U.S. patent application number 11/573066 was filed with the patent office on 2008-02-14 for method of manufacturing a tubular member.
This patent application is currently assigned to ENVENTURE GLOBAL TECHNOLOGY, LLC. Invention is credited to David Paul Brisco, Scott Costa, Malcolm Gray, Grigoriy Grinberg, Mark Shuster, Russell Wasson, Brock Wayne Watson.
Application Number | 20080035251 11/573066 |
Document ID | / |
Family ID | 35908122 |
Filed Date | 2008-02-14 |
United States Patent
Application |
20080035251 |
Kind Code |
A1 |
Brisco; David Paul ; et
al. |
February 14, 2008 |
Method of Manufacturing a Tubular Member
Abstract
A method of manufacturing a tubular member.
Inventors: |
Brisco; David Paul; (Duncan,
OK) ; Watson; Brock Wayne; (Carrollton, TX) ;
Shuster; Mark; (Voorburg, NL) ; Gray; Malcolm;
(Houston, TX) ; Grinberg; Grigoriy; (Sylvania,
OH) ; Costa; Scott; (Katy, TX) ; Wasson;
Russell; (Houston, TX) |
Correspondence
Address: |
King & Spaiding L.L.P. Todd Mattingly
ll00 Louisiana Street Suite 4000
Houston
TX
77002
US
|
Assignee: |
ENVENTURE GLOBAL TECHNOLOGY,
LLC
15995 North Barkers Landing, Suite 350
Houston
TX
77079
|
Family ID: |
35908122 |
Appl. No.: |
11/573066 |
Filed: |
August 11, 2005 |
PCT Filed: |
August 11, 2005 |
PCT NO: |
PCT/US05/28819 |
371 Date: |
July 26, 2007 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60600679 |
Aug 11, 2004 |
|
|
|
Current U.S.
Class: |
148/559 ;
166/378 |
Current CPC
Class: |
C22C 38/00 20130101;
Y10T 436/23 20150115; E21B 43/106 20130101; E21B 43/105 20130101;
E21B 29/10 20130101; E21B 43/103 20130101 |
Class at
Publication: |
148/559 ;
166/378 |
International
Class: |
C21D 9/08 20060101
C21D009/08; E21B 17/00 20060101 E21B017/00 |
Claims
1. 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.
2. The method of claim 1, wherein the tubular member comprises a
wellbore casing.
3. The method of claim 1, wherein the tubular member comprises a
pipeline.
4. The method of claim 1, wherein the tubular member comprises a
structural support.
5. The method of claim 1, wherein the preexisting structure
comprises a wellbore that traverses a subterranean formation.
6. The method of claim 1, wherein the characteristics are selected
from a group consisting of yield point and ductility.
7. The method of claim 1, wherein processing the tubular member
within the preexisting structure until the tubular member is
characterized one or more final characteristics comprises: radially
expanding and plastically deforming the tubular member within the
preexisting structure.
8. 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.
9. The method of claim 8, wherein 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.
10. The method of claim 8, wherein 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.
11. The method of claim 8, wherein 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.
12. The method of claim 8, wherein the provided tubular member
comprises a microstructure comprising one or more of the following:
martensite, pearlite, vanadium carbide, nickel carbide, or titanium
carbide.
13. The method of claim 8, wherein the provided tubular member
comprises a microstructure comprising one or more of the following:
pearlite or pearlite striation.
14. The method of claim 8, wherein 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.
15. The method of claim 8, wherein the heat treating comprises
heating the provided tubular member for about 10 minutes at
790.degree. C.
16. The method of claim 8, wherein the quenching comprises
quenching the heat treated tubular member in water.
17. The method of claim 8, wherein following the quenching, the
tubular member comprises a microstructure comprising one or more of
the following: ferrite, grain pearlite, or martensite.
18. The method of claim 8, wherein following the quenching, the
tubular member comprises a microstructure comprising one or more of
the following: ferrite, martensite, or bainite.
19. The method of claim 8, wherein following the quenching, the
tubular member comprises a microstructure comprising one or more of
the following: bainite, pearlite, or ferrite.
20. The method of claim 8, wherein following the quenching, the
tubular member comprises a yield strength of about 67 ksi and a
tensile strength of about 95 ksi.
21. The method of claim 8, wherein following the quenching, the
tubular member comprises a yield strength of about 82 ksi and a
tensile strength of about 130 ksi.
22. The method of claim 8, wherein following the quenching, the
tubular member comprises a yield strength of about 60 ksi and a
tensile strength of about 97 ksi.
23. The method of claim 8, further comprising: positioning the
quenched tubular member within a preexisting structure; and
radially expanding and plastically deforming the tubular member
within the preexisting structure.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of the filing date of
U.S. provisional patent application Ser. No. 60/600,679, attorney
docket number 25791.194, filed on Aug. 11, 2004, the disclosure
which is incorporated herein by reference.
[0002] This application is a continuation-in-part of one or more of
the following: (1) PCT application US02/04353, filed on Feb. 14,
2002, attorney docket no. 25791.50.02, which claims priority from
U.S. provisional patent application Ser. No. 60/270,007, attorney
docket no. 25791.50, filed on Feb. 20, 2001; (2) 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; and (3) U.S. provisional patent application Ser. No.
60/585,370, attorney docket number 25791.299, filed on Jul. 2,
2004, 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 U.S.
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 U.S.
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 U.S.
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 U.S. 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 U.S. provisional
application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent
application Ser. No. 09/523,468, attorney docket no. 25791.11.02,
filed on Mar. 10, 2000, which claims priority from U.S. provisional
application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No.
6,568,471, which was filed as U.S. patent application Ser. No.
09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from U.S. provisional application
60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240,
which was filed as U.S. patent application Ser. No. 09/511,941,
attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which
claims priority from U.S. provisional application 60/121,907, filed
on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as
U.S. patent application Ser. No. 09/588,946, attorney docket no.
25791.17.02, filed on Jun. 7, 2000, which claims priority from U.S.
provisional application 60/137,998, filed on Jun. 7, 1999, (10)
U.S. patent application Ser. No. 09/981,916, attorney docket no.
25791.18, filed on Oct. 18, 2001 as a continuation-in-part
application of U.S. Pat. No. 6,328,113, which was filed as U.S.
patent application Ser. No. 09/440,338, attorney docket number
25791.9.02, filed on Nov. 15, 1999, which claims priority from U.S.
provisional application 60/108,558, filed on Nov. 16, 1998, (11)
U.S. Pat. No. 6,604,763, which was filed as U.S. application Ser.
No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from U.S. 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 U.S. 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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application Ser. No. 60/162,671, attorney docket no. 25791.27,
filed on Nov. 1, 1999, (15) U.S. provisional patent application
Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep.
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(17) U.S. Pat. No. 6,564,875, which was filed as U.S. application
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2000, which claims priority from U.S. provisional patent
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filed on Oct. 12, 1999, (18) U.S. patent application Ser. No.
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filed on Oct. 12, 1999, (19) U.S. patent application Ser. No.
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which claims priority from U.S. provisional patent application Ser.
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1999, (20) U.S. patent application Ser. No. 10/303,992, filed on
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priority from U.S. provisional patent application Ser. No.
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(21) U.S. provisional patent application Ser. No. 60/165,228,
attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S.
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which claims priority from U.S. provisional patent application Ser.
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2001, (24) U.S. patent application Ser. No. 10/311,412, filed on
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priority from U.S. provisional patent application Ser. No.
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(25) U.S. patent application Ser. No. 10/___,___, filed on Dec. 18,
2002, attorney docket no. 25791.46.07, which claims priority from
U.S. provisional patent application Ser. No. 60/221,645, attorney
docket no. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent
application Ser. No. 10/322,947, filed on Jan. 22, 2003, attorney
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patent application Ser. No. 60/233,638, attorney docket no.
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No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from U.S. provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
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(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
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U.S. provisional patent application Ser. No. 60/262,434, attorney
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application Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney
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patent application Ser. No. 60/259,486, attorney docket no.
25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patent
application Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney
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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 U.S. 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 U.S. 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.
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U.S. provisional patent application Ser. No. 60/326,886, attorney
docket no. 25791.60, filed on Oct. 3, 2001, (38) PCT Application
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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.
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2000, which claims priority from U.S. provisional application
60/124,042, filed on Mar. 11, 1999, (40) U.S. patent application
Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney docket no.
25791.63, which is a divisional of U.S. patent application Ser. No.
09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, which claims priority from U.S. 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.
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2000, which claims priority from U.S. 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.
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2000, which claims priority from U.S. 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.
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2000, which claims priority from U.S. provisional application
60/124,042, filed on Mar. 11, 1999, (44) PCT application US
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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
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filed on Dec. 27, 2001, (46) U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, which is a continuation-in-part application of U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from U.S. provisional application
60/108,558, filed on Nov. 16, 1998, (47) U.S. utility patent
application Ser. No. 10/516,467, attorney docket no. 25791.70,
filed on Dec. 10, 2001, which is a continuation application of U.S.
utility patent application Ser. No. 09/969,922, attorney docket no.
25791.69, filed on Oct. 3, 2001, which is a continuation-in-part
application of U.S. Pat. No. 6,328,113, which was filed as U.S.
patent application Ser. No. 09/440,338, attorney docket number
25791.9.02, filed on Nov. 15, 1999, which claims priority from U.S.
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 U.S. patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
U.S. 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.
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No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from U.S. 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 U.S. patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from U.S. 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 U.S.
patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
U.S. 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 U.S. patent application Ser.
No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from U.S. 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 U.S. patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from U.S. 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 U.S.
patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
U.S. 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 U.S. patent application Ser.
No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24,
2000, which claims priority from U.S. 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 U.S. patent application Ser. No. 09/588,946, attorney
docket no. 25791.17.02, filed on Jun. 7, 2000, which claims
priority from U.S. 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 U.S.
patent application Ser. No. 09/512,895, attorney docket no.
25791.12.02, filed on Feb. 24, 2000, which claims priority from
U.S. 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 U.S. patent application Ser.
No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,
2000, which claims priority from U.S. 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 U.S. patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from U.S. 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 U.S.
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25791.17.02, filed on Jun. 7, 2000, which claims priority from U.S.
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U.S. provisional patent application Ser. No. 60/412,177, attorney
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(90) PCT application US 03/24779, filed on Aug. 8, 2003, attorney
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Pat. No. 6,557,640, which was filed as U.S. patent application Ser.
No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7,
2000, which claims priority from U.S. 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 U.S. provisional application 60/119,611,
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60/448,526, attorney docket no. 25791.185, filed on Feb. 18, 2003,
(99) U.S. provisional patent application Ser. No. 60/461,539,
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25791.239, filed on Mar. 9, 2003, (108) U.S. provisional patent
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attorney docket no. 25791.256, filed on Apr. 23, 2003, which is a
continuation of U.S. patent application Ser. No. 09/523,468,
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claims priority from U.S. provisional application 60/124,042, filed
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No. 60/457,965, attorney docket no. 25791.260, filed on Mar. 27,
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09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from U.S. provisional application
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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,
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Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
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filed on Nov. 15, 1999, which claims priority from U.S. provisional
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patent application Ser. No. 10/418,688, attorney docket no.
25791.257, which was filed on Apr. 18, 2003, as a division of U.S.
utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
U.S. provisional application 60/124,042, filed on Mar. 11, 1999,
(122) PCT patent application serial no. PCT/US04/06246, attorney
docket no. 25791.238.02, filed on Feb. 26, 2004, (123) PCT patent
application serial number PCT/US04/08170, attorney docket number
25791.40.02, filed on Mar. 15, 2004, (124) PCT patent application
serial number PCT/US04/08171, attorney docket number 25791.236.02,
filed on Mar. 15, 2004, (125) PCT patent application serial number
PCT/US04/08073, attorney docket number 25791.262.02, filed on Mar.
18, 2004, (126) PCT patent application serial number
PCT/US04/07711, attorney docket number 25791.253.02, filed on Mar.
11, 2004, (127) PCT patent application serial number
PCT/US2004/009434, 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/2004/011973, 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, and (133) U.S. provisional patent application Ser. No.
60/585,370, attorney docket number 25791.299, filed on Jul. 2,
2004, the disclosures of which are incorporated herein by
reference.
[0003] BACKGROUND OF THE INVENTION
[0004] This invention relates generally to oil and gas exploration,
and in particular to forming and repairing wellbore casings to
facilitate oil and gas exploration.
SUMMARY OF THE INVENTION
[0005] According to one aspect of the present invention, a method
of manufacturing a tubular member is provided 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.
[0006] According to another aspect of the present invention, a
method of manufacturing an expandable tubular member has been
provided 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.
BRIEF DESCRIPTION OF THE DRAWINGS
[0007] FIG. 1 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0008] 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.
[0009] 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.
[0010] 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.
[0011] 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.
[0012] 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.
[0013] FIG. 7 is a fragmentary cross sectional illustration of an
embodiment of a series of overlapping expandable tubular
members.
[0014] FIG. 8 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0015] 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.
[0016] 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.
[0017] 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.
[0018] 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.
[0019] 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.
[0020] FIG. 14 is a fragmentary cross sectional view of an
exemplary embodiment of an expandable tubular member positioned
within a preexisting structure.
[0021] 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.
[0022] 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.
[0023] 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.
[0024] FIG. 18 is a flow chart illustration of an exemplary
embodiment of a method of processing an expandable tubular
member.
[0025] 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.
[0026] FIG. 20 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0027] FIG. 21 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0028] FIG. 35a is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable tubular member.
[0029] 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.
[0030] FIG. 36a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0031] FIG. 36b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0032] FIG. 36c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0033] FIG. 37a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0034] FIG. 37b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0035] FIG. 37c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0036] FIG. 38a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0037] FIG. 38b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0038] FIG. 38c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
[0039] 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.
[0040] 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.
[0041] 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.
[0042] 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.
[0043] 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.
[0044] 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.
[0045] 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.
[0046] 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.
[0047] 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.
[0048] 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.
[0049] 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.
[0050] 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.
[0051] 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.
[0052] 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.
[0053] 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.
[0054] 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.
[0055] 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.
[0056] 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.
[0057] 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.
[0058] In an exemplary embodiment, the anisotropy ratio AR for the
first and second expandable tubular members is defined by the
following equation: AR=ln (WT.sub.f/WT.sub.o)/ln (D.sub.f/D.sub.o);
[0059] where AR=anisotropy ratio; [0060] where WT.sub.f=final wall
thickness of the expandable tubular member following the radial
expansion and plastic deformation of the expandable tubular member;
[0061] 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; [0062] 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 [0063] 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.
[0064] In an exemplary embodiment, the anisotropy ratio AR for the
first and/or second expandable tubular members, 204 and 204, is
greater than
[0065] 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.
[0066] 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.
[0067] 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.
[0068] 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
[0069] 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: [0070] i.
f=r.times.n [0071] ii. where f=expandability coefficient; [0072] 1.
r=anisotropy coefficient; and [0073] 2. n=strain hardening
exponent.
[0074] 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.
[0075] 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.
[0076] 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 Element and Percentage By Weight Steel
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
[0077] 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.
[0078] 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
[0079] 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.
[0080] 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
[0081] 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 Absorbed Steel Yield Yield
Elongation Ani- Energy Expandability Alloy ksi Ratio % sotropy
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 --
[0082] 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.
[0083] In an exemplary embodiment, the carbon equivalent Ce, 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 [0084] where
C.sub.e=carbon equivalent value; [0085] a. C=carbon percentage by
weight; [0086] b. Mn=manganese percentage by weight; [0087] c.
Cr=chromium percentage by weight; [0088] d. Mo=molybdenum
percentage by weight; [0089] e. V32 vanadium percentage by weight;
[0090] f. Ti=titanium percentage by weight; [0091] g. Nb=niobium
percentage by weight; [0092] h. Ni=nickel percentage by weight; and
[0093] i. Cu=copper percentage by weight.
[0094] In an exemplary embodiment, the carbon equivalent value Ce,
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.
[0095] In an exemplary embodiment, the carbon equivalent Ce, 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 [0096] where C.sub.e=carbon
equivalent value; [0097] a. C=carbon percentage by weight; [0098]
b. Si=silicon percentage by weight; [0099] c. Mn=manganese
percentage by weight; [0100] d. Cu=copper percentage by weight;
[0101] e. Cr=chromium percentage by weight; [0102] f. Ni=nickel
percentage by weight; [0103] g. Mo=molybdenum percentage by weight;
[0104] h. V=vanadium percentage by weight; and [0105] i. B=boron
percentage by weight.
[0106] 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.
[0107] In several exemplary embodiments, the first and second
tubular members described above with reference to FIGS. 1 to 21 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.
[0108] 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.
[0109] 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.
[0110] 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.
[0111] 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.
[0112] 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.
[0113] 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.
[0114] In an exemplary embodiment, the expandable tubular member
3602a is then quenched in water in step 3606.
[0115] 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.
[0116] 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.
[0117] 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.
[0118] 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.
[0119] 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.
[0120] In an exemplary embodiment, the expandable tubular member
3702a is then quenched in water in step 3706.
[0121] 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.
[0122] 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.
[0123] 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.
[0124] 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.
[0125] 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.
[0126] In an exemplary embodiment, the expandable tubular member
3802a is then quenched in water in step 3806.
[0127] 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.
[0128] 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.
[0129] 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.
[0130] 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.
[0131] 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.
[0132] 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.
[0133] 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.
* * * * *