AU2005242124A1 - Lubricant coating for expandable tubular members - Google Patents

Description

P/00/011 Regulation 3.2

AUSTRALIA

Patents Act 1990 COMPLETE SPECIFICATION STANDARD PATENT

(ORIGINAL)

Name of Applicant: Actual Inventors: Address for Service: Invention Title: Shell Internationale Research Maatschappij of Carel van Bylandtlaan 30, 2596 HR The Hague, The Netherlands Lev RING Andrei FILLIPOV Mike COWAN Bill DEAN DAVIES COLLISON CAVE, Patent Trademark Attorneys, of 1 Nicholson Street, Melbourne, 3000, Victoria, Australia Ph: 03 9254 2777 Fax: 03 9254 2770 Attorney Code: DM "Lubricant coating for expandable tubular members" The following statement is a full description of this invention, including the best method of performing it known to us:- Q:\OPER\PHH\12696520 2 December.doc 31/8/04 LUBRICANT COATING FOR EXPANDABLE TUBULAR MEMBERS Cross Reference To Related Applications This application claims the benefit of the filing date of: U.S. Provisional Patent Application serial no. 60/159,039, attorney docket no. 25791.36, filed on October 12, 1999; and U.S. Provisional Patent Application serial no.

60/165,228, attorney docket no. 25791.39, filed on November 12, 1999, the disclosures of which are incorporated herein by reference.

This application is related to the following co-pending applications: Provisional Patent Attorney Filing Date Application Number Docket No.

LO 60/108,558 25791.9 11-16-1998 60/111,293 25791.3 12-7-1998 60/119,611 25791.8 2-11-1999 60/121,702 25791.7 2-25-1999 60/121,841 25791.12 2-26-1999 60/121,907 25791.16 2-26-1999 60/124,042 25791.11 3-11-1999 60/131,106 25791.23 4-26-1999 60/137,998 25791.17 6-7-1999 60/143,039 25791.26 7-9-1999 60/146,203 25791.25 7-29-1999 60/154,047 25791.29 9-16-1999 60/159,082 25791.34 10-12-1999 60/159,039 25791.36 10-12-1999 60/159,033 25791.37 10-12-1999 60/162,671 25791.27 11-01-1999 Applicants incorporate by reference the disclosures of these applications.

-1c Background of the Invention This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.

Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously tI installed casing of an upper borehole interval. As a consequence of this procedure S 10 the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores.

Summary of the Invention According to one aspect of the present invention, an expandable tubular assembly is provided that includes one or more tubular members and a layer of a lubricant coupled to the interior surfaces of the tubular members.

According to another aspect of the present invention, a method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure is provided that includes coating the interior surfaces of the tubular members with a lubricant, positioning the tubular members within a Spreexisting structure and radially expanding the tubular members into contact Uwith the preexisting structure.

According to another aspect of the present invention, an apparatus is IDprovided that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a lubricant, positioning the tubular members within a preexisting structure, and radially expanding the tubular members into contact with the V) preexisting structure.

According to another aspect of the present invention, an expandable tubular assembly is provided that includes one or more tubular members, and a layer of a first part of a lubricant coupled to the interior surfaces of the tubular members.

According to another aspect of the present invention, a method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure is provided that includes positioning the expandable tubular assembly into the preexisting structure, injecting a quantity of alubricant material into contact with the expandable tubular assembly, and radially expanding the expandable tubular assembly into contact with the preexisting structure.

According to another aspect of the present invention, an apparatus is provided that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure, inj ecting a quantity of a lubricant material into contact with the tubular members, and radially expanding the tubular members into contact with the preexisting structure.

According to another aspect of the present invention, a method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure is provided that includes coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant, Sand radially expanding the tubular members into contact with the preexisting U structure.

According to another aspect of the present invention, an apparatus is NO provided that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the J preexisting structure by the process of: coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic materials having a second part of the t lubricant into contact with the coating of the first part of the lubricant, and radially expanding the tubular members into contact with the preexisting structure.

Brief Description of the Drawings Fig. 1 is a flow chart illustrating a preferred embodiment of a method for coupling a plurality of tubular members to a preexisting structure.

Fig. 2 is cross sectional illustration of a plurality of tubular members including in internal coating of a lubricant.

Fig. 3 is a fragmentary cross sectional illustration of the radial expansion of the tubular members of Fig. 2 into contact with a preexisting structure.

Fig. 4 is a flow chart illustrating an alternative preferred embodiment of a method for coupling a plurality of tubular members to a preexisting structure.

Detailed Description A method and apparatus for coupling tubular members to a preexisting structure is provided. The internal surfaces of the tubular members are coated with a lubricant. The tubular members are then radially expanded into contact with a preexisting structure. In several alternative embodiments, the method and apparatus are used to form and/or repair a wellbore casing, a pipeline, or a structural support.

In Fig. 1, a preferred embodiment of a method 100 for forming and/or repairing a wellbore casing, pipeline, or structural support includes the steps of: providing one or more tubular members in step 105; applying a lubricant coating to the interior walls of the tubular members in step 110; coupling the first and second tubular members in step 115; and radially expanding the tubular members into contact with the preexisting structure in step 120.

As illustrated in Fig. 2, in a preferred embodiment, in step 105, a first tubular member 205 having a first threaded portion 210 and a second tubular member 215 having a second threaded portion 220 are provided. The first and second tubular members, 205 and 215, may be any number of conventional commercially available tubular members. In a preferred embodiment, the first tubular member 205 includes a recess 225 containing a sealing member 230 and a retaining ring 235. In a preferred embodiment, the first and second tubular members, 205 and 210, are further provided substantially as disclosed in one or more of the following co-pending applications: Provisional Patent Attorney Filing Date Application Number Docket No.

60/108,558 25791.9 11-16-1998 60/111,293 25791.3 12-7-1998 60/119,611 25791.8 2-11-1999 60/121,702 25791.7 2-25-1999 60/121,841 25791.12 2-26-1999 60/121,907 25791.16 2-26-1999 60/124,042 25791.11 3-11-1999 60/131,106 25791.23 4-26-1999 60/137,998 25791.17 6-7-1999 60/143,039 25791.26 7-9-1999 60/146,203 25791.25 7-29-1999 60/154,047 25791.29 9-16-1999 60/159,082 25791.34 10-12-1999 60/159,039 25791.36 10-12-1999 60/159,033 25791.37 10-12-1999 60/162,671 25791.27 11-01-1999

I

cj Applicants incorporate by reference the disclosures of these applications.

O In a preferred embodiment, in step 110, a coating 240 of a lubricant is applied to the interior surfaces of the first and second tubular members, 205 and N 215. The coating 240 of lubricant may be applied prior to, or after, the first and second tubular members, 205 and 215, are coupled. The coating 240 of lubricant may be applied using any number of conventional methods such as, for example, dipping, spraying, sputter coating or electrostatic deposition. In a preferred embodiment, the coating 240 of lubricant is chemically, mechanically, and/or ln adhesively bonded to the interior surfaces of the first and second tubular members, 0 10 205 and 215, in order to optimally provide a durable and consistent lubricating effect. In a preferred embodiment, the force that bonds the lubricant to the interior surfaces of the first and second tubular members, 205 and 215, is greater than the shear force applied during the radial expansion process.

In a preferred embodiment, the coating 240 of lubricant is applied to the interior surfaces of the first and second tubular members, 205 and 215, by first applying a phenolic primer to the interior surfaces of the first and second tubular members, 205 and 215, and then bonding the coating 240 of lubricant to the phenolic primer using an antifriction paste having the coating 240 of lubricant carried in an epoxy resin. In a preferred embodiment, the antifriction paste includes, by weight, 40-80% epoxy resin, 15-30% molybdenum disulfide, 10-15% graphite, 5-10% aluminum, 5-10% copper, 8-15% alumisilicate, and 5-10% polyethylenepolyamine. In a preferred embodiment, the antifriction paste is provided substantially as disclosed in U.S. Patent No. 4,329,238, the disclosure of which is incorporate herein by reference.

The coating 240 of lubricant may be any number of conventional commercially available lubricants such as, for example, metallic soaps or zinc phosphates. In a preferred embodiment, the coating 240 of lubricant is compatible with conventional water, oil and synthetic base mud formulations. In a preferred embodiment, the coating 240 of lubricant reduces metal-to-metal frictional forces, operating pressures, reduces frictional forces by about 50%, and provides a coefficient of dynamic friction of between about 0.08 to 0.1 during the radial expansion process. In a preferred embodiment, the coating 240 of lubricant does -6- Snot increase the toxicity of conventional base mud formulations and will not sheer U in synthetic mud. In a preferred embodiment, the coating 240 of lubricant is stable for temperatures ranging from about -100 to 500 In a preferred embodiment, IN the coating 240 of lubricant is stable when exposed to shear stresses. In a preferred embodiment, the coating 240 of lubricant is stable for storage periods of up to about 5 years. In a preferred embodiment, the coating 240 of lubricant provides corrosion protection for expandable tubular members during storage and transport.

l t In a preferred embodiment, the coating 240 of lubricant includes sodium, calcium, and/or zinc stearates; and/or zinc and/or manganese phosphates; and/or and/or C-Phos-58-M; and/or C-Phos-58-R; and/or polytetrafluoroethylene (PTFE); and/or molybdenum disulfide; and/or metallic soaps (stearates, oleates, in order to optimally provide a coating of lubricant.

In a preferred embodiment, the coating 240 of lubricant provides a sliding coefficient of friction less than about 0.20 in order to optimally reduce the force required to radially expand the tubular members, 205 and 215, using an expansion cone.

In a preferred embodiment, in step 115, the first and second tubular members, 205 and 215, are coupled. The first and second tubular members, 205 and 215, may be coupled using a threaded connection, or, alternatively, the first and second tubular members, 205 and 215, may be coupled by welding or brazing.

In a preferred embodiment, the first and second tubular members, 205 and 215, are coupled substantially as disclosed in provisional patent application serial number 60/159,033, attorney docket number 25791.37, filed on October 12, 1999, the disclosure of which is incorporated herein by reference.

As illustrated in Fig. 3, in steps 120, the first and second tubular members 205 and 215 are then positioned within a preexisting structure 505, and radially expanded into contact with the interior walls of the preexisting structure 505 using an expansion cone 510. The tubular members 205 and 215 may be radially expanded into intimate contact with the interior walls of the preexisting structure 505, for example, by: pushing or pulling the expansion cone 510 through the interior of the tubular members 205 and 215; and/or pressurizing the region -7within the tubular members 205 and 215 behind the expansion cone 510 with a fluid. In a preferred embodiment, one or more sealing members 515 are further provided on the outer surface of the tubular members 205 and 215, in order to optimally seal the interface between the radially expanded tubular members 205 and 215 and the interior walls of the preexisting structure 505.

In a preferred embodiment, the radial expansion of the tubular members 205 and 215 into contact with the interior walls of the preexisting structure 505 is performed substantially as disclosed in one or more of the following co-pending patent applications: .0 U.S. Provisional Attorney Filing Date Patent Application Docket No.

Number 60/108,558 25791.9 11-16-1998 60/111,293 25791.3 12-7-1998 60/119,611 25791.8 2-11-1999 60/121,702 25791.7 2-25-1999 60/121,841 25791.12 2-26-1999 60/121,907 25791.16 2-26-1999 60/124,042 25791.11 3-11-1999 i0 60/131,106 25791.23 4-26-1999 60/137,998 25791.17 6-7-1999 60/143,039 25791.26 7-9-1999 60/146,203 25791.25 7-29-1999 60/154,047 25791.29 9-16-1999 60/159,082 25791.34 10-12-1999 60/159,039 25791.36 10-12-1999 60/159,033 25791.37 10-12-1999 60/162,671 25791.27 11-01-1999 O The disclosures of each of the above co-pending patent applications are Sincorporated by reference.

As illustrated in Fig. 4, an alternate embodiment of a method 400 for ID forming and/or repairing awellbore casing, pipeline, or structural support includes the steps of:. providing one or more tubular members in step 405; applying a coating including a first part of a lubricant to the interior walls of the tubular members in step 410; coupling the first and second tubular members in step 415; and radially expanding the tubular members into contact with the preexisting structure while also circulating fluidic materials into contact with the interior walls of the tubular members having a second part of the lubricant in step 420.

In a preferred embodiment, in step 410, a coating including a first part of a lubricant is applied to the interior walls of the tubular members, 205 and 215.

In a preferred embodiment, the first part of the lubricant forms a first part of a metallic soap. In an preferred embodiment, the first part of the lubricant coating includes zinc phosphate.

In a preferred embodiment, in step 420, a second part of the lubricant is circulated within a fluidic carrier into contact with the coating of the first part of the lubricant applied to the interior walls of the tubular members, 205 and 215. In a preferred embodiment, the first and second parts react to form a lubricating layer between the interior walls of the tubular members, 205 and 215, and the exterior surface of the expansion cone. In this manner, a lubricating layer is provided in exact concentration, exactly when and where it is needed. Furthermore, because the second part of the lubricant is circulated in a carrier fluid, the dynamic interface between the interior surfaces of the tubular members, 205 and 215, and the exterior surface of the expansion cone 510 is also preferably provided with hydrodynamic lubrication. In a preferred embodiment, the first and second parts of the lubricant react to form a metallic soap. In a preferred embodiment, the second part of the lubricant is sodium, calcium and/or zinc stearate.

In several experimental exemplary embodiments of the methods 100 and 400, the following observations were made regarding lubricant coatings for expandable tubular members: boundary lubrication with a lubricant coating having high adhesion (high film/shear strength) to the expandable tubular is the singlemost important lubricant/lubrication process in the radial expansion Iprocess; hydrodynamic lubrication plays a secondary role in the lubrication process; expandable tubular lubricant coating offers the more reliable and more effective form of boundary lubrication; a liquid lubricant viscosity and/or film strength that provides S 10 effective, consistent boundary lubrication typically limits the effectiveness of additives for the mud alone to provide the necessary lubrication while maintaining drilling fluid properties (rheology, toxicity); consistent reductions of 20 to 25 percent in propagation force during the radial expansion process (compared to uncoated expandable tubular control results) were obtained with the following dry film coatings: polytetrafluoroethylene (PTFE), molybdenum disulfide, and metallic soap (stearates), these results are for laboratory tests on one inch dry pipe, in the absence of any drilling fluid; a 20 to 25 percent reduction in propagation- force during the radial expansion process was observed; synthetic oil muds do not typically provide sufficient, reliable lubrication for uncoated pipe; the coefficient of friction for expandable tubular lubricant coatings remains essentially constant across a wide temperature range; the expected application range for expandable tubular casing expansion is between 40 'F and 400 this range is well within the essentially constant range for coefficient of friction for good coatings; and good extreme pressure boundary lubricants have a characteristic of performing better (lower coefficients of friction) as the load increases, O coefficients of friction between 0.02 and 0.08 are reported for some 0 coatings.

SIn a preferred embodiment, the optimum lubrication for in-situ expandable ND tubular radial expansion operations using the methods 100 and/or 400 includes a combination of lubrication techniques and lubricants. These can be summarized as follows: extreme pressure lubricants/lubrication techniques; and (2) hydrodynamic lubrication from the fluid in the pipe during expansion.

Extreme pressure lubrication is preferably provided by: liquid extreme pressure lubricants added to the fluid drilling fluid, etc) in contact with the internal surface of the expandable tubular during the radial expansion process, and/or solid lubricants added to the fluid added to, or contained within, the fluid in contact with the internal surface of the expandable tubular member during the radial expansion process, and/or solid lubricants applied to the internal surface of the expandable tubular member to be radially expanded, and/or (4) combinations of and above.

Liquid extreme pressure lubricant additives preferably work by chemically adhering to or being strongly attracted to the surface of the expandable tubular to be expanded. These types of liquid extreme pressure lubricant additives preferably form a 'film' on the surface of the expandable tubular member. The adhesive strength of this film is preferably greater than the shearing force along the internal surface of the expandable tubular member during the radial expansion process. This adhesive force is referred to as film strength. The film strength can be increased by increasing the viscosity of the fluid. Common viscosifiers, such as polymeric additives, are preferably added to the fluid in contact with the internal surface of the expandable tubular member during the radial expansion process to increase lubrication. In a preferred embodiment, these liquid extreme pressure lubricant additives include one or more of the following: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives such as, for example, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes such as, for example, styrene butadiene latex, urethane latexes, styrene-maleic annhydride -11copolymers, viscosity index improvers for motor oils such as polyacrylate esters, Sblock copolymers including styrene, isoprene butadiene and ethylene, ethylene acrylic acid copolymers.

IN In a preferred embodiment, extreme pressure lubrication is provided using solid lubricants that are applied to the internal surface of the expandable tubular member. These solid lubricants can be applied using various conventional Smethods of applying a film to a surface. In a preferred embodiment, these solid Slubricants are applied in a manner that ensures that the solid lubricants remain on the surface of the expandable tubular member during installation and radial expansion of the expandable tubular member. The solid lubricants preferably include one or more of the following: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), or silicone polymers.

Furthermore, blends of these solid lubricants are preferred.

In a preferred embodiment, the solid lubricants are applied directly to the expandable tubulars as coatings. The coating of the solid lubricant preferably includes a binder to help hold or fix the solid lubricant to the expandable tubular.

The binders preferably include curable resins such as, for example, epoxies, acrylic, urea-formaldehyde, melamine formaldehyde, furan based resins, acetone formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, etc. The binder is preferably selected to withstand the expected temperature range, pH, salinity and fluid types during the installation and radial expansion operations.

Polymeric materials are preferably used to bind the solid lubricants to the expandable tubular such as, for example, "self-adhesive" polymers such as those copolymers or terpolymers based upon vinyl acetate, vinyl chloride, maleic annhydride/maleic acid, and ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers and ethylene-vinyl acetate copolymers. In an alternative embodiment, the solid lubricants are applied as suspensions of fine particles in a carrier solvent without the presence/use of a chemical binder.

In a preferred embodiment, the solid lubricant coating and the liquid lubricant additive (added to the fluid in contact with the internal surface of the expandable tubular member during the radial expansion process) interact during the radial expansion process to improve the overall lubrication. In an exemplary -12- O embodiment, for phosphate solid lubricant coatings, manganese phosphate is O preferred over zinc or iron phosphate because it more effectively attracts and retains liquid lubricant additives such as oils, esters, amides, etc.

IN In a preferred embodiment, solid lubricant coatings use binders that provide low friction that is enhanced under extreme pressure conditions by the presence of the solid lubricant. Preferred solid lubricant coatings includes one or more of the following: graphite, molybdenum disulfide, silicone polymers and polytetrafluoroethylene (PTFE). In a preferred embodiment, blends of these materials are used since each material has lubrication characteristics that 0 10 optimally work at different stages in the radial expansion process. In a preferred embodiment, a solid, dry film lubricant coating for the internal surface of the expandable tubular includes: 1 to 90 percent solids by volume; more preferably, 5 to 70 percent solids by volume; and most preferably, 15 to percent solids by volume. In a preferred embodiment, the solid lubricants include: 5 to 80 percent graphite; 5 to 80 percent molybdenum disulfide; 1 to percent PTFE; and 1 to 40 percent silicone polymers.

In several exemplary embodiment, the liquid lubricant additives include one or more of the following: esters including: organic acid esters (preferably fatty acid esters) such as, for example, trimethylol propane, isopropyl, penterithritol, n-butyl, etc.; glycerol tri(acetoxy stearate) and N,N' ethylene bis 12 hydroxystearate and octyl hydroxystearate; phosphate and phosphite such as, for example, butylated triphenyl phosphate and isodiphenyl phosphate; (2) sulfurized natural and synthetic oils; alkanolamides such as, for example, coco diethanolamide; amines and amine salts; olefins and polyolefins; C-8 to C-18 linear alcohols and derivatives containing or consisting of esters, amines, carboxylates, etc.; overbased sulfonates such as, for example, calcium sulfonate, sodium sulfonate, magnesium sulfonate; polyethylene glycols; silicones and siloxanes such as, for example, dimethylpolysiloxanes and fluorosilicone derivatives; (10) dinonyl phenols; and (11) ethylene oxide/propylene oxide block copolymers.

An expandable tubular assembly has been described that includes one or more tubular members and a layer of a lubricant coupled to the interior surfaces -13- O of the tubular members. In a preferred embodiment, the lubricant includes a U metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese Sphosphate, C-Lube-10, C-PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and silicone polymers. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the lubricant is chemically bonded to the interior surfaces of the tubular members. In V a preferred embodiment, the lubricant is mechanically bonded to the interior O 10 surfaces of the tubular members. In a preferred embodiment, the lubricant is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the layer of lubricant includes: a binder and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the layer of lubricant includes about 1% to of the solid lubricant material by volume. In a preferred embodiment, the layer of lubricant includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the layer of lubricant includes about 15% to of the solid lubricant material by volume.

A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure has also been described that includes coating the interior surfaces of the tubular members with a lubricant, -14- 0 positioning the tubular members within a preexisting structure and radially 0 expanding the tubular members into contact with the preexisting structure. In a Qpreferred embodiment, the lubricant coating includes a metallic soap. In a IN preferred embodiment, the lubricant coating is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and silicone polymers.

In a preferred embodiment, the lubricant coating provides a sliding friction l coefficient of less than about 0.20. In a preferred embodiment, the lubricant 0 10 coating is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant coating includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the lubricant coating includes: a binder, and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the lubricant coating includes about 1% to 90% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 15% to 50% of the solid lubricant material by volume. In a preferred embodiment, the method further includes: injecting a o quantity of a lubricating material into contact with the expandable tubular 0 assembly. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the lubricating material includes a second part of I the lubricating substance.

An apparatus has also been described that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a lubricant, positioning the n tubular members within a preexisting structure, and radially expanding the tubular members into contact with the preexisting structure. In a preferred embodiment, the lubricant coating includes a metallic soap. In a preferred embodiment, the lubricant coating is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and silicone polymers. In a preferred embodiment, the lubricant coating provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the lubricant coating is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant coating includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the lubricant coating includes: a binder and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the -16csolid lubricant material includes: about 5 to 80 percent of graphite, about 5 to percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the I lubricant coating includes about 1% to 90% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 5% to of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 15% to 50% of the solid lubricant material by volume. In a preferred embodiment, the method further includes: injecting a Squantity of a lubricating material into contact with the expandable tubular assembly. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the injected lubricating material includes a second part of the lubricating substance.

An expandable tubular assembly has also been described that includes one or more tubular members and a layer of a first part of a lubricant coupled to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant includes a metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-Lube-10, C-PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and silicone polymers. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the lubricant is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the layer of lubricant includes: a binder and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a -17- 0 preferred embodiment, the solid lubricant material is selected from the group 0 consisting of: graphite, molybdenum disulfide, silicone polymers, and Spolytetrafluoroethylene. In a preferred embodiment, the solid lubricant material IN includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the layer of lubricant includes about 1% to I 90% of the solid lubricant material by volume. In a preferred embodiment, the 0 10 layer of lubricant includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the layer of lubricant includes about 15% to of the solid lubricant material by volume.

A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure has also been described that includes positioning the expandable tubular assembly into the preexisting structure, injecting a quantity of a lubricant material into contact with the expandable tubular assembly, and radially expanding the expandable tubular assembly into contact with the preexisting structure. In a preferred embodiment, the injected lubricant material includes a liquid lubricant material. In a preferred embodiment, the liquid lubricant material is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vinyl acetate copolymers, polyvinyl pyrrolidone, copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, isoprene butadiene and ethylene, ethylene acrylic acid copolymers, esters, organic acid esters, trimethylol propane, isopropyl, penterithritol, n-butyl, glycerol triacetoxy stearate, N,N' ethylene bis 12 hydroxystearate, octyl hydroxystearate, phosphate, phosphite, butylated triphenyl phospate, isodiphenyl phosphate, sulfurized natural oils, synthetic oils, alkanolamides, coco diethanolamide, amines, amine salts, olefins, polyolefins, C-8 -18- O to C-18 linear alcohols and derivatives including esters, amines, carboxylates, 0 overbased sulfonates, calcium sulfonate, sodium sulfonate, magnesium sulfonate, polyethylene glycols, silicones, siloxanes, dimethylpolysiloxanes, fluorosilicone N0 derivatives, dinonyl phenols, and ethylene oxide/propylene oxide block copolymers.

In a preferred embodiment, the injected lubricant material includes a solid j lubricant material. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. In a aI preferred embodiment, the method further includes: coating the interior surfaces of the tubular members with a lubricant prior to positioning the tubular members within the preexisting structure. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the injected lubricating material includes a second part of the lubricating substance.

An apparatus has also been described that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure, injecting a quantity of a lubricant material into contact with the tubular members, and radially expanding the tubular members into contact with the preexisting structure. In a preferred embodiment, the injected lubricant material includes a liquid lubricant material. In a preferred embodiment, the liquid lubricant material is selected from the group consisting of: polyacrylamide polymers, AMPSacrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vinyl acetate copolymers, polyvinyl pyrrolidone, copolymers including polyolefms, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, isoprene butadiene and ethylene, ethylene acrylic acid copolymers, esters, organic acid esters, trimethylol propane, isopropyl, penterithritol, n-butyl, glycerol triacetoxy stearate, N,N' ethylene bis 12 hydroxystearate, octyl hydroxystearate, phosphate, phosphite, butylated triphenyl phospate, isodiphenyl phosphate, sulfurized natural oils, 19- Ssynthetic oils, alkanolamides, coco diethanolamide, amines, amine salts, olefins, 0 polyolefins, C-8 to C-18 linear alcohols and derivatives including esters, amines, carboxylates, overbased sulfonates, calcium sulfonate, sodium sulfonate, magnesium sulfonate, polyethylene glycols, silicones, siloxanes, dimethylpolysiloxanes, fluorosilicone derivatives, dinonyl phenols, and ethylene oxide/propylene oxide block copolymers. In a preferred embodiment, the injected lubricant material includes a solid lubricant material. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, l~ molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and 0 10 silicone polymers. In a preferred embodiment, the apparatus further includes: coating the interior surfaces of the tubular members with a lubricant prior to positioning the tubular members within the preexisting structure. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the injected lubricating material includes a second part of the lubricating substance.

A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure has also been described that includes: coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant, and radially expanding the tubular members into contact with the preexisting structure. In a preferred embodiment, the lubricant includes a metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-Lube-10, C-PHOS-58-M, and C-PHOS-58-R. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the first part of the lubricant is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is adhesively bonded to the interior surface of the tubular O members. In a preferred embodiment, the method further includes: combining the 0 first and second parts of the lubricant to generate the lubricant.

An apparatus has also been described that includes a preexisting structure IN and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic materials having a second part of the lubricant into contact with the coating Sof the first part of the lubricant, and radially expanding the tubular members into 0 10 contact with the preexisting structure. In a preferred embodiment, the lubricant includes a metallic soap. In apreferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-Lube-O10, C-PHOS-58-M, and C-PHOS-58-R. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the first part of the lubricant is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the apparatus further includes combining the first and second parts of the lubricant to generate the lubricant.

Although this detailed description has shown and described illustrative embodiments of the invention, this description contemplates a wide range of modifications, changes, and substitutions. In some instances, one may employ some features of the present invention without a corresponding use of the other features. Accordingly, it is appropriate that readers should construe the appended claims broadly, and in a manner consistent with the scope of the invention.

-21-

Claims (73)

1. An expandable tubular assembly, comprising: one or more tubular members coupled to one another; and a layer of a lubricant coupled to the interior surfaces of the tubular members.

2. A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure, comprising: coating the interior surfaces of the tubular members with a lubricant; positioning the tubular members within a preexisting structure; and radially expanding the tubular members into contact with the preexisting structure.

3. An apparatus, comprising: a preexisting structure; and one or more tubular members coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a lubricant; positioning the tubular members within a preexisting structure; and radially expanding the tubular members into contact with the preexisting structure.

4. An expandable tubular assembly, comprising: one or more tubular members; and a layer of a first part of a lubricant coupled to the interior surfaces of the tubular members. A method of coupling an expandable tubular assembly including one or more -22- I U tubular members to a preexisting structure, comprising: IND positioning the expandable tubular assembly into the preexisting structure; injecting a quantity of a lubricant material into contact with the expandable tubular assembly; and radially expanding the expandable tubular assembly into contact with the preexisting structure.

6. An apparatus, comprising: a preexisting structure; and one or more tubular members coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure; injecting a quantity of a lubricant material into contact with the tubular members; and radially expanding the tubular members into contact with the preexisting structure.

7. A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure, comprising: coating the interior surfaces of the tubular members with a first part of a lubricant; positioning the tubular members within a preexisting structure; circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant; and radially expanding the tubular members into contact with the preexisting structure.

8. An apparatus, comprising: a preexisting structure; and -23- U one or more tubular members coupled to the preexisting structure by the IN process of: coating the interior surfaces of the tubular members with a first part of a lubricant; positioning the tubular members within a preexisting structure; circulating a fluidic materials having a second part of the lubricant into Scontact with the coating of the first part of the lubricant; and Sradially expanding the tubular members into contact with the preexisting structure.

9. The expandable tubular assembly of claim 1, wherein the tubular members comprise wellbore casings. The expandable tubular assembly of claim 1, wherein the tubular members comprise underground pipes.

11. The expandable tubular assembly of claim 1, wherein the tubular members comprise structural supports. S 12. The expandable tubular assembly of claim 1, wherein the coating of lubricant is chemically bonded to the interior surfaces of the tubular members.

13. The expandable tubular assembly of claim 1, wherein the coating of lubricant is mechanically bonded to the interior surfaces of the tubular members.

14. The expandable tubular assembly of claim 1, wherein the coating of lubricant is adhesively bonded to the interior surfaces of the tubular members. The expandable tubular assembly of claim 1, wherein the coating of lubricant -24- o includes: O a primer coating coupled to the interior surfaces of the tubular members; and a coating of an antifriction paste coupled to the primer.

16. The expandable tubular assembly of claim 1, wherein the coating of lubricant includes, by weight: I40-80% epoxy resin, 15-30% molybdenum disulfide, 10-15% graphite, 5-10% 0aluminum, 5-10% copper, 8-15% alumisilicate, and 5-10% polyethylenepolyamine.

17. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises a metallic soap.

18. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises zinc phosphate.

19. The expandable tubular assembly of claim 1, wherein the coating of lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1. The expandable tubular assembly of claim 1, wherein the coating of lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps.

21. The expandable tubular assembly of claim 1, wherein the coating of lubricant provides a sliding coefficient of friction less than about 0.20.

22. The expandable tubular assembly of claim 1, wherein the coating of lubricant is U

74. The apparatus of claim 3, wherein the coating of lubricant comprises: O a solid lubricant; and a binder. The apparatus of claim 72, wherein the binder is selected from the group consisting of: Sepoxy, acrylic, urea-formaldehyde, melamine formaldehyde, furan based resin, Sacetone formaldehyde, phenolic, alkyd resins, and silicone modified alkyd resin.

76. The apparatus of claim 72, wherein the binder is selected from the group consisting of: vinyl acetate, vinyl chloride, maleic annhydride, maleic acid, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, and ethylene- vinyl acetate copolymers.

77. The apparatus of claim 3, wherein the coating of lubricant comprises a suspension of particles in a carrier solvent.

78. The apparatus of claim 3, the coating of lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate.

79. The apparatus of claim 3, wherein the coating of lubricant comprises: about 1 to 90 percent solids by volume. The apparatus of claim 77, wherein the coating of lubricant comprises: about 5 to 70 percent solids by volume. -26- o O O 69. The apparatus of claim 3, wherein the coating of lubricant provides a coefficient S of dynamic friction of between about 0.08 to 0.1. 70. The apparatus of claim 3, wherein the coating of lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese 0 phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, O polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. 71. The apparatus of claim 3, wherein the coating of lubricant provides a sliding coefficient of friction less than about 0.20. 72. The apparatus of claim 3, wherein the coating of lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene LU butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers. 73. The apparatus of claim 3, wherein the coating of lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. -27- pipes. The apparatus of claim 3, wherein the tubular members comprise underground 61. The apparatus of claim 3, wherein the tubular members comprise structural supports. 62. The apparatus of claim 3, wherein the coating of lubricant is chemically bonded to the interior surfaces of the tubular members. 63. The apparatus of claim 3, wherein the coating of lubricant is mechanically bonded to the interior surfaces of the tubular members. 64. The apparatus of claim 3, wherein the coating of lubricant is adhesively bonded to the interior surfaces of the tubular members. The apparatus of claim 3, wherein the coating of lubricant includes: a primer coating coupled to the interior surfaces of the tubular members; and a coating of an antifriction paste coupled to the primer. 66. The apparatus of claim 3, wherein the coating of lubricant includes, by weight: 40-80% epoxy resin, 15-30% molybdenum disulfide, 10-15% graphite, 5-10% aluminum, 5-10% copper, 8-15% alumisilicate, and 5-10% polyethylenepolyamine. 67. soap. The apparatus of claim 3, wherein the coating of lubricant comprises a metallic 68. The apparatus of claim 3, wherein the coating of lubricant comprises zinc phosphate. -28- o 57. The method of claim 2, wherein the coating of lubricant comprises: IN about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and about 1 to 40 percent silicone polymers. 58. The method of claim 2, wherein the coating of lubricant comprises one or more of the following: ester; sulfurized oil; alkanolamides; amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester; derivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; silicone; siloxane; dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. 59. The apparatus of claim 3, wherein the tubular members comprise wellbore casings. -29- a binder. O The method of claim 47, wherein the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, melamine formaldehyde, furan based resin, acetone formaldehyde, phenolic, alkyd resins, and silicone modified alkyd Q a resin. 51. The method of claim 47, wherein the binder is selected from the group consisting of: vinyl acetate, vinyl chloride, maleic annhydride, maleic acid, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, and ethylene- vinyl acetate copolymers. 52. The method of claim 2, wherein the coating of lubricant comprises a suspension of particles in a carrier solvent. 53. The method of claim 2, the coating of lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate. 54. The method of claim 2, wherein the coating of lubricant comprises: about 1 to 90 percent solids by volume. 55. The method of claim 52, wherein the coating of lubricant comprises: about 5 to 70 percent solids by volume. 56. The method of claim 53, wherein the coating of lubricant comprises: about 15 to 50 percent solids by volume. o The method of claim 2, wherein the coating of lubricant is selected from the S group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. S 46. The method of claim 2, wherein the coating of lubricant provides a sliding coefficient of friction less than about 0.20. 47. The method of claim 2, wherein the coating of lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene Zu butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers. 48. The method of claim 2, wherein the coating of lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. 49. The method of claim 2, wherein the coating of lubricant comprises: a solid lubricant; and -31 U supports. \O 37. The method of claim 2, wherein the coating of lubricant is chemically bonded to the interior surfaces of the tubular members. (-i (-i 38. The method of claim 2, wherein the coating of lubricant is mechanically bonded S to the interior surfaces of the tubular members. (-i 39. The method of claim 2, wherein the coating of lubricant is adhesively bonded to the interior surfaces of the tubular members. The method of claim 2, wherein the coating of lubricant includes: a primer coating coupled to the interior surfaces of the tubular members; and a coating of an antifriction paste coupled to the primer. 41. The method of claim 2, wherein the coating of lubricant includes, by weight: 40-80% epoxy resin, 15-30% molybdenum disulfide, 10-15% graphite, 5-10% aluminum, 5-10% copper, 8-15% alumisilicate, and 5-10% polyethylenepolyamine. Lv 42. The method of claim 2, wherein the coating of lubricant comprises a metallic soap. 43. The method of claim 2, wherein the coating of lubricant comprises zinc phosphate. 44. The method of claim 2, wherein the coating of lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1. -32- o O Sabout 1 to 40 percent silicone polymers. O 33. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises one or more of the following: ester; sulfurized oil; 0 alkanolamides; Samine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; derivatives of C-8 to C-18 linear alcohol including ester; derivatives of C-8 to C-18 linear alcohol including amine; derivatives of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; silicone; siloxane; zu dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. 34. The method of claim 2, wherein the tubular members comprise wellbore casings. The method of claim 2, wherein the tubular members comprise underground pipes. 36. The method of claim 2, wherein the tubular members comprise structural -33- U Sfrom the group consisting of: O vinyl acetate, vinyl chloride, maleic annhydride, maleic acid, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, and ethylene- vinyl acetate copolymers. 27. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises a suspension of particles in a carrier solvent. 28. The expandable tubular assembly of claim 1, the coating of lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate. 29. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises: about I to 90 percent solids by volume. The expandable tubular assembly of claim 29, wherein the coating of lubricant comprises: about 5 to 70 percent solids by volume. 31. The expandable tubular assembly of claim 30, wherein the coating of lubricant comprises: about 15 to 50 percent solids by volume. 32. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and -34- o Sselected from the group consisting of: 0 polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, Sviscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers. 23. The expandable tubular assembly of claim 1, wherein the coating of lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. 24. The expandable tubular assembly of claim 1, wherein the coating of lubricant comprises: a solid lubricant; and a binder. The expandable tubular assembly of claim 24, wherein the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, melamine formaldehyde, furan based resin, acetone formaldehyde, phenolic, alkyd resins, and silicone modified alkyd resin. 26. The expandable tubular assembly of claim 24, wherein the binder is selected U

120. The method of claim 5, wherein the lubricant is selected from the group S consisting of: manganese phosphate, zinc phosphate, and iron phosphate.

121. The method of claim 5, wherein the lubricant comprises: about 1 to 90 percent solids by volume.

122. The method of claim 119, wherein the lubricant comprises: about 5 to 70 percent solids by volume.

123. The method of claim 120, wherein the lubricant comprises: about 15 to 50 percent solids by volume.

124. The method of claim 5, wherein the lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and about 1 to 40 percent silicone polymers.

125. The method of claim 5, wherein the lubricant comprises one or more of the following: ester; sulfurized oil; alkanolamides; amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; -36- o consisting of: IN sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. 116. The method of claim 5, wherein the lubricant provides a sliding coefficient of friction less than about 0.20. 117. The method of claim 5, wherein the lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers. 118. The method of claim 5, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. 119. The method of claim 5, wherein the lubricant comprises a suspension of particles in a carrier solvent. -37- polyolefins; 0° C-8 to C-18 linear alcohol; derivatives of -8 to 8 linear alcohol including ester; derivatives of C-8 to C-18 linear alcohol including aminester; Sderivatives of C-8 to C-18 linear alcohol including amine; Sderivatives of C-8 to C-18 linear alcohol including carboxylate; sulfonate; I polyethylene glycol; O silicone; siloxane; dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. 109. The method of claim 5, wherein the tubular members comprise wellbore casings. 110. The method of claim 5, wherein the tubular members comprise underground pipes. 111. The method of claim 5, wherein the tubular members comprise structural supports. 112. The method of claim 5, wherein the lubricant comprises a metallic soap. 113. The method of claim 5, wherein the lubricant comprises zinc phosphate. 114. The method of claim 5, wherein the lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1. 115. The method of claim 5, wherein the lubricant is selected from the group -38- U Smanganese phosphate, zinc phosphate, and iron phosphate. \O 104. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises: about 1 to 90 percent solids by volume. 105. The expandable tubular assembly of claim 102, wherein the layer of the first part of the lubricant comprises: about 5 to 70 percent solids by volume. 106. The expandable tubular assembly of claim 103, wherein the layer of the first part of the lubricant comprises: about 15 to 50 percent solids by volume. 107. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about I to 40 percent PTFE; and Lu about 1 to 40 percent silicone polymers. 108. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises one or more of the following: ester; sulfurized oil; alkanolamides; amine; amine salt; olefin; -39- o O O copolymers. 0 98. The expandable tubular assembly of claim 4, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers. 0 99. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises: a solid lubricant; and a binder. 100. The expandable tubular assembly of claim 97, wherein the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, melamine formaldehyde, furan based resin, acetone formaldehyde, phenolic, alkyd resins, and silicone modified alkyd resin. 101. The expandable tubular assembly of claim 97, wherein the binder is selected 4V from the group consisting of: vinyl acetate, vinyl chloride, maleic annhydride, maleic acid, ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers, and ethylene- vinyl acetate copolymers. 102. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises a suspension of particles in a carrier solvent. 103. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant is selected from the group consisting of: 92. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises a metallic soap. 93. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant comprises zinc phosphate. 94. The expandable tubular assembly of claim 4, wherein the lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1. The expandable tubular assembly of claim 4, wherein the lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. 96. The expandable tubular assembly of claim 4, wherein the lubricant provides a sliding coefficient of friction less than about 0.20. 97. from The expandable tubular assembly of claim 4, wherein the lubricant is selected the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid -41 U 84. The expandable tubular assembly of claim 4, wherein the tubular members ID comprise wellbore casings. The expandable tubular assembly of claim 4, wherein the tubular members comprise underground pipes. I 86. The expandable tubular assembly of claim 4, wherein the tubular members comprise structural supports. 87. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant is chemically bonded to the interior surfaces of the tubular members. 88. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant is mechanically bonded to the interior surfaces of the tubular members. 89. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant is adhesively bonded to the interior surfaces of the tubular members. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant includes: a primer coating coupled to the interior surfaces of the tubular members; and a coating of an antifriction paste coupled to the primer. 91. The expandable tubular assembly of claim 4, wherein the layer of the first part of the lubricant includes, by weight: 40-80% epoxy resin, 15-30% molybdenum disulfide, 10-15% graphite, 5-10% aluminum, 5-10% copper, 8-15% alumisilicate, and 5-10% polyethylenepolyamine. -42- o 81. The apparatus of claim 78, wherein the coating of lubricant comprises: O about 15 to 50 percent solids by volume. 82. The apparatus of claim 3, wherein the coating of lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; n about 1 to 40 percent PTFE; and Sabout 1 to 40 percent silicone polymers. 83. The apparatus of claim 3, wherein the coating of lubricant comprises one or more of the following: ester; sulfurized oil; alkanolamides; amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; u derivative of C-8 to C-18 linear alcohol including ester; derivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; silicone; siloxane; dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. -43- U \O derivative of C-8 to C-18 linear alcohol including ester; Nderivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; Spolyethylene glycol; silicone; Ssiloxane; Sdinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer.

126. The apparatus of claim 6, wherein the tubular members comprise wellbore casings.

127. The apparatus of claim 6, wherein the tubular members comprise underground pipes.

128. The apparatus of claim 6, wherein the tubular members comprise structural supports.

129. The apparatus of claim 6, wherein the lubricant comprises a metallic soap.

130. The apparatus of claim 6, wherein the lubricant comprises zinc phosphate.

131. The apparatus of claim 6, wherein the lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1.

132. The apparatus of claim 6, wherein the lubricant is selected from the group consisting of: -44- o O sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps.

133. The apparatus of claim 6, wherein the lubricant provides a sliding coefficient of friction less than about 0.20. 0 134. The apparatus of claim 6, wherein the lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers. 4U

135. The apparatus of claim 6, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers.

136. The apparatus of claim 6, wherein the lubricant comprises a suspension of particles in a carrier solvent.

137. The apparatus of claim 6, wherein the lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate.

138. The apparatus of claim 6, wherein the lubricant comprises: about 1 to 90 percent solids by volume.

139. The apparatus of claim 136, wherein the lubricant comprises: about 5 to 70 percent solids by volume.

140. The apparatus of claim 137, wherein the lubricant comprises: about 15 to 50 percent solids by volume.

141. The apparatus of claim 6, wherein the lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and about 1 to 40 percent silicone polymers.

142. The apparatus of claim 6, wherein the lubricant comprises one or more of the 2U following: ester; sulfurized oil; alkanolamides; amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester; -46- -I derivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; silicone; siloxane; n dinonyl phenol; Sethylene oxide block copolymer; and propylene oxide block copolymer.

143. The method of claim 7, wherein the tubular members comprise wellbore casings.

144. The method of claim 7, wherein the tubular members comprise underground pipes.

145. The method of claim 7, wherein the tubular members comprise structural supports.

146. The method of claim 7, wherein the lubricant comprises a metallic soap.

147. The method of claim 7, wherein the lubricant comprises zinc phosphate.

148. The method of claim 7, wherein the lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1.

149. The method of claim 7, wherein the lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, -47- o O O Spolytetrafluoroethylene, molybdenum disulfide, and metallic soaps.

150. The method of claim 7, wherein the lubricant provides a sliding coefficient of friction less than about 0.20.

151. The method of claim 7, wherein the lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers.

152. The method of claim 7, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers.

153. The method of claim 7, wherein the lubricant comprises a suspension of particles in a carrier solvent.

154. The method of claim 7, wherein the lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate. -48- o

155. The method of claim 7, wherein the lubricant comprises: I about 1 to 90 percent solids by volume. S 156. The method of claim 153, wherein the lubricant comprises: Sabout 5 to 70 percent solids by volume. V) 157. The method of claim 154, wherein the lubricant comprises: Sabout 15 to 50 percent solids by volume.

158. The method of claim 7, wherein the lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and about 1 to 40 percent silicone polymers.

159. The method of claim 7, wherein the lubricant comprises one or more of the following: ester; sulfurized oil; 1u alkanolamides; amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester; derivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; -49- polyethylene glycol; Isilicone; siloxane; dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. 0 160. The apparatus of claim 8, wherein the tubular members comprise wellbore casings.

161. The apparatus of claim 8, wherein the tubular members comprise underground pipes.

162. The apparatus of claim 8, wherein the tubular members comprise structural supports.

163. The apparatus of claim 8, wherein the lubricant comprises a metallic soap.

164. The apparatus of claim 8, wherein the lubricant comprises zinc phosphate.

165. The apparatus of claim 8, wherein the lubricant provides a coefficient of dynamic friction of between about 0.08 to 0.1.

166. The apparatus of claim 8, wherein the lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, C-Lube-10, C-Phos-58-M, C-Phos-58-R, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. o S167. The apparatus of claim 8, wherein the lubricant provides a sliding coefficient of 0 friction less than about 0.20. O

168. The apparatus of claim 8, wherein the lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose I derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, 0 polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers.

169. The apparatus of claim 8, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers.

170. The apparatus of claim 8, wherein the lubricant comprises a suspension of particles in a carrier solvent.

171. The apparatus of claim 8, wherein the lubricant is selected from the group consisting of: manganese phosphate, zinc phosphate, and iron phosphate.

172. The apparatus of claim 8, wherein the lubricant comprises: -51 o O Sabout 1 to 90 percent solids by volume. O

173. The apparatus of claim 170, wherein the lubricant comprises: about 5 to 70 percent solids by volume. t 174. The apparatus of claim 171, wherein the lubricant comprises: Sabout 15 to 50 percent solids by volume.

175. The apparatus of claim 8, wherein the lubricant comprises: about 5 to 80 percent graphite; about 5 to 80 percent molybdenum disulfide; about 1 to 40 percent PTFE; and about 1 to 40 percent silicone polymers.

176. The apparatus of claim 8, wherein the lubricant comprises one or more of the following: ester; sulfurized oil; alkanolamides; zu amine; amine salt; olefin; polyolefins; C-8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester; derivative of C-8 to C-18 linear alcohol including amine; derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; -52- r dinonyl phenol; ethylene oxide block copolymer; and propylene oxide block copolymer. -53-