ester with
ethoxylated lauryl alcohol and phosphoric acid ester with
ethoxylated tridecyl alcohol from Houghton international (Houghton
5653). 6 0.4-1.5% Phosphoric Phosphoric acid. acid An example
commercially available product is phosphoric acid from Rhodia. 7
0.08-1.5% Viscosity Polyacrylates, polymethacrylates, modifier
vinylpyrrolidone/methacrylate-copolymers, polyvinylpyrrolidones,
polybutanes, olefin- copolymers, styrene/-acrylate-copolymers,
polyethers, such as for example, styrene or butadiene-styrene
polymer. An example commercially available product is Styrene
Hydrocarbon Polymer from Lubrizol Corporation (Lubrizol .RTM.
7440S). 8 0.1-0.5% Pour-point Polymethacrylates, alkylated
naphthalene depressant derivatives, such as for example, alkyl
ester copolymers. An example commercially available product is
Alkyl ester copolymer from Lubrizol Corporation (Lubrizol 6662) 9
0.01-0.2% Defoamer Silicon based antifoam agent. An example
commercially available product is Silicon based antifoam agent from
Ultra Additives (Foam Ban 103) 10 0-5% Carboxylic Alkali,
alkanolamine, alkyl amine or alkoxylated acid soaps amine salts of
mono- or dibasic fatty acids, or mixture thereof. An example
commercially available product is Soap formed in situ as a product
of reaction between Tall Oil Fatty Acids (Sylvatal .RTM. D30LR from
Arizona Chemical Co.) and triethanol amine (TEA 99 from Huntsman
Corporation)
The lubricant may optionally contain various other additives, or
mixture thereof, in order to improve the basic properties. In an
exemplary embodiment, these further additives may include other
antioxidants, metal deactivators, viscosity improvers,
extreme-pressure additives, pour-point depressants, antifoam
agents, dispersants, detergents, corrosion inhibitors, emulsifiers,
demulsifiers and friction modifiers.
[0574] Exemplary experiments have shown that the lubricants
identified in the table below, H1, H2, H3, H4, H5, H6, and H7,
identified by the specified components in the weight percentages
and the component manufactures and/or distributors indicated may
perform in a system for lubricating the interface between an
expansion cone and a tubular member: TABLE-US-00008 Manufacture/
Example Lubricants Component Distributor H1 H2 H3 H4 H5 H6 H7 1
Canola oil Agri-Pure 60 77.81% 64.25% 90.89% 68.71% 82.07% 80.68%
80.31% 2 Tolyltriazole Cobratec TT- 0.04% 0.05% 0.02% 0.04% 0.03%
0.04% 0.04% 100 3 Aminic Irganox L 57 0 1% 0 0.5% 0.5% 0 0
antioxidant Phenolic BHT 1.0% 2% 0.5% 1% 0.5% 1% 1.1% antioxidant 4
Sulfurized Additin RC- 10% 12% 4% 12% 9% vegetable oil 2515 Or
Sulfurized HSL 10% 8% lard oil 5 Phosphoric Rhodofac RS 9% 12% 4%
10% 5% 9% 8% acid ester 410 + Rhodofac with PC ethoxylated 100
lauryl alcohol and phosphoric acid ester with ethoxylated tridecyl
alcohol 6 Phosphoric Phosphoric 1% 1.5% 0.4% 1.1% 0.5% 1% 0.8% acid
acid 7 Styrene Lubrizol 0.8% 1.5% 0.08% 1.5% 0.1% 0.1% 0.4%
Hydrocarbon 7440S Polymer 8 Alkyl ester Lubrizol 6662 0.3% 0.5%
0.1% 0.1% 0.2% 0.1% 0.3% copolymer 9 Silicon Foam Ban 0.05% 0.2%
0.01% 0.05 0.1% 0.08% 0.05% based 103 antifoam agent 10 Carboxylic
Sylvatal .RTM. 0 5% 0 5% 1% 0 0 acid soap D30LR + TEA 99
[0575] In addition introducing lubricants between an expansion cone
and a tubular member to reduce the coefficient of friction, the
cone geometry, type of cone material, the cone texture (such as,
for example, oil pocket on the surface of the cone) and coatings on
the cone all affect the overall coefficient of friction between the
expansion cone and the tubular member material, coating and
finish.
Expansion Cone Material
[0576] When selecting the material for an expansion cone to reduce
the coefficient of friction between an expansion cone and a tubular
member in a system for lubricating the interface between an
expansion cone and a tubular member during the expansion process,
several factors may be considered, including, among other things,
the coefficient of friction between the expansion cone and the
tubular member, the size and complexity of the expansion cone,
material hardness, compressive strength, wear resistance, corrosion
resistance, toughness, surface finish ability and coatings. In an
exemplary embodiment, example expansion cone materials include,
high chrome, high carbon and molybdenum based tool steels, as well
as a few powdered materials.
[0577] In several exemplary embodiments, the following commercially
available expansion cone materials may be used in a system for
lubricating the interface between an expansion cone and a tubular
member: DC53, D2, D5, D7, M2, M4, CPM M4, 10V AND 3V. Referring to
FIGS. 71a, 71b, 71c, and 71d, the hardness, toughness, relative
wear resistance and temper temperature characteristics are shown
for each of the cone materials listed in the table above,
respectively. FIG. 71e shows some hardness characteristics for some
of the additional cone materials not listed above. Example
expansion cone material manufactures and/or distributors are as
follows: [0578] 1. International Mold Steel, Inc., of Florence, Ky.
distributes DC53 material; and [0579] 2. Crucible Materials
Corporation of Syracuse, N.Y. distributes D2, CPM M4, 10V AND 3V
materials. The characteristics of each material are specified
below.
[0580] In an exemplary embodiment, an example of a DC53 material
has the following characteristics:
[0581] Higher hardness (62-63 HRc) than D2 after heat
treatment;
[0582] Twice the toughness of D2 with superior wear resistance;
[0583] 20% higher fatigue strength than D2;
[0584] Smaller primary carbides than D2 protect the die from
chipping and cracking;
[0585] Secondary refining process (DLF) reduces impurities;
[0586] Machines and grinds up to 40% faster than D2; and
[0587] Less residual stress after wire EDMing.
[0588] In an exemplary embodiment, an example of a DC53 material
has the following Coefficient of Thermal Expansion
(x10-6/C..degree.): TABLE-US-00009 .about.100.degree. C.
.about.200.degree. .about.300.degree. .about.400.degree.
.about.500.degree. .about.600.degree. .about.700.degree. DC53 12.2
12.0 12.3 12.8 13.2 13.4 13.0 Annealed
[0589] In an exemplary embodiment, an example of a DC53 material
has the following Coefficient of Thermal Conductivity
(cal/cmsec.degree. C.): TABLE-US-00010 Room Temp. 100.degree. C.
200.degree. 300.degree. 400.degree. 500.degree. 600.degree. DC53
0.057 0.060 0.064 0.064 0.065 0.062 Quenched and Tempered
[0590] In an exemplary embodiment, an example of a DC53 material
has the following physical data: TABLE-US-00011 Physical
Characteristic Data Young's modulus (E) 21,700 Specific Gravity
7.87 Modulus of Rigidity (G) 8,480 Poisson's Ratio (v) 0.28
[0591] In an exemplary embodiment, an example of a DC53 material
can be hardened to 62-63 HRc in the same manner as D2, and when
tempered at high temperatures (520.degree. to 530.degree. C.), it
assumes excellent properties. Even when tempered at lower
temperatures (180.degree. to 200.degree. C.), its performance is
equivalent to or better than that of D2. This improved
hardenability makes heat treatment easier and reduces hardness
problems due to vacuum heat treatment, which uses gas cooling.
[0592] In an exemplary embodiment, an example of a DC53 material
displays superior wear-resistance to D2 when tempered at high
temperatures (520.degree. C.) and equal wear resistance to D2 when
tempered at low temperatures. High resistance to temper softening
minimizes seizing and galling on the die surface. DC53 is ideal for
dies needing to maintain high surface hardness against frictional
heat between the die surface and the worked materials.
[0593] In an exemplary embodiment, an example of a D2 material is,
AISI Type D2 Tool Steel that is air-quenched from 1010.degree. C.
and tempered at 450.degree. C., which falls into the following
subcategories: cold work steel; high carbon steel; metal; and tool
steel. The AISI Type D2 Tool Steel has the following
properties:
[0594] Mechanical Properties Metric English Comments-- [0595]
Hardness, Knoop 682 Converted from Rockwell C hardness; [0596]
Hardness, Rockwell C 58; [0597] Hardness, Vickers 661; [0598] Izod
Impact, Unnotched 63 J 46.5 ft-lb; and
[0599] Thermal Properties-- [0600] CTE, linear 20.degree. C. 10.5
.mu.m/m-.degree. C. 5.83 .mu.in/in-.degree. F. 20-100.degree. C.;
[0601] CTE, linear 250.degree. C. 11.8 .mu.m/m-.degree. C. 6.56
.mu.in/in-.degree. F. from 0-300.degree. C. (68-570.degree. F.);
and [0602] CTE, linear 500.degree. C. 12.5 .mu.m/m-.degree. C. 6.94
.mu.in/in-.degree. F. from 0-500.degree. C. (68-930.degree.
F.).
[0603] In an exemplary embodiment, the AISI Type D2 Tool Steel has
the following material composition: TABLE-US-00012 Component Wt. %
C 1.4-1.6 Co Max 1 Cr 11-13 Mn Max 0.6 Mo 0.7-1.2 P Max 0.03 S Max
0.03 Si Max 0.6 V Max 1.1
[0604] In an exemplary embodiment, an example of a D3 material is,
AISI Type D3 Tool Steel that is oil-quenched from 980.degree. C.
(1800.degree. F.) and tempered at 450.degree. C., which falls into
the following subcategories: cold work steel; high carbon steel;
metal; and tool steel. The AISI Type D3 Tool Steel has the
following properties:
[0605] Mechanical Properties Metric English Comments-- [0606]
Hardness, Knoop 682 682 Converted from Rockwell C hardness; [0607]
Hardness, Rockwell C 58 58; [0608] Hardness, Vickers 661 661;
[0609] Izod Impact, Unnotched 29 J 21.4 ft-lb; and
[0610] Thermal Properties-- [0611] CTE, linear 20.degree. C. 10.7
.mu.m/m-.degree. C. 5.94 .mu.in/in-.degree. F. 20-100.degree. C.;
[0612] CTE, linear 250.degree. C. 12.1 .mu.m/m-.degree. C. 6.72
.mu.in/in-.degree. F. from 0-300.degree. C. (68-570.degree. F.);
and [0613] CTE, linear 500.degree. C. 12.8 .mu.m/m-.degree. C. 7.11
.mu.in/in-.degree. F. from 0-500.degree. C. (68-930.degree.
F.).
[0614] In an exemplary embodiment, the AISI Type D3 Tool Steel has
the following material composition: TABLE-US-00013 Component Wt. %
C 2-2.35 Cr 11-13 Mn Max 0.6 P Max 0.03 S Max 0.03 Si Max 0.6 V Max
1.1 W Max 1
[0615] In an exemplary embodiment, an example of a D5 material has
the following characteristics: TABLE-US-00014 Category
Characteristic Principal This alloy is one of the Cold Work, high
Carbon/ Design Chromium type tool steels. It is capable of deep
Features hardening with minimal distortion from air quenching after
heat treatment. It has low resistance to heat softening and should
not be used at elevated temperatures. Applications Applications
include thread rolling, blanking or forming dies operating at
temperatures below 900 F. Machinability Machinability of D5 is
relatively poor. Using water hardening (W group) simple alloy tool
steel as a base of 100% the D5 alloy would rate 40%. Forming
Forming is by means of forging or machining Welding The alloy may
be welded. Consult the alloy supplier for proper procedures. Heat
Treatment Preheat very slowly up to 1500 F. then increase
temperature to 1850 F. and hold at temperature for 20 to 45
minutes. Air cool (air quench). Forging Forge at 1950 F. down to
1750 F. Do not forge below 1700 F. Cold Working Cold working with
the alloy in the annealed condition may be accomplished by
conventional methods. Annealing Anneal at 1625 F. followed by slow
cooling in the furnace at a rate of cooling of 40 F. per hour or
less. Aging Not applicable to this alloy. Tempering Temper between
400 F. (Rockwell C 61) and 1000 F. (Rockwell C 54). Hardening See
"Heat Treatment" and "Tempering".
[0616] In an exemplary embodiment, an example of a D5 material has
the following material composition: TABLE-US-00015 Component Wt. %
Carbon 1.4-1.6 Chromium 11-13 Cobalt 2.5-3.5 Iron Balance Manganese
0.6 max Molybdenum 0.7-1.2 Phosphorus 0.03 max Silicon 0.6 max
Sulfur 0.03 max Vanadium 1 max
[0617] In an exemplary embodiment, an example of a D5 material has
the following physical data: TABLE-US-00016 Physical Characteristic
Data Density (lb/cu. in.) 0.283 Specific Gravity 7.8 Melting Point
(Deg F.) 2600 Modulus of Elasticity Tension 29
[0618] In an exemplary embodiment, an example of a D7 material has
the following characteristics: TABLE-US-00017 Category
Characteristic Principal Design This alloy is one of the Cold Work,
high Carbon/ Features Chromium type tool steels. Corrosion
Corrosion resistance of this alloy is better than that of
Resistance plain carbon steels. However it will rust unless given
protective treatment. Applications include thread rolling, blanking
or forming dies operating at temperatures below 900 F.
[0619] In an exemplary embodiment, an example of a D7 material has
the following material composition: TABLE-US-00018 Component Wt. %
Carbon 2.15-2.5 Chromium 11.5-13.5 Iron Balance Manganese 0.6 max
Molybdenum 0.7-1.2 Phosphorus 0.03 max Silicon 0.6 max Sulfur 0.03
max Vanadium 3.8-4.4
[0620] In an exemplary embodiment, an example of a D7 material has
the following physical data: TABLE-US-00019 Physical Characteristic
Data Density (lb/cu. in.) 0.283
[0621] In an exemplary embodiment, an example of a M2 material is,
Allegheny Ludlum M2 Tool Steel, UNS T11302, which falls into the
following subcategories: metal; tool steel. The Allegheny Ludlum M2
Tool Steel has the following material composition: TABLE-US-00020
Component Wt. % C 0.84 Cr 4.15 Fe 83 Mo 4.65 V 1.85 W 5.65
[0622] In an exemplary embodiment, an example of a M4 has the
following material composition: TABLE-US-00021 Component Wt. %
Carbon 1.25-1.4 Chromium 3.75-4.75 Iron Balance Manganese 0.15-0.4
Molybdenum 4.25-5.5 Phosphorus 0.03 max Silicon 0.2-0.45 Sulfur
0.03 max Tungsten 5.25-6.5 Vanadium 3.75-4.5
[0623] In an exemplary embodiment, an example of a M4 material has
the following characteristics: TABLE-US-00022 Category
Characteristic Principal Design M4 is another in the Molybdenum
High Speed Tool Features Steels. It has a relatively high 1.3%
carbon content for high hardness and excellent wear resistance.
Applications Used for cutting tools of all types for machining
operations. Machinability Machinability is relatively low, rating
40% that of the water hardening (W group) tool steels which are
relatively easy to machine. Forming Forming in the annealed
condition is satisfactory by conventional methods. Welding This is
an alloy steel and may be welded. Consult the supplier for details.
Heat Treatment Preheat at 1450 F. and then heat rapidly to 2225 F.
for 3 to 5 minutes followed by oil, salt bath or air quench.
Forging Forge at 2050 F. down to 1700 F. Do not attempt to continue
forging below 1700 F. Cold Working Cold working may be accomplished
by conventional methods with the alloy in the annealed condition.
Annealing Anneal at 1625 F. and slow furnace cool at 40 F. per hour
or less. Aging Not applicable to this alloy. Tempering Temper at
1050 F. for a Rockwell C hardness of 62 to 66. Hardening See "Heat
Treatment" and "Tempering". Corrosion Not normally employed in
applications requiring Resistance corrosion resistance. Hot Working
M4 may be hot forged. No data in regard to hot working. Consult the
alloy supplier for temperatures. Other Comments M4 is one of the
best of the Molybdenum High Speed Tool Steels in regard to wear
resistance. However it has low toughness.
[0624] In an exemplary embodiment, an example of a M4 material has
the following physical data: TABLE-US-00023 Physical Characteristic
Data Density (lb/cu. in.) 0.295 Specific Gravity 8.16 Melting Point
(Deg F.) 2600 Modulus of Elasticity Tension 29
[0625] In an exemplary embodiment, the characteristics of exemplary
CPM M4, 10V and 3V materials may be found in the resources listed
below. TABLE-US-00024 Cone Materials Manufacture/Distributor Data
Sheet (if available) CPM M4 Crucible Materials DS351 12/01 CPM M4
Corporation, Syracuse, New Crucible Material Corp. York 10V
Crucible Materials DS317 03/02 CPM 10V Corporation, Syracuse, New
Crucible Material Corp. York 3V Crucible Materials DS406 03/02
CPM3V Corporation, Syracuse, New Crucible Material Corp. York
Expansion Cone Coating and Polish
[0626] Several expansion cone finish techniques may be used to
reduce the surface roughness of the an expansion cone, including
for example applying coating, polishing the surface, chrome
plating, cryogenics and REM.RTM. Isotropic Finishing (available
from Taylor Race Engineering, Plano, Tex.). When selecting a
coating for an expansion cone in a system for lubricating the
interface between an expansion cone and a tubular member during the
expansion process, several factors may be considered, including the
coefficient of friction between an expansion cone and a tubular
member, cone material hardness, cone wear resistance, surface
finish and the compatibility of the coating to the cone
material.
[0627] In several exemplary experimental embodiments, the following
coatings with specified characteristics may be utilized as a
coating for an expansion cone in a tubular member during the
expansion process: TABLE-US-00025 PVD CVD CVD for DLC's Thermal
Spray Deposition 200-450.degree. C. 500-1000.degree. C.
200-450.degree. C. <150.degree. C. Temperature Hardness
2000-4000 HV 2000-5000 HV Up to 8000 HV 900-1700 HV Adhesion (Bond)
Excellent Excellent Excellent Good Coating Thickness 3-5 microns
1-5 microns 1-3 microns .003-.008 inch Coatable Most metals Many
Most metals Most metals Materials restrictions Repairability Most
coatings, Typically none, Typically none, Most coatings, strip and
recoat some coatings some able to strip and strippable burn off
recoat Post Coating None Possible Heat None Grinding or Processing
Treating Machining
[0628] In an exemplary embodiment, at least two thin film
deposition processes may be used as coatings for an expansion cone
in a tubular member during the expansion process; Chemical Vapor
Deposition (CVD) and Physical Vapor Deposition (PVD). Both
processes may yield hard coatings with high lubricity for forming
and cutting. Each coating is very thin, such as, for example, in
the order of microns, and the bond to the expansion cone substrate
surface is a metallurgical bond. These two features of vapor
deposition coatings are very conducive for high load and shear
application. Thin film coatings are typically used with a cone
material to support the coating. Referring to FIG. 71e, a
comparison of the hardness of a few thin film coatings and cone
materials is presented.
[0629] Many CVD coatings are processed at temperature above 500C,
which may have an impact on the expansion cone material hardness.
Re-hardening is available for the expansion cone material in the
event that hardness is lost during the CVD coating process.
However, for many metals, the dimensional tolerance of the
component may change during the re-hardening process and may need
to be accounted for. In an exemplary embodiment, a low process
temperature Diamond Like Carbon (DLC) coating may be used as a
coating for an expansion cone in a tubular member during the
expansion process.
[0630] PVD coatings are well suited to function as a coating for an
expansion cone in a tubular member during the expansion process.
The PVD thin film coatings are typically processed at temperature
below 400 C, which may not effect the hardness of the expansion
cone material. PVD typically produce well bonded, high hardness
coatings. In an exemplary embodiment, either a Titanium Nitride or
Titanium Carbonitride coating may be used as a coating for an
expansion cone in a tubular member during the expansion
process.
[0631] The thermal spray coating process typically requires a soft
expansion cone material for a high strength coating bond, which may
be important during the tubular member expansion process due to the
potential for high shear forces on the expansion cone. A high
strength bond with an expansion cone may be obtained with a very
high velocity thermal spray equipment. Post-coating work, such as
for example, machining or grinding, may be utilized after the
application of a thermal spray coating to an expansion cone to
achieve the desired surface.
[0632] The REM.RTM. Isotropic Finishing process for an expansion
cone involves two steps. The first step, the refinement process,
involves a chemical interaction on the surface of the expansion
cone. A soft, thin (one micron) film is formed on the surface of
the expansion cone. The expansion cone interacts with the ceramic
media in a special vibratory tub, this film is physically removed
from the peaks of the processed part and the valleys are
unaffected. The chemically induced film re-forms only at the peaks
that are interacting with the vibratory media, and the process
repeats itself. Over time, the peaks are removed, leaving only the
valleys, producing the improved micro finish on the expansion cone.
The second step is the burnish process. After the required micro
finish is achieved, a mild alkaline mixture is introduced. After a
relatively short period a polished, chrome-like finish is produced.
In addition to the polishing effects, this step effectively removes
all traces of the film formation on the expansion cone from the
refinement process.
[0633] Referring to FIG. 72, an example method 7880 for radially
expanding a tubular member is described. In an exemplary
embodiment, the expansion cone and tubular member are placed in a
wellbore, step 7880. Lubrication is introduced into the interface
between the expansion cone and the tubular member, step 7884.
Tubular member is radially expanded by the expansion cone using one
or more conventional methods in step 7884, by, for example,
displacing, translating, and/or rotating the expansion cone
relative to the tubular member.
[0634] In an exemplary embodiment, one or more of the lubrication
systems, expansion devices and elements of the expansion cones
5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100,
6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 are incorporated
into the method 7880 for expanding tubular members described above
with reference to FIG. 72. In an exemplary embodiment, one or more
of the lubricant delivery systems 7200, 7300, 7400, 7500, 7600,
7700, 7800 and 7900 are incorporated into the method 7880 and
apparatus for expanding tubular members described above with
reference to FIG. 72. In an exemplary embodiment, one or more of
the lubricants described above are incorporated into the method
7880 and apparatus for expanding tubular members described above
with reference to FIG. 72. In an exemplary embodiment, one or more
of the cone materials described above are incorporated into the
method 7880 and apparatus for expanding tubular members described
above with reference to FIG. 72. In an exemplary embodiment, one or
more of the cone finish techniques described above are incorporated
into the method 7880 and apparatus for expanding tubular members
described above with reference to FIG. 72.
[0635] In several exemplary embodiment, one or more of the
lubrication systems and lubricants described above are incorporated
into the methods and apparatus for expanding tubular members
described above with reference to FIGS. 1-30. In several exemplary
embodiments, one or more of the lubrication systems, expansion
devices and elements of the expansion cones 5100, 5200, 5300, 5400,
5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700,
6800, 6900, 7000 and 7100 are incorporated into the methods and
apparatus for expanding tubular members described above with
reference to FIGS. 1-99. In several exemplary embodiments, one or
more of the lubricant delivery systems 7200, 7300, 7400, 7500,
7600, 7700, 7800 and 7900 are incorporated into the methods and
apparatus for expanding tubular members described above with
reference to FIGS. 1-99. In several exemplary embodiments, one or
more of the lubricants described above are incorporated into the
methods and apparatus for expanding tubular members described above
with reference to FIGS. 1-99. In an exemplary embodiment, one or
more of the cone materials described above are incorporated into
the methods and apparatus for expanding tubular members described
above with reference to FIGS. 1-99. In an exemplary embodiment, one
or more of the cone finish techniques described above are
incorporated into the methods and apparatus for expanding tubular
members described above with reference to FIGS. 1-99.
[0636] In this manner, the amount of force required to radially
expand a tubular member in the formation and/or repair of a
wellbore casing, pipeline, or structural support is significantly
reduced. Furthermore, the increased lubrication provided to the
interface between an expansion cone and tubular member greatly
reduces the amount of galling or seizure caused by the interface
between the expansion cone and the tubular member during the radial
expansion process thereby permitting larger continuous sections of
tubulars to be radially expanded in a single continuous operation.
Thus, use of the expansion cones 5100, 5200, 5300, 5400, 5500,
5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800,
6900, 7000 and 7100 and/or lubricant delivery systems 7200, 7300,
7400, 7500, 7600, 7700, 7800 and 7900 and/or the lubricants
described above reduces the operating pressures required for radial
expansion and thereby reduces the sizes of the required hydraulic
pumps and related equipment. In addition, failure, bursting, and/or
buckling of tubular members during the radial expansion process is
significantly reduced, and the success ratio of the radial
expansion process is greatly increased.
[0637] In several exemplary embodiments, one or more of the
lubrication systems, lubricants, lubricant delivery systems,
expansion cone materials and cone finish techniques described above
may be incorporated into one or more of the following conventional
expansion devices: a) an expansion cone; b) a rotary expansion
device; c) a hydroforming expansion device; d) an impulsive force
expansion device; e) any one of the expansion devices commercially
available from, or disclosed in any of the published patent
applications or issued patents, of Weatherford International, Baker
Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger,
and/or Enventure Global Technology L.L.C.
[0638] In several exemplary embodiments, a tubular members may be
radially expanded and plastically deformed using one or more of the
lubrication systems, lubricants, lubricant delivery systems,
expansion cone materials and cone finish techniques described above
in conjunction with other conventional methods for radially
expanding and plastically deforming tubular members such as, for
example, internal pressurization, hydroforming, and/or roller
expansion devices and/or any one or combination of the conventional
commercially available expansion products and services available
from Baker Hughes, Weatherford International, and/or Enventure
Global Technology L.L.C.
[0639] In several exemplary experimental embodiments, many of the
lubricants specified above were tested with different types of
expansion cones in tubular member in different conditions to
determine the expansion forces necessary to expand the respective
tubular members. For comparison purposes, tests were also performed
on various different tubular members and cones without lubricants.
The results of the tests relate to the effect of friction on a
system for lubricating the interface between an expansion cone and
a tubular member.
[0640] The following equation defines the effective force
(F.sub.eff) of a system for reducing the coefficient of friction in
the interface between an expansion cone and a tubular member during
the expansion process: F.sub.eff=k.sub.geo(F/(2 sin
.beta.+.mu..sub.fric); (25) where:
[0641] F=Force on Tool (Input Pressure)
[0642] F.sub.eff=Effective Force on the Cone Surface
[0643] k.sub.geo=Coefficient of Geometry
[0644] .mu..sub.fric=Coefficient of Friction
[0645] .beta.=Cone Angle.
The following equation defines the expansion force (F) on an
expansion cone of a system radially expanding a tubular member
using an expansion cone during the expansion process:
F=.pi.Dt(1+fcot.beta.)Y.epsilon. (26) where:
[0646] F--Expansion force;
[0647] D--Inside diameter of tubular member;
[0648] t--Wall thickness of tubular member'
[0649] f--Coefficient of friction between the tubular member and
expansion cone;
[0650] Y--Yield strength the tubular material; and
[0651] .epsilon.--Expansion rate of the tubular material.
[0652] FIG. 73a illustrates the forces on expansion cone 8000 in
tubular member 8002 during the expansion process. It is apparent
from the equations listed directly above that the load on the
expansion cone surface may be an important parameter in system and
that the exemplary embodiments of structures of the surfaces of the
systems; mechanisms for delivering lubricating fluid to the
surfaces of the systems; lubricating fluids delivered to the
system; different compositions of the system; and compositions of
the tubular member described above have an impact on that load.
[0653] FIG. 73b illustrates example elements in a system for
lubricating the interface between an expansion cone and a tubular
member during the expansion process that may have an impact on the
effective friction forces of the system. Such elements include, the
surface 8102 of the tubular member 8100, the coating 8104 on the
surface 8102 such as, for example, a low friction soft coating, the
surface 8106 of the expansion cone 8108, the coating 8110 on the
expansion cone 8108 such as, for example, a self-lubricating hard
film, and the lubricant 8112 such as, for example, oil or grease
and lubricated mud located between the tubular member 8100 and the
expansion cone 8108. Regarding the surfaces of expansion cone 8108
and tubular member 8100, both the surface roughness, such as, for
example, a rough or polished finish, and the texture, such as, for
example, a pattern in the surface may play a role in contributing
to the overall friction of the system.
[0654] Referring to FIGS. 73c and 73d, illustrations of a smoother
expansion cone finish and a rougher expansion cone finish,
respectively, will now be described. For discussion purposes only,
the term roughness refers to the roughness 8010 of the planar part
of the surface. The term texture refers to the patter in the
surface, such as, for example, the holes 8012 in the surface. The
holes may represent oil pockets will capture oil that in turn acts
as a liquid ball bearing and thus may increase the lubricity of the
surface of the expansion cone. A range of roughness for an
expansion cone that may decrease the coefficient of friction
between an expansion cone and a tubular member during radial
expansion and plastic deformation is 0.02-0.1 micrometers.
[0655] In an exemplary embodiment, a calculation was completed to
determine the effective force F.sub.eff on a cone surface and the
energy equations necessary to calculate frictional effects for
tribological elements, that is the elements that have an impact on
coefficient of friction between an expansion cone and a tubular
member during the expansion process. The system was modeled for
static and dynamic conditions. The tool velocity in the system
allowed for static kinematic calculations with static and dynamic
coefficients of friction. A preliminary evaluation shows that up to
25% of input pressure may be required to compensate for dynamic
frictional effects and that the effective force on the cone could
exceed 5000 psi during tubular member expansion.
[0656] During the expansion process, a tubular member may withstand
a finite amount of expansion pressure from an expansion cone, the
maximum acceptable expansion pressure, beyond which tubular member
failure may occur, including fracturing and splitting. Laboratory
tests have shown that the maximum acceptable expansion pressure for
an 51/2'' LSX-80 tubular member having a 0.3'' wall thickness is
approximately 5000 psi. Referring to FIG. 74, a chart illustrates a
curve depicting the pressure (y-axis) versus coefficient of
friction (x-axis) for an 51/2'' LSX-80 tubular member having a
0.3'' wall thickness. The maximum coefficient of friction
corresponding to the maximum acceptable pressure for the 51/2''
LSX-80 tubular member having a 0.3'' wall thickness is
approximately 0.2. Referring to FIGS. 75 and 76, charts illustrate
information similar to that shown in FIG. 74 on a logarithmic
scale; one showing pressure in terms of pounds per square inch and
the other showing pressure in terms of pounds. As illustrated in
FIGS. 74, 75 and 76, as the coefficient of friction increases, the
expansion pressure increases.
[0657] Referring to FIG. 77, a chart depicting the results in an
exemplary experimental embodiment that shows the expansion forces
in pounds per square inch over time applied to a 6'' LSX80 tubular
member coated with a Gear Kote coating, which is a graphite based
coating distributed by Commercial Coating Services International,
Ltd. The expansion process began with no lubricant between the
expansion cone and the tubular member, period 8900. A steady
increase in expansion force was observed. After the introduction of
oil between the expansion cone and the tubular member at point
8902, the expansion force decreased significantly over the period
8904 suggesting that expansion force is related to the coefficient
of friction between the expansion cone and the tubular member.
Expansion forces increased over time during the expansion process
in the period 8904 after the introduction of oil, but did so at a
much slower rate than under the dry friction conditions in period
8900. Once a lubricant, such as, for example oil, is introduce
during the expansion process, the system coefficient of friction is
reduced and thus the expansion forces decreases.
[0658] In several exemplary embodiments, many of the lubricants
specified above were tested with different types of expansion cones
in tubular members in different conditions to determine the
expansion forces necessary to expand the respective tubular
members. For comparison purposes, tests were also performed on
various different tubular members and cones with out lubricants.
The results of the test are shown in FIG. 78-FIG. 98.
[0659] Referring to FIG. 78, a chart depicting the results of
experimental test that show the coefficient of friction for several
different combinations of expansion systems using a 15/8'' Low
Carbon Steel expansion cone made of D2 material is shown. The
following samples are represented on the chart: TABLE-US-00026
Expansion System Components Tubular Expansion Cone Member External
Expansion Tubular Internal Surface Cone Coefficient Sample member
Coating Coating Lubricant Finish of Friction 1 Heavy None None None
None 0.36-0.40 corroded 2 Clean None None None None 0.16-0.22
tubular member 3 Clean None None Oleon None 0.14-0.16 tubular
member 4 Clean Graphite None None None 0.12-0.15 tubular based
member coating 5 Clean None None H1 None 0.09-0.14 tubular member 6
Clean EGT MS- None None None 0.08-0.10 tubular 9075 member 7 Clean
EGT MS- None H1 None 0.04-0.05 tubular 9075 member 8 Clean EGT MS-
DC53 cone H1 REM 0.02-0.03 tubular 9075 material + member Phygen
film
The lowest coefficient of friction, approximately 0.02, resulted
from Sample 8. Sample 7 also produce a low coefficient of friction
in the order of approximately 0.05 EGT MS-9075 is a Teflon based
coating (polytetrafluoroethylene or PTFE), distributed by Enventure
Global Technology, L.L.C., Houston Tex., is shown. Phygen film is a
chrome nitride coating and is distributed by Phygen, Inc.,
Minneapolis, Minn.
[0660] Referring to FIG. 79a, a three dimensional photograph having
a 5.times. magnification and a field of the view 1.20.times.0.90 mm
of the surface of an expansion cone made of D2 material is shown.
The expansion cone made of D2 material, has the following surface
characteristics: TABLE-US-00027 Surface Characteristic Value Ra:
277.930 nm Rz: 3.13 um Rpk: 377.167 nm Rk: 829.31 nm Rvk: 216.287
nm Sty X Pc: 3.88/mm Sty Y Pc: 6.13/mm NormVolume: 0.822 BCM
[0661] The surface characteristics listed in the table above are
well known. Some of the characteristics listed in the table above
have the following meanings: [0662] a. Ra is the roughness average,
is the arithmetic average of the absolute values of the surface
height deviations measured from the best fitting plane, cylinder or
sphere; [0663] b. Rz is the average maximum height of the surface;
[0664] c. Rpk--is the reduced peak height, a measure of the peak
height above the nominal/core roughness; [0665] d. Rvk is the
reduced valley depth, which is a measure of the valley depth below
the nominal/core roughness; and [0666] e. Rk is the core roughness
depth which is a measure of the nominal or "core" roughness
(peak-to-valley) of the surface with the predominant peaks and
valleys removed.
[0667] Referring to FIG. 79b, a three dimensional photograph having
a 5.times. magnification and a field of the view 1.20.times.0.90 mm
of the surface of an expansion cone made of DC53 material having a
Phygen film and REM polish is shown. The expansion cone made of
DC53 material, has the following surface characteristics:
TABLE-US-00028 Surface Characteristic Value Ra: 60.205 nm Rz: 1.99
um Rpk: 25.009 nm Rk: 152.12 nm Rvk: 92.963 nm Sty X Pc: 2.21/mm
Sty Y Pc: 3.53/mm NormVolume: 0.047 BCM
[0668] Referring to FIGS. 80a and 80b, photo micrographs of the
expansion cone made of D2 material shown in FIG. 79a and the
expansion cone made of DC53 material shown in FIG. 79b are shown,
respectively.
[0669] Referring to FIGS. 81a and 81b, an x-profile of the an
expansion cone made of D2 material shown in FIG. 79a and the
expansion cone made of DC53 shown in FIG. 81b are shown,
respectively. Note in FIG. 81b that a hole pocket 9000 in surface
the expansion cone made of DC53 exists, which may create an oil
pocket. Hole pockets may be desirable and may enhance the reduction
of the effect of friction on the expansion system. Hole pockets may
collect oil, act as a liquid ball bearings when in contact with a
tubular member and may increase the lubricity of the system by
introducing more lubricant in the interface between the expansion
cone and the tubular member.
[0670] Referring to FIGS. 82a and 82b, the bearing ratio for the
expansion cone made of D2 shown in FIG. 79a and the expansion cone
made of DC53 shown in FIG. 79b are shown, respectively. The bearing
ratio represents the length of material surface (expressed as a
percentage of the evaluation length L) at a depth below the highest
peak.
[0671] Referring to FIG. 83a, a three dimensional photograph having
a 50.times. magnification and a field of the view 1.20.times.0.90
mm of the surface of an expansion cone made of D2 material is
shown. The expansion cone made of D2 material, has the following
surface characteristics: TABLE-US-00029 Surface Characteristic
Value Ra: 275.671 nm Rz: 2.34 um Rpk: 262.729 nm Rk: 872.91 nm Rvk:
270.620 nm Sty X Pc: 22.83/mm Sty Y Pc: 38.65/mm NormVolume: 0.469
BCM
[0672] Referring to FIG. 83b, three dimensional photographs having
a 50.times. magnification and a field of the view 1.20.times.0.90
mm of the surface of an expansion cone made of DC53 material having
a Phygen film and REM polish is shown. The expansion cone made of
DC53 material, has the following surface characteristics:
TABLE-US-00030 Surface Characteristic Value Ra: 55.085 nm Rz:
678.35 nm Rpk: 32.764 nm Rk: 163.53 nm Rvk: 82.624 nm Sty X Pc:
48.84/mm Sty Y Pc: 61.73/mm NormVolume: 0.075 BCM
[0673] Referring to FIGS. 84a and 84b, photo micrographs of the
expansion cone made of D2 material shown in FIG. 83a and the
expansion cone made of DC53 material shown in FIG. 83b are shown,
respectively.
[0674] Referring to FIGS. 85a and 85b, an x-profile of the
expansion cone made of D2 material shown in FIG. 83a and the
expansion cone made of DC53 material shown in FIG. 83b are shown,
respectively.
[0675] Referring to FIGS. 86a and 86b, the bearing ratio for the
expansion cone made of D2 material shown in FIG. 83a and the
expansion cone made of DC53 material shown in FIG. 83b,
respectively, are shown.
[0676] Referring to FIG. 87, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems, which
range from a system using only a cone to a system with a cone,
combined with one or more of the friction reduction mechanisms,
such as for example, a tubular member coating, a cone coating, a
lubricant between the expansion cone and the tubular member, and a
cone finish, in a corroded tubular member exposed to seawater for
24 hours is shown. Several of the tribological elements identified
in FIG. 39a analyzed during the tests. The following samples are
represented on the chart: TABLE-US-00031 Expansion System
Components Expansion Tubular Cone Ex- Member External pansion
Approximate Sam- Cone Internal Surface Lu- Cone Load Range ple
Material Coating Coating bricant Finish (Lbs) 1 DC53 None Phygen
film None REM 22000-23500 2 D2 None None None None 22300-22900 3
DC53 None Phygen film H1 REM 17000-17200 4 D2 None None H1 None
20500-20900 5 DC53 None Phygen film H6 REM 15800-16000 6 D2 None
None H6 None 16900-17100 7 D2 Gear None None None 15800-17500 Kote
8 D2 Gear None Sea None 13800-15500 Kote Water
[0677] Referring to FIG. 88, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member coated with EGT MS-9075, distributed by Enventure
Global Technology, L.L.C., Houston Tex., is shown. The following
samples are represented on the chart: TABLE-US-00032 Expansion
System Components Tubular Expansion Cone Member External Expansion
Approximate Expansion Internal Surface Cone Load Range Sample Cone
Coating Coating Lubricant Finish (Lbs) 1 DC53 EGT MS- Phygen film
None REM 22000-23500 9075 2 D2 EGT MS- None None None 22300-22900
9075 3 DC53 EGT MS- Phygen film H1 REM 12900-13200 9075 4 D2 EGT
MS- None H1 None 12000-12300 9075 5 DC53 EGT MS- Phygen film H6 REM
12800-12900 9075 6 D2 EGT MS- None H6 None 13500-13800 9075 7 D2
Gear None None None 15800-17500 Kote 8 D2 Gear None Sea None
13800-15500 Kote Water
[0678] Referring to FIG. 89, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member coated with a Brighton White Teflon-based coating
with sea water is shown. The following samples are represented on
the chart: TABLE-US-00033 Expansion System Components Expansion
Tubular Cone Ex- Member External pansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 DC53 Brighton Phygen film None REM 22000-23500 White
Teflon- based 2 D2 Brighton None None None 22300-22900 White
Teflon- based 3 DC53 Brighton Phygen film H1 REM 11500-12000 White
Teflon- based 4 D2 Brighton None H1 None 13200-14000 White Teflon-
based 5 DC53 Brighton Phygen film H6 REM 12800-13100 White Teflon-
based 6 D2 Brighton None H6 None 12200-12500 White Teflon- based 7
D2 Gear Kote None None None 15800-17500 8 D2 Gear Kote None Sea
None 13800-15500 Water
[0679] Referring to FIG. 90, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member coated with Brighton Grey Acrilic-based coating is
shown. The following samples are represented on the chart:
TABLE-US-00034 Expansion System Components Expansion Tubular Cone
Ex- Member External pansion Approximate Sam- Internal Surface Lu-
Cone Load Range ple Cone Coating Coating bricant Finish (Lbs) 1
DC53 Brighton Phygen film None REM 22000-23500 Grey Acrilic- based
2 D2 Brighton None None None 22300-22900 White Teflon 3 DC53
Brighton Phygen film H1 REM 13000-13200 Grey Acrilic- based 4 D2
Brighton None H1 None 14000-14400 Grey Acrilic- based 5 DC53
Brighton Phygen film H6 REM 12700-12900 Grey Acrilic- based 6 D2
Brighton None H6 None 14300-14800 Grey Acrilic- based 7 D2 Gear
Kote None None None 15800-17500 8 D2 Gear Kote None Sea None
13800-15500 Water
[0680] Referring to FIG. 91, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00035 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 DC53 Phygen film None REM 17800-18200 2 DC53 Phygen film H1
REM 14400-14900 3 DC53 Phygen film H7 REM 16400-17200
[0681] Referring to FIG. 92, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00036 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 DC53 None Phygen film None REM 15000-17700 2 DC53 None
Phygen film Oleon REM 16400-17400 3 DC53 None Phygen film H1 REM
16300-16800 4 DC53 None Phygen film H2 REM 15800-16800 5 DC53 None
Phygen film H3 REM 14500-16800 6 DC53 None Phygen film H4 REM
15300-17200 7 DC53 None Phygen film H5 REM 14100-16900 8 DC53 None
Phygen film H6 REM 14600-15800
[0682] Referring to FIG. 93, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00037 Expansion System Components Expansion
Tubular Cone Ex- Member External pansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 None None None None None 0 2 D2 Gear Kote None None None
15500-17600 3 DC53 None Phygen film Oleon REM 16800-17100 4 DC53
None Phygen film H1 REM 16300-16800 5 DC53 None Phygen film H2 REM
15700-16200 6 DC53 None Phygen film H3 REM 14500-15400 7 DC53 None
Phygen film H4 REM 17700-18100 8 DC53 None Phygen film H5 REM
14100-14500 9 DC53 None Phygen film H6 REM 14600-14800 10
16400-16600 11 DC53 None Phygen film Belesta REM 14800-15200
[0683] Referring to FIG. 94, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00038 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 D2 Gear Kote None None REM 15500-17700 2 D2 Gear Kote None
Oleon REM 16400-17400 3 D2 Gear Kote None H1 REM 16300-16800 4 D2
Gear Kote None H2 REM 15800-16800 5 D2 Gear Kote None H4 REM
14500-16800 6 D2 Gear Kote None H5 REM 15300-17200 7 D2 Gear Kote
None H6 REM 14100-16900 8 D2 Gear Kote None H7 REM 14600-15400
[0684] Referring to FIG. 95, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00039 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 DC53 None Phygen film None REM 19200-23000 2 DC53 None
Phygen film None REM 13800-15500 3 DC53 None Phygen film Oleon REM
17800-18400 4 DC53 None Phygen film H1 REM 14300-14500 5 DC53 None
Phygen film H3 REM 15000-15500 6 DC53 None Phygen film H5 REM
15800-16100 7 DC53 None Phygen film H6 REM 15600-15900
[0685] Referring to FIG. 96, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a LSX80
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00040 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Internal Surface
Lu- Cone Load Range Sample Cone Coating Coating bricant Finish
(Lbs) 1 D2 None None Oleon None 19700-20100 2 D2 None None H1 None
1600-16300 3 D2 None None H2 None 16800-17400 4 D2 None None H3
None 17200-17900 5 D2 None None H4 None 15500-15700 6 D2 None None
H5 None 17700-18000 7 D2 None None H6 None 14700-15200 8 D2 None
None H7 None 15800-16000 9 D2 None None HPL None 18500-18800
[0686] Referring to FIG. 97, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a LSX80
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00041 Expansion System Components Expansion
Tubular Cone Member External Expansion Approximate Sam- Internal
Surface Lu- Cone Load Range ple Cone Coating Coating bricant Finish
(Lbs) 1 D2 Gear Kote None None None 16000-16200 2 D2 Gear Kote None
Oleon None 1500-15600 3 D2 Gear Kote None H1 None 12500-12700 4 D2
Gear Kote None H2 None 14500-14700 5 D2 Gear Kote None H3 None
13900-14100 6 D2 Gear Kote None H4 None 12500-12800 7 D2 Gear Kote
None H5 None 14100-14500 8 D2 Gear Kote None H6 None 11600-12200 9
D2 Gear Kote None H7 None 12400-12700
[0687] Referring to FIG. 98, a chart depicting the results of
experimental tests that show the expansion forces in terms of load
for several different combinations of expansion systems in a LSX80
tubular member is shown. The following samples are represented on
the chart: TABLE-US-00042 Expansion System Components Expansion
Tubular Cone Approximate Member External Expansion Load Sam-
Internal Surface Lu- Cone Range ple Cone Coating Coating bricant
Finish (Lbs) 1 D2 Gear Kote None None None 13400-13700 2 D2 Gear
Kote None Oleon None 12700-13000 3 D2 Gear Kote None H1 None
11700-12100 4 D2 Gear Kote None H3 None 12700-12900 5 D2 Gear Kote
None H5 None 11500-12200
[0688] Referring to FIG. 99a, another exemplary embodiment of a
system for lubricating the interface between an expansion cone and
a tubular member during the expansion process will now be
described. As illustrated in FIG. 99a, an expansion cone 10000,
having a front end 10000a and a rear end 10000b, includes a tapered
portion 10005 having an outer surface 10010, a spiral
circumferential grooves 10015, and radial ports 10016. Referring to
FIG. 99b, a photo micrograph of the outer surface 10010 of
expansion cone 10000 of FIG. 99a is shown.
[0689] Referring to FIG. 99c, an embodiment of a system 10100 for
lubricating the interface between an expansion cone and a tubular
member during the expansion process will now be described. As
illustrated in FIG. 99c, an expansion cone 10102 includes a body
10104 that defines a centrally positioned longitudinal passage
10106, longitudinal passage 10112, radial passage 10116a, fluidicly
coupled to the longitudinal passage 10112, radial passages,
fluidicly coupled to the longitudinal passage 10106, and includes a
front end face 10120, a rear end face 10122, and a tapered external
expansion surface 10124 including spaced apart external grooves,
10124a, 10124b, and 10124c, that are fluidicly coupled to the
radial passages, fluidicly coupled to the longitudinal passage
10106 through radial ports, respectively. A tubular member 10128
that defines a longitudinal passage 10128a and is received within,
mates with, and is coupled to the centrally positioned longitudinal
passage 10106 of the expansion cone. A tubular member 10128 that
defines a longitudinal passage 10128a and is received within, mates
with, and is coupled to the centrally positioned longitudinal
passage 10112 of the expansion cone.
[0690] In an exemplary embodiment, during operation of the system
10100, the expansion cone 10102 is positioned within, and displaced
relative to, an expandable tubular member thereby radially
expanding and plastically deforming the expandable tubular member.
In an exemplary embodiment, the expansion cone 10102 is displaced
relative to the expandable tubular member by injecting a
pressurized fluidic material 10132 into and through the passage
10128a of the tubular member 10128. As a result, the expansion cone
10102 is displaced in a direction 10133 relative to the expandable
tubular member. In an exemplary embodiment, the fluidic material
10132 includes one or more lubricant materials suitable for
lubricating the interface between the expansion cone 10102 and the
expandable tubular member during the radial expansion process. In
an exemplary embodiment, a second pressurized fluidic material
10144 is injected into and through the passage 10129a of the
tubular member 10129 though pump 10130. In an exemplary embodiment,
the fluidic material 10144 includes one or more lubricant materials
suitable for lubricating the interface between the expansion cone
10102 and the expandable tubular member during the radial expansion
process. The pressurized fluidic material 10132 may be then
conveyed into the external grooves, 10124a, 10124b, and 10124c,
into an interface between the expansion cone 10102 and the
expandable tubular member. Similarly, in an exemplary embodiment,
the fluidic material 10132 is conveyed through the radial passage
10129a, of the tubular member 10129 and through radial passage,
10116, into a passageway between the expansion cone 10102 and the
tubular member.
[0691] In an exemplary embodiment, the rate of injection of the
fluidic material 10144 into the external grooves, 10124a, 10124b,
and 10124c, depends on the selected operating pressure of the
fluidic material. In this manner, during the radial expansion
process, the fluidic material 10144 may be controllably injected
and metered into the interface between the tapered external
expansion surface 10124 of the expansion cone 10102 and the
expandable tubular member 10130 continuously during the radial
expansion and plastic deformation of the tubular member. In an
exemplary embodiment, the fluidic material 10144 may be injected
into the external grooves, 10124a, 10124b, and 10124c only when
required, or as desired. Thus, the trailing edge portion of the
interface between the tapered external expansion surface 10124 of
the expansion cone 10102 and the expandable tubular member 10130
may be provided with an increased supply of lubricant, thereby
reducing the amount of force required to radially expand and
plastically deform the expandable tubular member.
[0692] The rate of injection of fluidic material 10132 into
passageway 10152 between expansion cone 10100 and tubular member
also depends the selected operating pressure of the fluidic
material. Since, both the pressures for both fluidic materials,
10132 and 10144, are individually controlled, the pressures may be
set at different operating pressures. In this manner, different
areas of the interface between the expansion cone 10100 and a
tubular member, during the radial expansion and plastic deformation
of the tubular member using the expansion cone, can be provided
with different formulations of lubricant materials and different
operating pressures thereby permitting the control of friction
within the interface to be precisely controlled.
[0693] One of the problems of the pipe material selection for
expandable tubular application is an apparent contradiction or
inconsistency between strength and elongation. To increase burst
and collapse strength, material with higher yield strength is used.
The higher yield strength generally corresponds to a decrease in
the fracture toughness and correspondingly limits the extent of
achievable expansion.
[0694] It is desirable to select the steel material for the tubing
by balancing steel strength with amount absorbed energy measure by
Charpy testing. Generally these tests are done on samples cut from
tubular members. It has been found to be beneficial to cut
directional samples both longitudinally oriented (aligned with the
axis) and circumferentially oriented (generally perpendicular to
the axis). This method of selecting samples is beneficial when both
directional orientations are used yet does not completely evaluate
possible and characteristic anisotropy throughout a tubular member.
Moreover, for small diameter tubing samples representative of the
circumferential direction may be difficult, and sometimes
impossible to obtain because of the significant curvature of the
tubing.
[0695] To further facilitate evaluation of a tubular member for
suitability for expansion it has been found beneficial according to
one aspect of the invention to consider the plastic strain ratio.
One such ratio is called a Lankford value (or r-value) which is the
ratio of the strains occurring in the width and thickness
directions measured in a single tension test. The plastic strain
ratio (r or Lankford-value) with a value of greater than 1.0 is
found to be more resistant to thinning and better suited to tubular
expansion. Such a Lankford value is found to be a measure of
plastic anisotropy. The Lankford value (r) may be calculated by the
Equation 2 below: r = ln .times. .times. b o b k ln .times. .times.
L k .times. b k l o .times. b o Equation .times. .times. 2 ##EQU9##
where, r--normal anisotropy coefficient b.sub.o &
b.sub.k--initial and final width L.sub.o & L.sub.k--initial and
final length
[0696] However, it is time consuming and labor intensive for this
parameter to be measured using samples cut from real parts such as
from the tubular members. The tubular members will have anisotropic
characteristics due to crystallographic or "grain" orientation and
mechanically induced differences such as impurities, inclusions,
and voids, requiring multiple samples for reliably complete
information. Moreover, with individual samples, only local
characteristics are determined and the complete anisotropy of the
tubular member may not be determinable. Further some of the tubular
members have small diameters so that cutting samples oriented in a
circumferential direction is not always possible. Information
regarding the characteristics in the circumferential direction has
been found to be important because the plastic deformation during
expansion of the tubular members occurs to a very large extent in
the circumferential direction,
[0697] One aspect of the present exemplary embodiments comprises
the development of an improved solution for anisotropy evaluation,
including a kind of plastic strain ratio similar to the Lankford
parameter that is measured using real tubular members subjected to
axial loading.
[0698] FIG. 100 depicts in a schematic fragmentary cross-sectional
view along a plane along and through the axis 1002 of a tubular
member 1000 that is tested with axial opposed forces 1004 and 1005.
The tubular member 1000 is axially stretched beyond the elastic
limit, through yielding and to ultimate yield or fracture.
Measurements of the force and the OD and ID during the process
produce test data that can be used in the formula below to produce
an expandability coefficient "f" as set forth in Equation 1 above.
Alternatively a coefficient called a formability anisotropy
coefficient F(r) that is function of the normal anisotropy Lankford
coefficient r may be determined as in Equation 3 below: F
.function. ( r ) = ln .times. .times. b o b k ln .times. .times. L
k .times. b k l o .times. b o Equation .times. .times. 3 ##EQU10##
F(r)--formability anisotropy coefficient b.sub.o &
b.sub.k--initial and final tube area (inch.sup.2) L.sub.o &
L.sub.k--initial and final tube length (inch)
b=(D.sup.2-d.sup.2)/4--cross section tube area.
[0699] In either circumstance, f or F(r), the use of this testing
method for an entire tubular member provides useful information
including anisotropic characteristics or anisotropy of the tubular
member for selecting or producing beneficial tubular members for
down hole expansion, similar to the use of the Lankford value for a
sheet material.
[0700] Just as values for stress and strain may be plotted for
solid specimen samples, as schematically depicted in FIG. 101, the
values for conducting a test on the tubular member may also be
plotted, as depicted in FIG. 102. On this basis the expansion
coefficient f (or the formability coefficient F(r)) may be
determined. It will be the best to measure distribution
(Tensile-elongation) in longitudinal and circumferential directions
simultaneously.
[0701] The foregoing expandability coefficient (or formability
coefficient) is found to be useful in predicting good expansion
results and may be further useful when used in combination with one
or more other properties of a tubular member selected from
stress-strain properties in one or more directional orientations of
the material, strength & elongation, Charpy V-notch impact
value in one or more directional orientations of the material,
stress burst rupture, stress collapse rupture, yield strength,
ductility, toughness, and strain-hardening exponent (n-value), and
hardness.
[0702] In an exemplary embodiment, a tribological system is used to
reduce friction and thereby minimize the expansion forces required
during the radial expansion and plastic deformation of the tubular
members that includes one or more of the following: (1) a tubular
tribology system; (2) a drilling mud tribology system; (3) a
lubrication tribology system; and (4) an expansion device tribology
system.
[0703] In an exemplary embodiment, the tubular tribology system
includes the application of coatings of lubricant to the interior
surface of the tubular members.
[0704] In an exemplary embodiment, the drilling mud tribology
system includes the addition of lubricating additives to the
drilling mud.
[0705] In an exemplary embodiment, the lubrication tribology system
includes the use of lubricating greases, self-lubricating expansion
devices, automated injection/delivery of lubricating greases into
the interface between an expansion device and the tubular members,
surfaces within the interface between the expansion device and the
expandable tubular member that are self-lubricating, surfaces
within the interface between the expansion device and the
expandable tubular member that are textured, self-lubricating
surfaces within the interface between the expansion device and the
expandable tubular member that include diamond and/or ceramic
inserts, thermosprayed coatings, fluoropolymer coatings, PVD films,
and/or CVD films.
[0706] In an exemplary embodiment, the tubular members include one
or more of the following characteristics: high burst and collapse,
the ability to be radially expanded more than about 40%, high
fracture toughness, defect tolerance, strain recovery @ 150 F, good
bending fatigue, optimal residual stresses, and corrosion
resistance to H.sub.2S in order to provide optimal characteristics
during and after radial expansion and plastic deformation.
[0707] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a charpy energy of at least
about 90 ft-lbs in order to provided enhanced characteristics
during and after radial expansion and plastic deformation of the
expandable tubular member.
[0708] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a weight percentage of carbon
of less than about 0.08% in order to provide enhanced
characteristics during and after radial expansion and plastic
deformation of the tubular members.
[0709] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having reduced sulfur content in
order to minimize hydrogen induced cracking.
[0710] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a weight percentage of carbon
of less than about 0.20% and a charpy-V-notch impact toughness of
at least about 6 joules in order to provide enhanced
characteristics during and after radial expansion and plastic
deformation of the tubular members.
[0711] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having a low weight percentage of
carbon in order to enhance toughness, ductility, weldability, shelf
energy, and hydrogen induced cracking resistance.
[0712] In several exemplary embodiments, the tubular members are
fabricated from a steel alloy having the following percentage
compositions in order to provide enhanced characteristics during
and after radial expansion and plastic deformation of the tubular
members: TABLE-US-00043 C Si Mn P S Al N Cu Cr Ni Nb Ti Co Mo
EXAMPLE A 0.030 0.22 1.74 0.005 0.0005 0.028 0.0037 0.30 0.26 0.15
0.095 0.014 0.0034 EXAMPLE 0.020 0.23 1.70 0.004 0.0005 0.026
0.0030 0.27 0.26 0.16 0.096 0.012 0.0021 B MIN EXAMPLE 0.032 0.26
1.92 0.009 0.0010 0.035 0.0047 0.32 0.29 0.18 0.120 0.016 0.0050 B
MAX EXAMPLE C 0.028 0.24 1.77 0.007 0.0008 0.030 0.0035 0.29 0.27
0.17 0.101 0.014 0.0028 0.0020 EXAMPLE D 0.08 0.30 0.5 0.07 0.005
0.010 0.10 0.50 0.10 EXAMPLE E 0.0028 0.009 0.17 0.011 0.006 0.027
0.0029 0.029 0.014 0.035 0.007 EXAMPLE F 0.03 0.1 0.1 0.015 0.005
18.0 0.6 9 5 EXAMPLE G 0.002 0.01 0.15 0.07 0.005 0.04 0.0025 0.015
0.010
[0713] In an exemplary embodiment, the ratio of the outside
diameter D of the tubular members to the wall thickness t of the
tubular members range from about 12 to 22 in order to enhance the
collapse strength of the radially expanded and plastically deformed
tubular members.
[0714] In an exemplary embodiment, the outer portion of the wall
thickness of the radially expanded and plastically deformed tubular
members includes tensile residual stresses in order to enhance the
collapse strength following radial expansion and plastic
deformation.
[0715] In several exemplary experimental embodiments, reducing
residual stresses in samples of the tubular members prior to radial
expansion and plastic deformation increased the collapse strength
of the radially expanded and plastically deformed tubular
members.
[0716] In several exemplary experimental embodiments, the collapse
strength of radially expanded and plastically deformed samples of
the tubulars were determined on an as-received basis, after strain
aging at 250 F for 5 hours to reduce residual stresses, and after
strain aging at 350 F for 14 days to reduce residual stresses as
follows: TABLE-US-00044 Collapse Strength After Tubular Sample 10%
Radial Expansion Tubular Sample 1 - as received from 4000 psi
manufacturer Tubular Sample 1 - strain aged at 250 F. for 4800 psi
5 hours to reduce residual stresses Tubular Sample 1 - strain aged
at 350 F. for 5000 psi 14 days to reduce residual stresses
[0717] As indicated by the above table, reducing residual stresses
in the tubular members, prior to radial expansion and plastic
deformation, significantly increased the resulting collapse
strength-post expansion.
[0718] In several exemplary experimental embodiments, the collapse
strength of radially expanded and plastically deformed samples of
the tubulars were determined on an as-received basis, after strain
aging at 250 F for 5 hours to reduce residual stresses, and after
strain aging at 350 F for 14 days to reduce residual stresses as
follows: TABLE-US-00045 Collapse Strength After 20% Tubular Sample
Radial Expansion Tubular Sample 1 - as received from 3000 psi
manufacturer Tubular Sample 1 - strain aged at 250 F. 4000 psi for
5 hours to reduce residual stresses Tubular Sample 1 - strain aged
at 350 F. 4250 psi for 14 days to reduce residual stresses
[0719] As indicated by the above table, reducing residual stresses
in the tubular members, prior to radial expansion and plastic
deformation, significantly increased the resulting collapse
strength-post expansion.
[0720] In an exemplary experimental embodiment, residual stresses
within a tubular member were decreased from about -12,000 psi to
about -6,000 psi, a reduction of about 105%. As a result, the
collapse strength of the resulting tubular member was increased
from about 1550 psi to about 1750 psi. This was an unexpected
result.
[0721] In several exemplary experimental embodiments, tubular
members were radially expanded and plastically deformed using
different lubricants to achieve a range of coefficients of friction
between the tubular members and a solid expansion cone during the
radial expansion and plastic deformation of the tubular members. As
a result, the following experimental results were obtained:
TABLE-US-00046 RATIO OF DIAMETER TO WALL THICKNESS WALL AFTER
COLLAPSE COEFFICIENT EXPANSION THICKNESS EXPANSION STRENGTH SAMPLE
OF FRICTION FORCE (lbf) (t) (D/t) (ksi) 1 0.125 145,900 0.305 24.8
2,379 2 0.075 143,000 0.350 21.6 3,243 3 0.02 149,900 0.450 16.8
5,837 4 0.02 125,800 0.500 15.1 5,359 5 0.02 125,800 0.500 15.1
8,443
The above tabular experimental results were unexpected. In
particular, the resulting collapse strength of the radially
expanded and plastically deformed tubular was increased by one or
more of the following: 1) reducing the coefficient of friction;
and/or 2) reducing the ratio of D/t.
[0722] Referring to FIG. 103, in an exemplary experimental
embodiment, a sample of steel pipe, for which the normal
manufacturing process was modified to include quenching and
tempering (the "Quenched and Tempered Steel Pipe No. 1"), was
tested to generate a stress vs. strain curve 10300. As illustrated
in FIG. 103, the yield point of the curve 10300 was 76.8 ksi.
Further stress and strain testing of the Quenched and Tempered
Steel Pipe No. 1, yielded the following characteristics:
TABLE-US-00047 Wall Width Thickness Elongation Reduction Reduction
Yield Yield/Tensile Longitudinal % PRIOR % PRIOR Strength Strength
% PRIOR TO TO Sample ksi Ratio TO FAILURE FAILURE FAILURE
Anisotropy Quenched 76.8 0.82 16% 32% 45% 0.65 and Tempered Steel
Pipe No. 1
The testing results for the Quenched and Tempered Steel Pipe No. 1,
illustrated in FIG. 103, and summarized above in tabular form were
unexpected results. Thus, the modification of the normal
manufacturing process of the Quenched and Tempered Steel Pipe No.
1, to include a quenching and tempering step, significantly and
unexpectedly, enhanced the performance characteristics of the pipe
thereby making the pipe particularly suited to use as an expandable
tubular.
[0723] Referring to FIG. 104, in an exemplary experimental
embodiment, a sample of 95/8'' steel pipe, for which the normal
manufacturing process was modified to include quenching and
tempering (the "Quenched and Tempered Steel Pipe No. 2"), a sample
of conventional 95/8'' NT80-HE steel pipe from Nippon Steel, and a
sample of conventional 95/8'' NT55-HE steel pipe from Nippon Steel
were tested to generate stress vs. strain curves 10400, 10402, and
10404, for the Quenched and Tempered Steel Pipe No. 2, the 95/8''
NT80-HE steel pipe from Nippon Steel, and the 95/8'' NT55-HE steel
pipe from Nippon Steel, respectively. As illustrated in FIG. 104,
the yield points of the curves 10400, 10402, and 10404, were 84.4
ksi, 61.5 ksi, and 73.7 ksi, respectively. Further stress and
strain testing of the Quenched and Tempered Steel Pipe No. 2, the
95/8'' NT80-HE steel pipe from Nippon Steel, and the 95/8'' NT55-HE
steel pipe from Nippon Steel, yielded the following
characteristics: TABLE-US-00048 Wall Width Thickness Elongation
Reduction Reduction Yield Yield/Tensile Longitudinal % PRIOR %
PRIOR Strength Strength % PRIOR TO TO Sample ksi Ratio TO FAILURE
FAILURE FAILURE Anisotropy Quenched 84.4 0.840 20.5% 40.0% 41.8%
0.935 and Tempered Steel Pipe No. 2 NT80-HE 61.5 0.62 16.5% 25.5%
47% 0.46 NT55-HE 73.7 0.67 13.5% 20.4% 37.5% 0.48
The testing results for the Quenched and Tempered Steel Pipe No. 2,
illustrated in FIG. 104, and summarized above in tabular form were
unexpected results. Thus, the modification of the normal
manufacturing process of the Quenched and Tempered Steel Pipe No.
2, to include a quenching and tempering step, significantly and
unexpectedly, enhanced the performance characteristics of the pipe,
relative to the conventional NT80-HE and NT55-HE pipes, thereby
making the pipe particularly suited to use as an expandable
tubular.
[0724] In an exemplary experimental embodiment, samples of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe Nos. 3 and 4"), were stress and strain tested and exhibited
the following characteristics: TABLE-US-00049 Value Quenched
Quenched and and Tempered Tempered Steel Pipe Steel Pipe
Characteristic No. 3 No. 4 YIELD STRENGTH 81.25 ksi 78.77 ksi Y/T
RATIO 0.829 0.822 ELONGATION PRIOR TO 14.88% 15.90% FAILURE WIDTH
REDUCTION PRIOR TO 37.8% 44.0% FAILURE WALL THICKNESS 43.25% 43.33%
REDUCTION PRIOR TO FAILURE ANISOTROPY 0.830 1.03
The tabular experimental results presented above were
unexpected.
[0725] In an exemplary experimental embodiment, samples of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe No. 5"), were stress and strain tested and exhibited the
following characteristics: TABLE-US-00050 Characteristic Value
YIELD STRENGTH 80.19 ksi Y/T RATIO 0.826 ELONGATION PRIOR TO 15.25%
FAILURE WIDTH REDUCTION PRIOR TO 40.4% FAILURE WALL THICKNESS 43.3%
REDUCTION PRIOR TO FAILURE ANISOTROPY 0.915
The tabular experimental results presented above were
unexpected.
[0726] In an exemplary experimental embodiment, a sample of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe Nos. 6 and 7"), a sample of conventional NT80-HE steel pipe
from Nippon Steel, and a sample of conventional NT55-HE steel pipe
from Nippon Steel were tested to determine absorbed energy and
flare expansion characteristics and exhibited the following
characteristics: TABLE-US-00051 Value Quenched Quenched and and
Tempered Tempered Steel Pipe Steel Pipe Characteristic No. 6 No. 7
NT80-HE NT55-HE ABSORBED ENERGY - 125 ft-lbs 145 ft-lbs 100 ft-lbs
50 ft-lbs LONGITUDINAL ABSORBED ENERGY - 59 ft-lbs 59 ft-lbs 40
ft-lbs 30 ft-lbs TRANSVERSE ABSORBED ENERGY - 176 ft-lbs 174 ft-lbs
70 ft-lbs 4 ft-lbs WELD FLARE EXPANSION 42% 52% 32% 30%
The testing results for the Quenched and Tempered Steel Pipe Nos. 6
and 7 summarized above in tabular form were unexpected results.
Thus, the modification of the normal manufacturing process of the
Quenched and Tempered Steel Pipe Nos. 6 and 7, to include a
quenching and tempering step, significantly and unexpectedly,
enhanced the performance characteristics of the pipe, relative to
the conventional NT80-HE and NT55-HE pipes, thereby making the
Quenched and Tempered Pipes particularly suited to use as an
expandable tubular.
[0727] In an exemplary embodiment, the flare expansion of the
Quenched and Tempered Steel Pipe Nos. 6 and 7, the sample of
conventional NT80-HE steel pipe from Nippon Steel, and the sample
of conventional NT55-HE steel pipe from Nippon Steel were performed
by pressing a tapered solid expansion cone into an end of the pipe
samples to radially expand and plastically deform the ends of the
pipe samples.
[0728] In an exemplary experimental embodiment, samples of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe No. 8"), were stress and strain tested and exhibited the
following characteristics: TABLE-US-00052 Characteristic Value
YIELD STRENGTH 88.8 ksi Y/T RATIO 0.86 ELONGATION PRIOR TO 22%
FAILURE WIDTH REDUCTION PRIOR TO 39% FAILURE WALL THICKNESS 41%
REDUCTION PRIOR TO FAILURE ANISOTROPY 0.93
The tabular experimental results presented above were
unexpected.
[0729] In an exemplary experimental embodiment, a sample of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe No. 9"), a sample of conventional NT80-HE steel pipe from
Nippon Steel, and a sample of conventional NT55-HE steel pipe from
Nippon Steel were tested to determine absorbed energy and flare
expansion characteristics and exhibited the following
characteristics: TABLE-US-00053 Value Quenched and Tempered Steel
Characteristic Pipe No. 9 NT80-HE NT55-HE YIELD STRENGTH 84.4 ksi
73.7 ksi 61.5 ksi YIELD/TENSILE 0.840 0.67 0.62 STRENGTH RATIO
ELONGATION 20.5% 13.5% 16.5% BEFORE FAILURE WIDTH REDUCTION 40.0%
20.4% 25.5% BEFORE FAILURE WALL THICKNESS 41.8% 37.5% 47% REDUCTION
BEFORE FAILURE ANISOTROPY 0.935 0.48 0.46
The testing results for the Quenched and Tempered Steel Pipe No. 9
summarized above in tabular form were unexpected results. Thus, the
modification of the normal manufacturing process of the Quenched
and Tempered Steel Pipe No. 9, to include a quenching and tempering
step, significantly and unexpectedly, enhanced the performance
characteristics of the pipe, relative to the conventional NT80-HE
and NT55-HE pipes, thereby making the Quenched and Tempered Pipes
particularly suited to use as an expandable tubular.
[0730] In an exemplary experimental embodiment, samples of steel
pipe, for which the normal manufacturing process was modified to
include quenching and tempering (the "Quenched and Tempered Steel
Pipe No. 10"), were stress and strain tested and exhibited the
following characteristics: TABLE-US-00054 Characteristic Value
YIELD STRENGTH 84.6 ksi Y/T RATIO 0.85 ELONGATION PRIOR TO 21%
FAILURE WIDTH REDUCTION PRIOR TO 39% FAILURE WALL THICKNESS 43%
REDUCTION PRIOR TO FAILURE ANISOTROPY 0.88
The tabular experimental results presented above were
unexpected.
[0731] In an exemplary embodiment, the composition of the Quench
and Temper Steel Pipe Nos. 1 to 10 included the following weight
percentages: TABLE-US-00055 C Si Mn P S Cu Cr Ni 0.27 0.14 1.28
0.009 0.005 0.14
In an exemplary embodiment, the quenching of the Quench and Temper
Steel Pipe Nos. 1 to 10 was provided at 970 C, and the tempering of
the Quench and Temper Steel Pipe Nos. 1 to 10 was provided for 10
minutes at 670 C.
[0732] In an exemplary embodiment, using a combination of
empirical, theoretical, and experimental data, electrical
resistance pipe ("ERW") tubular members most suitable for radial
expansion and plastic deformation exhibit the following
characteristics: TABLE-US-00056 Characteristic Value ABSORBED
ENERGY IN THE at least 80 ft-lb LONGITUDINAL DIRECTION ABSORBED
ENERGY IN THE at least 60 ft-lb TRANSVERSE DIRECTION ABSORBED
ENERGY IN THE at least 60 ft-lb TRANSVERSE WELD AREA FLARE
EXPANSION 45% to 75% MINIMUM W/O CRACKS TENSILE STRENGTH 60 TO 120
ksi YIELD STRENGTH 40 TO 100 ksi Y/T RATIO 40% to 85% MAXIMUM
LONGITUDINAL A MINIMUM OF 22% to 35% ELONGATION PRIOR TO FAILURE
WIDTH REDUCTION PRIOR A MINIMUM OF 30% to 45% TO FAILURE WALL
THICKNESS REDUCTION A MINIMUM OF 30% to 45% PRIOR TO FAILURE
ANISOTROPY A MINIMUM OF 0.8 to 1.5
[0733] In an exemplary experimental embodiment, based upon
theoretical, empirical, and experimental data, tubular members that
exhibit the following characteristics are best suited for radial
expansion and plastic deformation: TABLE-US-00057 Characteristic
Value YIELD STRENGTH 50 to 95 ksi Y/T RATIO less than 0.5 to 0.82
ELONGATION PRIOR TO greater than 16 to 30% FAILURE WIDTH REDUCTION
PRIOR TO greater than 32 to 45% FAILURE WALL THICKNESS greater than
30 to 45% REDUCTION PRIOR TO FAILURE ANISOTROPY greater than 0.65
to 1.5
[0734] In an exemplary embodiment, as illustrated in FIGS. 105 and
106, in an exemplary embodiment, a method 10500 of processing
tubular members is implemented in which, in step 10502, a
manufactured tubular member 10502a is received. In step 10504, the
manufactured tubular member 10502a is then cold rolled to provide a
cold-rolled tubular member 10504a. In step 10506, the cold-rolled
tubular member 10504a is then inter critical annealed to provide an
annealed tubular member 10506a. In step 10508, the annealed tubular
member 10506a is then positioned within a wellbore and radially
expanded and plastically deformed in a conventional manner to
provide a radially expanded and plastically deformed tubular member
10508a. In step 10510, the radially expanded and plastically
deformed tubular member 10508a is then baked within the wellbore,
using the ambient temperatures within the wellbore, to provide an
after-baked tubular member 10510a. As illustrated in FIG. 106, the
ultimate and final yield strength of the after-baked tubular member
10510a is greater than the yield strength of the manufactured
tubular member 10502a. In an exemplary embodiment, the manufactured
tubular member 10502a is a dual phase steel pipe or a
Transformation Induced Plasticity ("TRIP") steel pipe.
[0735] In an exemplary embodiment, the dual phase steel
manufactured pipe 10502a includes a microstructure having about 15%
to 30% martensite and ferrite. In an exemplary embodiment, the dual
phase steel manufactured pipe 10502a includes a composition of 0.1%
C, 1.2% Mn, and 0.3% Si.
[0736] In an exemplary embodiment, as illustrated in FIG. 107, when
the manufactured pipe 10502a is a dual phase steel, the initial
microstructure of the pipe includes ferrite and pearlite. In an
exemplary embodiment, in step 10506, the intercritical annealing of
the cold rolled pipe 10504a is performed at about 750 C. As a
result of the intercritical annealing, at least some of the
pearlite is converted to austentite. Following the completion of
the intercritical annealing in step 10506, the annealed pipe 10506a
is allowed to cool. As a result of the cooling, at least some of
the austentite in the annealed pipe 10506a is converted to
martensite. In an exemplary embodiment, in step 10510, the baking
of the radially expanded and plastically deformed pipe 10508a is
provided within the wellbore at temperatures ranging from about 100
C to 250 C. In an exemplary embodiment, as a result of the baking
step 10510, the radially expanded and plastically deformed pipe
10508a is stress-relieved and bake hardened.
[0737] In an exemplary embodiment, in step 10504 of the method
10500, as illustrated in FIG. 108, the temperature of the
manufactured steel pipe 10502a follows a curve 10802 in which the
steel pipe is deformed throughout the cooling progression of the
curve at a plurality of separate stages, 10802a and 10802b. In an
exemplary embodiment, during the first pipe rolling stage 10802a,
insoluble precipitates within the pipe 10502a retard austentite
growth and the deformation also promotes precipitation. In an
exemplary embodiment, during the second pipe rolling state 10802b,
insoluble precipitates within the pipe 10502a inhibit
recrystallization and austentite grains are conditioned. As a
result, the ultimate yield and collapse strength of the baked pipe
10510a is enhanced.
[0738] In several exemplary embodiments, the teachings of the
present disclosure are combined with one or more of the teachings
disclosed in FR 2 841 626, filed on Jun. 28, 2002, and published on
Jan. 2, 2004, the disclosure of which is incorporated herein by
reference.
[0739] A method of forming a tubular liner within a preexisting
structure is provided that includes positioning a tubular assembly
within the preexisting structure; and radially expanding and
plastically deforming the tubular assembly within the preexisting
structure, wherein, prior to the radial expansion and plastic
deformation of the tubular assembly, a predetermined portion of the
tubular assembly has a lower yield point than another portion of
the tubular assembly. In an exemplary embodiment, the predetermined
portion of the tubular assembly has a higher ductility and a lower
yield point prior to the radial expansion and plastic deformation
than after the radial expansion and plastic deformation. In an
exemplary embodiment, the predetermined portion of the tubular
assembly has a higher ductility prior to the radial expansion and
plastic deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the tubular assembly has a lower yield point prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the tubular assembly has a larger inside
diameter after the radial expansion and plastic deformation than
other portions of the tubular assembly. In an exemplary embodiment,
the method further includes positioning another tubular assembly
within the preexisting structure in overlapping relation to the
tubular assembly; and radially expanding and plastically deforming
the other tubular assembly within the preexisting structure,
wherein, prior to the radial expansion and plastic deformation of
the tubular assembly, a predetermined portion of the other tubular
assembly has a lower yield point than another portion of the other
tubular assembly. In an exemplary embodiment, the inside diameter
of the radially expanded and plastically deformed other portion of
the tubular assembly is equal to the inside diameter of the
radially expanded and plastically deformed other portion of the
other tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly includes an end
portion of the tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly includes a plurality
of predetermined portions of the tubular assembly. In an exemplary
embodiment, the predetermined portion of the tubular assembly
includes a plurality of spaced apart predetermined portions of the
tubular assembly. In an exemplary embodiment, the other portion of
the tubular assembly includes an end portion of the tubular
assembly. In an exemplary embodiment, the other portion of the
tubular assembly includes a plurality of other portions of the
tubular assembly. In an exemplary embodiment, the other portion of
the tubular assembly includes a plurality of spaced apart other
portions of the tubular assembly. In an exemplary embodiment, the
tubular assembly includes a plurality of tubular members coupled to
one another by corresponding tubular couplings. In an exemplary
embodiment, the tubular couplings include the predetermined
portions of the tubular assembly; and wherein the tubular members
comprise the other portion of the tubular assembly. In an exemplary
embodiment, one or more of the tubular couplings include the
predetermined portions of the tubular assembly. In an exemplary
embodiment, one or more of the tubular members include the
predetermined portions of the tubular assembly. In an exemplary
embodiment, the predetermined portion of the tubular assembly
defines one or more openings. In an exemplary embodiment, one or
more of the openings include slots. In an exemplary embodiment, the
anisotropy for the predetermined portion of the tubular assembly is
greater than 1. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In
an exemplary embodiment, the strain hardening exponent for the
predetermined portion of the tubular assembly is greater than 0.12.
In an exemplary embodiment, the anisotropy for the predetermined
portion of the tubular assembly is greater than 1; and the strain
hardening exponent for the predetermined portion of the tubular
assembly is greater than 0.12. In an exemplary embodiment, the
predetermined portion of the tubular assembly is a first steel
alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si,
0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the
yield point of the predetermined portion of the tubular assembly is
at most about 46.9 ksi prior to the radial expansion and plastic
deformation; and the yield point of the predetermined portion of
the tubular assembly is at least about 65.9 ksi after the radial
expansion and plastic deformation. In an exemplary embodiment, the
yield point of the predetermined portion of the tubular assembly
after the radial expansion and plastic deformation is at least
about 40% greater than the yield point of the predetermined portion
of the tubular assembly prior to the radial expansion and plastic
deformation. In an exemplary embodiment, the anisotropy of the
predetermined portion of the tubular assembly, prior to the radial
expansion and plastic deformation, is about 1.48. In an exemplary
embodiment, the predetermined portion of the tubular assembly
includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017%
P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly is at most about 57.8 ksi prior to the
radial expansion and plastic deformation; and the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the tubular assembly includes a third
steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30%
Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment,
the anisotropy of the predetermined portion of the tubular
assembly, prior to the radial expansion and plastic deformation, is
about 1.92. In an exemplary embodiment, the predetermined portion
of the tubular assembly includes a fourth steel alloy including:
0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7%
Cr. In an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is about 1.34. In an exemplary embodiment, the
yield point of the predetermined portion of the tubular assembly is
at most about 46.9 ksi prior to the radial expansion and plastic
deformation; and wherein the yield point of the predetermined
portion of the tubular assembly is at least about 65.9 ksi after
the radial expansion and plastic deformation. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly after the radial expansion and plastic deformation
is at least about 40% greater than the yield point of the
predetermined portion of the tubular assembly prior to the radial
expansion and plastic deformation. In an exemplary embodiment, the
anisotropy of the predetermined portion of the tubular assembly,
prior to the radial expansion and plastic deformation, is at least
about 1.48. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and the
yield point of the predetermined portion of the tubular assembly is
at least about 74.4 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly after the radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the predetermined portion of the tubular
assembly prior to the radial expansion and plastic deformation. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is at least about 1.04. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is at least about 1.92. In an exemplary embodiment,
the anisotropy of the predetermined portion of the tubular
assembly, prior to the radial expansion and plastic deformation, is
at least about 1.34. In an exemplary embodiment, the anisotropy of
the predetermined portion of the tubular assembly, prior to the
radial expansion and plastic deformation, ranges from about 1.04 to
about 1.92. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly, prior to the radial
expansion and plastic deformation, ranges from about 47.6 ksi to
about 61.7 ksi. In an exemplary embodiment, the expandability
coefficient of the predetermined portion of the tubular assembly,
prior to the radial expansion and plastic deformation, is greater
than 0.12. In an exemplary embodiment, the expandability
coefficient of the predetermined portion of the tubular assembly is
greater than the expandability coefficient of the other portion of
the tubular assembly. In an exemplary embodiment, the tubular
assembly includes a wellbore casing, a pipeline, or a structural
support. In an exemplary embodiment, the carbon content of the
predetermined portion of the tubular assembly is less than or equal
to 0.12 percent; and wherein the carbon equivalent value for the
predetermined portion of the tubular assembly is less than 0.21. In
an exemplary embodiment, the carbon content of the predetermined
portion of the tubular assembly is greater than 0.12 percent; and
wherein the carbon equivalent value for the predetermined portion
of the tubular assembly is less than 0.36. In an exemplary
embodiment, a yield point of an inner tubular portion of at least a
portion of the tubular assembly is less than a yield point of an
outer tubular portion of the portion of the tubular assembly. In an
exemplary embodiment, yield point of the inner tubular portion of
the tubular body varies as a function of the radial position within
the tubular body. In an exemplary embodiment, the yield point of
the inner tubular portion of the tubular body varies in an linear
fashion as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the inner
tubular portion of the tubular body varies in an non-linear fashion
as a function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the outer tubular portion
of the tubular body varies as a function of the radial position
within the tubular body. In an exemplary embodiment, the yield
point of the outer tubular portion of the tubular body varies in an
linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
outer tubular portion of the tubular body varies in an non-linear
fashion as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the inner
tubular portion of the tubular body varies as a function of the
radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies as a
function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies in a linear fashion as a function of the
radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies in a
linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
inner tubular portion of the tubular body varies in a linear
fashion as a function of the radial position within the tubular
body; and wherein the yield point of the outer tubular portion of
the tubular body varies in a non-linear fashion as a function of
the radial position within the tubular body. In an exemplary
embodiment, the yield point of the inner tubular portion of the
tubular body varies in a non-linear fashion as a function of the
radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies in a
linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
inner tubular portion of the tubular body varies in a non-linear
fashion as a function of the radial position within the tubular
body; and wherein the yield point of the outer tubular portion of
the tubular body varies in a non-linear fashion as a function of
the radial position within the tubular body. In an exemplary
embodiment, the rate of change of the yield point of the inner
tubular portion of the tubular body is different than the rate of
change of the yield point of the outer tubular portion of the
tubular body. In an exemplary embodiment, the rate of change of the
yield point of the inner tubular portion of the tubular body is
different than the rate of change of the yield point of the outer
tubular portion of the tubular body. In an exemplary embodiment,
prior to the radial expansion and plastic deformation, at least a
portion of the tubular assembly comprises a microstructure
comprising a hard phase structure and a soft phase structure. In an
exemplary embodiment, prior to the radial expansion and plastic
deformation, at least a portion of the tubular assembly comprises a
microstructure comprising a transitional phase structure. In an
exemplary embodiment, the hard phase structure comprises
martensite. In an exemplary embodiment, the soft phase structure
comprises ferrite. In an exemplary embodiment, the transitional
phase structure comprises retained austentite. In an exemplary
embodiment, the hard phase structure comprises martensite; wherein
the soft phase structure comprises ferrite; and wherein the
transitional phase structure comprises retained austentite. In an
exemplary embodiment, the portion of the tubular assembly
comprising a microstructure comprising a hard phase structure and a
soft phase structure comprises, by weight percentage, about 0.1% C,
about 1.2% Mn, and about 0.3% Si.
[0740] An expandable tubular member has been described that
includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P,
0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an
exemplary embodiment, a yield point of the tubular member is at
most about 46.9 ksi prior to a radial expansion and plastic
deformation; and a yield point of the tubular member is at least
about 65.9 ksi after the radial expansion and plastic deformation.
In an exemplary embodiment, the yield point of the tubular member
after the radial expansion and plastic deformation is at least
about 40% greater than the yield point of the tubular member prior
to the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the tubular member, prior to a radial
expansion and plastic deformation, is about 1.48. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0741] An expandable tubular member has been described that
includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P,
0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an
exemplary embodiment, a yield point of the tubular member is at
most about 57.8 ksi prior to a radial expansion and plastic
deformation; and the yield point of the tubular member is at least
about 74.4 ksi after the radial expansion and plastic deformation.
In an exemplary embodiment, a yield point of the of the tubular
member after a radial expansion and plastic deformation is at least
about 28% greater than the yield point of the tubular member prior
to the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the tubular member, prior to a radial
expansion and plastic deformation, is about 1.04. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0742] An expandable tubular member has been described that
includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P,
0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an
exemplary embodiment, the anisotropy of the tubular member, prior
to a radial expansion and plastic deformation, is about 1.92. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0743] An expandable tubular member has been described that
includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P,
0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary
embodiment, the anisotropy of the tubular member, prior to a radial
expansion and plastic deformation, is about 1.34. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0744] An expandable tubular member has been described, wherein the
yield point of the expandable tubular member is at most about 46.9
ksi prior to a radial expansion and plastic deformation; and
wherein the yield point of the expandable tubular member is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the tubular member
includes a wellbore casing, a pipeline, or a structural
support.
[0745] An expandable tubular member has been described, wherein a
yield point of the expandable tubular member after a radial
expansion and plastic deformation is at least about 40% greater
than the yield point of the expandable tubular member prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0746] An expandable tubular member has been described, wherein the
anisotropy of the expandable tubular member, prior to the radial
expansion and plastic deformation, is at least about 1.48. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0747] An expandable tubular member has been described, wherein the
yield point of the expandable tubular member is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the expandable tubular member is at
least about 74.4 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the tubular member
includes a wellbore casing, a pipeline, or a structural
support.
[0748] An expandable tubular member has been described, wherein the
yield point of the expandable tubular member after a radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the expandable tubular member prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0749] An expandable tubular member has been described, wherein the
anisotropy of the expandable tubular member, prior to the radial
expansion and plastic deformation, is at least about 1.04. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0750] An expandable tubular member has been described, wherein the
anisotropy of the expandable tubular member, prior to the radial
expansion and plastic deformation, is at least about 1.92. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0751] An expandable tubular member has been described, wherein the
anisotropy of the expandable tubular member, prior to the radial
expansion and plastic deformation, is at least about 1.34. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0752] An expandable tubular member has been described, wherein the
anisotropy of the expandable tubular member, prior to the radial
expansion and plastic deformation, ranges from about 1.04 to about
1.92. In an exemplary embodiment, the tubular member includes a
wellbore casing, a pipeline, or a structural support.
[0753] An expandable tubular member has been described, wherein the
yield point of the expandable tubular member, prior to the radial
expansion and plastic deformation, ranges from about 47.6 ksi to
about 61.7 ksi. In an exemplary embodiment, the tubular member
includes a wellbore casing, a pipeline, or a structural
support.
[0754] An expandable tubular member has been described, wherein the
expandability coefficient of the expandable tubular member, prior
to the radial expansion and plastic deformation, is greater than
0.12. In an exemplary embodiment, the tubular member includes a
wellbore casing, a pipeline, or a structural support.
[0755] An expandable tubular member has been described, wherein the
expandability coefficient of the expandable tubular member is
greater than the expandability coefficient of another portion of
the expandable tubular member. In an exemplary embodiment, the
tubular member includes a wellbore casing, a pipeline, or a
structural support.
[0756] An expandable tubular member has been described, wherein the
tubular member has a higher ductility and a lower yield point prior
to a radial expansion and plastic deformation than after the radial
expansion and plastic deformation. In an exemplary embodiment, the
tubular member includes a wellbore casing, a pipeline, or a
structural support.
[0757] A method of radially expanding and plastically deforming a
tubular assembly including a first tubular member coupled to a
second tubular member has been described that includes radially
expanding and plastically deforming the tubular assembly within a
preexisting structure; and using less power to radially expand each
unit length of the first tubular member than to radially expand
each unit length of the second tubular member. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0758] A system for radially expanding and plastically deforming a
tubular assembly including a first tubular member coupled to a
second tubular member has been described that includes means for
radially expanding the tubular assembly within a preexisting
structure; and means for using less power to radially expand each
unit length of the first tubular member than required to radially
expand each unit length of the second tubular member. In an
exemplary embodiment, the tubular member includes a wellbore
casing, a pipeline, or a structural support.
[0759] A method of manufacturing a tubular member has been
described that includes processing a tubular member until the
tubular member is characterized by one or more intermediate
characteristics; positioning the tubular member within a
preexisting structure; and processing the tubular member within the
preexisting structure until the tubular member is characterized one
or more final characteristics. In an exemplary embodiment, the
tubular member includes a wellbore casing, a pipeline, or a
structural support. In an exemplary embodiment, the preexisting
structure includes a wellbore that traverses a subterranean
formation. In an exemplary embodiment, the characteristics are
selected from a group consisting of yield point and ductility. In
an exemplary embodiment, processing the tubular member within the
preexisting structure until the tubular member is characterized one
or more final characteristics includes: radially expanding and
plastically deforming the tubular member within the preexisting
structure.
[0760] An apparatus has been described that includes an expandable
tubular assembly; and an expansion device coupled to the expandable
tubular assembly; wherein a predetermined portion of the expandable
tubular assembly has a lower yield point than another portion of
the expandable tubular assembly. In an exemplary embodiment, the
expansion device includes a rotary expansion device, an axially
displaceable expansion device, a reciprocating expansion device, a
hydroforming expansion device, and/or an impulsive force expansion
device. In an exemplary embodiment, the predetermined portion of
the tubular assembly has a higher ductility and a lower yield point
than another portion of the expandable tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly has a higher ductility than another portion of the
expandable tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly has a lower yield
point than another portion of the expandable tubular assembly. In
an exemplary embodiment, the predetermined portion of the tubular
assembly includes an end portion of the tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly includes a plurality of predetermined portions of the
tubular assembly. In an exemplary embodiment, the predetermined
portion of the tubular assembly includes a plurality of spaced
apart predetermined portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
includes an end portion of the tubular assembly. In an exemplary
embodiment, the other portion of the tubular assembly includes a
plurality of other portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
includes a plurality of spaced apart other portions of the tubular
assembly. In an exemplary embodiment, the tubular assembly includes
a plurality of tubular members coupled to one another by
corresponding tubular couplings. In an exemplary embodiment, the
tubular couplings comprise the predetermined portions of the
tubular assembly; and wherein the tubular members comprise the
other portion of the tubular assembly. In an exemplary embodiment,
one or more of the tubular couplings comprise the predetermined
portions of the tubular assembly. In an exemplary embodiment, one
or more of the tubular members comprise the predetermined portions
of the tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly defines one or more
openings. In an exemplary embodiment, one or more of the openings
comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In
an exemplary embodiment, the anisotropy for the predetermined
portion of the tubular assembly is greater than 1. In an exemplary
embodiment, the strain hardening exponent for the predetermined
portion of the tubular assembly is greater than 0.12. In an
exemplary embodiment, the anisotropy for the predetermined portion
of the tubular assembly is greater than 1; and wherein the strain
hardening exponent for the predetermined portion of the tubular
assembly is greater than 0.12. In an exemplary embodiment, the
predetermined portion of the tubular assembly includes a first
steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24%
Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment,
the yield point of the predetermined portion of the tubular
assembly is at most about 46.9 ksi. In an exemplary embodiment, the
anisotropy of the predetermined portion of the tubular assembly is
about 1.48. In an exemplary embodiment, the predetermined portion
of the tubular assembly includes a second steel alloy including:
0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01%
Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of
the predetermined portion of the tubular assembly is at most about
57.8 ksi. In an exemplary embodiment, the anisotropy of the
predetermined portion of the tubular assembly is about 1.04. In an
exemplary embodiment, the predetermined portion of the tubular
assembly includes a third steel alloy including: 0.08% C, 0.82% Mn,
0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly is about 1.92. In an exemplary
embodiment, the predetermined portion of the tubular assembly
includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02%
P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly is at least about 1.34. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 46.9 ksi. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly is at least about 1.48. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly is at least about 1.04. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly is at least about 1.92. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly is at least about 1.34. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly ranges from about 1.04 to about 1.92. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly ranges from about 47.6 ksi to about 61.7
ksi. In an exemplary embodiment, the expandability coefficient of
the predetermined portion of the tubular assembly is greater than
0.12. In an exemplary embodiment, the expandability coefficient of
the predetermined portion of the tubular assembly is greater than
the expandability coefficient of the other portion of the tubular
assembly. In an exemplary embodiment, the tubular assembly includes
a wellbore casing, a pipeline, or a structural support. In an
exemplary embodiment, the carbon content of the predetermined
portion of the tubular assembly is less than or equal to 0.12
percent; and wherein the carbon equivalent value for the
predetermined portion of the tubular assembly is less than 0.21. In
an exemplary embodiment, the carbon content of the predetermined
portion of the tubular assembly is greater than 0.12 percent; and
wherein the carbon equivalent value for the predetermined portion
of the tubular assembly is less than 0.36. In an exemplary
embodiment, a yield point of an inner tubular portion of at least a
portion of the tubular assembly is less than a yield point of an
outer tubular portion of the portion of the tubular assembly. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies as a function of the radial position
within the tubular body. In an exemplary embodiment, the yield
point of the inner tubular portion of the tubular body varies in an
linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
inner tubular portion of the tubular body varies in an non-linear
fashion as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the outer
tubular portion of the tubular body varies as a function of the
radial position within the tubular body. In an exemplary
embodiment, the yield point of the outer tubular portion of the
tubular body varies in an linear fashion as a function of the
radial position within the tubular body. In an exemplary
embodiment, the yield point of the outer tubular portion of the
tubular body varies in an non-linear fashion as a function of the
radial position within the tubular body. In an exemplary
embodiment, the yield point of the inner tubular portion of the
tubular body varies as a function of the radial position within the
tubular body; and wherein the yield point of the outer tubular
portion of the tubular body varies as a function of the radial
position within the tubular body. In an exemplary embodiment, the
yield point of the inner tubular portion of the tubular body varies
in a linear fashion as a function of the radial position within the
tubular body; and wherein the yield point of the outer tubular
portion of the tubular body varies in a linear fashion as a
function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies in a linear fashion as a function of the
radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies in a
non-linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
inner tubular portion of the tubular body varies in a non-linear
fashion as a function of the radial position within the tubular
body; and wherein the yield point of the outer tubular portion of
the tubular body varies in a linear fashion as a function of the
radial position within the tubular body. In an exemplary
embodiment, the yield point of the inner tubular portion of the
tubular body varies in a non-linear fashion as a function of the
radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies in a
non-linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the rate of change of the
yield point of the inner tubular portion of the tubular body is
different than the rate of change of the yield point of the outer
tubular portion of the tubular body. In an exemplary embodiment,
the rate of change of the yield point of the inner tubular portion
of the tubular body is different than the rate of change of the
yield point of the outer tubular portion of the tubular body. In an
exemplary embodiment, at least a portion of the tubular assembly
comprises a microstructure comprising a hard phase structure and a
soft phase structure. In an exemplary embodiment, prior to the
radial expansion and plastic deformation, at least a portion of the
tubular assembly comprises a microstructure comprising a
transitional phase structure. In an exemplary embodiment, wherein
the hard phase structure comprises martensite. In an exemplary
embodiment, wherein the soft phase structure comprises ferrite. In
an exemplary embodiment, wherein the transitional phase structure
comprises retained austentite. In an exemplary embodiment, the hard
phase structure comprises martensite; wherein the soft phase
structure comprises ferrite; and wherein the transitional phase
structure comprises retained austentite. In an exemplary
embodiment, the portion of the tubular assembly comprising a
microstructure comprising a hard phase structure and a soft phase
structure comprises, by weight percentage, about 0.1% C, about 1.2%
Mn, and about 0.3% Si. In an exemplary embodiment, at least a
portion of the tubular assembly comprises a microstructure
comprising a hard phase structure and a soft phase structure. In an
exemplary embodiment, the portion of the tubular assembly
comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P,
0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01%
Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the portion
of the tubular assembly comprises, by weight percentage, 0.18% C,
1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03%
Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary
embodiment, the portion of the tubular assembly comprises, by
weight percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,
0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and
0.01% Ti. In an exemplary embodiment, the portion of the tubular
assembly comprises a microstructure comprising one or more of the
following: martensite, pearlite, vanadium carbide, nickel carbide,
or titanium carbide. In an exemplary embodiment, the portion of the
tubular assembly comprises a microstructure comprising one or more
of the following: pearlite or pearlite striation. In an exemplary
embodiment, the portion of the tubular assembly comprises a
microstructure comprising one or more of the following: grain
pearlite, widmanstatten martensite, vanadium carbide, nickel
carbide, or titanium carbide. In an exemplary embodiment, the
portion of the tubular assembly comprises a microstructure
comprising one or more of the following: ferrite, grain pearlite,
or martensite. In an exemplary embodiment, the portion of the
tubular assembly comprises a microstructure comprising one or more
of the following: ferrite, martensite, or bainite. In an exemplary
embodiment, the portion of the tubular assembly comprises a
microstructure comprising one or more of the following: bainite,
pearlite, or ferrite. In an exemplary embodiment, the portion of
the tubular assembly comprises a yield strength of about 67 ksi and
a tensile strength of about 95 ksi. In an exemplary embodiment, the
portion of the tubular assembly comprises a yield strength of about
82 ksi and a tensile strength of about 130 ksi. In an exemplary
embodiment, the portion of the tubular assembly comprises a yield
strength of about 60 ksi and a tensile strength of about 97
ksi.
[0761] An expandable tubular member has been described, wherein a
yield point of the expandable tubular member after a radial
expansion and plastic deformation is at least about 5.8% greater
than the yield point of the expandable tubular member prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the tubular member includes a wellbore casing, a
pipeline, or a structural support.
[0762] A method of determining the expandability of a selected
tubular member has been described that includes determining an
anisotropy value for the selected tubular member, determining a
strain hardening value for the selected tubular member; and
multiplying the anisotropy value times the strain hardening value
to generate an expandability value for the selected tubular member.
In an exemplary embodiment, an anisotropy value greater than 0.12
indicates that the tubular member is suitable for radial expansion
and plastic deformation. In an exemplary embodiment, the tubular
member includes a wellbore casing, a pipeline, or a structural
support.
[0763] A method of radially expanding and plastically deforming
tubular members has been described that includes selecting a
tubular member; determining an anisotropy value for the selected
tubular member; determining a strain hardening value for the
selected tubular member; multiplying the anisotropy value times the
strain hardening value to generate an expandability value for the
selected tubular member; and if the anisotropy value is greater
than 0.12, then radially expanding and plastically deforming the
selected tubular member. In an exemplary embodiment, the tubular
member includes a wellbore casing, a pipeline, or a structural
support. In an exemplary embodiment, radially expanding and
plastically deforming the selected tubular member includes:
inserting the selected tubular member into a preexisting structure;
and then radially expanding and plastically deforming the selected
tubular member. In an exemplary embodiment, the preexisting
structure includes a wellbore that traverses a subterranean
formation.
[0764] A radially expandable multiple tubular member apparatus has
been described that includes a first tubular member; a second
tubular member engaged with the first tubular member forming a
joint; a sleeve overlapping and coupling the first and second
tubular members at the joint; the sleeve having opposite tapered
ends and a flange engaged in a recess formed in an adjacent tubular
member; and one of the tapered ends being a surface formed on the
flange. In an exemplary embodiment, the recess includes a tapered
wall in mating engagement with the tapered end formed on the
flange. In an exemplary embodiment, the sleeve includes a flange at
each tapered end and each tapered end is formed on a respective
flange. In an exemplary embodiment, each tubular member includes a
recess. In an exemplary embodiment, each flange is engaged in a
respective one of the recesses. In an exemplary embodiment, each
recess includes a tapered wall in mating engagement with the
tapered end formed on a respective one of the flanges.
[0765] A method of joining radially expandable multiple tubular
members has also been described that includes providing a first
tubular member; engaging a second tubular member with the first
tubular member to form a joint; providing a sleeve having opposite
tapered ends and a flange, one of the tapered ends being a surface
formed on the flange; and mounting the sleeve for overlapping and
coupling the first and second tubular members at the joint, wherein
the flange is engaged in a recess formed in an adjacent one of the
tubular members. In an exemplary embodiment, the method further
includes providing a tapered wall in the recess for mating
engagement with the tapered end formed on the flange. In an
exemplary embodiment, the method further includes providing a
flange at each tapered end wherein each tapered end is formed on a
respective flange. In an exemplary embodiment, the method further
includes providing a recess in each tubular member. In an exemplary
embodiment, the method further includes engaging each flange in a
respective one of the recesses. In an exemplary embodiment, the
method further includes providing a tapered wall in each recess for
mating engagement with the tapered end formed on a respective one
of the flanges.
[0766] A radially expandable multiple tubular member apparatus has
been described that includes a first tubular member; a second
tubular member engaged with the first tubular member forming a
joint; and a sleeve overlapping and coupling the first and second
tubular members at the joint; wherein at least a portion of the
sleeve is comprised of a frangible material.
[0767] A radially expandable multiple tubular member apparatus has
been described that includes a first tubular member; a second
tubular member engaged with the first tubular member forming a
joint; and a sleeve overlapping and coupling the first and second
tubular members at the joint; wherein the wall thickness of the
sleeve is variable.
[0768] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member; engaging a second tubular member with the first tubular
member to form a joint; providing a sleeve comprising a frangible
material; and mounting the sleeve for overlapping and coupling the
first and second tubular members at the joint.
[0769] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member; engaging a second tubular member with the first tubular
member to form a joint; providing a sleeve comprising a variable
wall thickness; and mounting the sleeve for overlapping and
coupling the first and second tubular members at the joint.
[0770] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; and means for increasing the axial
compression loading capacity of the coupling between the first and
second tubular members before and after a radial expansion and
plastic deformation of the first and second tubular members.
[0771] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; and means for increasing the axial
tension loading capacity of the coupling between the first and
second tubular members before and after a radial expansion and
plastic deformation of the first and second tubular members.
[0772] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; and means for increasing the axial
compression and tension loading capacity of the coupling between
the first and second tubular members before and after a radial
expansion and plastic deformation of the first and second tubular
members.
[0773] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; and means for avoiding stress risers in
the coupling between the first and second tubular members before
and after a radial expansion and plastic deformation of the first
and second tubular members.
[0774] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; and means for inducing stresses at
selected portions of the coupling between the first and second
tubular members before and after a radial expansion and plastic
deformation of the first and second tubular members.
[0775] In several exemplary embodiments of the apparatus described
above, the sleeve is circumferentially tensioned; and wherein the
first and second tubular members are circumferentially
compressed.
[0776] In several exemplary embodiments of the method described
above, the method further includes maintaining the sleeve in
circumferential tension; and maintaining the first and second
tubular members in circumferential compression before, during,
and/or after the radial expansion and plastic deformation of the
first and second tubular members.
[0777] An expandable tubular assembly has been described that
includes a first tubular member, a second tubular member coupled to
the first tubular member, a first threaded connection for coupling
a portion of the first and second tubular members, a second
threaded connection spaced apart from the first threaded connection
for coupling another portion of the first and second tubular
members, a tubular sleeve coupled to and receiving end portions of
the first and second tubular members, and a sealing element
positioned between the first and second spaced apart threaded
connections for sealing an interface between the first and second
tubular member, wherein the sealing element is positioned within an
annulus defined between the first and second tubular members. In an
exemplary embodiment, the annulus is at least partially defined by
an irregular surface. In an exemplary embodiment, the annulus is at
least partially defined by a toothed surface. In an exemplary
embodiment, the sealing element comprises an elastomeric material.
In an exemplary embodiment, the sealing element comprises a
metallic material. In an exemplary embodiment, the sealing element
comprises an elastomeric and a metallic material.
[0778] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member, providing a second tubular member, providing a sleeve,
mounting the sleeve for overlapping and coupling the first and
second tubular members, threadably coupling the first and second
tubular members at a first location, threadably coupling the first
and second tubular members at a second location spaced apart from
the first location, and sealing an interface between the first and
second tubular members between the first and second locations using
a compressible sealing element. In an exemplary embodiment, the
sealing element includes an irregular surface. In an exemplary
embodiment, the sealing element includes a toothed surface. In an
exemplary embodiment, the sealing element comprises an elastomeric
material. In an exemplary embodiment, the sealing element comprises
a metallic material. In an exemplary embodiment, the sealing
element comprises an elastomeric and a metallic material.
[0779] An expandable tubular assembly has been described that
includes a first tubular member, a second tubular member coupled to
the first tubular member, a first threaded connection for coupling
a portion of the first and second tubular members, a second
threaded connection spaced apart from the first threaded connection
for coupling another portion of the first and second tubular
members, and a plurality of spaced apart tubular sleeves coupled to
and receiving end portions of the first and second tubular members.
In an exemplary embodiment, at least one of the tubular sleeves is
positioned in opposing relation to the first threaded connection;
and wherein at least one of the tubular sleeves is positioned in
opposing relation to the second threaded connection. In an
exemplary embodiment, at least one of the tubular sleeves is not
positioned in opposing relation to the first and second threaded
connections.
[0780] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member, providing a second tubular member, threadably coupling the
first and second tubular members at a first location, threadably
coupling the first and second tubular members at a second location
spaced apart from the first location, providing a plurality of
sleeves, and mounting the sleeves at spaced apart locations for
overlapping and coupling the first and second tubular members. In
an exemplary embodiment, at least one of the tubular sleeves is
positioned in opposing relation to the first threaded coupling; and
wherein at least one of the tubular sleeves is positioned in
opposing relation to the second threaded coupling. In an exemplary
embodiment, at least one of the tubular sleeves is not positioned
in opposing relation to the first and second threaded
couplings.
[0781] An expandable tubular assembly has been described that
includes a first tubular member, a second tubular member coupled to
the first tubular member, and a plurality of spaced apart tubular
sleeves coupled to and receiving end portions of the first and
second tubular members.
[0782] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member, providing a second tubular member, providing a plurality of
sleeves, coupling the first and second tubular members, and
mounting the sleeves at spaced apart locations for overlapping and
coupling the first and second tubular members.
[0783] An expandable tubular assembly has been described that
includes a first tubular member, a second tubular member coupled to
the first tubular member, a threaded connection for coupling a
portion of the first and second tubular members, and a tubular
sleeves coupled to and receiving end portions of the first and
second tubular members, wherein at least a portion of the threaded
connection is upset. In an exemplary embodiment, at least a portion
of tubular sleeve penetrates the first tubular member.
[0784] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member, providing a second tubular member, threadably coupling the
first and second tubular members, and upsetting the threaded
coupling. In an exemplary embodiment, the first tubular member
further comprises an annular extension extending therefrom, and the
flange of the sleeve defines an annular recess for receiving and
mating with the annular extension of the first tubular member. In
an exemplary embodiment, the first tubular member further comprises
an annular extension extending therefrom; and the flange of the
sleeve defines an annular recess for receiving and mating with the
annular extension of the first tubular member.
[0785] A radially expandable multiple tubular member apparatus has
been described that includes a first tubular member, a second
tubular member engaged with the first tubular member forming a
joint, a sleeve overlapping and coupling the first and second
tubular members at the joint, and one or more stress concentrators
for concentrating stresses in the joint. In an exemplary
embodiment, one or more of the stress concentrators comprises one
or more external grooves defined in the first tubular member. In an
exemplary embodiment, one or more of the stress concentrators
comprises one or more internal grooves defined in the second
tubular member. In an exemplary embodiment, one or more of the
stress concentrators comprises one or more openings defined in the
sleeve. In an exemplary embodiment, one or more of the stress
concentrators comprises one or more external grooves defined in the
first tubular member; and one or more of the stress concentrators
comprises one or more internal grooves defined in the second
tubular member. In an exemplary embodiment, one or more of the
stress concentrators comprises one or more external grooves defined
in the first tubular member; and one or more of the stress
concentrators comprises one or more openings defined in the sleeve.
In an exemplary embodiment, one or more of the stress concentrators
comprises one or more internal grooves defined in the second
tubular member; and one or more of the stress concentrators
comprises one or more openings defined in the sleeve. In an
exemplary embodiment, one or more of the stress concentrators
comprises one or more external grooves defined in the first tubular
member; wherein one or more of the stress concentrators comprises
one or more internal grooves defined in the second tubular member;
and wherein one or more of the stress concentrators comprises one
or more openings defined in the sleeve.
[0786] A method of joining radially expandable multiple tubular
members has been described that includes providing a first tubular
member, engaging a second tubular member with the first tubular
member to form a joint, providing a sleeve having opposite tapered
ends and a flange, one of the tapered ends being a surface formed
on the flange, and concentrating stresses within the joint. In an
exemplary embodiment, concentrating stresses within the joint
comprises using the first tubular member to concentrate stresses
within the joint. In an exemplary embodiment, concentrating
stresses within the joint comprises using the second tubular member
to concentrate stresses within the joint. In an exemplary
embodiment, concentrating stresses within the joint comprises using
the sleeve to concentrate stresses within the joint. In an
exemplary embodiment, concentrating stresses within the joint
comprises using the first tubular member and the second tubular
member to concentrate stresses within the joint. In an exemplary
embodiment, concentrating stresses within the joint comprises using
the first tubular member and the sleeve to concentrate stresses
within the joint. In an exemplary embodiment, concentrating
stresses within the joint comprises using the second tubular member
and the sleeve to concentrate stresses within the joint. In an
exemplary embodiment, concentrating stresses within the joint
comprises using the first tubular member, the second tubular
member, and the sleeve to concentrate stresses within the
joint.
[0787] A system for radially expanding and plastically deforming a
first tubular member coupled to a second tubular member by a
mechanical connection has been described that includes means for
radially expanding the first and second tubular members, and means
for maintaining portions of the first and second tubular member in
circumferential compression following the radial expansion and
plastic deformation of the first and second tubular members.
[0788] A system for radially expanding and plastically deforming a
first tubular member coupled to a second tubular member by a
mechanical connection has been described that includes means for
radially expanding the first and second tubular members; and means
for concentrating stresses within the mechanical connection during
the radial expansion and plastic deformation of the first and
second tubular members.
[0789] A system for radially expanding and plastically deforming a
first tubular member coupled to a second tubular member by a
mechanical connection has been described that includes means for
radially expanding the first and second tubular members; means for
maintaining portions of the first and second tubular member in
circumferential compression following the radial expansion and
plastic deformation of the first and second tubular members; and
means for concentrating stresses within the mechanical connection
during the radial expansion and plastic deformation of the first
and second tubular members.
A radially expandable tubular member apparatus has been described
that includes a first tubular member; a second tubular member
engaged with the first tubular member forming a joint; and a sleeve
overlapping and coupling the first and second tubular members at
the joint; wherein, prior to a radial expansion and plastic
deformation of the apparatus, a predetermined portion of the
apparatus has a lower yield point than another portion of the
apparatus. In an exemplary embodiment, the carbon content of the
predetermined portion of the apparatus is less than or equal to
0.12 percent; and wherein the carbon equivalent value for the
predetermined portion of the apparatus is less than 0.21. In an
exemplary embodiment, the carbon content of the predetermined
portion of the apparatus is greater than 0.12 percent; and wherein
the carbon equivalent value for the predetermined portion of the
apparatus is less than 0.36. In an exemplary embodiment, the
apparatus further includes means for maintaining portions of the
first and second tubular member in circumferential compression
following the radial expansion and plastic deformation of the first
and second tubular members. In an exemplary embodiment, the
apparatus further includes means for concentrating stresses within
the mechanical connection during the radial expansion and plastic
deformation of the first and second tubular members. In an
exemplary embodiment, the apparatus further includes means for
maintaining portions of the first and second tubular member in
circumferential compression following the radial expansion and
plastic deformation of the first and second tubular members; and
means for concentrating stresses within the mechanical connection
during the radial expansion and plastic deformation of the first
and second tubular members. In an exemplary embodiment, the
apparatus further includes one or more stress concentrators for
concentrating stresses in the joint. In an exemplary embodiment,
one or more of the stress concentrators comprises one or more
external grooves defined in the first tubular member. In an
exemplary embodiment, one or more of the stress concentrators
comprises one or more internal grooves defined in the second
tubular member. In an exemplary embodiment, one or more of the
stress concentrators comprises one or more openings defined in the
sleeve. In an exemplary embodiment, one or more of the stress
concentrators comprises one or more external grooves defined in the
first tubular member; and wherein one or more of the stress
concentrators comprises one or more internal grooves defined in the
second tubular member. In an exemplary embodiment, one or more of
the stress concentrators comprises one or more external grooves
defined in the first tubular member; and wherein one or more of the
stress concentrators comprises one or more openings defined in the
sleeve. In an exemplary embodiment, one or more of the stress
concentrators comprises one or more internal grooves defined in the
second tubular member; and wherein one or more of the stress
concentrators comprises one or more openings defined in the sleeve.
In an exemplary embodiment, one or more of the stress concentrators
comprises one or more external grooves defined in the first tubular
member; wherein one or more of the stress concentrators comprises
one or more internal grooves defined in the second tubular member;
and wherein one or more of the stress concentrators comprises one
or more openings defined in the sleeve. In an exemplary embodiment,
the first tubular member further comprises an annular extension
extending therefrom; and wherein the flange of the sleeve defines
an annular recess for receiving and mating with the annular
extension of the first tubular member. In an exemplary embodiment,
the apparatus further includes a threaded connection for coupling a
portion of the first and second tubular members; wherein at least a
portion of the threaded connection is upset. In an exemplary
embodiment, at least a portion of tubular sleeve penetrates the
first tubular member. In an exemplary embodiment, the apparatus
further includes means for increasing the axial compression loading
capacity of the joint between the first and second tubular members
before and after a radial expansion and plastic deformation of the
first and second tubular members. In an exemplary embodiment, the
apparatus further includes means for increasing the axial tension
loading capacity of the joint between the first and second tubular
members before and after a radial expansion and plastic deformation
of the first and second tubular members. In an exemplary
embodiment, the apparatus further includes means for increasing the
axial compression and tension loading capacity of the joint between
the first and second tubular members before and after a radial
expansion and plastic deformation of the first and second tubular
members. In an exemplary embodiment, the apparatus further includes
means for avoiding stress risers in the joint between the first and
second tubular members before and after a radial expansion and
plastic deformation of the first and second tubular members. In an
exemplary embodiment, the apparatus further includes means for
inducing stresses at selected portions of the coupling between the
first and second tubular members before and after a radial
expansion and plastic deformation of the first and second tubular
members. In an exemplary embodiment, the sleeve is
circumferentially tensioned; and wherein the first and second
tubular members are circumferentially compressed. In an exemplary
embodiment, the means for increasing the axial compression loading
capacity of the coupling between the first and second tubular
members before and after a radial expansion and plastic deformation
of the first and second tubular members is circumferentially
tensioned; and wherein the first and second tubular members are
circumferentially compressed. In an exemplary embodiment, the means
for increasing the axial tension loading capacity of the coupling
between the first and second tubular members before and after a
radial expansion and plastic deformation of the first and second
tubular members is circumferentially tensioned; and wherein the
first and second tubular members are circumferentially compressed.
In an exemplary embodiment, the means for increasing the axial
compression and tension loading capacity of the coupling between
the first and second tubular members before and after a radial
expansion and plastic deformation of the first and second tubular
members is circumferentially tensioned; and wherein the first and
second tubular members are circumferentially compressed. In an
exemplary embodiment, the means for avoiding stress risers in the
coupling between the first and second tubular members before and
after a radial expansion and plastic deformation of the first and
second tubular members is circumferentially tensioned; and wherein
the first and second tubular members are circumferentially
compressed. In an exemplary embodiment, the means for inducing
stresses at selected portions of the coupling between the first and
second tubular members before and after a radial expansion and
plastic deformation of the first and second tubular members is
circumferentially tensioned; and wherein the first and second
tubular members are circumferentially compressed. In an exemplary
embodiment, at least a portion of the sleeve is comprised of a
frangible material. In an exemplary embodiment, the wall thickness
of the sleeve is variable. In an exemplary embodiment, the
predetermined portion of the apparatus has a higher ductility and a
lower yield point prior to the radial expansion and plastic
deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the apparatus has a higher ductility prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the apparatus has a lower yield point
prior to the radial expansion and plastic deformation than after
the radial expansion and plastic deformation. In an exemplary
embodiment, the predetermined portion of the apparatus has a larger
inside diameter after the radial expansion and plastic deformation
than other portions of the tubular assembly. In an exemplary
embodiment, the sleeve is circumferentially tensioned; and wherein
the first and second tubular members are circumferentially
compressed. In an exemplary embodiment, the sleeve is
circumferentially tensioned; and wherein the first and second
tubular members are circumferentially compressed. In an exemplary
embodiment, the apparatus further includes positioning another
apparatus within the preexisting structure in overlapping relation
to the apparatus; and radially expanding and plastically deforming
the other apparatus within the preexisting structure; wherein,
prior to the radial expansion and plastic deformation of the
apparatus, a predetermined portion of the other apparatus has a
lower yield point than another portion of the other apparatus. In
an exemplary embodiment, the inside diameter of the radially
expanded and plastically deformed other portion of the apparatus is
equal to the inside diameter of the radially expanded and
plastically deformed other portion of the other apparatus. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises an end portion of the apparatus. In an exemplary
embodiment, the predetermined portion of the apparatus comprises a
plurality of predetermined portions of the apparatus. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises a plurality of spaced apart predetermined portions of the
apparatus. In an exemplary embodiment, the other portion of the
apparatus comprises an end portion of the apparatus. In an
exemplary embodiment, the other portion of the apparatus comprises
a plurality of other portions of the apparatus. In an exemplary
embodiment, the other portion of the apparatus comprises a
plurality of spaced apart other portions of the apparatus. In an
exemplary embodiment, the apparatus comprises a plurality of
tubular members coupled to one another by corresponding tubular
couplings. In an exemplary embodiment, the tubular couplings
comprise the predetermined portions of the apparatus; and wherein
the tubular members comprise the other portion of the apparatus. In
an exemplary embodiment, one or more of the tubular couplings
comprise the predetermined portions of the apparatus. In an
exemplary embodiment, one or more of the tubular members comprise
the predetermined portions of the apparatus. In an exemplary
embodiment, the predetermined portion of the apparatus defines one
or more openings. In an exemplary embodiment, one or more of the
openings comprise slots. In an exemplary embodiment, the anisotropy
for the predetermined portion of the apparatus is greater than 1.
In an exemplary embodiment, the anisotropy for the predetermined
portion of the apparatus is greater than 1. In an exemplary
embodiment, the strain hardening exponent for the predetermined
portion of the apparatus is greater than 0.12. In an exemplary
embodiment, the anisotropy for the predetermined portion of the
apparatus is greater than 1; and wherein the strain hardening
exponent for the predetermined portion of the apparatus is greater
than 0.12. In an exemplary embodiment, the predetermined portion of
the apparatus comprises a first steel alloy comprising: 0.065% C,
1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and
0.02% Cr. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus is at most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the apparatus is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus after the radial expansion
and plastic deformation is at least about 40% greater than the
yield point of the predetermined portion of the apparatus prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is about 1.48. In an exemplary embodiment, the predetermined
portion of the apparatus comprises a second steel alloy comprising:
0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01%
Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the
apparatus is at least about 74.4 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus after the radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the predetermined portion of the apparatus
prior to the radial expansion and plastic deformation. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the apparatus comprises a third steel
alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,
0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the apparatus, prior to
the radial expansion and plastic deformation, is about 1.92. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02%
P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is about 1.34. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus is at most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the apparatus is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus after the radial expansion
and plastic deformation is at least about 40% greater than the
yield point of the predetermined portion of the apparatus prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is at least about 1.48. In an exemplary embodiment, the yield point
of the predetermined portion of the apparatus is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the
apparatus is at least about 74.4 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus after the radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the predetermined portion of the apparatus
prior to the radial expansion and plastic deformation. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, is at least about 1.04. In an exemplary embodiment,
the anisotropy of the predetermined portion of the apparatus, prior
to the radial expansion and plastic deformation, is at least about
1.92. In an exemplary embodiment, the anisotropy of the
predetermined portion of the apparatus, prior to the radial
expansion and plastic deformation, is at least about 1.34. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, ranges from about 1.04 to about 1.92. In an exemplary
embodiment, the yield point of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary
embodiment, the expandability coefficient of the predetermined
portion of the apparatus, prior to the radial expansion and plastic
deformation, is greater than 0.12. In an exemplary embodiment, the
expandability coefficient of the predetermined portion of the
apparatus is greater than the expandability coefficient of the
other portion of the apparatus. In an exemplary embodiment, the
apparatus comprises a wellbore casing. In an exemplary embodiment,
the apparatus comprises a pipeline. In an exemplary embodiment, the
apparatus comprises a structural support.
[0791] A radially expandable tubular member apparatus has been
described that includes a first tubular member; a second tubular
member engaged with the first tubular member forming a joint; a
sleeve overlapping and coupling the first and second tubular
members at the joint; the sleeve having opposite tapered ends and a
flange engaged in a recess formed in an adjacent tubular member;
and one of the tapered ends being a surface formed on the flange;
wherein, prior to a radial expansion and plastic deformation of the
apparatus, a predetermined portion of the apparatus has a lower
yield point than another portion of the apparatus. In an exemplary
embodiment, the recess includes a tapered wall in mating engagement
with the tapered end formed on the flange. In an exemplary
embodiment, the sleeve includes a flange at each tapered end and
each tapered end is formed on a respective flange. In an exemplary
embodiment, each tubular member includes a recess. In an exemplary
embodiment, each flange is engaged in a respective one of the
recesses. In an exemplary embodiment, each recess includes a
tapered wall in mating engagement with the tapered end formed on a
respective one of the flanges. In an exemplary embodiment, the
predetermined portion of the apparatus has a higher ductility and a
lower yield point prior to the radial expansion and plastic
deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the apparatus has a higher ductility prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the apparatus has a lower yield point
prior to the radial expansion and plastic deformation than after
the radial expansion and plastic deformation. In an exemplary
embodiment, the predetermined portion of the apparatus has a larger
inside diameter after the radial expansion and plastic deformation
than other portions of the tubular assembly. In an exemplary
embodiment, the apparatus further includes positioning another
apparatus within the preexisting structure in overlapping relation
to the apparatus; and radially expanding and plastically deforming
the other apparatus within the preexisting structure; wherein,
prior to the radial expansion and plastic deformation of the
apparatus, a predetermined portion of the other apparatus has a
lower yield point than another portion of the other apparatus. In
an exemplary embodiment, the inside diameter of the radially
expanded and plastically deformed other portion of the apparatus is
equal to the inside diameter of the radially expanded and
plastically deformed other portion of the other apparatus. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises an end portion of the apparatus. In an exemplary
embodiment, the predetermined portion of the apparatus comprises a
plurality of predetermined portions of the apparatus. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises a plurality of spaced apart predetermined portions of the
apparatus. In an exemplary embodiment, the other portion of the
apparatus comprises an end portion of the apparatus. In an
exemplary embodiment, the other portion of the apparatus comprises
a plurality of other portions of the apparatus. In an exemplary
embodiment, the other portion of the apparatus comprises a
plurality of spaced apart other portions of the apparatus. In an
exemplary embodiment, the apparatus comprises a plurality of
tubular members coupled to one another by corresponding tubular
couplings. In an exemplary embodiment, the tubular couplings
comprise the predetermined portions of the apparatus; and wherein
the tubular members comprise the other portion of the apparatus. In
an exemplary embodiment, one or more of the tubular couplings
comprise the predetermined portions of the apparatus. In an
exemplary embodiment, one or more of the tubular members comprise
the predetermined portions of the apparatus. In an exemplary
embodiment, the predetermined portion of the apparatus defines one
or more openings. In an exemplary embodiment, one or more of the
openings comprise slots. In an exemplary embodiment, the anisotropy
for the predetermined portion of the apparatus is greater than 1.
In an exemplary embodiment, the anisotropy for the predetermined
portion of the apparatus is greater than 1. In an exemplary
embodiment, the strain hardening exponent for the predetermined
portion of the apparatus is greater than 0.12. In an exemplary
embodiment, the anisotropy for the predetermined portion of the
apparatus is greater than 1; and wherein the strain hardening
exponent for the predetermined portion of the apparatus is greater
than 0.12. In an exemplary embodiment, the predetermined portion of
the apparatus comprises a first steel alloy comprising: 0.065% C,
1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and
0.02% Cr. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus is at most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the apparatus is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus after the radial expansion
and plastic deformation is at least about 40% greater than the
yield point of the predetermined portion of the apparatus prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is about 1.48. In an exemplary embodiment, the predetermined
portion of the apparatus comprises a second steel alloy comprising:
0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01%
Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the
apparatus is at least about 74.4 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus after the radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the predetermined portion of the apparatus
prior to the radial expansion and plastic deformation. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the apparatus comprises a third steel
alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si,
0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the apparatus, prior to
the radial expansion and plastic deformation, is about 1.92. In an
exemplary embodiment, the predetermined portion of the apparatus
comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02%
P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is about 1.34. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus is at most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the apparatus is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the apparatus after the radial expansion
and plastic deformation is at least about 40% greater than the
yield point of the predetermined portion of the apparatus prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
is at least about 1.48. In an exemplary embodiment, the yield point
of the predetermined portion of the apparatus is at most about 57.8
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the
apparatus is at least about 74.4 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the apparatus after the radial
expansion and plastic deformation is at least about 28% greater
than the yield point of the predetermined portion of the apparatus
prior to the radial expansion and plastic deformation. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, is at least about 1.04. In an exemplary embodiment,
the anisotropy of the predetermined portion of the apparatus, prior
to the radial expansion and plastic deformation, is at least about
1.92. In an exemplary embodiment, the anisotropy of the
predetermined portion of the apparatus, prior to the radial
expansion and plastic deformation, is at least about 1.34. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the apparatus, prior to the radial expansion and plastic
deformation, ranges from about 1.04 to about 1.92. In an exemplary
embodiment, the yield point of the predetermined portion of the
apparatus, prior to the radial expansion and plastic deformation,
ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary
embodiment, the expandability coefficient of the predetermined
portion of the apparatus, prior to the radial expansion and plastic
deformation, is greater than 0.12. In an exemplary embodiment, the
expandability coefficient of the predetermined portion of the
apparatus is greater than the expandability coefficient of the
other portion of the apparatus. In an exemplary embodiment, the
apparatus comprises a wellbore casing. In an exemplary embodiment,
the apparatus comprises a pipeline. In an exemplary embodiment, the
apparatus comprises a structural support.
[0792] A method of joining radially expandable tubular members has
been provided that includes: providing a first tubular member;
engaging a second tubular member with the first tubular member to
form a joint; providing a sleeve; mounting the sleeve for
overlapping and coupling the first and second tubular members at
the joint; wherein the first tubular member, the second tubular
member, and the sleeve define a tubular assembly; and radially
expanding and plastically deforming the tubular assembly; wherein,
prior to the radial expansion and plastic deformation, a
predetermined portion of the tubular assembly has a lower yield
point than another portion of the tubular assembly. In an exemplary
embodiment, the carbon content of the predetermined portion of the
tubular assembly is less than or equal to 0.12 percent; and wherein
the carbon equivalent value for the predetermined portion of the
tubular assembly is less than 0.21. In an exemplary embodiment, the
carbon content of the predetermined portion of the tubular assembly
is greater than 0.12 percent; and wherein the carbon equivalent
value for the predetermined portion of the tubular assembly is less
than 0.36. In an exemplary embodiment, the method further includes:
maintaining portions of the first and second tubular member in
circumferential compression following a radial expansion and
plastic deformation of the first and second tubular members. In an
exemplary embodiment, the method further includes: concentrating
stresses within the joint during a radial expansion and plastic
deformation of the first and second tubular members. In an
exemplary embodiment, the method further includes: maintaining
portions of the first and second tubular member in circumferential
compression following a radial expansion and plastic deformation of
the first and second tubular members; and concentrating stresses
within the joint during a radial expansion and plastic deformation
of the first and second tubular members. In an exemplary
embodiment, the method further includes: concentrating stresses
within the joint. In an exemplary embodiment, concentrating
stresses within the joint comprises using the first tubular member
to concentrate stresses within the joint. In an exemplary
embodiment, concentrating stresses within the joint comprises using
the second tubular member to concentrate stresses within the joint.
In an exemplary embodiment, concentrating stresses within the joint
comprises using the sleeve to concentrate stresses within the
joint. In an exemplary embodiment, concentrating stresses within
the joint comprises using the first tubular member and the second
tubular member to concentrate stresses within the joint. In an
exemplary embodiment, concentrating stresses within the joint
comprises using the first tubular member and the sleeve to
concentrate stresses within the joint. In an exemplary embodiment,
concentrating stresses within the joint comprises using the second
tubular member and the sleeve to concentrate stresses within the
joint. In an exemplary embodiment, concentrating stresses within
the joint comprises using the first tubular member, the second
tubular member, and the sleeve to concentrate stresses within the
joint. In an exemplary embodiment, at least a portion of the sleeve
is comprised of a frangible material. In an exemplary embodiment,
the sleeve comprises a variable wall thickness. In an exemplary
embodiment, the method further includes maintaining the sleeve in
circumferential tension; and maintaining the first and second
tubular members in circumferential compression. In an exemplary
embodiment, the method further includes maintaining the sleeve in
circumferential tension; and maintaining the first and second
tubular members in circumferential compression. In an exemplary
embodiment, the method further includes: maintaining the sleeve in
circumferential tension; and maintaining the first and second
tubular members in circumferential compression. In an exemplary
embodiment, the method further includes: threadably coupling the
first and second tubular members at a first location; threadably
coupling the first and second tubular members at a second location
spaced apart from the first location; providing a plurality of
sleeves; and mounting the sleeves at spaced apart locations for
overlapping and coupling the first and second tubular members. In
an exemplary embodiment, at least one of the tubular sleeves is
positioned in opposing relation to the first threaded coupling; and
wherein at least one of the tubular sleeves is positioned in
opposing relation to the second threaded coupling. In an exemplary
embodiment, at least one of the tubular sleeves is not positioned
in opposing relation to the first and second threaded couplings. In
an exemplary embodiment, the method further includes: threadably
coupling the first and second tubular members; and upsetting the
threaded coupling. In an exemplary embodiment, the first tubular
member further comprises an annular extension extending therefrom;
and wherein the flange of the sleeve defines an annular recess for
receiving and mating with the annular extension of the first
tubular member. In an exemplary embodiment, the predetermined
portion of the tubular assembly has a higher ductility and a lower
yield point prior to the radial expansion and plastic deformation
than after the radial expansion and plastic deformation. In an
exemplary embodiment, the predetermined portion of the tubular
assembly has a higher ductility prior to the radial expansion and
plastic deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the tubular assembly has a lower yield point prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the tubular assembly has a larger inside
diameter after the radial expansion and plastic deformation than
the other portion of the tubular assembly. In an exemplary
embodiment, the method further includes: positioning another
tubular assembly within the preexisting structure in overlapping
relation to the tubular assembly; and radially expanding and
plastically deforming the other tubular assembly within the
preexisting structure; wherein, prior to the radial expansion and
plastic deformation of the tubular assembly, a predetermined
portion of the other tubular assembly has a lower yield point than
another portion of the other tubular assembly. In an exemplary
embodiment, the inside diameter of the radially expanded and
plastically deformed other portion of the tubular assembly is equal
to the inside diameter of the radially expanded and plastically
deformed other portion of the other tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly comprises an end portion of the tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly comprises a plurality of predetermined portions of the
tubular assembly. In an exemplary embodiment, the predetermined
portion of the tubular assembly comprises a plurality of spaced
apart predetermined portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
comprises an end portion of the tubular assembly. In an exemplary
embodiment, the other portion of the tubular assembly comprises a
plurality of other portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
comprises a plurality of spaced apart other portions of the tubular
assembly. In an exemplary embodiment, the tubular assembly
comprises a plurality of tubular members coupled to one another by
corresponding tubular couplings. In an exemplary embodiment, the
tubular couplings comprise the predetermined portions of the
tubular assembly; and wherein the tubular members comprise the
other portion of the tubular assembly. In an exemplary embodiment,
one or more of the tubular couplings comprise the predetermined
portions of the tubular assembly. In an exemplary embodiment, one
or more of the tubular members comprise the predetermined portions
of the tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly defines one or more
openings. In an exemplary embodiment, one or more of the openings
comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In
an exemplary embodiment, the anisotropy for the predetermined
portion of the tubular assembly is greater than 1. In an exemplary
embodiment, the strain hardening exponent for the predetermined
portion of the tubular assembly is greater than 0.12. In an
exemplary embodiment, the anisotropy for the predetermined portion
of the tubular assembly is greater than 1; and wherein the strain
hardening exponent for the predetermined portion of the tubular
assembly is greater than 0.12. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a first
steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S,
0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 46.9 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
65.9 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 40% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.48. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a second
steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a third
steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,
0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.92. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a fourth
steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45%
Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the tubular assembly,
prior to the radial expansion and plastic deformation, is about
1.34. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly is at most about 46.9
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the tubular
assembly is at least about 65.9 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the tubular assembly after the radial
expansion and plastic deformation is at least about 40% greater
than the yield point of the predetermined portion of the tubular
assembly prior to the radial expansion and plastic deformation. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is at least about 1.48. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is at least about 1.04. In an exemplary embodiment,
the anisotropy of the predetermined portion of the tubular
assembly, prior to the radial expansion and plastic deformation, is
at least about 1.92. In an exemplary embodiment, the anisotropy of
the predetermined portion of the tubular assembly, prior to the
radial expansion and plastic deformation, is at least about 1.34.
In an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, ranges from about 1.04 to about 1.92. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly, prior to the radial expansion and plastic
deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly, prior to the radial
expansion and plastic deformation, is greater than 0.12. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly is greater than the
expandability coefficient of the other portion of the tubular
assembly. In an exemplary embodiment, the tubular assembly
comprises a wellbore casing. In an exemplary embodiment, the
tubular assembly comprises a pipeline. In an exemplary embodiment,
the tubular assembly comprises a structural support.
[0793] A method of joining radially expandable tubular members has
been described that includes: providing a first tubular member;
engaging a second tubular member with the first tubular member to
form a joint; providing a sleeve having opposite tapered ends and a
flange, one of the tapered ends being a surface formed on the
flange; mounting the sleeve for overlapping and coupling the first
and second tubular members at the joint, wherein the flange is
engaged in a recess formed in an adjacent one of the tubular
members; wherein the first tubular member, the second tubular
member, and the sleeve define a tubular assembly; and radially
expanding and plastically deforming the tubular assembly; wherein,
prior to the radial expansion and plastic deformation, a
predetermined portion of the tubular assembly has a lower yield
point than another portion of the tubular assembly. In an exemplary
embodiment, the method further includes: providing a tapered wall
in the recess for mating engagement with the tapered end formed on
the flange. In an exemplary embodiment, the method further
includes: providing a flange at each tapered end wherein each
tapered end is formed on a respective flange. In an exemplary
embodiment, the method further includes: providing a recess in each
tubular member. In an exemplary embodiment, the method further
includes: engaging each flange in a respective one of the recesses.
In an exemplary embodiment, the method further includes: providing
a tapered wall in each recess for mating engagement with the
tapered end formed on a respective one of the flanges. In an
exemplary embodiment, the predetermined portion of the tubular
assembly has a higher ductility and a lower yield point prior to
the radial expansion and plastic deformation than after the radial
expansion and plastic deformation. In an exemplary embodiment, the
predetermined portion of the tubular assembly has a higher
ductility prior to the radial expansion and plastic deformation
than after the radial expansion and plastic deformation. In an
exemplary embodiment, the predetermined portion of the tubular
assembly has a lower yield point prior to the radial expansion and
plastic deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the tubular assembly has a larger inside diameter after the
radial expansion and plastic deformation than the other portion of
the tubular assembly. In an exemplary embodiment, the method
further includes: positioning another tubular assembly within the
preexisting structure in overlapping relation to the tubular
assembly; and radially expanding and plastically deforming the
other tubular assembly within the preexisting structure; wherein,
prior to the radial expansion and plastic deformation of the
tubular assembly, a predetermined portion of the other tubular
assembly has a lower yield point than another portion of the other
tubular assembly. In an exemplary embodiment, the inside diameter
of the radially expanded and plastically deformed other portion of
the tubular assembly is equal to the inside diameter of the
radially expanded and plastically deformed other portion of the
other tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises an end
portion of the tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a plurality
of predetermined portions of the tubular assembly. In an exemplary
embodiment, the predetermined portion of the tubular assembly
comprises a plurality of spaced apart predetermined portions of the
tubular assembly. In an exemplary embodiment, the other portion of
the tubular assembly comprises an end portion of the tubular
assembly. In an exemplary embodiment, the other portion of the
tubular assembly comprises a plurality of other portions of the
tubular assembly. In an exemplary embodiment, the other portion of
the tubular assembly comprises a plurality of spaced apart other
portions of the tubular assembly. In an exemplary embodiment, the
tubular assembly comprises a plurality of tubular members coupled
to one another by corresponding tubular couplings. In an exemplary
embodiment, the tubular couplings comprise the predetermined
portions of the tubular assembly; and wherein the tubular members
comprise the other portion of the tubular assembly. In an exemplary
embodiment, one or more of the tubular couplings comprise the
predetermined portions of the tubular assembly. In an exemplary
embodiment, one or more of the tubular members comprise the
predetermined portions of the tubular assembly. In an exemplary
embodiment, the predetermined portion of the tubular assembly
defines one or more openings. In an exemplary embodiment, one or
more of the openings comprise slots. In an exemplary embodiment,
the anisotropy for the predetermined portion of the tubular
assembly is greater than 1. In an exemplary embodiment, the
anisotropy for the predetermined portion of the tubular assembly is
greater than 1. In an exemplary embodiment, the strain hardening
exponent for the predetermined portion of the tubular assembly is
greater than 0.12. In an exemplary embodiment, the anisotropy for
the predetermined portion of the tubular assembly is greater than
1; and wherein the strain hardening exponent for the predetermined
portion of the tubular assembly is greater than 0.12. In an
exemplary embodiment, the predetermined portion of the tubular
assembly comprises a first steel alloy comprising: 0.065% C, 1.44%
Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
In an exemplary embodiment, the yield point of the predetermined
portion of the tubular assembly is at most about 46.9 ksi prior to
the radial expansion and plastic deformation; and wherein the yield
point of the predetermined portion of the tubular assembly is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly after the radial
expansion and plastic deformation is at least about 40% greater
than the yield point of the predetermined portion of the tubular
assembly prior to the radial expansion and plastic deformation. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is about 1.48. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a second
steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a third
steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,
0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.92. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a fourth
steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45%
Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the tubular assembly,
prior to the radial expansion and plastic deformation, is about
1.34. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly is at most about 46.9
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the tubular
assembly is at least about 65.9 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the tubular assembly after the radial
expansion and plastic deformation is at least about 40% greater
than the yield point of the predetermined portion of the tubular
assembly prior to the radial expansion and plastic deformation. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is at least about 1.48. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is at least about 1.04. In an exemplary embodiment,
the anisotropy of the predetermined portion of the tubular
assembly, prior to the radial expansion and plastic deformation, is
at least about 1.92. In an exemplary embodiment, the anisotropy of
the predetermined portion of the tubular assembly, prior to the
radial expansion and plastic deformation, is at least about 1.34.
In an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, ranges from about 1.04 to about 1.92. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly, prior to the radial expansion and plastic
deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly, prior to the radial
expansion and plastic deformation, is greater than 0.12. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly is greater than the
expandability coefficient of the other portion of the tubular
assembly. In an exemplary embodiment, the tubular assembly
comprises a wellbore casing. In an exemplary embodiment, the
tubular assembly comprises a pipeline. In an exemplary embodiment,
the tubular assembly comprises a structural support.
[0794] An expandable tubular assembly has been described that
includes a first tubular member; a second tubular member coupled to
the first tubular member; a first threaded connection for coupling
a portion of the first and second tubular members; a second
threaded connection spaced apart from the first threaded connection
for coupling another portion of the first and second tubular
members; a tubular sleeve coupled to and receiving end portions of
the first and second tubular members; and a sealing element
positioned between the first and second spaced apart threaded
connections for sealing an interface between the first and second
tubular member; wherein the sealing element is positioned within an
annulus defined between the first and second tubular members; and
wherein, prior to a radial expansion and plastic deformation of the
assembly, a predetermined portion of the assembly has a lower yield
point than another portion of the apparatus. In an exemplary
embodiment, the predetermined portion of the assembly has a higher
ductility and a lower yield point prior to the radial expansion and
plastic deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the assembly has a higher ductility prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the assembly has a lower yield point prior
to the radial expansion and plastic deformation than after the
radial expansion and plastic deformation. In an exemplary
embodiment, the predetermined portion of the assembly has a larger
inside diameter after the radial expansion and plastic deformation
than other portions of the tubular assembly. In an exemplary
embodiment, the assembly further includes: positioning another
assembly within the preexisting structure in overlapping relation
to the assembly; and radially expanding and plastically deforming
the other assembly within the preexisting structure; wherein, prior
to the radial expansion and plastic deformation of the assembly, a
predetermined portion of the other assembly has a lower yield point
than another portion of the other assembly. In an exemplary
embodiment, the inside diameter of the radially expanded and
plastically deformed other portion of the assembly is equal to the
inside diameter of the radially expanded and plastically deformed
other portion of the other assembly. In an exemplary embodiment,
the predetermined portion of the assembly comprises an end portion
of the assembly. In an exemplary embodiment, the predetermined
portion of the assembly comprises a plurality of predetermined
portions of the assembly. In an exemplary embodiment, the
predetermined portion of the assembly comprises a plurality of
spaced apart predetermined portions of the assembly. In an
exemplary embodiment, the other portion of the assembly comprises
an end portion of the assembly. In an exemplary embodiment, the
other portion of the assembly comprises a plurality of other
portions of the assembly. In an exemplary embodiment, the other
portion of the assembly comprises a plurality of spaced apart other
portions of the assembly. In an exemplary embodiment, the assembly
comprises a plurality of tubular members coupled to one another by
corresponding tubular couplings. In an exemplary embodiment, the
tubular couplings comprise the predetermined portions of the
assembly; and wherein the tubular members comprise the other
portion of the assembly. In an exemplary embodiment, one or more of
the tubular couplings comprise the predetermined portions of the
assembly. In an exemplary embodiment, one or more of the tubular
members comprise the predetermined portions of the assembly. In an
exemplary embodiment, the predetermined portion of the assembly
defines one or more openings. In an exemplary embodiment, one or
more of the openings comprise slots. In an exemplary embodiment,
the anisotropy for the predetermined portion of the assembly is
greater than 1. In an exemplary embodiment, the anisotropy for the
predetermined portion of the assembly is greater than 1. In an
exemplary embodiment, the strain hardening exponent for the
predetermined portion of the assembly is greater than 0.12. In an
exemplary embodiment, the anisotropy for the predetermined portion
of the assembly is greater than 1; and wherein the strain hardening
exponent for the predetermined portion of the assembly is greater
than 0.12. In an exemplary embodiment, the predetermined portion of
the assembly comprises a first steel alloy comprising: 0.065% C,
1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and
0.02% Cr. In an exemplary embodiment, the yield point of the
predetermined portion of the assembly is at most about 46.9 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the assembly is at
least about 65.9 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the assembly after the radial expansion
and plastic deformation is at least about 40% greater than the
yield point of the predetermined portion of the assembly prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
assembly, prior to the radial expansion and plastic deformation, is
about 1.48. In an exemplary embodiment, the predetermined portion
of the assembly comprises a second steel alloy comprising: 0.18% C,
1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and
0.03% Cr. In an exemplary embodiment, the yield point of the
predetermined portion of the assembly is at most about 57.8 ksi
prior to the radial expansion and plastic deformation; and wherein
the yield point of the predetermined portion of the assembly is at
least about 74.4 ksi after the radial expansion and plastic
deformation. In an exemplary embodiment, the yield point of the
predetermined portion of the assembly after the radial expansion
and plastic deformation is at least about 28% greater than the
yield point of the predetermined portion of the assembly prior to
the radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
assembly, prior to the radial expansion and plastic deformation, is
about 1.04. In an exemplary embodiment, the predetermined portion
of the assembly comprises a third steel alloy comprising: 0.08% C,
0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and
0.05% Cr. In an exemplary embodiment, the anisotropy of the
predetermined portion of the assembly, prior to the radial
expansion and plastic deformation, is about 1.92. In an exemplary
embodiment, the predetermined portion of the assembly comprises a
fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001%
S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the assembly, prior to
the radial expansion and plastic deformation, is about 1.34. In an
exemplary embodiment, the yield point of the predetermined portion
of the assembly is at most about 46.9 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the assembly is at least about 65.9
ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the assembly after the radial expansion and plastic deformation
is at least about 40% greater than the yield point of the
predetermined portion of the assembly prior to the radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy
of the predetermined portion of the assembly, prior to the radial
expansion and plastic deformation, is at least about 1.48. In an
exemplary embodiment, the yield point of the predetermined portion
of the assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the assembly is at least about 74.4
ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the assembly after the radial expansion and plastic deformation
is at least about 28% greater than the yield point of the
predetermined portion of the assembly prior to the radial expansion
and plastic deformation. In an exemplary embodiment, the anisotropy
of the predetermined portion of the assembly, prior to the radial
expansion and plastic deformation, is at least about 1.04. In an
exemplary embodiment, the anisotropy of the predetermined portion
of the assembly, prior to the radial expansion and plastic
deformation, is at least about 1.92. In an exemplary embodiment,
the anisotropy of the predetermined portion of the assembly, prior
to the radial expansion and plastic deformation, is at least about
1.34. In an exemplary embodiment, the anisotropy of the
predetermined portion of the assembly, prior to the radial
expansion and plastic deformation, ranges from about 1.04 to about
1.92. In an exemplary embodiment, the yield point of the
predetermined portion of the assembly, prior to the radial
expansion and plastic deformation, ranges from about 47.6 ksi to
about 61.7 ksi. In an exemplary embodiment, the expandability
coefficient of the predetermined portion of the assembly, prior to
the radial expansion and plastic deformation, is greater than 0.12.
In an exemplary embodiment, the expandability coefficient of the
predetermined portion of the assembly is greater than the
expandability coefficient of the other portion of the assembly. In
an exemplary embodiment, the assembly comprises a wellbore casing.
In an exemplary embodiment, the assembly comprises a pipeline. In
an exemplary embodiment, the assembly comprises a structural
support. In an exemplary embodiment, the annulus is at least
partially defined by an irregular surface. In an exemplary
embodiment, the annulus is at least partially defined by a toothed
surface. In an exemplary embodiment, the sealing element comprises
an elastomeric material. In an exemplary embodiment, the sealing
element comprises a metallic material. In an exemplary embodiment,
the sealing element comprises an elastomeric and a metallic
material.
[0795] A method of joining radially expandable tubular members is
provided that includes providing a first tubular member; providing
a second tubular member; providing a sleeve; mounting the sleeve
for overlapping and coupling the first and second tubular members;
threadably coupling the first and second tubular members at a first
location; threadably coupling the first and second tubular members
at a second location spaced apart from the first location; sealing
an interface between the first and second tubular members between
the first and second locations using a compressible sealing
element, wherein the first tubular member, second tubular member,
sleeve, and the sealing element define a tubular assembly; and
radially expanding and plastically deforming the tubular assembly;
wherein, prior to the radial expansion and plastic deformation, a
predetermined portion of the tubular assembly has a lower yield
point than another portion of the tubular assembly. In an exemplary
embodiment, the sealing element includes an irregular surface. In
an exemplary embodiment, the sealing element includes a toothed
surface. In an exemplary embodiment, the sealing element comprises
an elastomeric material. In an exemplary embodiment, the sealing
element comprises a metallic material. In an exemplary embodiment,
the sealing element comprises an elastomeric and a metallic
material. In an exemplary embodiment, the predetermined portion of
the tubular assembly has a higher ductility and a lower yield point
prior to the radial expansion and plastic deformation than after
the radial expansion and plastic deformation. In an exemplary
embodiment, the predetermined portion of the tubular assembly has a
higher ductility prior to the radial expansion and plastic
deformation than after the radial expansion and plastic
deformation. In an exemplary embodiment, the predetermined portion
of the tubular assembly has a lower yield point prior to the radial
expansion and plastic deformation than after the radial expansion
and plastic deformation. In an exemplary embodiment, the
predetermined portion of the tubular assembly has a larger inside
diameter after the radial expansion and plastic deformation than
the other portion of the tubular assembly. In an exemplary
embodiment, the method further includes: positioning another
tubular assembly within the preexisting structure in overlapping
relation to the tubular assembly; and radially expanding and
plastically deforming the other tubular assembly within the
preexisting structure; wherein, prior to the radial expansion and
plastic deformation of the tubular assembly, a predetermined
portion of the other tubular assembly has a lower yield point than
another portion of the other tubular assembly. In an exemplary
embodiment, the inside diameter of the radially expanded and
plastically deformed other portion of the tubular assembly is equal
to the inside diameter of the radially expanded and plastically
deformed other portion of the other tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly comprises an end portion of the tubular assembly. In an
exemplary embodiment, the predetermined portion of the tubular
assembly comprises a plurality of predetermined portions of the
tubular assembly. In an exemplary embodiment, the predetermined
portion of the tubular assembly comprises a plurality of spaced
apart predetermined portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
comprises an end portion of the tubular assembly. In an exemplary
embodiment, the other portion of the tubular assembly comprises a
plurality of other portions of the tubular assembly. In an
exemplary embodiment, the other portion of the tubular assembly
comprises a plurality of spaced apart other portions of the tubular
assembly. In an exemplary embodiment, the tubular assembly
comprises a plurality of tubular members coupled to one another by
corresponding tubular couplings. In an exemplary embodiment, the
tubular couplings comprise the predetermined portions of the
tubular assembly; and wherein the tubular members comprise the
other portion of the tubular assembly. In an exemplary embodiment,
one or more of the tubular couplings comprise the predetermined
portions of the tubular assembly. In an exemplary embodiment, one
or more of the tubular members comprise the predetermined portions
of the tubular assembly. In an exemplary embodiment, the
predetermined portion of the tubular assembly defines one or more
openings. In an exemplary embodiment, one or more of the openings
comprise slots. In an exemplary embodiment, the anisotropy for the
predetermined portion of the tubular assembly is greater than 1. In
an exemplary embodiment, the anisotropy for the predetermined
portion of the tubular assembly is greater than 1. In an exemplary
embodiment, the strain hardening exponent for the predetermined
portion of the tubular assembly is greater than 0.12. In an
exemplary embodiment, the anisotropy for the predetermined portion
of the tubular assembly is greater than 1; and wherein the strain
hardening exponent for the predetermined portion of the tubular
assembly is greater than 0.12. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a first
steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S,
0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 46.9 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
65.9 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 40% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.48. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a second
steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.04. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a third
steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S,
0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is about 1.92. In an exemplary embodiment, the
predetermined portion of the tubular assembly comprises a fourth
steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45%
Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the
anisotropy of the predetermined portion of the tubular assembly,
prior to the radial expansion and plastic deformation, is about
1.34. In an exemplary embodiment, the yield point of the
predetermined portion of the tubular assembly is at most about 46.9
ksi prior to the radial expansion and plastic deformation; and
wherein the yield point of the predetermined portion of the tubular
assembly is at least about 65.9 ksi after the radial expansion and
plastic deformation. In an exemplary embodiment, the yield point of
the predetermined portion of the tubular assembly after the radial
expansion and plastic deformation is at least about 40% greater
than the yield point of the predetermined portion of the tubular
assembly prior to the radial expansion and plastic deformation. In
an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, is at least about 1.48. In an exemplary
embodiment, the yield point of the predetermined portion of the
tubular assembly is at most about 57.8 ksi prior to the radial
expansion and plastic deformation; and wherein the yield point of
the predetermined portion of the tubular assembly is at least about
74.4 ksi after the radial expansion and plastic deformation. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly after the radial expansion and plastic
deformation is at least about 28% greater than the yield point of
the predetermined portion of the tubular assembly prior to the
radial expansion and plastic deformation. In an exemplary
embodiment, the anisotropy of the predetermined portion of the
tubular assembly, prior to the radial expansion and plastic
deformation, is at least about 1.04. In an exemplary embodiment,
the anisotropy of the predetermined portion of the tubular
assembly, prior to the radial expansion and plastic deformation, is
at least about 1.92. In an exemplary embodiment, the anisotropy of
the predetermined portion of the tubular assembly, prior to the
radial expansion and plastic deformation, is at least about 1.34.
In an exemplary embodiment, the anisotropy of the predetermined
portion of the tubular assembly, prior to the radial expansion and
plastic deformation, ranges from about 1.04 to about 1.92. In an
exemplary embodiment, the yield point of the predetermined portion
of the tubular assembly, prior to the radial expansion and plastic
deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly, prior to the radial
expansion and plastic deformation, is greater than 0.12. In an
exemplary embodiment, the expandability coefficient of the
predetermined portion of the tubular assembly is greater than the
expandability coefficient of the other portion of the tubular
assembly. In an exemplary embodiment, the tubular assembly
comprises a wellbore casing. In an exemplary embodiment, the
tubular assembly comprises a pipeline. In an exemplary embodiment,
the tubular assembly comprises a structural support. In an
exemplary embodiment, the sleeve comprises: a plurality of spaced
apart tubular sleeves coupled to and receiving end portions of the
first and second tubular members. In an exemplary embodiment, the
first tubular member comprises a first threaded connection; wherein
the second tubular member comprises a second threaded connection;
wherein the first and second threaded connections are coupled to
one another; wherein at least one of the tubular sleeves is
positioned in opposing relation to the first threaded connection;
and wherein at least one of the tubular sleeves is positioned in
opposing relation to the second threaded connection. In an
exemplary embodiment, the first tubular member comprises a first
threaded connection; wherein the second tubular member comprises a
second threaded connection; wherein the first and second threaded
connections are coupled to one another; and wherein at least one of
the tubular sleeves is not positioned in opposing relation to the
first and second threaded connections. In an exemplary embodiment,
the carbon content of the tubular member is less than or equal to
0.12 percent; and wherein the carbon equivalent value for the
tubular member is less than 0.21. In an exemplary embodiment, the
tubular member comprises a wellbore casing.
[0796] An expandable tubular member has been described, wherein the
carbon content of the tubular member is greater than 0.12 percent;
and wherein the carbon equivalent value for the tubular member is
less than 0.36. In an exemplary embodiment, the tubular member
comprises a wellbore casing.
[0797] A method of selecting tubular members for radial expansion
and plastic deformation has been described that includes: selecting
a tubular member from a collection of tubular member; determining a
carbon content of the selected tubular member; determining a carbon
equivalent value for the selected tubular member; and if the carbon
content of the selected tubular member is less than or equal to
0.12 percent and the carbon equivalent value for the selected
tubular member is less than 0.21, then determining that the
selected tubular member is suitable for radial expansion and
plastic deformation.
[0798] A method of selecting tubular members for radial expansion
and plastic deformation has been described that includes: selecting
a tubular member from a collection of tubular member; determining a
carbon content of the selected tubular member; determining a carbon
equivalent value for the selected tubular member; and if the carbon
content of the selected tubular member is greater than 0.12 percent
and the carbon equivalent value for the selected tubular member is
less than 0.36, then determining that the selected tubular member
is suitable for radial expansion and plastic deformation.
[0799] An expandable tubular member has been described that
includes: a tubular body; wherein a yield point of an inner tubular
portion of the tubular body is less than a yield point of an outer
tubular portion of the tubular body. In an exemplary embodiment,
the yield point of the inner tubular portion of the tubular body
varies as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the inner
tubular portion of the tubular body varies in an linear fashion as
a function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies in an non-linear fashion as a function
of the radial position within the tubular body. In an exemplary
embodiment, the yield point of the outer tubular portion of the
tubular body varies as a function of the radial position within the
tubular body. In an exemplary embodiment, the yield point of the
outer tubular portion of the tubular body varies in an linear
fashion as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the outer
tubular portion of the tubular body varies in an non-linear fashion
as a function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies as a function of the radial position
within the tubular body; and wherein the yield point of the outer
tubular portion of the tubular body varies as a function of the
radial position within the tubular body. In an exemplary
embodiment, the yield point of the inner tubular portion of the
tubular body varies in a linear fashion as a function of the radial
position within the tubular body; and wherein the yield point of
the outer tubular portion of the tubular body varies in a linear
fashion as a function of the radial position within the tubular
body. In an exemplary embodiment, the yield point of the inner
tubular portion of the tubular body varies in a linear fashion as a
function of the radial position within the tubular body; and
wherein the yield point of the outer tubular portion of the tubular
body varies in a non-linear fashion as a function of the radial
position within the tubular body. In an exemplary embodiment, the
yield point of the inner tubular portion of the tubular body varies
in a non-linear fashion as a function of the radial position within
the tubular body; and wherein the yield point of the outer tubular
portion of the tubular body varies in a linear fashion as a
function of the radial position within the tubular body. In an
exemplary embodiment, the yield point of the inner tubular portion
of the tubular body varies in a non-linear fashion as a function of
the radial position within the tubular body; and wherein the yield
point of the outer tubular portion of the tubular body varies in a
non-linear fashion as a function of the radial position within the
tubular body. In an exemplary embodiment, the rate of change of the
yield point of the inner tubular portion of the tubular body is
different than the rate of change of the yield point of the outer
tubular portion of the tubular body. In an exemplary embodiment,
the rate of change of the yield point of the inner tubular portion
of the tubular body is different than the rate of change of the
yield point of the outer tubular portion of the tubular body.
[0800] A method of manufacturing an expandable tubular member has
been described that includes: providing a tubular member; heat
treating the tubular member; and quenching the tubular member;
wherein following the quenching, the tubular member comprises a
microstructure comprising a hard phase structure and a soft phase
structure. In an exemplary embodiment, the provided tubular member
comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P,
0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01%
Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the
provided tubular member comprises, by weight percentage, 0.18% C,
1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03%
Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary
embodiment, the provided tubular member comprises, by weight
percentage, 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06%
Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.
In an exemplary embodiment, the provided tubular member comprises a
microstructure comprising one or more of the following: martensite,
pearlite, vanadium carbide, nickel carbide, or titanium carbide. In
an exemplary embodiment, the provided tubular member comprises a
microstructure comprising one or more of the following: pearlite or
pearlite striation. In an exemplary embodiment, the provided
tubular member comprises a microstructure comprising one or more of
the following: grain pearlite, widmanstatten martensite, vanadium
carbide, nickel carbide, or titanium carbide. In an exemplary
embodiment, the heat treating comprises heating the provided
tubular member for about 10 minutes at 790.degree. C. In an
exemplary embodiment, the quenching comprises quenching the heat
treated tubular member in water. In an exemplary embodiment,
following the quenching, the tubular member comprises a
microstructure comprising one or more of the following: ferrite,
grain pearlite, or martensite. In an exemplary embodiment,
following the quenching, the tubular member comprises a
microstructure comprising one or more of the following: ferrite,
martensite, or bainite. In an exemplary embodiment, following the
quenching, the tubular member comprises a microstructure comprising
one or more of the following: bainite, pearlite, or ferrite. In an
exemplary embodiment, following the quenching, the tubular member
comprises a yield strength of about 67 ksi and a tensile strength
of about 95 ksi. In an exemplary embodiment, following the
quenching, the tubular member comprises a yield strength of about
82 ksi and a tensile strength of about 130 ksi. In an exemplary
embodiment, following the quenching, the tubular member comprises a
yield strength of about 60 ksi and a tensile strength of about 97
ksi. In an exemplary embodiment, the method further includes:
positioning the quenched tubular member within a preexisting
structure; and radially expanding and plastically deforming the
tubular member within the preexisting structure.
[0801] A system for radially expanding and plastically deforming a
tubular member has been described that includes an expansion device
positioned in the tubular member, wherein the coefficient of
friction between the expansion device and the tubular member during
radial expansion and plastic deformation is less than 0.08. In an
exemplary embodiment, the coefficient of friction is in the range
of 0.02 to 0.05. In an exemplary embodiment, the system includes a
lubricant between the tubular member and the expansion device. In
an exemplary embodiment, the lubricant includes oil based
lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil,
grease, water based lubricants, drilling mud, drilling mud and
solid lubricants, grease combined with a solid lubricant, at least
10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the system includes a coating on the expansion device.
In an exemplary embodiment, the coating may be Phygen film. In an
exemplary embodiment, the system includes a coating on the tubular
member. In an exemplary embodiment, the coating on the tubular
member includes PTFE, PTFE based or graphite based. In an exemplary
embodiment, the expansion device includes DC53 material, DC2
material, DC3 material, DC5 material, DC7 material, M2 material,
CPM M4 material, 10V material, 3V material. In an exemplary
embodiment, the expansion device includes an REM finish, a
processed finish, or a relatively smooth surface roughness. In an
exemplary embodiment, the expansion device includes a relatively
smooth surface roughness and includes relatively evenly space oil
pockets. In an exemplary embodiment, the expansion device includes
a smooth surface roughness in the range of 0.02 to 0.1 micrometers
In an exemplary embodiment, the lubricant is injected through at
least a portion of the expansion device between the tubular member
and the expansion device. In an exemplary embodiment, the lubricant
is injected through at least a portion of the expansion device
between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
lubricant is injected through at least two portions of the
expansion device between the tubular member and the expansion
device at two different pressures. In an exemplary embodiment, the
expansion device includes a tapered portion with an outer surface,
internal flow passage in the tapered portion and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
30 degrees. In an exemplary embodiment, the expansion device
includes a tapered portion with an outer surface, internal flow
passage in the tapered portion, and at least one circumferential
groove having a first edge and a second edge having with a sliding
angle on the outer surface of the tapered portion fluidicly coupled
to the internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 10 degrees. In an
exemplary embodiment, the system includes a lubricant between the
tubular member and the expansion device, comprising at least nine
components selected from the group consisting of: a base oil; metal
deactivator; antioxidants; sulfurized natural oils; phosphate
ester; phosphoric acid; viscosity modifier; pour-point depressant;
defoamer; and carboxylic acid soaps. In an exemplary embodiment,
the expansion device includes, a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the tubular member has a non-uniform wall thickness and
the expansion device includes a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the lubricant is stored in a reservoir with electrodes
that are electrically coupled a capacitor in the expansion device
and is injected through at least a portion of the expansion device
between the tubular member and the expansion device when the
capacitors discharges. In an exemplary embodiment, the expansion
device includes a wellbore casing, a pipeline, or a structural
support. In an exemplary embodiment, the expansion device includes
expansion cone.
[0802] A method of radially expanding and plastically deforming a
tubular member has been described that includes positioning an
expansion device having a first tapered end and a second end at
least partially within the tubular member, displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, and wherein the coefficient
of friction between the expansion device and the tubular member
during radial expansion and plastic deformation is less than 0.08.
In an exemplary embodiment, the coefficient of friction is in the
range of 0.02 to 0.05. In an exemplary embodiment, the method
includes injecting lubricant between the tubular member and the
expansion device. In an exemplary embodiment, the lubricant
includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5
oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud,
drilling mud and solid lubricants, grease combined with a solid
lubricant, at least 10% Graphite, or at least 10% Molybdenum
Disulfide. In an exemplary embodiment, the method includes applying
a coating on the expansion device prior to positioning within the
tubular member. In an exemplary embodiment, the coating may be
Phygen film. In an exemplary embodiment, the method includes
applying a coating on the tubular member prior to positioning the
expansion device within the tubular member. In an exemplary
embodiment, the coating on the tubular member includes PTFE, PTFE
based or graphite based. In an exemplary embodiment, the expansion
device includes DC53 material, DC2 material, DC3 material, DC5
material, DC7 material, M2 material, CPM M4 material, 10V material,
3V material. In an exemplary embodiment, the expansion device
includes an REM finish, a processed finish, or a relatively smooth
surface roughness. In an exemplary embodiment, the expansion device
includes a relatively smooth surface roughness and includes
relatively evenly space oil pockets. In an exemplary embodiment,
the expansion device includes a smooth surface roughness in the
range of 0.02 to 0.1 micrometers In an exemplary embodiment, the
method includes injecting lubricant through at least a portion of
the expansion device between the tubular member and the expansion
device. In an exemplary embodiment, the method includes injecting
lubricant through at least a portion of the expansion device
between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
method includes injecting lubricant through at least two portions
of the expansion device between the tubular member and the
expansion device at two different pressures. In an exemplary
embodiment, the expansion device includes a tapered portion with an
outer surface, internal flow passage in the tapered portion and at
least one circumferential groove having a first edge and a second
edge having with a sliding angle on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the sliding angle is less than or
equal to 30 degrees. In an exemplary embodiment, the expansion
device includes a tapered portion with an outer surface, internal
flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the method includes
injecting lubricant between the tubular member and the expansion
device, comprising at least nine components selected from the group
consisting of: a base oil; metal deactivator; antioxidants;
sulfurized natural oils; phosphate ester; phosphoric acid;
viscosity modifier; pour-point depressant; defoamer; and carboxylic
acid soaps. In an exemplary embodiment, the expansion device
includes a tapered portion having a tapered faceted polygonal outer
expansion surface. In an exemplary embodiment, the expansion device
includes, a tapered portion having a tapered faceted polygonal
outer expansion surface. In an exemplary embodiment, the tubular
member has a non-uniform wall thickness and the expansion device
includes a tapered portion having a tapered faceted polygonal outer
expansion surface. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges. In an
exemplary embodiment, the expansion device includes a wellbore
casing, a pipeline, or a structural support. In an exemplary
embodiment, the expansion device includes expansion cone.
[0803] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member and means
for displacing the expansion device relative to the tubular member
to radially expand and plastically deform the tubular member,
wherein the coefficient of friction between the expansion device
and the tubular member during radial expansion and plastic
deformation is less than 0.08. In an exemplary embodiment, the
coefficient of friction is in the range of 0.02 to 0.05. In an
exemplary embodiment, the system, includes a means for injecting
lubricant between the tubular member and the expansion device. In
an exemplary embodiment, the lubricant includes oil based
lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil,
grease, water based lubricants, drilling mud, drilling mud and
solid lubricants, grease combined with a solid lubricant, at least
10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the system includes a means for applying a coating on
the expansion device prior to positioning within the tubular
member. In an exemplary embodiment, the coating may be Phygen film.
In an exemplary embodiment, the method includes applying a coating
on the tubular member prior to positioning the expansion device
within the tubular member. In an exemplary embodiment, the coating
on the tubular member includes PTFE, PTFE based or graphite based.
In an exemplary embodiment, the expansion device includes DC53
material, DC2 material, DC3 material, DC5 material, DC7 material,
M2 material, CPM M4 material, 10V material, 3V material. In an
exemplary embodiment, the expansion device includes an REM finish,
a processed finish, or a relatively smooth surface roughness. In an
exemplary embodiment, the expansion device includes a relatively
smooth surface roughness and includes relatively evenly space oil
pockets. In an exemplary embodiment, the expansion device includes
a smooth surface roughness in the range of 0.02 to 0.1 micrometers
In an exemplary embodiment, the system includes a means for
injecting lubricant through at least a portion of the expansion
device between the tubular member and the expansion device. In an
exemplary embodiment, the system includes a means for injecting
lubricant through at least a portion of the expansion device
between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
system includes a means for injecting lubricant through at least
two portions of the expansion device between the tubular member and
the expansion device at two different pressures. In an exemplary
embodiment, the expansion device includes a tapered portion with an
outer surface, internal flow passage in the tapered portion and at
least one circumferential groove having a first edge and a second
edge having with a sliding angle on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the sliding angle is less than or
equal to 30 degrees. In an exemplary embodiment, the expansion
device includes a tapered portion with an outer surface, internal
flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the system includes a means
for injecting lubricant between the tubular member and the
expansion device, comprising at least nine components selected from
the group consisting of: a base oil; metal deactivator;
antioxidants; sulfurized natural oils; phosphate ester; phosphoric
acid; viscosity modifier; pour-point depressant; defoamer; and
carboxylic acid soaps. In an exemplary embodiment, the expansion
device includes a tapered portion having a tapered faceted
polygonal outer expansion surface. In an exemplary embodiment, the
expansion device includes, a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the tubular member has a non-uniform wall thickness and
the expansion device includes a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the lubricant is stored in a reservoir with electrodes
that are electrically coupled a capacitor in the expansion device
and is injected through at least a portion of the expansion device
between the tubular member and the expansion device when the
capacitors discharges. In an exemplary embodiment, the expansion
device includes a wellbore casing, a pipeline, or a structural
support. In an exemplary embodiment, the expansion device includes
expansion cone.
[0804] A lubricant for injecting in an interface between a tubular
member and an expansion device has been describe that includes at
least eight components selected from the group consisting of: a
base oil; metal deactivator; antioxidants; sulfurized natural oils;
phosphate ester; phosphoric acid; viscosity modifier; pour-point
depressant; defoamer; and carboxylic acid soaps. In an exemplary
embodiment, the lubricant by weight includes: 64.25-90.89% base
oil; 0.02-0.05% metal deactivator; 0.5-3.0% antioxidants; 4-12%
sulfurized natural oils; 4-12% phosphate ester; 0.4-1.5% phosphoric
acid; 0.08-1.5% viscosity modifier; 0.1-0.5% pour-point depressant;
0.01-0.2% defoamer; and 0-5% carboxylic acid soaps.
[0805] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes
77.81% canola oil; 0.04% tolyltriazole; 1.0% phenolic antioxidant;
10% sulfurized natural oil or sulferized lard oil; 9% phosphate
ester; 1% phosphoric acid; 0.8% styrene hydrocarbon polymer; 0.3%
alkyl ester copolymer; and 0.05% silicon based antifoam agent.
[0806] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
64.25% canola oil; 0.05% tolyltriazole; 1.0% aminic antioxidant;
2.0% phenolic antioxidant, 12% sulfurized natural oil or sulferized
lard oil; 12% phosphate ester; 1.5% phosphoric acid; 1.5% styrene
hydrocarbon polymer; 0.5% alkyl ester copolymer; 0.2% silicon based
antifoam agent, and 5% carbozylic acid soap.
[0807] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
90.89% canola oil; 0.02% tolyltriazole; 0.5% phenolic antioxidant;
4% sulfurized natural oil or sulferized lard oil; 4% phosphate
ester; 0.4% phosphoric acid; 0.08% styrene hydrocarbon polymer;
0.1% alkyl ester copolymer; and 0.01% silicon based antifoam
agent.
[0808] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
68.71% canola oil; 0.04% tolyltriazole; 0.5% aminic antioxidant,
1.0% phenolic antioxidant; 12% sulfurized natural oil or sulferized
lard oil; 10% phosphate ester; 1.1% phosphoric acid; 1.5% styrene
hydrocarbon polymer; 0.1% alkyl ester copolymer; 0.05% silicon
based antifoam agent, and 5% carbozylic acid soap.
[0809] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
82.07% canola oil; 0.03% tolyltriazole; 0.5% aminic antioxidant,
0.5% phenolic antioxidant; 10% sulfurized natural oil or sulferized
lard oil; 5% phosphate ester; 0.5% phosphoric acid; 0.1% styrene
hydrocarbon polymer; 0.2% alkyl ester copolymer; 0.1% silicon based
antifoam agent, and 1% carbozylic acid soap.
[0810] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
80.68% canola oil; 0.04% tolyltriazole; 1% phenolic antioxidant; 8%
sulfurized natural oil or sulferized lard oil; 9% phosphate ester;
1% phosphoric acid; 0.1% styrene hydrocarbon polymer; 0.1% alkyl
ester copolymer; and 0.08% silicon based antifoam agent.
[0811] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes:
80.31% canola oil; 0.04% tolyltriazole; 1.1% phenolic antioxidant;
9% sulfurized natural oil or sulferized lard oil; 8% phosphate
ester; 0.8% phosphoric acid; 0.4% styrene hydrocarbon polymer; 0.3%
alkyl ester copolymer; and 0.05% silicon based antifoam agent.
[0812] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes: at
least 10% Graphite.
[0813] A lubricant for injecting in an interface between a tubular
member and an expansion device has been described that includes: at
least 10% Molybedenum Disulfide in a thickener in with a dropping
point above 350-400F.
[0814] An expansion device for radially expanding and plastically
deforming the tubular member has been described that includes one
or more expansion surfaces on the expansion device for engaging the
interior surface of the tubular member during the radial expansion
and plastic deformation of the tubular member; and a lubrication
device operably coupled to the expansion surface for injecting
lubricant into an interface between the expansion surface and the
tubular member during the radial expansion and plastic deformation
of the tubular member when a predetermined pressure for lubrication
is reached. In an exemplary embodiment, the lubrication device
includes a pump. In an exemplary embodiment, the lubrication device
includes a reservoir operably coupled to the expansion surface for
house a lubricant; a means for pressurizing the lubricant; and a
means for injecting the lubricant in the reservoir into the
interface when the predetermine pressure is reached. In an
exemplary embodiment, the lubrication device includes a reservoir
operably coupled to the expansion surface for house a lubricant; a
means for pressurizing the lubricant, and a valve fluidicly coupled
to the reservoir and the expansion surface for injecting the
lubricant into the interface when the predetermine pressure is
reached. In an exemplary embodiment, the lubrication device
includes a reservoir operably coupled to the expansion surface for
house a lubricant, a means for pressurizing the lubricant, a
pressure enhancer operably coupled to the reservoir to increase the
pressure on the lubricant in the reservoir, and a valve fluidicly
coupled to the reservoir and the expansion surface for injecting
the lubricant into the interface when the predetermine pressure is
reached. In an exemplary embodiment, the lubrication device
includes a reservoir operably coupled to the expansion surface for
house a lubricant, a means for pressurizing the lubricant, a piston
operably coupled to the reservoir, and a valve fluidicly coupled to
the reservoir and the expansion surface for injecting the lubricant
into the interface when the predetermine pressure is reached. In an
exemplary embodiment, the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08. In an exemplary embodiment,
the lubrication device includes the coefficient of friction between
the expansion device and the tubular member during radial expansion
and plastic deformation is in the range of 0.02 to 0.05. In an
exemplary embodiment, the lubricant includes oil based lubricants,
H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease,
water based lubricants, drilling mud, drilling mud and solid
lubricants, grease combined with a solid lubricant, at least 10%
Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the expansion device includes a coating on the
expansion device. In an exemplary embodiment, the coating may be
Phygen film. In an exemplary embodiment, the expansion device
includes a coating on the tubular member. In an exemplary
embodiment, the coating on the tubular member includes PTFE, PTFE
based or graphite based. In an exemplary embodiment, the expansion
device includes DC53 material, DC2 material, DC3 material, DC5
material, DC7 material, M2 material, CPM M4 material, 10V material,
3V material. In an exemplary embodiment, the expansion device
includes an REM finish, a processed finish, or a relatively smooth
surface roughness. In an exemplary embodiment, the expansion device
includes a relatively smooth surface roughness and includes
relatively evenly space oil pockets. In an exemplary embodiment,
the expansion device includes a smooth surface roughness in the
range of 0.02 to 0.1 micrometers In an exemplary embodiment, the
lubricant is injected through at least a portion of the expansion
device between the tubular member and the expansion device. In an
exemplary embodiment, the expansion device includes a means for
injecting lubricant through at least a portion of the expansion
device between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
expansion device includes a means for injecting lubricant through
at least two portions of the expansion device between the tubular
member and the expansion device at two different pressures. In an
exemplary embodiment, the expansion device includes a tapered
portion with an outer surface, internal flow passage in the tapered
portion and at least one circumferential groove having a first edge
and a second edge having with a sliding angle on the outer surface
of the tapered portion fluidicly coupled to the internal flow
passage for receiving lubricant during radial expansion and plastic
deformation of the tubular member, wherein the sliding angle is
less than or equal to 30 degrees. In an exemplary embodiment, the
expansion device includes a tapered portion with an outer surface,
internal flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the expansion device
includes a lubricant between the tubular member and the expansion
device, comprising at least nine components selected from the group
consisting of: a base oil; metal deactivator; antioxidants;
sulfurized natural oils; phosphate ester; phosphoric acid;
viscosity modifier; pour-point depressant; defoamer; and carboxylic
acid soaps. In an exemplary embodiment, the expansion device
includes, a tapered portion having a tapered faceted polygonal
outer expansion surface. In an exemplary embodiment, the tubular
member has a non-uniform wall thickness and the expansion device
includes a tapered portion having a tapered faceted polygonal outer
expansion surface. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges. In an
exemplary embodiment, the expansion device includes a wellbore
casing, a pipeline, or a structural support. In an exemplary
embodiment, the expansion device includes expansion cone.
[0815] A method for radially expanding and plastically deforming
the tubular member has been described that includes positioning an
expansion device having one or more expansion surfaces in the
interior surface of the tubular member, displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, and operating a lubrication
device to inject lubricant into an interface between the expansion
surface and the tubular member when a predetermined lubricant
pressure is reached. In an exemplary embodiment, the lubrication
device includes a pump. In an exemplary embodiment, the lubrication
device includes a reservoir operably coupled to the expansion
surface for house a lubricant; a means for pressurizing the
lubricant; and a means for injecting the lubricant in the reservoir
into the interface when the predetermine pressure is reached. In an
exemplary embodiment, the lubrication device includes a reservoir
operably coupled to the expansion surface for house a lubricant; a
means for pressurizing the lubricant, and a valve fluidicly coupled
to the reservoir and the expansion surface for injecting the
lubricant into the interface when the predetermine pressure is
reached. In an exemplary embodiment, the lubrication device
includes a reservoir operably coupled to the expansion surface for
house a lubricant, a means for pressurizing the lubricant, a
pressure enhancer operably coupled to the reservoir to increase the
pressure on the lubricant in the reservoir, and a valve fluidicly
coupled to the reservoir and the expansion surface for injecting
the lubricant into the interface when the predetermine pressure is
reached. In an exemplary embodiment, the lubrication device
includes a reservoir operably coupled to the expansion surface for
house a lubricant, a means for pressurizing the lubricant, a piston
operably coupled to the reservoir, and a valve fluidicly coupled to
the reservoir and the expansion surface for injecting the lubricant
into the interface when the predetermine pressure is reached. In an
exemplary embodiment, the coefficient of friction between the
expansion device and the tubular member during radial expansion and
plastic deformation is less than 0.08. In an exemplary embodiment,
the lubrication device includes the coefficient of friction between
the expansion device and the tubular member during radial expansion
and plastic deformation is in the range of 0.02 to 0.05. In an
exemplary embodiment, the lubricant includes oil based lubricants,
H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease,
water based lubricants, drilling mud, drilling mud and solid
lubricants, grease combined with a solid lubricant, at least 10%
Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the expansion device includes a coating on the
expansion device. In an exemplary embodiment, the coating may be
Phygen film. In an exemplary embodiment, the expansion device
includes a coating on the tubular member. In an exemplary
embodiment, the coating on the tubular member includes PTFE, PTFE
based or graphite based. In an exemplary embodiment, the expansion
device includes DC53 material, DC2 material, DC3 material, DC5
material, DC7 material, M2 material, CPM M4 material, 10V material,
3V material. In an exemplary embodiment, the expansion device
includes an REM finish, a processed finish, or a relatively smooth
surface roughness. In an exemplary embodiment, the expansion device
includes a relatively smooth surface roughness and includes
relatively evenly space oil pockets. In an exemplary embodiment,
the expansion device includes a smooth surface roughness in the
range of 0.02 to 0.1 micrometers In an exemplary embodiment, the
method includes injecting lubricant through at least two portions
of the expansion device between the tubular member and the
expansion device at two different pressures. In an exemplary
embodiment, the expansion device includes a tapered portion with an
outer surface, internal flow passage in the tapered portion, at
least one circumferential groove having a first edge and a second
edge having with a sliding angle on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the sliding angle is less than or
equal to 30 degrees and the expansion surfaces are located on the
tapered portion. In an exemplary embodiment, the expansion device
includes a tapered portion with an outer surface, internal flow
passage in the tapered portion, at least one circumferential groove
having a first edge and a second edge having with a sliding angle
on the outer surface of the tapered portion fluidicly coupled to
the internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 10 degrees and the
expansion surfaces are located on the tapered portion. In an
exemplary embodiment, the lubricant includes at least nine
components selected from the group consisting of: a base oil; metal
deactivator; antioxidants; sulfurized natural oils; phosphate
ester; phosphoric acid; viscosity modifier; pour-point depressant;
defoamer; and carboxylic acid soaps. In an exemplary embodiment,
the expansion device includes a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the tubular member includes a tapered portion having a
tapered faceted polygonal outer expansion surface. In an exemplary
embodiment, the lubricant is stored in a reservoir with electrodes
that are electrically coupled a capacitor in the expansion device
and the method includes charging the capacitor, discharging the
capacitor through the electrodes, and injecting the lubricant
through at least a portion of the expansion device between the
tubular member and the expansion device when the capacitors
discharges. In an exemplary embodiment, the tubular member includes
a wellbore casing, a pipeline or a structural support. In an
exemplary embodiment, the expansion device includes an expansion
cone.
[0816] A lubricant delivery assembly for radially expanding and
plastically deforming a tubular member has been described that
includes an expansion cone having a tapered portion with an outer
surface, at least one reservoir for housing a lubricant, at least
one circumferential groove on the outer surface fluidicly connected
to the reservoir, and a lubricant injection mechanism to force
lubricant into the at least one circumferential groove while
radially expanding and plastically deforming the tubular member
when a predetermined lubricant pressure is reached. In an exemplary
embodiment, the lubricant injection mechanism is a valve and the
lubricant is drilling fluid received in the reservoir. In an
exemplary embodiment, the reservoir is fluidicly connected to
drilling fluid used to expand the tubular member and the lubricant
injection mechanism includes a pressure accelerator received within
the reservoir that separates the drilling fluid and the media.
[0817] An expansion device for radially expanding and plastically
deforming a tubular member has been described that includes a
tapered portion with an outer surface, internal flow passage in the
tapered portion, and at least one circumferential groove having a
first edge and a second edge with a predetermined sliding angle on
the outer surface of the tapered portion fluidicly coupled to the
internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 30 degrees.
[0818] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member; a tapered portion with
an outer surface internal flow passage in the tapered portion and
at least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member.
[0819] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least ones circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, and
at least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the lubricant in the leading portion
is at pressure different from the lubricant in the tapered
portion.
[0820] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, and
at least one circumferential groove having a first edge and a
second edge with a second predetermined sliding angle on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member; wherein the second
sliding angle is less than or equal to 30 degrees.
[0821] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, and
at least one circumferential groove having a first edge and a
second edge with a second predetermined sliding angle on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, wherein the second
sliding angle is less than or equal to 30 degrees.
[0822] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member from the internal flow
passage, a tapered portion with an outer surface, internal flow
passage in the tapered portion, and at least one circumferential
groove having a first edge and a second edge with a second
predetermined sliding angle on the outer surface of the tapered
portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member; wherein the second sliding angle is less
than or equal to 30 degrees, wherein the lubricant in the leading
portion is at pressure different from the lubricant in the tapered
portion.
[0823] A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than 0.08 has been described that includes altering at least
one of the elements selected from the group consisting of:
expansion device geometry, expansion device composition, expansion
device surface roughness, expansion device texture, expansion
device coating, lubricant composition, lubricant environmental
issues, lubricant frictional modifiers, tubular member roughness,
and tubular member coating.
[0824] A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than or equal to 0.05 has been describe that includes altering
at least one of the elements selected from the group consisting of:
expansion device geometry, expansion device composition, expansion
device surface roughness, expansion device texture, expansion
device coating, lubricant composition, lubricant environmental
issues, lubricant frictional modifiers, tubular member roughness,
and tubular member coating.
[0825] A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than or equal to 0.02 has been describe that includes altering
at least one of the elements selected from the group consisting of:
expansion device geometry, expansion device composition, expansion
device surface roughness, expansion device texture, expansion
device coating, lubricant composition, lubricant environmental
issues, lubricant frictional modifiers, tubular member roughness,
and tubular member coating.
[0826] A lubrication system for lubricating an interface between a
first element and a second element has been described that includes
a vaporizer proximate to the interface for vaporizing a lubricant
to inject the lubricant in the interface. In an exemplary
embodiment, the first element includes an expansion device and the
second element includes tubular member during radial expansion and
plastic deformation of the tubular member. In an exemplary
embodiment, the vaporizer includes a reservoir for housing a
lubricant, and an electric pulse generator to create an electric
pulse in the lubricant. In an exemplary embodiment, the electric
impulse generator includes at least two electrodes housed in the
reservoir and at least one capacitor electrically coupled to the
electrode. In an exemplary embodiment, the vaporizer includes a
reservoir for housing a lubricant and an magnetic pulse generator
to create a magnetic pulse in the lubricant. In an exemplary
embodiment, the electric impulse generator includes magnetic coil
housed in the reservoir. In an exemplary embodiment, the system
includes an expansion device for positioning in a tubular member
and wherein the coefficient of friction between the expansion
device and the tubular member during radial expansion and plastic
deformation is less than 0.08. In an exemplary embodiment, the
coefficient of friction is in the range of 0.02 to 0.05. In an
exemplary embodiment, the system includes a lubricant between the
tubular member and the expansion device. In an exemplary
embodiment, the lubricant includes oil based lubricants, H1 oil, H2
oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based
lubricants, drilling mud, drilling mud and solid lubricants, grease
combined with a solid lubricant, at least 10% Graphite, or at least
10% Molybdenum Disulfide. In an exemplary embodiment, the system
includes a coating on the expansion device. In an exemplary
embodiment, the coating may be Phygen film. In an exemplary
embodiment, the system includes a coating on the tubular member. In
an exemplary embodiment, the coating on the tubular member includes
PTFE, PTFE based or graphite based. In an exemplary embodiment, the
expansion device includes DC53 material, DC2 material, DC3
material, DC5 material, DC7 material, M2 material, CPM M4 material,
10V material, 3V material. In an exemplary embodiment, the
expansion device includes an REM finish, a processed finish, or a
relatively smooth surface roughness. In an exemplary embodiment,
the expansion device includes a relatively smooth surface roughness
and includes relatively evenly space oil pockets. In an exemplary
embodiment, the expansion device includes a smooth surface
roughness in the range of 0.02 to 0.1 micrometers In an exemplary
embodiment, the lubricant is injected through at least a portion of
the expansion device between the tubular member and the expansion
device. In an exemplary embodiment, the lubricant is injected
through at least a portion of the expansion device between the
tubular member and the expansion device when a predetermined
pressure is met. In an exemplary embodiment, the lubricant is
injected through at least two portions of the expansion device
between the tubular member and the expansion device at two
different pressures. In an exemplary embodiment, the expansion
device includes a tapered portion with an outer surface, internal
flow passage in the tapered portion and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
30 degrees. In an exemplary embodiment, the expansion device
includes a tapered portion with an outer surface, internal flow
passage in the tapered portion, and at least one circumferential
groove having a first edge and a second edge having with a sliding
angle on the outer surface of the tapered portion fluidicly coupled
to the internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 10 degrees. In an
exemplary embodiment, the system includes a lubricant between the
tubular member and the expansion device, comprising at least nine
components selected from the group consisting of: a base oil; metal
deactivator; antioxidants; sulfurized natural oils; phosphate
ester; phosphoric acid; viscosity modifier; pour-point depressant;
defoamer; and carboxylic acid soaps. In an exemplary embodiment,
the expansion device includes, a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the tubular member has a non-uniform wall thickness and
the expansion device includes a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the expansion device includes a wellbore casing, a
pipeline, or a structural support. In an exemplary embodiment, the
expansion device includes expansion cone.
[0827] A method for lubricating an interface between a first
element and a second element has been described that includes
vaporizing a lubricant proximate to the interface to inject the
lubricant in the interface. In an exemplary embodiment, the first
element includes an expansion device and the second element
includes tubular member during radial expansion and plastic
deformation of the tubular member. In an exemplary embodiment, the
method includes housing a lubricant in a reservoir having an exit
passageway and generating an electric pulse in the reservoir,
thereby vaporizing the lubricant and causing a pressure pulse to
force lubricant out of the exit passageway. In an exemplary
embodiment, the electric pulse is generated by discharging a
capacitor through electrodes stored in the lubricant. In an
exemplary embodiment, the method includes housing a lubricant in a
reservoir having an exit passageway; and generating a magnetic
pulse in the reservoir, thereby vaporizing the lubricant and
causing a pressure pulse to force lubricant out of the exit
passageway. In an exemplary embodiment, the magnetic pulse is
generated by current running current through magnetic coils stored
in the lubricant. In an exemplary embodiment, the method includes
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member, displacing
the expansion device relative to the tubular member to radially
expand and plastically deform the tubular member; and wherein the
coefficient of friction between the expansion device and the
tubular member during radial expansion and plastic deformation is
less than 0.08. In an exemplary embodiment, the coefficient of
friction is in the range of 0.02 to 0.05. In an exemplary
embodiment, the method includes injecting lubricant between the
tubular member and the expansion device. In an exemplary
embodiment, the lubricant includes oil based lubricants, H1 oil, H2
oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based
lubricants, drilling mud, drilling mud and solid lubricants, grease
combined with a solid lubricant, at least 10% Graphite, or at least
10% Molybdenum Disulfide. In an exemplary embodiment, the method
includes applying a coating on the expansion device prior to
positioning within the tubular member. In an exemplary embodiment,
the coating may be Phygen film. In an exemplary embodiment, the
method includes applying a coating on the tubular member prior to
positioning the expansion device within the tubular member. In an
exemplary embodiment, the coating on the tubular member includes
PTFE, PTFE based or graphite based. In an exemplary embodiment, the
expansion device includes DC53 material, DC2 material, DC3
material, DC5 material, DC7 material, M2 material, CPM M4 material,
10V material, 3V material. In an exemplary embodiment, the
expansion device includes an REM finish, a processed finish, or a
relatively smooth surface roughness. In an exemplary embodiment,
the expansion device includes a relatively smooth surface roughness
and includes relatively evenly space oil pockets. In an exemplary
embodiment, the expansion device includes a smooth surface
roughness in the range of 0.02 to 0.1 micrometers In an exemplary
embodiment, the method includes injecting lubricant through at
least a portion of the expansion device between the tubular member
and the expansion device. In an exemplary embodiment, the method
includes injecting lubricant through at least a portion of the
expansion device between the tubular member and the expansion
device when a predetermined pressure is met. In an exemplary
embodiment, the method includes injecting lubricant through at
least two portions of the expansion device between the tubular
member and the expansion device at two different pressures. In an
exemplary embodiment, the expansion device includes a tapered
portion with an outer surface, internal flow passage in the tapered
portion and at least one circumferential groove having a first edge
and a second edge having with a sliding angle on the outer surface
of the tapered portion fluidicly coupled to the internal flow
passage for receiving lubricant during radial expansion and plastic
deformation of the tubular member, wherein the sliding angle is
less than or equal to 30 degrees. In an exemplary embodiment, the
expansion device includes a tapered portion with an outer surface,
internal flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the method includes
injecting lubricant between the tubular member and the expansion
device, comprising at least nine components selected from the group
consisting of: a base oil; metal deactivator; antioxidants;
sulfurized natural oils; phosphate ester; phosphoric acid;
viscosity modifier; pour-point depressant; defoamer; and carboxylic
acid soaps. In an exemplary embodiment, the expansion device
includes a tapered portion having a tapered faceted polygonal outer
expansion surface. In an exemplary embodiment, the expansion device
includes, a tapered portion having a tapered faceted polygonal
outer expansion surface. In an exemplary embodiment, the tubular
member has a non-uniform wall thickness and the expansion device
includes a tapered portion having a tapered faceted polygonal outer
expansion surface. In an exemplary embodiment, the expansion device
includes a wellbore casing, a pipeline, or a structural support. In
an exemplary embodiment, the expansion device includes expansion
cone.
[0828] A system for lubricating an interface between a first
element and a second element has been described that includes means
for vaporizing a lubricant proximate to the interface to inject the
lubricant in the interface. In an exemplary embodiment, the area
includes an interface between an expansion device and a tubular
member during radial expansion and plastic deformation of the
tubular member. In an exemplary embodiment, the means for
vaporizing includes a means for housing a lubricant in a reservoir
having an exit passageway and a means for generating an electric
pulse in the reservoir, thereby vaporizing the lubricant and
causing a pressure pulse to force lubricant out of the exit
passageway. In an exemplary embodiment, the electric pulse is
generated by discharging a capacitor through electrodes stored in
the lubricant. In an exemplary embodiment, the means for vaporizing
includes means for housing a lubricant in a reservoir having an
exit passageway, and means for generating a magnetic pulse in the
reservoir, thereby vaporizing the lubricant and causing a pressure
pulse to force lubricant out of the exit passageway. In an
exemplary embodiment, the magnetic pulse is generated by current
running current through magnetic coils stored in the lubricant. In
an exemplary embodiment, the system includes means for positioning
an expansion device having a first tapered end and a second end at
least partially within a tubular member, means for displacing the
expansion device relative to the tubular member to radially expand
and plastically deform the tubular member, and wherein the
coefficient of friction between the expansion device and the
tubular member during radial expansion and plastic deformation is
less than 0.08. In an exemplary embodiment, the coefficient of
friction is in the range of 0.02 to 0.05. In an exemplary
embodiment, the system, includes a means for injecting lubricant
between the tubular member and the expansion device. In an
exemplary embodiment, the lubricant includes oil based lubricants,
H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease,
water based lubricants, drilling mud, drilling mud and solid
lubricants, grease combined with a solid lubricant, at least 10%
Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the system includes a means for applying a coating on
the expansion device prior to positioning within the tubular
member. In an exemplary embodiment, the coating may be Phygen film.
In an exemplary embodiment, the method includes applying a coating
on the tubular member prior to positioning the expansion device
within the tubular member. In an exemplary embodiment, the coating
on the tubular member includes PTFE, PTFE based or graphite based.
In an exemplary embodiment, the expansion device includes DC53
material, DC2 material, DC3 material, DC5 material, DC7 material,
M2 material, CPM M4 material, 10V material, 3V material. In an
exemplary embodiment, the expansion device includes an REM finish,
a processed finish, or a relatively smooth surface roughness. In an
exemplary embodiment, the expansion device includes a relatively
smooth surface roughness and includes relatively evenly space oil
pockets. In an exemplary embodiment, the expansion device includes
a smooth surface roughness in the range of 0.02 to 0.1 micrometers
In an exemplary embodiment, the system includes a means for
injecting lubricant through at least a portion of the expansion
device between the tubular member and the expansion device. In an
exemplary embodiment, the system includes a means for injecting
lubricant through at least a portion of the expansion device
between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
system includes a means for injecting lubricant through at least
two portions of the expansion device between the tubular member and
the expansion device at two different pressures. In an exemplary
embodiment, the expansion device includes a tapered portion with an
outer surface, internal flow passage in the tapered portion and at
least one circumferential groove having a first edge and a second
edge having with a sliding angle on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the sliding angle is less than or
equal to 30 degrees. In an exemplary embodiment, the expansion
device includes a tapered portion with an outer surface, internal
flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the system includes a means
for injecting lubricant between the tubular member and the
expansion device, comprising at least nine components selected from
the group consisting of: a base oil; metal deactivator;
antioxidants; sulfurized natural oils; phosphate ester; phosphoric
acid; viscosity modifier; pour-point depressant; defoamer; and
carboxylic acid soaps. In an exemplary embodiment, the expansion
device includes a tapered portion having a tapered faceted
polygonal outer expansion surface. In an exemplary embodiment, the
expansion device includes, a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the tubular member has a non-uniform wall thickness and
the expansion device includes a tapered portion having a tapered
faceted polygonal outer expansion surface. In an exemplary
embodiment, the expansion device includes a wellbore casing, a
pipeline, or a structural support. In an exemplary embodiment, the
expansion device includes expansion cone.
[0829] A system for radially expanding and plastically deforming a
tubular member has been described that includes an expansion device
positioned in the tubular member, and wherein the coefficient of
friction between the expansion device and the tubular member during
radial expansion and plastic deformation is less than 0.08 and
wherein lubricant is stored in a reservoir with a magnetic coil in
the expansion device and is injected through at least a portion of
the expansion device between the tubular member and the expansion
device when current runs through the magnetic coil.
[0830] A system for radially expanding and plastically deforming a
tubular member has been described that includes an expansion device
positioned in the tubular member, and wherein the coefficient of
friction between the expansion device and the tubular member during
radial expansion and plastic deformation is less than 0.08 and
wherein lubricant is stored in a reservoir and injected through at
least a portion of the expansion device between the tubular member
and the expansion device when vaporized.
[0831] A method of radially expanding and plastically deforming a
tubular member has been described that includes positioning an
expansion device having a first tapered end and a second end at
least partially within the tubular member, displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, and injecting a lubricant
stored in a reservoir with a magnetic coil in the expansion device
through at least a portion of the expansion device between the
tubular member and the expansion device when current runs through
the magnetic coil, and wherein the coefficient of friction between
the expansion device and the tubular member during radial expansion
and plastic deformation is less than 0.08.
[0832] A method of radially expanding and plastically deforming a
tubular member has been described that includes positioning an
expansion device having a first tapered end and a second end at
least partially within the tubular member, displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, and vaporizing a lubricant
stored in a reservoir in the expansion device and injecting it
through at least a portion of the expansion device between the
tubular member and the expansion device, and wherein the
coefficient of friction between the expansion device and the
tubular member during radial expansion and plastic deformation is
less than 0.08.
[0833] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member, means for
displacing the expansion device relative to the tubular member to
radially expand and plastically deform the tubular member, and
wherein the coefficient of friction between the expansion device
and the tubular member during radial expansion and plastic
deformation is less than 0.08 and wherein lubricant is stored in a
reservoir and injected through at least a portion of the expansion
device between the tubular member and the expansion device when
vaporized.
[0834] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member, means for
displacing the expansion device relative to the tubular member to
radially expand and plastically deform the tubular member; and
wherein the coefficient of friction between the expansion device
and the tubular member during radial expansion and plastic
deformation is less than 0.08 and wherein lubricant is stored in a
reservoir with a magnetic coil in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when current runs
through the magnetic coil.
[0835] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member, means for
displacing the expansion device relative to the tubular member to
radially expand and plastically deform the tubular member, and
means for vaporizing lubricant stored in a reservoir and injecting
it through at least a portion of the expansion device between the
tubular member and the expansion device, wherein the coefficient of
friction between the expansion device and the tubular member during
radial expansion and plastic deformation is less than 0.08.
[0836] A system for radially expanding and plastically deforming a
tubular member has been described that includes means for
positioning an expansion device having a first tapered end and a
second end at least partially within the tubular member, means for
displacing the expansion device relative to the tubular member to
radially expand and plastically deform the tubular member, and
means for vaporizing lubricant stored in a reservoir and injecting
it through at least a portion of the expansion device between the
tubular member and the expansion device, wherein the coefficient of
friction between the expansion device and the tubular member during
radial expansion and plastic deformation is less than 0.08 and
wherein means for vaporizes comprises a magnetic coil in the
reservoir operably connected to a power source.
[0837] An expansion device for radially expanding and plastically
deforming the tubular member has been described that includes one
or more expansion surfaces on the expansion device for engaging the
interior surface of the tubular member during the radial expansion
and plastic deformation of the tubular member; and a lubrication
device operably coupled to the expansion surface for injecting
lubricant into an interface between the expansion surface and the
tubular member during the radial expansion and plastic deformation
of the tubular member when a predetermined lubricant pressure is
reached, wherein lubricant is stored in a reservoir in the
lubrication device and injected through at least a portion of the
expansion device between the tubular member and the expansion
device when vaporized.
[0838] An expansion device for radially expanding and plastically
deforming the tubular member has been described that includes one
or more expansion surfaces on the expansion device for engaging the
interior surface of the tubular member during the radial expansion
and plastic deformation of the tubular member, and a lubrication
device operably coupled to the expansion surface for injecting
lubricant into an interface between the expansion surface and the
tubular member during the radial expansion and plastic deformation
of the tubular member when a predetermined lubricant pressure is
reached, and wherein lubricant is stored in a reservoir with a
magnetic coil in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when current runs through the magnetic
coil.
[0839] A method for radially expanding and plastically deforming
the tubular member has been described that includes positioning an
expansion device having one or more expansion surfaces in the
interior surface of the tubular member, displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, operating a lubrication
device to inject lubricant into an interface between the expansion
surface and the tubular member when a predetermined lubricant
pressure is reached, and wherein lubricant is stored in a reservoir
in the lubrication device and injected through at least a portion
of the expansion device between the tubular member and the
expansion device when vaporized.
[0840] A method for radially expanding and plastically deforming
the tubular member has been described that includes positioning an
expansion device having one or more expansion surfaces in the
interior surface of the tubular member; displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member, operating a lubrication
device to inject lubricant into an interface between the expansion
surface and the tubular member when a predetermined lubricant
pressure is reached, and wherein lubricant is stored in a reservoir
with a magnetic coil in the expansion device and is injected
through at least a portion of the expansion device between the
tubular member and the expansion device when current runs through
the magnetic coil.
[0841] A lubricant delivery assembly for radially expanding and
plastically deforming a tubular member has been described that
includes an expansion cone having a tapered portion with an outer
surface, at least one reservoir for housing a lubricant, at least
one circumferential groove on the outer surface fluidicly connected
to the reservoir and a lubricant injection mechanism to force
lubricant into the at least one circumferential groove while
radially expanding and plastically deforming the tubular member
when a predetermined lubricant pressure is reached. In an exemplary
embodiment, the lubricant is stored in a reservoir with a magnetic
coil in the expansion device and is injected through at least a
portion of the expansion device between the tubular member and the
expansion device when current runs through the magnetic coil. In an
exemplary embodiment, the lubricant is stored in a reservoir in the
lubrication device and injected through at least a portion of the
expansion device between the tubular member and the expansion
device when vaporized. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges.
[0842] An expansion device for radially expanding and plastically
deforming a tubular member has been described that includes a
tapered portion with an outer surface, internal flow passage in the
tapered portion, and at least one circumferential groove having a
first edge and a second edge with a predetermined sliding angle on
the outer surface of the tapered portion fluidicly coupled to the
internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 30 degrees. In an
exemplary embodiment, the lubricant is stored in a reservoir with a
magnetic coil in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when current runs through the magnetic
coil. In an exemplary embodiment, the lubricant is stored in a
reservoir in the lubrication device and injected through at least a
portion of the expansion device between the tubular member and the
expansion device when vaporized. In an exemplary embodiment, the
lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0843] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion and
at least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member. In an exemplary embodiment, the lubricant is
stored in a reservoir with a magnetic coil in the expansion device
and is injected through at least a portion of the expansion device
between the tubular member and the expansion device when current
runs through the magnetic coil. In an exemplary embodiment, the
lubricant is stored in a reservoir in the lubrication device and
injected through at least a portion of the expansion device between
the tubular member and the expansion device when vaporized. In an
exemplary embodiment, the lubricant is stored in a reservoir with
electrodes that are electrically coupled a capacitor in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when the capacitors discharges.
[0844] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, at
least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the lubricant in the leading portion
is at pressure different from the lubricant in the tapered portion.
In an exemplary embodiment, the lubricant is stored in a reservoir
with a magnetic coil in the expansion device and is injected
through at least a portion of the expansion device between the
tubular member and the expansion device when current runs through
the magnetic coil. In an exemplary embodiment, the lubricant is
stored in a reservoir in the lubrication device and injected
through at least a portion of the expansion device between the
tubular member and the expansion device when vaporized. In an
exemplary embodiment, the lubricant is stored in a reservoir with
electrodes that are electrically coupled a capacitor in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when the capacitors discharges.
[0845] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, at
least one circumferential groove having a first edge and a second
edge with a second predetermined sliding angle on the outer surface
of the tapered portion fluidicly coupled to the internal flow
passage for receiving lubricant during radial expansion and plastic
deformation of the tubular member; wherein the second sliding angle
is less than or equal to 30 degrees. In an exemplary embodiment,
the lubricant is stored in a reservoir with a magnetic coil in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when current runs through the magnetic coil. In an exemplary
embodiment, the lubricant is stored in a reservoir in the
lubrication device and injected through at least a portion of the
expansion device between the tubular member and the expansion
device when vaporized. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges.
[0846] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, at
least one circumferential groove having a first edge and a second
edge with a second predetermined sliding angle on the outer surface
of the tapered portion fluidicly coupled to the internal flow
passage for receiving lubricant during radial expansion and plastic
deformation of the tubular member; wherein the second sliding angle
is less than or equal to 30 degrees. In an exemplary embodiment,
the lubricant is stored in a reservoir with a magnetic coil in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when current runs through the magnetic coil. In an exemplary
embodiment, the lubricant is stored in a reservoir in the
lubrication device and injected through at least a portion of the
expansion device between the tubular member and the expansion
device when vaporized. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges.
[0847] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member from the internal flow
passage, a tapered portion with an outer surface, internal flow
passage in the tapered portion, at least one circumferential groove
having a first edge and a second edge with a second predetermined
sliding angle on the outer surface of the tapered portion fluidicly
coupled to the internal flow passage for receiving lubricant during
radial expansion and plastic deformation of the tubular member;
wherein the second sliding angle is less than or equal to 30
degrees, wherein the lubricant in the leading portion is at
pressure different from the lubricant in the tapered portion. In an
exemplary embodiment, the lubricant is stored in a reservoir with a
magnetic coil in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when current runs through the magnetic
coil. In an exemplary embodiment, the lubricant is stored in a
reservoir in the lubrication device and injected through at least a
portion of the expansion device between the tubular member and the
expansion device when vaporized. In an exemplary embodiment, the
lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0848] A method of reducing the coefficient of friction between the
expansion device and the tubular member during radial expansion to
less than 0.08 has been described that includes altering at least
one of the elements selected from the group consisting of:
expansion device geometry, expansion device composition, expansion
device surface roughness, expansion device texture, expansion
device coating, lubricant composition, lubricant environmental
issues, lubricant frictional modifiers, tubular member roughness,
and tubular member coating. In an exemplary embodiment, the
lubricant is stored in a reservoir with a magnetic coil in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when current runs through the magnetic coil. In an exemplary
embodiment, the lubricant is stored in a reservoir in the
lubrication device and injected through at least a portion of the
expansion device between the tubular member and the expansion
device when vaporized. In an exemplary embodiment, the lubricant is
stored in a reservoir with electrodes that are electrically coupled
a capacitor in the expansion device and is injected through at
least a portion of the expansion device between the tubular member
and the expansion device when the capacitors discharges.
[0849] A system for radially expanding and plastically deforming a
tubular member having a non-uniform wall thickness has been
disclosed that includes an expansion device having one or more
expansion surfaces and a tapered portion having a tapered faceted
polygonal outer expansion surface in the interior surface of the
tubular member. In an alternate embodiment, the system includes
lubricant between the tubular member and the expansion device. In
an exemplary embodiment, the lubricant includes oil based
lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil,
grease, water based lubricants, drilling mud, drilling mud and
solid lubricants, grease combined with a solid lubricant, at least
10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary
embodiment, the system includes a coating on the expansion device.
In an exemplary embodiment, the coating may be Phygen film. In an
exemplary embodiment, the system includes a coating on the tubular
member. In an exemplary embodiment, the coating on the tubular
member includes PTFE, PTFE based or graphite based. In an exemplary
embodiment, the expansion device includes DC53 material, DC2
material, DC3 material, DC5 material, DC7 material, M2 material,
CPM M4 material, 10V material, 3V material. In an exemplary
embodiment, the expansion device includes an REM finish, a
processed finish, or a relatively smooth surface roughness. In an
exemplary embodiment, the expansion device includes a relatively
smooth surface roughness and includes relatively evenly space oil
pockets. In an exemplary embodiment, the expansion device includes
a smooth surface roughness in the range of 0.02 to 0.1 micrometers
In an exemplary embodiment, the lubricant is injected through at
least a portion of the expansion device between the tubular member
and the expansion device. In an exemplary embodiment, the lubricant
is injected through at least a portion of the expansion device
between the tubular member and the expansion device when a
predetermined pressure is met. In an exemplary embodiment, the
lubricant is injected through at least two portions of the
expansion device between the tubular member and the expansion
device at two different pressures. In an exemplary embodiment, the
expansion device includes a tapered portion with an outer surface,
internal flow passage in the tapered portion and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
30 degrees. In an exemplary embodiment, the expansion device
includes a tapered portion with an outer surface, internal flow
passage in the tapered portion, and at least one circumferential
groove having a first edge and a second edge having with a sliding
angle on the outer surface of the tapered portion fluidicly coupled
to the internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 10 degrees. In an
exemplary embodiment, the system includes a lubricant between the
tubular member and the expansion device, comprising at least nine
components selected from the group consisting of: a base oil; metal
deactivator; antioxidants; sulfurized natural oils; phosphate
ester; phosphoric acid; viscosity modifier; pour-point depressant;
defoamer; and carboxylic acid soaps. In an exemplary embodiment,
the lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges. In an exemplary embodiment, the expansion device
includes a wellbore casing, a pipeline, or a structural support. In
an exemplary embodiment, the expansion device includes expansion
cone.
[0850] A method of radially expanding and plastically deforming a
tubular member having a non-uniform wall thickness has been
described that includes positioning an expansion device having one
or more expansion surfaces and a tapered portion having a tapered
faceted polygonal outer expansion surface in the interior surface
of the tubular member, and displacing the expansion device relative
to the tubular member to radially expand and plastically deform the
tubular member. In an exemplary embodiment, the method includes
injecting lubricant between the tubular member and the expansion
device. In an exemplary embodiment, the lubricant includes oil
based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil,
H7 oil, grease, water based lubricants, drilling mud, drilling mud
and solid lubricants, grease combined with a solid lubricant, at
least 10% Graphite, or at least 10% Molybdenum Disulfide. In an
exemplary embodiment, the method includes applying a coating on the
expansion device prior to positioning within the tubular member. In
an exemplary embodiment, the coating may be Phygen film. In an
exemplary embodiment, the method includes applying a coating on the
tubular member prior to positioning the expansion device within the
tubular member. In an exemplary embodiment, the coating on the
tubular member includes PTFE, PTFE based or graphite based. In an
exemplary embodiment, the expansion device includes DC53 material,
DC2 material, DC3 material, DC5 material, DC7 material, M2
material, CPM M4 material, 10V material, 3V material. In an
exemplary embodiment, the expansion device includes an REM finish,
a processed finish, or a relatively smooth surface roughness. In an
exemplary embodiment, the expansion device includes a relatively
smooth surface roughness and includes relatively evenly space oil
pockets. In an exemplary embodiment, the expansion device includes
a smooth surface roughness in the range of 0.02 to 0.1 micrometers
In an exemplary embodiment, the method includes injecting lubricant
through at least a portion of the expansion device between the
tubular member and the expansion device. In an exemplary
embodiment, the method includes injecting lubricant through at
least a portion of the expansion device between the tubular member
and the expansion device when a predetermined pressure is met. In
an exemplary embodiment, the method includes injecting lubricant
through at least two portions of the expansion device between the
tubular member and the expansion device at two different pressures.
In an exemplary embodiment, the expansion device includes a tapered
portion with an outer surface, internal flow passage in the tapered
portion and at least one circumferential groove having a first edge
and a second edge having with a sliding angle on the outer surface
of the tapered portion fluidicly coupled to the internal flow
passage for receiving lubricant during radial expansion and plastic
deformation of the tubular member, wherein the sliding angle is
less than or equal to 30 degrees. In an exemplary embodiment, the
expansion device includes a tapered portion with an outer surface,
internal flow passage in the tapered portion, and at least one
circumferential groove having a first edge and a second edge having
with a sliding angle on the outer surface of the tapered portion
fluidicly coupled to the internal flow passage for receiving
lubricant during radial expansion and plastic deformation of the
tubular member, wherein the sliding angle is less than or equal to
10 degrees. In an exemplary embodiment, the method includes
injecting lubricant between the tubular member and the expansion
device, comprising at least nine components selected from the group
consisting of: a base oil; metal deactivator; antioxidants;
sulfurized natural oils; phosphate ester; phosphoric acid;
viscosity modifier; pour-point depressant; defoamer; and carboxylic
acid soaps. In an exemplary embodiment, the lubricant is stored in
a reservoir with electrodes that are electrically coupled a
capacitor in the expansion device and is injected through at least
a portion of the expansion device between the tubular member and
the expansion device when the capacitors discharges. In an
exemplary embodiment, the expansion device includes a wellbore
casing, a pipeline, or a structural support. In an exemplary
embodiment, the expansion device includes expansion cone.
[0851] An expansion device for radially expanding and plastically
deforming a tubular member has been described that includes a
tapered portion with an outer surface, internal flow passage in the
tapered portion, and at least one circumferential groove having a
first edge and a second edge with a predetermined sliding angle on
the outer surface of the tapered portion fluidicly coupled to the
internal flow passage for receiving lubricant during radial
expansion and plastic deformation of the tubular member, wherein
the sliding angle is less than or equal to 30 degrees; and wherein
lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0852] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface; internal flow passage in the tapered portion; and
at least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein lubricant is stored in a reservoir
with electrodes that are electrically coupled a capacitor in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when the capacitors discharges.
[0853] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion; and
at least one circumferential groove on the outer surface of the
tapered portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member, wherein the lubricant in the leading portion
is at pressure different from the lubricant in the tapered portion,
and wherein lubricant is stored in a reservoir with electrodes that
are electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0854] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion, and
at least one circumferential groove having a first edge and a
second edge with a second predetermined sliding angle on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member; wherein the second
sliding angle is less than or equal to 30 degrees, wherein
lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0855] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member, a tapered portion with
an outer surface, internal flow passage in the tapered portion; and
at least one circumferential groove having a first edge and a
second edge with a second predetermined sliding angle on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member; wherein the second
sliding angle is less than or equal to 30 degrees, wherein
lubricant is stored in a reservoir with electrodes that are
electrically coupled a capacitor in the expansion device and is
injected through at least a portion of the expansion device between
the tubular member and the expansion device when the capacitors
discharges.
[0856] An expansion cone for radially expanding and plastically
deforming a tubular member has been described that includes a
leading portion with an outer surface, internal flow passage in the
leading portion, at least one circumferential groove on the outer
surface of the tapered portion fluidicly coupled to the internal
flow passage for receiving lubricant during radial expansion and
plastic deformation of the tubular member from the internal flow
passage, a tapered portion with an outer surface, internal flow
passage in the tapered portion; and at least one circumferential
groove having a first edge and a second edge with a second
predetermined sliding angle on the outer surface of the tapered
portion fluidicly coupled to the internal flow passage for
receiving lubricant during radial expansion and plastic deformation
of the tubular member; wherein the second sliding angle is less
than or equal to 30 degrees, wherein the lubricant in the leading
portion is at pressure different from the lubricant in the tapered
portion, and wherein lubricant is stored in a reservoir with
electrodes that are electrically coupled a capacitor in the
expansion device and is injected through at least a portion of the
expansion device between the tubular member and the expansion
device when the capacitors discharges.
[0857] A system for radially expanding and plastically deforming a
tubular member having non-uniform wall thickness has been described
that includes means for positioning an expansion device having one
or more expansion surfaces and a tapered portion having a tapered
faceted polygonal outer expansion surface in the interior surface
of the tubular member; and means for displacing the expansion
device relative to the tubular member to radially expand and
plastically deform the tubular member.
[0858] A system for radially expanding and plastically deforming a
tubular member has been described that includes an expansion cone
of D53 material having a phygen coating and an REM finish and H1
oil wherein the tubular member is coated with PTFE.
[0859] A method of increasing a collapse strength of a tubular
member after a radial expansion and plastic deformation of the
tubular member using an expansion device has been described that
includes reducing a coefficient of friction between the tubular
member and the expansion device during the radial expansion and
plastic deformation of the tubular member; and reducing a ratio of
a diameter of the tubular member to a wall thickness of the tubular
member. In an exemplary embodiment, the coefficient of friction is
less than 0.075. In an exemplary embodiment, the ratio of the
diameter of the tubular member to a wall thickness of the tubular
member is less than 21.6. In an exemplary embodiment, the collapse
strength of a tubular member after the radial expansion and plastic
deformation of the tubular member using an expansion device is
greater than 5000 ksi.
[0860] A system for radially expanding and plastically deforming a
tubular member has been described that includes a tubular member,
and an expansion device positioned within the tubular member,
wherein the coefficient of friction between the tubular member and
the expansion device is less than 0.075, and wherein the ratio of
the diameter of the tubular member to a wall thickness of the
tubular member is less than 21.6.
[0861] A method of radially expanding and plastically deforming a
tubular member using an expansion device has been described that
includes quenching and tempering the tubular member; positioning
the tubular member within a preexisting structure; and radially
expanding and plastically deforming the tubular member. In an
exemplary embodiment, the yield strength of the tubular member
ranges from about 76.8 ksi to 88.8 ksi. In an exemplary embodiment,
the ratio of the yield strength to the tensile strength of the
tubular member ranges from about 0.82 to 0.86. In an exemplary
embodiment, the longitudinal elongation of the tubular member prior
to failure ranges from about 14.8% to 22.0%. In an exemplary
embodiment, the width reduction of the tubular member prior to
failure ranges from about 32% to 44.0%. In an exemplary embodiment,
the width thickness reduction of the tubular member prior to
failure ranges from about 41.0% to 45%. In an exemplary embodiment,
the anisotropy of the tubular member ranges from about 0.65 to
1.03. In an exemplary embodiment, the absorbed energy in the
longitudinal direction of the tubular member ranges from about 125
to 145 ft-lbs. In an exemplary embodiment, the absorbed energy in
the transverse direction of the tubular member ranges from about 59
to 59 ft-lbs. In an exemplary embodiment, the absorbed energy in a
welded portion of the tubular member ranges from about 174 to 176
ft-lbs. In an exemplary embodiment, a flared expansion of an end of
tubular member ranged from about 42 to 52%. In an exemplary
embodiment, the tubular member comprises, by weight percentage:
0.27 C, 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr. In an
exemplary embodiment, the quenching of the tubular member is
provided at about 970 C; and the tempering the tubular member is
provided at about 670 C.
[0862] A radially expandable and plastically deformable tubular
member has been described that includes a yield strength ranging
from about 76.8 ksi to 88.8 ksi, a ratio of the yield strength to a
tensile strength of the tubular member ranging from about 0.82 to
0.86, a longitudinal elongation of the tubular member prior to
failure ranging from about 14.8% to 22.0%, a width reduction of the
tubular member prior to failure ranging from about 32% to 44.0%, a
width thickness reduction of the tubular member prior to failure
ranges from about 41.0% to 45%, and an anisotropy of the tubular
member ranges from about 0.65 to 1.03. In an exemplary embodiment,
an absorbed energy in the longitudinal direction of the tubular
member ranges from about 125 to 145 ft-lbs. In an exemplary
embodiment, the absorbed energy in the transverse direction of the
tubular member ranges from about 59 to 59 ft-lbs. In an exemplary
embodiment, the absorbed energy in a welded portion of the tubular
member ranges from about 174 to 176 ft-lbs. In an exemplary
embodiment, a flared expansion of an end of tubular member ranged
from about 42 to 52%. In an exemplary embodiment, the tubular
member comprises, by weight percentage: 0.27 C, 0.14 Si; 1.28 Mn;
0.009 P; 0.005 S; and 0.14 Cr.
[0863] A radially expandable and plastically deformable tubular
member has been described that includes: a yield strength ranging
from about 40.0 ksi to 100.0 ksi; a ratio of the yield strength to
a tensile strength of the tubular member ranging from about 0.40 to
0.85; a longitudinal elongation of the tubular member prior to
failure ranging from at least about 22.0 to 35.0%; a width
reduction of the tubular member prior to failure ranging from at
least about 30.0% to 45.0%; a width thickness reduction of the
tubular member prior to failure ranges from at least about 30.0% to
45.0%; and an anisotropy of the tubular member ranges from at least
about 0.65 to 1.50. In an exemplary embodiment, an absorbed energy
in the longitudinal direction of the tubular member is at least
about 80 ft-lbs. In an exemplary embodiment, the absorbed energy in
the transverse direction of the tubular member is at least about 60
ft-lbs. In an exemplary embodiment, the absorbed energy in a welded
portion of the tubular member is at least about 60 ft-lbs. In an
exemplary embodiment, a flared expansion of an end of tubular
member ranges from at least about 45 to 75%.
[0864] A method of manufacturing a tubular member has been
described that includes fabricating a tubular member; positioning
the tubular member within a preexisting structure; radially
expanding and plastically deforming the tubular member within the
preexisting structure; and baking the tubular member within the
preexisting structure. In an exemplary embodiment, the preexisting
structure comprises a wellbore. In an exemplary embodiment, the
fabricated tubular member comprises a dual phase steel pipe. In an
exemplary embodiment, the fabricated tubular member comprises a
microstructure comprising about 15 to 30% martensite; and ferrite.
In an exemplary embodiment, the fabricated tubular member
comprises, by weight percentage: 0.1 C, 1.2 Mn; and 0.3 Si. In an
exemplary embodiment, the fabricated tubular member comprises a
TRIP steel pipe. In an exemplary embodiment, fabricating the
tubular member comprises: cold rolling the tubular member; and
inter critical annealing the tubular member. In an exemplary
embodiment, the fabricated tubular member comprises a dual phase
steel pipe. In an exemplary embodiment, prior to the cold rolling,
the fabricated tubular member comprises a microstructure comprising
ferrite and pearlite. In an exemplary embodiment, the inter
critical annealing is performed at about 750 C. In an exemplary
embodiment, after the inter critical annealing, the fabricated
tubular member comprises a microstructure comprising ferrite and at
least one of pearlite and austentite. In an exemplary embodiment,
the method further comprising: cooling the tubular member after the
inter critical annealing. In an exemplary embodiment, after the
cooling, the tubular member comprises a microstructure comprising
martensite. In an exemplary embodiment, the baking is provided at
about 100 C to 250 C. In an exemplary embodiment, following at
least a portion of the baking, the tubular member comprises a
bake-hardened portion. In an exemplary embodiment, following at
least a portion of the baking, the tubular member comprises a
stress-relieved portion. In an exemplary embodiment, following at
least a portion of the baking, the tubular member comprises a
bake-hardened portion and a stress-relieved portion. In an
exemplary embodiment, the cold rolling comprises: allowing the
tubular member to cool over time from a first temperature to a
second temperature along a temperature versus time curve; and at a
plurality of stages along the curve, deforming the tubular member.
In an exemplary embodiment, at a first stage along the curve,
insoluble precipitates within the tubular member retard austentite
growth. In an exemplary embodiment, at a first stage along the
curve, deformation of the tubular member promotes precipitation. In
an exemplary embodiment, at a second stage along the curve,
insoluble precipitates within the tubular member inhibit
recrystallization. In an exemplary embodiment, at a second stage
along the curve, austentite grains are conditioned.
[0865] It is understood that variations may be made in the
foregoing without departing from the scope of the invention. For
example, the teachings of the present illustrative embodiments may
be used to provide a wellbore casing, a pipeline, or a structural
support. Furthermore, the elements and teachings of the various
illustrative embodiments may be combined in whole or in part in
some or all of the illustrative embodiments. In addition, one or
more of the elements and teachings of the various illustrative
embodiments may be omitted, at least in part, and/or combined, at
least in part, with one or more of the other elements and teachings
of the various illustrative embodiments.
[0866] 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.
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