U.S. patent application number 11/573465 was filed with the patent office on 2008-10-23 for low carbon steel expandable tubular.
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 | 20080257542 11/573465 |
Document ID | / |
Family ID | 35908122 |
Filed Date | 2008-10-23 |
United States Patent
Application |
20080257542 |
Kind Code |
A1 |
Brisco; David Paul ; et
al. |
October 23, 2008 |
Low Carbon Steel Expandable Tubular
Abstract
A low carbon steel expandable tubular (10, 100, 200).
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; (Bourbon, MO) |
Correspondence
Address: |
Conley Rose, P.C
P.O. Box 3267
Houston
TX
77253-3267
US
|
Assignee: |
ENVENTURE GLOBAL TECHNOLOGY,
LLC
Houston
TX
|
Family ID: |
35908122 |
Appl. No.: |
11/573465 |
Filed: |
August 11, 2005 |
PCT Filed: |
August 11, 2005 |
PCT NO: |
PCT/US05/28473 |
371 Date: |
May 6, 2008 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
60600679 |
Aug 11, 2004 |
|
|
|
Current U.S.
Class: |
166/207 ;
166/242.1; 166/380 |
Current CPC
Class: |
Y10T 436/23 20150115;
E21B 43/103 20130101; E21B 43/105 20130101; E21B 43/106 20130101;
E21B 29/10 20130101; C22C 38/00 20130101 |
Class at
Publication: |
166/207 ;
166/242.1; 166/380 |
International
Class: |
E21B 43/00 20060101
E21B043/00; E21B 17/00 20060101 E21B017/00 |
Claims
1. An expandable tubular member, wherein 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.
2. The tubular member of claim 1, wherein the tubular member
comprises a wellbore casing.
3. An expandable tubular member, 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.
4. The tubular member of claim 3, wherein the tubular member
comprises a wellbore casing.
5. A method for manufacturing an expandable member used to complete
a structure by radially expanding and plastically deforming the
expandable member, comprising: forming the expandable member from a
steel alloy comprising a weight percentage of carbon of less than
about 0.08%.
6. An expandable member for use in completing a wellbore by
radially expanding and plastically deforming the expandable member
at a downhole location in the wellbore, comprising: a steel alloy
comprising a weight percentage of carbon of less than about
0.08%.
7. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members positioned
within the wellbore; wherein one or more of the radially expanded
and plastically deformed expandable members are fabricated from a
steel alloy comprising a weight percentage of carbon of less than
about 0.08%.
8. A method for manufacturing an expandable member used to complete
a structure by radially expanding and plastically deforming the
expandable member, comprising: forming the expandable member from a
steel alloy comprising a weight percentage of carbon of less than
about 0.20% and a charpy V-notch impact toughness of at least about
6 joules.
9. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: a steel alloy comprising a weight percentage of carbon
of less than about 0.20% and a charpy V-notch impact toughness of
at least about 6 joules.
10. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members; wherein one
or more of the radially expanded and plastically deformed
expandable members are fabricated from a steel alloy comprising a
weight percentage of carbon of less than about 0.20% and a charpy
V-notch impact toughness of at least about 6 joules.
11. A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member, comprising: forming the expandable
member from a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5.
12. An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member,
comprising: a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5.
13. A structural completion, comprising: one or more radially
expanded and plastically deformed expandable members; wherein one
or more of the radially expanded and plastically deformed
expandable members are fabricated from a steel alloy comprising the
following ranges of weight percentages: C, from about 0.002 to
about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10
to about 1.92; P, from about 0.004 to about 0.07; S, from about
0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01;
Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb,
up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo,
up to about 5.
14. A method for manufacturing a tubular member used to complete a
wellbore by radially expanding the tubular member at a downhole
location in the wellbore comprising: forming a steel alloy
comprising a concentration of carbon between approximately 0.002%
and 0.08% by weight of the steel alloy.
15. The method of claim 14, further comprising forming the steel
alloy with a concentration of niobium comprising between
approximately 0.015% and 0.12% by weight of the steel alloy.
16. The method of claim 14, further comprising: forming the steel
alloy with low concentrations of niobium and titanium; and limiting
the total concentration of niobium and titanium to less than
approximately 0.6% by weight of the steel alloy.
17. An expandable tubular member fabricated from a steel alloy
having a concentration of carbon between approximately 0.002% and
0.08% by weight of the steel alloy.
18. A method for manufacturing an expandable tubular member used to
complete a wellbore completion within a wellbore that traverses a
subterranean formation by radially expanding and plastically
deforming the expandable tubular member within the wellbore,
comprising: forming the expandable tubular member from a steel
alloy comprising a charpy energy of at least about 90 ft-lbs;
forming the expandable member from a steel alloy comprising a
charpy V-notch impact toughness of at least about 6 joules; forming
the expandable member from a steel alloy comprising the following
ranges of weight percentages: C, from about 0.002 to about 0.08;
Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about
1.92; P, from about 0.004 to about 0.07; S, from about 0.0008 to
about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to
about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about
0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about
5; forming the expandable tubular member with a ratio of the of an
outside diameter of the expandable tubular member to a wall
thickness of the expandable tubular member ranging from about 12 to
22; and strain aging the expandable tubular member prior to the
radial expansion and plastic deformation of the expandable tubular
member within the wellbore.
19. An expandable tubular member for use in completing a wellbore
completion within a wellbore that traverses a subterranean
formation by radially expanding and plastically deforming the
expandable tubular member within the wellbore, comprising: a steel
alloy having a charpy energy of at least about 90 ft-lbs; a steel
alloy having a charpy V-notch impact toughness of at least about 6
joules; and a steel alloy comprising the following ranges of weight
percentages: C, from about 0.002 to about 0.08; Si, from about
0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from
about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al,
up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up
to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to
about 0.6; Co, up to about 9; and Mo, up to about 5; wherein a
ratio of the of an outside diameter of the expandable tubular
member to a wall thickness of the expandable tubular member ranging
from about 12 to 22; and wherein the expandable tubular member is
strain aged prior to the radial expansion and plastic deformation
of the expandable tubular member within the wellbore.
20. A wellbore completion positioned within a wellbore that
traverses a subterranean formation, comprising: one or more
radially expanded and plastically deformed expandable tubular
members positioned within the wellbore completion; wherein one or
more of the radially expanded and plastically deformed expandable
tubular members are fabricated from: a steel alloy comprising a
charpy energy of at least about 90 ft-lbs; a steel alloy comprising
a charpy V-notch impact toughness of at least about 6 joules; and a
steel alloy comprising the following ranges of weight percentages:
C, from about 0.002 to about 0.08; Si, from about 0.009 to about
0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 to
about 0.07; S, from about 0.0008 to about 0.006; Al, up to about
0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about
0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6;
Co, up to about 9; and Mo, up to about 5; wherein at least one of
the expandable members comprises a ratio of the of an outside
diameter of the expandable member to a wall thickness of the
expandable member ranging from about 12 to 22; wherein an outer
portion of the wall thickness of at least one of the radially
expanded and plastically deformed expandable comprises tensile
residual stresses; and wherein at least one of the expandable
tubular member is strain aged prior to the radial expansion and
plastic deformation of the expandable tubular member within the
wellbore.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] 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
provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S.
patent application Ser. No. 09/510,913, attorney docket no.
25791.7.02, filed on Feb. 23, 2000, which claims priority from
provisional application 60/121,702, filed on Feb. 25, 1999, (3)
U.S. patent application Ser. No. 09/502,350, attorney docket no.
25791.8.02, filed on Feb. 10, 2000, which claims priority from
provisional application 60/119,611, filed on Feb. 11, 1999, (4)
U.S. Pat. No. 6,328,113, which was filed as U.S. patent application
Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on
Nov. 15, 1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application
Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul.
1, 2002, which claims priority from provisional application
60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application
Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar.
10, 2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471,
which was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent
application Ser. No. 09/511,941, attorney docket no. 25791.16.02,
filed on Feb. 24, 2000, which claims priority from provisional
application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No.
6,557,640, which was filed as patent application Ser. No.
09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000,
which claims priority from provisional application 60/137,998,
filed on Jun. 7, 1999, (10) U.S. patent application Ser. No.
09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as
a continuation-in-part application of U.S. Pat. No. 6,328,113,
which was filed as U.S. patent application Ser. No. 09/440,338,
attorney docket number 25791.9.02, filed on Nov. 15, 1999, which
claims priority from provisional application 60/108,558, filed on
Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as
application Ser. No. 09/559,122, attorney docket no. 25791.23.02,
filed on Apr. 26, 2000, which claims priority from provisional
application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent
application Ser. No. 10/030,593, attorney docket no. 25791.25.08,
filed on Jan. 8, 2002, which claims priority from provisional
application 60/146,203, filed on Jul. 29, 1999, (13) U.S.
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no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application
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filed on Nov. 1, 1999, (15) U.S. provisional patent application
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(17) U.S. Pat. No. 6,564,875, which was filed as application Ser.
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which claims priority from provisional patent application Ser. No.
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(18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27,
2002, attorney docket no. 25791.36.03, which claims priority from
provisional patent application Ser. No. 60/159,039, attorney docket
no. 25791.36, filed on Oct. 12, 1999, (19) U.S. patent application
Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no.
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application Ser. No. 60/159,033, attorney docket no. 25791.37,
filed on Oct. 12, 1999, (20) U.S. patent application Ser. No.
10/303,992, filed on Nov. 22, 2002, attorney docket no.
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application Ser. No. 60/212,359, attorney docket no. 25791.38,
filed on Jun. 19, 2000, (21) U.S. provisional patent application
Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov.
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(23) PCT application US02/2477, filed on Jun. 26, 2002, attorney
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patent application Ser. No. 60/303,711, attorney docket no.
25791.44, filed on Jul. 6, 2001, (24) U.S. patent application Ser.
No. 10/311,412, filed on Dec. 12, 2002, attorney docket no.
25791.45.07, which claims priority from provisional patent
application Ser. No. 60/221,443, attorney docket no. 25791.45,
filed on Jul. 28, 2000, (25) U.S. patent application Ser. No.
10/______, filed on Dec. 18, 2002, attorney docket no. 25791.46.07,
which claims priority from provisional patent application Ser. No.
60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000,
(26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22,
2003, attorney docket no. 25791.47.03, which claims priority from
provisional patent application Ser. No. 60/233,638, attorney docket
no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application
Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no.
25791.48.06, which claims priority from provisional patent
application Ser. No. 60/237,334, attorney docket no. 25791.48,
filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on
Feb. 14, 2002, attorney docket no. 25791.50.02, which claims
priority from U.S. provisional patent application Ser. No.
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(29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13,
2003, attorney docket no. 25791.51.06, which claims priority from
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application Ser. No. 60/259,486, attorney docket no. 25791.52,
filed on Jan. 3, 2001, (31) U.S. provisional patent application
Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no.
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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.
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filed on Dec. 7, 1998, (33) U.S. Pat. No. 6,561,227, which was
filed as patent application Ser. No. 09/852,026, filed on May. 9,
2001, attorney docket no. 25791.56, as a divisional application of
U.S. Pat. No. 6,497,289, which was filed as U.S. patent application
Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec.
3, 1999, which claims priority from provisional application
60/111,293, filed on Dec. 7, 1998, (34) U.S. patent application
Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no.
25791.57, as a divisional application of U.S. Pat. No. 6,497,289,
which was filed as U.S. patent application Ser. No. 09/454,139,
attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which
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provisional application 60/318,021, filed on Sep. 7, 2001, attorney
docket no. 25791.58, (36) PCT Application US02/24399, attorney
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priority from U.S. provisional patent application Ser. No.
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(37) PCT Application US02/29856, attorney docket no. 25791.60.02,
filed on Sep. 19, 2002, which claims priority from U.S. provisional
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attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which
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(39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25,
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provisional application 60/124,042, filed on Mar. 11, 1999, (40)
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2001, attorney docket no. 25791.63, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
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provisional application 60/124,042, filed on Mar. 11, 1999, (41)
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2001, attorney docket no. 25791.64, which is a divisional of U.S.
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provisional application 60/124,042, filed on Mar. 11, 1999, (42)
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2001, attorney docket no. 25791.65, which is a divisional of U.S.
patent application Ser. No. 09/523,468, attorney docket no.
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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.
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provisional application 60/124,042, filed on Mar. 11, 1999, (44)
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priority from provisional application 60/108,558, filed on Nov. 16,
1998, (47) U.S. utility patent application Ser. No. 10/516,467,
attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a
continuation application of U.S. utility patent application Ser.
No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3,
2001, which is a continuation-in-part application of U.S. Pat. No.
6,328,113, which was filed as U.S. patent application Ser. No.
09/440,338, attorney docket number 25791.9.02, filed on Nov. 15,
1999, which claims priority from provisional application
60/108,558, filed on Nov. 16, 1998, (48) PCT application US
03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02,
which claims priority from U.S. provisional patent application Ser.
No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15,
2002, (49) U.S. patent application Ser. No. 10/074,703, attorney
docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (50) U.S. patent application
Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb.
12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
was filed as patent application Ser. No. 09/512,895, attorney
docket no. 25791.12.02, filed on Feb. 24, 2000, which claims
priority from provisional application 60/121,841, filed on Feb. 26,
1999, (51) U.S. patent application Ser. No. 10/076,660, attorney
docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional
of U.S. Pat. No. 6,568,471, which was filed as patent application
Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb.
24, 2000, which claims priority from provisional application
60/121,841, filed on Feb. 26, 1999, (52) U.S. patent application
Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb.
15, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which
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of U.S. Pat. No. 6,568,471, which was filed as patent application
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(65) PCT application US 03/15020, filed on May 12, 2003, attorney
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claims priority from U.S. provisional patent
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(68) U.S. patent application Ser. No. 10/331,718, attorney docket
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2002, (79) PCT application US 03/18530, filed on Jun. 11, 2003,
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2002, (81) PCT application US 03/20870, filed on Jul. 2, 2003,
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provisional patent application Ser. No. 60/405,394, attorney docket
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priority from U.S. provisional patent application Ser. No.
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(91) U.S. provisional patent application Ser. No. 60/423,363,
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no. 25791.127, filed on Sep. 20, 2002, (93) U.S. provisional patent
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filed on Sep. 20, 2002, (94) U.S. provisional patent application
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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
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filed on Feb. 18, 2003, (99) U.S. provisional patent application
Ser. No. 60/461,539, attorney docket no. 25791.186, filed on Apr.
9, 2003, (100) U.S. provisional patent application Ser. No.
60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003,
(101) U.S. provisional patent application Ser. No. 60/436,106,
attorney docket no. 25791.200, filed on Dec. 23, 2002, (102) U.S.
provisional patent application Ser. No. 60/442,942, attorney docket
no. 25791.213, filed on Jan. 27, 2003, (103) U.S. provisional
patent application Ser. No. 60/442,938, attorney docket no.
25791.225, filed on Jan. 27, 2003, (104) U.S. provisional patent
application Ser. No. 60/418,687, attorney docket no. 25791.228,
filed on Apr. 18, 2003, (105) U.S. provisional patent application
Ser. No. 60/454,896, attorney docket no. 25791.236, filed on Mar.
14, 2003, (106) U.S. provisional patent application Ser. No.
60/450,504, attorney docket no. 25791.238, filed on Feb. 26, 2003,
(107) U.S. provisional patent application Ser. No. 60/451,152,
attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S.
provisional patent application Ser. No. 60/455,124, attorney docket
no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional
patent application Ser. No. 60/453,678, attorney docket no.
25791.253, filed on Mar. 11, 2003, (110) U.S. patent application
Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr.
23, 2003, which is a continuation of U.S. patent application Ser.
No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10,
2000, which claims priority from provisional application
60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent
application Ser. No. 60/457,965, attorney docket no. 25791.260,
filed on Mar. 27, 2003, (112) U.S. provisional patent application
Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar.
18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent
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25791.268, filed on May 12, 2003, which is a continuation of U.S.
Pat. No. 6,604,763, which was filed as application Ser. No.
09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26,
2000, which claims priority from provisional application
60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent
application Ser. No. 60/459,776, attorney docket no. 25791.270,
filed on Apr. 2, 2003, (116) U.S. provisional patent application
Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr.
8, 2003, (117) U.S. provisional patent application Ser. No.
60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003,
(118) U.S. provisional patent application Ser. No. 60/463,586,
attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S.
provisional patent application Ser. No. 60/472,240, attorney docket
no. 25791.286, filed on May 20, 2003, (120) U.S. patent application
Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul.
14, 2003, which is a continuation-in-part of U.S. utility patent
application Ser. No. 09/969,922, attorney docket no. 25791.69,
filed on Oct. 3, 2001, which is a continuation-in-part application
of U.S. Pat. No. 6,328,113, which was filed as U.S. patent
application Ser. No. 09/440,338, attorney docket number 25791.9.02,
filed on Nov. 15, 1999, which claims priority from provisional
application 60/108,558, filed on Nov. 16, 1998, (121) U.S. utility
patent application Ser. No. 10/418,688, attorney docket no.
25791.257, which was filed on Apr. 18, 2003, as a division of U.S.
utility patent application Ser. No. 09/523,468, attorney docket no.
25791.11.02, filed on Mar. 10, 2000, which claims priority from
provisional application 60/124,042, filed on Mar. 11, 1999, (122)
PCT patent application serial number 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,
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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, an
expandable tubular member is provided, wherein 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.
[0006] According to another aspect of the present invention, an
expandable tubular member is provided, 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.
[0007] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member includes forming the expandable member from a
steel alloy comprising a weight percentage of carbon of less than
about 0.08%.
[0008] According to another aspect of the present invention, an
expandable member for use in completing a wellbore by radially
expanding and plastically deforming the expandable member at a
downhole location in the wellbore includes a steel alloy comprising
a weight percentage of carbon of less than about 0.08%.
[0009] According to another aspect of the present invention, a
structural completion includes one or more radially expanded and
plastically deformed expandable members positioned within the
wellbore; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising a weight percentage of carbon of less than about
0.08%.
[0010] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member includes forming the expandable member from a
steel alloy comprising a weight percentage of carbon of less than
about 0.20% and a charpy V-notch impact toughness of at least about
6 joules.
[0011] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member includes
a steel alloy comprising a weight percentage of carbon of less than
about 0.20% and a charpy V-notch impact toughness of at least about
6 joules.
[0012] According to another aspect of the present invention, a
structural completion includes one or more radially expanded and
plastically deformed expandable members; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from a steel alloy comprising a weight percentage of
carbon of less than about 0.20% and a charpy V-notch impact
toughness of at least about 6 joules.
[0013] According to another aspect of the present invention, a
method for manufacturing an expandable member used to complete a
structure by radially expanding and plastically deforming the
expandable member includes forming the expandable member from a
steel alloy comprising the following ranges of weight percentages:
[0014] C, from about 0.002 to about 0.08; [0015] Si, from about
0.009 to about 0.30; [0016] Mn, from about 0.10 to about 1.92;
[0017] P, from about 0.004 to about 0.07; [0018] S, from about
0.0008 to about 0.006; [0019] Al, up to about 0.04; [0020] N, up to
about 0.01; [0021] Cu, up to about 0.3; [0022] Cr, up to about 0.5;
[0023] Ni, up to about 18; [0024] Nb, up to about 0.12; [0025] Ti,
up to about 0.6; [0026] Co, up to about 9; and [0027] Mo, up to
about 5.
[0028] According to another aspect of the present invention, an
expandable member for use in completing a structure by radially
expanding and plastically deforming the expandable member includes
a steel alloy comprising the following ranges of weight
percentages: [0029] C, from about 0.002 to about 0.08; [0030] Si,
from about 0.009 to about 0.30; [0031] Mn, from about 0.10 to about
1.92; [0032] P, from about 0.004 to about 0.07; [0033] S, from
about 0.0008 to about 0.006; [0034] Al, up to about 0.04; [0035] N,
up to about 0.01; [0036] Cu, up to about 0.3; [0037] Cr, up to
about 0.5; [0038] Ni, up to about 18; [0039] Nb, up to about 0.12;
[0040] Ti, up to about 0.6; [0041] Co, up to about 9; and [0042]
Mo, up to about 5.
[0043] According to another aspect of the present invention, a
structural completion includes one or more radially expanded and
plastically deformed expandable members; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from a steel alloy comprising the following ranges of
weight percentages: [0044] C, from about 0.002 to about 0.08;
[0045] Si, from about 0.009 to about 0.30; [0046] Mn, from about
0.10 to about 1.92; [0047] P, from about 0.004 to about 0.07;
[0048] S, from about 0.0008 to about 0.006; [0049] Al, up to about
0.04; [0050] N, up to about 0.01; [0051] Cu, up to about 0.3;
[0052] Cr, up to about 0.5; [0053] Ni, up to about 18; [0054] Nb,
up to about 0.12; [0055] Ti, up to about 0.6; [0056] Co, up to
about 9; and [0057] Mo, up to about 5.
[0058] According to another aspect of the present invention, a
method for manufacturing a tubular member used to complete a
wellbore by radially expanding the tubular member at a downhole
location in the wellbore includes forming a steel alloy comprising
a concentration of carbon between approximately 0.002% and 0.08% by
weight of the steel alloy.
[0059] According to another aspect of the present invention, an
expandable tubular member is fabricated from a steel alloy having a
concentration of carbon between approximately 0.002% and 0.08% by
weight of the steel alloy.
[0060] According to another aspect of the present invention, a
method for manufacturing an expandable tubular member used to
complete a wellbore completion within a wellbore that traverses a
subterranean formation by radially expanding and plastically
deforming the expandable tubular member within the wellbore
includes forming the expandable tubular member from a steel alloy
comprising a charpy energy of at least about 90 ft-lbs; forming the
expandable member from a steel alloy comprising a charpy V-notch
impact toughness of at least about 6 joules; forming the expandable
member from a steel alloy comprising the following ranges of weight
percentages: [0061] C, from about 0.002 to about 0.08; [0062] Si,
from about 0.009 to about 0.30; [0063] Mn, from about 0.10 to about
1.92; [0064] P, from about 0.004 to about 0.07; [0065] S, from
about 0.0008 to about 0.006; [0066] Al, up to about 0.04; [0067] N,
up to about 0.01; [0068] Cu, up to about 0.3; [0069] Cr, up to
about 0.5; [0070] Ni, up to about 18; [0071] Nb, up to about 0.12;
[0072] Ti, up to about 0.6; [0073] Co, up to about 9; and [0074]
Mo, up to about 5; forming the expandable tubular member with a
ratio of the of an outside diameter of the expandable tubular
member to a wall thickness of the expandable tubular member ranging
from about 12 to 22; and strain aging the expandable tubular member
prior to the radial expansion and plastic deformation of the
expandable tubular member within the wellbore.
[0075] According to another aspect of the present invention, an
expandable tubular member for use in completing a wellbore
completion within a wellbore that traverses a subterranean
formation by radially expanding and plastically deforming the
expandable tubular member within the wellbore includes a steel
alloy having a charpy energy of at least about 90 ft-lbs; a steel
alloy having a charpy V-notch impact toughness of at least about 6
joules; and a steel alloy comprising the following ranges of weight
percentages: [0076] C, from about 0.002 to about 0.08; [0077] Si,
from about 0.009 to about 0.30; [0078] Mn, from about 0.10 to about
1.92; [0079] P, from about 0.004 to about 0.07; [0080] S, from
about 0.0008 to about 0.006; [0081] Al, up to about 0.04; [0082] N,
up to about 0.01; [0083] Cu, up to about 0.3; [0084] Cr, up to
about 0.5; [0085] Ni, up to about 18; [0086] Nb, up to about 0.12;
[0087] Ti, up to about 0.6; [0088] Co, up to about 9; and [0089]
Mo, up to about 5; wherein a ratio of the of an outside diameter of
the expandable tubular member to a wall thickness of the expandable
tubular member ranging from about 12 to 22; and wherein the
expandable tubular member is strain aged prior to the radial
expansion and plastic deformation of the expandable tubular member
within the wellbore.
[0090] According to another aspect of the present invention, a
wellbore completion positioned within a wellbore that traverses a
subterranean formation includes one or more radially expanded and
plastically deformed expandable tubular members positioned within
the wellbore completion; wherein one or more of the radially
expanded and plastically deformed expandable tubular members are
fabricated to from a steel alloy comprising a charpy energy of at
least about 90 ft-lbs; a steel alloy comprising a charpy V-notch
impact toughness of at least about 6 joules; and a steel alloy
comprising the following ranges of weight percentages: [0091] C,
from about 0.002 to about 0.08; [0092] Si, from about 0.009 to
about 0.30; [0093] Mn, from about 0.10 to about 1.92; [0094] P,
from about 0.004 to about 0.07; [0095] S, from about 0.0008 to
about 0.006; [0096] Al, up to about 0.04; [0097] N, up to about
0.01; [0098] Cu, up to about 0.3; [0099] Cr, up to about 0.5;
[0100] Ni, up to about 18; [0101] Nb, up to about 0.12; [0102] Ti,
up to about 0.6; [0103] Co, up to about 9; and [0104] Mo, up to
about 5; wherein at least one of the expandable members comprises a
ratio of the of an outside diameter of the expandable member to a
wall thickness of the expandable member ranging from about 12 to
22; wherein an outer portion of the wall thickness of at least one
of the radially expanded and plastically deformed expandable
comprises tensile residual stresses; and wherein at least one of
the expandable tubular member is strain aged prior to the radial
expansion and plastic deformation of the expandable tubular member
within the wellbore.
BRIEF DESCRIPTION OF THE DRAWINGS
[0105] FIG. 1 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0106] 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.
[0107] 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.
[0108] 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.
[0109] 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.
[0110] 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.
[0111] FIG. 7 is a fragmentary cross sectional illustration of an
embodiment of a series of overlapping expandable tubular
members.
[0112] FIG. 8 is a fragmentary cross sectional view of an exemplary
embodiment of an expandable tubular member positioned within a
preexisting structure.
[0113] 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.
[0114] 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.
[0115] 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.
[0116] 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.
[0117] 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.
[0118] FIG. 14 is a fragmentary cross sectional view of an
exemplary embodiment of an expandable tubular member positioned
within a preexisting structure.
[0119] 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.
[0120] 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.
[0121] 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.
[0122] FIG. 18 is a flow chart illustration of an exemplary
embodiment of a method of processing an expandable tubular
member.
[0123] 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.
[0124] FIG. 20 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0125] FIG. 21 is a graphical illustration of stress/strain curves
for an exemplary embodiment of an expandable tubular member.
[0126] FIG. 35a is a fragmentary cross-sectional illustration of an
exemplary embodiment of an expandable tubular member.
[0127] 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.
[0128] FIG. 36a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0129] FIG. 36b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0130] FIG. 36c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0131] FIG. 37a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0132] FIG. 37b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0133] FIG. 37c is an illustration of the microstructure of an
exemplary embodiment of a tubular member after thermal
processing.
[0134] FIG. 38a is a flow chart illustration of an exemplary
embodiment of a method for processing a tubular member.
[0135] FIG. 38b is an illustration of the microstructure of an
exemplary embodiment of a tubular member prior to thermal
processing.
[0136] 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
[0137] 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.
[0138] 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.
[0139] 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.
[0140] 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.
[0141] 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.
[0142] 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.
[0143] 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.
[0144] 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.
[0145] 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.
[0146] 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.
[0147] 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.
[0148] 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.
[0149] 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.
[0150] 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.
[0151] 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.
[0152] 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.
[0153] 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.
[0154] 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.
[0155] 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.
[0156] In an exemplary embodiment, the anisotropy ratio AR for the
first and second expandable tubular members is defined by the
following equation:
AR=In(WT.sub.f/WT.sub.o)/In(D.sub.f/D.sub.o); [0157] where
AR=anisotropy ratio; [0158] where WT.sub.f=final wall thickness of
the expandable tubular member following the radial expansion and
plastic deformation of the expandable tubular member; [0159] 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; [0160] 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 [0161] 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.
[0162] In an exemplary embodiment, the anisotropy ratio AR for the
first and/or second expandable tubular members, 204 and 204, is
greater than 1.
[0163] In an exemplary exoperimental 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.
[0164] 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.
[0165] 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.
[0166] 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
[0167] 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: [0168] i.
f=r.times.n [0169] ii. where f=expandability coefficient; [0170] 1.
r=anisotropy coefficient; and [0171] 2. n=strain hardening
exponent.
[0172] 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.
[0173] 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.
[0174] 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
[0175] 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.
[0176] 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
[0177] 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.
[0178] 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
[0179] 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 Expand- Steel Yield Yield Elongation Energy
ability 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 --
[0180] 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.
[0181] 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
where C.sub.e=carbon equivalent value; [0182] a. C=carbon
percentage by weight; [0183] b. Mn=manganese percentage by weight;
[0184] c. Cr=chromium percentage by weight; [0185] d. Mo=molybdenum
percentage by weight; [0186] e. V=vanadium percentage by weight;
[0187] f. Ti=titanium percentage by weight; [0188] g. Nb=niobium
percentage by weight; [0189] h. Ni=nickel percentage by weight; and
[0190] i. Cu=copper percentage by weight.
[0191] 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.
[0192] 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
where C.sub.e=carbon equivalent value; [0193] a. C=carbon
percentage by weight; [0194] b. Si=silicon percentage by weight;
[0195] c. Mn=manganese percentage by weight; [0196] d. Cu=copper
percentage by weight; [0197] e. Cr=chromium percentage by weight;
[0198] f. Ni=nickel percentage by weight; [0199] g. Mo=molybdenum
percentage by weight; [0200] h. V=vanadium percentage by weight;
and [0201] i. B=boron percentage by weight.
[0202] 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.
[0203] 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. 11, 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.
[0204] 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.
[0205] 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.
[0206] 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.
[0207] 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.
[0208] 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.
[0209] 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.
[0210] In an exemplary embodiment, the expandable tubular member
3602a is then quenched in water in step 3606.
[0211] 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.
[0212] 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.
[0213] 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.
[0214] 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.
[0215] 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.
[0216] In an exemplary embodiment, the expandable tubular member
3702a is then quenched in water in step 3706.
[0217] 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.
[0218] 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.
[0219] 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.
[0220] 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.
[0221] 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.
[0222] In an exemplary embodiment, the expandable tubular member
3802a is then quenched in water in step 3806.
[0223] 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.
[0224] 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.
[0225] 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.
[0226] 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.
[0227] 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.
[0228] 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.
[0229] In an exemplary embodiment, the tubular members are
fabricated from a steel alloy having reduced sulfur content in
order to minimize hydrogen induced cracking.
[0230] 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.
[0231] 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.
[0232] 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-00006 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 0.1 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
[0233] 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.
[0234] 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.
[0235] 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.
[0236] 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-00007 Collapse Strength After 10% Radial Tubular Sample
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
[0237] 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.
[0238] An expandable tubular member has been described, wherein 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.
[0239] 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.
[0240] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising a
weight percentage of carbon of less than about 0.08%.
[0241] An expandable member for use in completing a wellbore by
radially expanding and plastically deforming the expandable member
at a downhole location in the wellbore has been described that
includes a steel alloy comprising a weight percentage of carbon of
less than about 0.08%.
[0242] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members positioned within the wellbore; wherein one or more of the
radially expanded and plastically deformed expandable members are
fabricated from a steel alloy comprising a weight percentage of
carbon of less than about 0.08%.
[0243] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising a
weight percentage of carbon of less than about 0.20% and a charpy
V-notch impact toughness of at least about 6 joules.
[0244] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes a steel alloy comprising a weight
percentage of carbon of less than about 0.20% and a charpy V-notch
impact toughness of at least about 6 joules.
[0245] A structural completion has been described that include one
or more radially expanded and plastically deformed expandable
members; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising a weight percentage of carbon of less than about
0.20% and a charpy V-notch impact toughness of at least about 6
joules.
[0246] A method for manufacturing an expandable member used to
complete a structure by radially expanding and plastically
deforming the expandable member has been described that includes
forming the expandable member from a steel alloy comprising the
following ranges of weight percentages: [0247] C, from about 0.002
to about 0.08; [0248] Si, from about 0.009 to about 0.30; [0249]
Mn, from about 0.10 to about 1.92; [0250] P, from about 0.004 to
about 0.07; [0251] S, from about 0.0008 to about 0.006; [0252] Al,
up to about 0.04; [0253] N, up to about 0.01; [0254] Cu, up to
about 0.3; [0255] Cr, up to about 0.5; [0256] Ni, up to about 18;
[0257] Nb, up to about 0.12; [0258] Ti, up to about 0.6; [0259] Co,
up to about 9; and [0260] Mo, up to about 5.
[0261] An expandable member for use in completing a structure by
radially expanding and plastically deforming the expandable member
has been described that includes a steel alloy comprising the
following ranges of weight percentages: [0262] C, from about 0.002
to about 0.08; [0263] Si, from about 0.009 to about 0.30; [0264]
Mn, from about 0.10 to about 1.92; [0265] P, from about 0.004 to
about 0.07; [0266] S, from about 0.0008 to about 0.006; [0267] Al,
up to about 0.04; [0268] N, up to about 0.01; [0269] Cu, up to
about 0.3; [0270] Cr, up to about 0.5; [0271] Ni, up to about 18;
[0272] Nb, up to about 0.12; [0273] Ti, up to about 0.6; [0274] Co,
up to about 9; and [0275] Mo, up to about 5.
[0276] A structural completion has been described that includes one
or more radially expanded and plastically deformed expandable
members; wherein one or more of the radially expanded and
plastically deformed expandable members are fabricated from a steel
alloy comprising the following ranges of weight percentages: [0277]
C, from about 0.002 to about 0.08; [0278] Si, from about 0.009 to
about 0.30; [0279] Mn, from about 0.10 to about 1.92; [0280] P,
from about 0.004 to about 0.07; [0281] S, from about 0.0008 to
about 0.006; [0282] Al, up to about 0.04; [0283] N, up to about
0.01; [0284] Cu, up to about 0.3; [0285] Cr, up to about 0.5;
[0286] Ni, up to about 18; [0287] Nb, up to about 0.12; [0288] Ti,
up to about 0.6; [0289] Co, up to about 9; and [0290] Mo, up to
about 5.
[0291] A method for manufacturing a tubular member used to complete
a wellbore by radially expanding the tubular member at a downhole
location in the wellbore has been described that includes forming a
steel alloy comprising a concentration of carbon between
approximately 0.002% and 0.08% by weight of the steel alloy. In one
exemplary embodiment, the method includes forming the steel alloy
with a concentration of niobium comprising between approximately
0.015% and 0.12% by weight of the steel alloy. In one exemplary
embodiment, the method includes forming the steel alloy with low
concentrations of niobium and titanium; and limiting the total
concentration of niobium and titanium to less than approximately
0.6% by weight of the steel alloy.
[0292] An expandable tubular member has been described that is
fabricated from a steel alloy having a concentration of carbon
between approximately 0.002% and 0.08% by weight of the steel
alloy.
[0293] A method for manufacturing an expandable tubular member used
to complete a wellbore completion within a wellbore that traverses
a subterranean formation by radially expanding and plastically
deforming the expandable tubular member within the wellbore has
been described that includes forming the expandable tubular member
from a steel alloy comprising a charpy energy of at least about 90
ft-lbs; forming the expandable member from a steel alloy comprising
a charpy V-notch impact toughness of at least about 6 joules;
forming the expandable member from a steel alloy comprising the
following ranges of weight percentages: [0294] C, from about 0.002
to about 0.08; [0295] Si, from about 0.009 to about 0.30; [0296]
Mn, from about 0.10 to about 1.92; [0297] P, from about 0.004 to
about 0.07; [0298] S, from about 0.0008 to about 0.006; [0299] Al,
up to about 0.04; [0300] N, up to about 0.01; [0301] Cu, up to
about 0.3; [0302] Cr, up to about 0.5; [0303] Ni, up to about 18;
[0304] Nb, up to about 0.12; [0305] Ti, up to about 0.6; [0306] Co,
up to about 9; and [0307] Mo, up to about 5; forming the expandable
tubular member with a ratio of the of an outside diameter of the
expandable tubular member to a wall thickness of the expandable
tubular member ranging from about 12 to 22; and strain aging the
expandable tubular member prior to the radial expansion and plastic
deformation of the expandable tubular member within the
wellbore.
[0308] An expandable tubular member for use in completing a
wellbore completion within a wellbore that traverses a subterranean
formation by radially expanding and plastically deforming the
expandable tubular member within the wellbore has been described
that includes a steel alloy having a charpy energy of at least
about 90 ft-lbs; a steel alloy having a charpy V-notch impact
toughness of at least about 6 joules; and a steel alloy comprising
the following ranges of weight percentages: [0309] C, from about
0.002 to about 0.08; [0310] Si, from about 0.009 to about 0.30;
[0311] Mn, from about 0.10 to about 1.92; [0312] P, from about
0.004 to about 0.07; [0313] S, from about 0.0008 to about 0.006;
[0314] Al, up to about 0.04; [0315] N, up to about 0.01; [0316] Cu,
up to about 0.3; [0317] Cr, up to about 0.5; [0318] Ni, up to about
18; [0319] Nb, up to about 0.12; [0320] Ti, up to about 0.6; [0321]
Co, up to about 9; and [0322] Mo, up to about 5; wherein a ratio of
the of an outside diameter of the expandable tubular member to a
wall thickness of the expandable tubular member ranging from about
12 to 22; and wherein the expandable tubular member is strain aged
prior to the radial expansion and plastic deformation of the
expandable tubular member within the wellbore.
[0323] A wellbore completion positioned within a wellbore that
traverses a subterranean formation has been described that includes
one or more radially expanded and plastically deformed expandable
tubular members positioned within the wellbore completion; wherein
one or more of the radially expanded and plastically deformed
expandable tubular members are fabricated from: [0324] a steel
alloy comprising a charpy energy of at least about 90 ft-lbs;
[0325] a steel alloy comprising a charpy V-notch impact toughness
of at least about 6 joules; and [0326] a steel alloy comprising the
following ranges of weight percentages: [0327] C, from about 0.002
to about 0.08; [0328] Si, from about 0.009 to about 0.30; [0329]
Mn, from about 0.10 to about 1.92; [0330] P, from about 0.004 to
about 0.07; [0331] S, from about 0.0008 to about 0.006; [0332] Al,
up to about 0.04; [0333] N, up to about 0.01; [0334] Cu, up to
about 0.3; [0335] Cr, up to about 0.5; [0336] Ni, up to about 18;
[0337] Nb, up to about 0.12; [0338] Ti, up to about 0.6; [0339] Co,
up to about 9; and [0340] Mo, up to about 5; wherein at least one
of the expandable members comprises a ratio of the of an outside
diameter of the expandable member to a wall thickness of the
expandable member ranging from about 12 to 22; wherein an outer
portion of the wall thickness of at least one of the radially
expanded and plastically deformed expandable comprises tensile
residual stresses; and wherein at least one of the expandable
tubular member is strain aged prior to the radial expansion and
plastic deformation of the expandable tubular member within the
wellbore.
[0341] 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.
[0342] 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.
* * * * *