US20080142213A1 - Radial expansion of a wellbore casing against a formation - Google Patents

Radial expansion of a wellbore casing against a formation Download PDF

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Publication number
US20080142213A1
US20080142213A1 US11/838,782 US83878207A US2008142213A1 US 20080142213 A1 US20080142213 A1 US 20080142213A1 US 83878207 A US83878207 A US 83878207A US 2008142213 A1 US2008142213 A1 US 2008142213A1
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US
United States
Prior art keywords
tubular member
expansion device
filed
relative
preexisting structure
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Abandoned
Application number
US11/838,782
Inventor
Darrell Scott Costa
Kevin K. Waddell
Edwin A. Zwald
Charles Butterfield
Mark Holland
Akindele Olufowoshe
Gregory M. Noel
Donald B. Campo
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Enventure Global Technology Inc
Original Assignee
Enventure Global Technology Inc
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from PCT/US2002/036267 external-priority patent/WO2003042487A2/en
Priority claimed from US10/303,992 external-priority patent/US7270188B2/en
Priority claimed from PCT/US2003/004837 external-priority patent/WO2003078785A2/en
Priority claimed from PCT/US2003/014153 external-priority patent/WO2003093623A2/en
Priority claimed from PCT/US2003/018530 external-priority patent/WO2003106130A2/en
Priority claimed from PCT/US2003/029460 external-priority patent/WO2004027200A2/en
Priority claimed from PCT/US2003/029859 external-priority patent/WO2004027205A2/en
Priority claimed from PCT/US2003/029858 external-priority patent/WO2004027204A2/en
Priority claimed from PCT/US2004/007711 external-priority patent/WO2004081346A2/en
Priority claimed from PCT/US2004/009434 external-priority patent/WO2004085790A2/en
Priority claimed from PCT/US2004/010317 external-priority patent/WO2004089608A2/en
Priority claimed from PCT/US2004/010762 external-priority patent/WO2004092528A2/en
Priority claimed from PCT/US2004/010712 external-priority patent/WO2004092527A2/en
Priority claimed from PCT/US2004/011177 external-priority patent/WO2004092530A2/en
Priority claimed from PCT/US2004/011973 external-priority patent/WO2004094766A2/en
Priority claimed from US10/938,225 external-priority patent/US7231985B2/en
Priority claimed from PCT/US2006/004809 external-priority patent/WO2006088743A2/en
Priority claimed from US11/531,041 external-priority patent/US20070227730A1/en
Application filed by Enventure Global Technology Inc filed Critical Enventure Global Technology Inc
Priority to US11/838,782 priority Critical patent/US20080142213A1/en
Assigned to ENVENTURE GLOBAL TECHNOLOGY, LLC reassignment ENVENTURE GLOBAL TECHNOLOGY, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: CAMPO, DONALD B., NOEL, GREGORY M., COSTA, DARRELL SCOTT, OLUFOWOSHE, AKINDELE, ZWALD, EDWIN A., JR., HOLLAND, MARK, WADDELL, KEVIN K., BUTTERFIELD, CHARLES A., JR.
Publication of US20080142213A1 publication Critical patent/US20080142213A1/en
Priority to US12/170,880 priority patent/US7823659B2/en
Abandoned legal-status Critical Current

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Classifications

    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/106—Couplings or joints therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B7/00—Special methods or apparatus for drilling
    • E21B7/20—Driving or forcing casings or pipes into boreholes, e.g. sinking; Simultaneously drilling and casing boreholes

Definitions

  • PCT patent application serial number PCT/US2005/028936 attorney docket number 25791.338.02, filed on Aug. 12, 2005;
  • PCT patent application serial number PCT/US2005/028669 attorney docket number 25791.194.02, filed on Aug. 11, 2005;
  • PCT patent application serial number PCT/US2005/028453 attorney docket number 25791.371, filed on Aug. 11, 2005;
  • PCT patent application serial number PCT/US2005/028641 attorney docket number 25791.372, filed on Aug. 11, 2005;
  • PCT patent application serial number PCT/US2005/028819 attorney docket number 25791.373, filed on Aug.
  • This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a wellbore that traverses a subterranean formation.
  • 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.
  • 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 at least a portion of the expandable tubular member into engagement with at least a portion of the interior surface of the wellbore.
  • FIG. 4 is a fragmentary cross sectional view of the expandable tubular member of FIG. 3 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member into engagement with at least another portion of the interior surface of the wellbore.
  • FIG. 5 is a graphical illustration of the operating pressure of the expansion device and the inside diameter of the wellbore during an exemplary experimental radial expansion and plastic deformation of the tubular member.
  • FIG. 6 is a graphical illustration of an exemplary experimental implementation of a pressure test and a pull test following an exemplary experimental radial expansion and plastic deformation of the tubular member.
  • FIG. 7 aa is a fragmentary cross sectional illustration of an exemplary embodiment of an expansion device assembly.
  • FIG. 7 ab is a fragmentary cross-sectional illustration of an exemplary embodiment of the casing release of the expansion device assembly of FIG. 7 aa.
  • FIG. 7 b is a fragmentary cross-sectional illustration of the placement of the expansion device assembly of FIG. 7 aa within a wellbore that traverses a subterranean formation.
  • FIG. 7 c is a fragmentary cross-sectional illustration of the operation of the expansion device assembly of FIG. 7 b within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 7 d is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 c within the wellbore to further radially expand and plastically deform the tubular member.
  • FIG. 7 e is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 c within the wellbore in which the expansion cone is released by the release device.
  • FIG. 7 f is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 e within the wellbore in which the casing release is operated.
  • FIG. 8 is a fragmentary cross-sectional illustration of an alternative embodiment of the operation of the expansion device assembly of FIG. 7 b within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 9 aa and 9 ab are fragmentary cross sectional illustrations of an exemplary embodiment of an expansion and drilling device assembly.
  • FIG. 9 b is a fragmentary cross-sectional illustration of the placement of the expansion and drilling device assembly of FIG. 9 a within a wellbore that traverses a subterranean formation.
  • FIG. 9 c is a fragmentary cross-sectional illustration of the operation of the expansion and drilling device assembly of FIG. 9 b to drill within the wellbore.
  • FIG. 9 d is a fragmentary cross-sectional illustration of the operation of the expansion and device assembly of FIG. 9 c within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 9 e is a fragmentary cross-sectional illustration of the further operation of the expansion and drilling device assembly of FIG. 9 d within the wellbore to further radially expand and plastically deform the tubular member.
  • FIG. 10 is a fragmentary cross-sectional illustration of an alternative embodiment of the operation of the expansion and drilling device assembly of FIG. 9 d within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 11 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expansion and drilling sub-assembly.
  • FIGS. 11 b and 11 c are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of the expansion and drilling sub-assembly of FIG. 11 a.
  • FIGS. 12 a to 12 c are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of an expansion system for forming a mono-diameter wellbore casing.
  • FIGS. 13 a to 13 d are fragmentary cross-sectional illustrations of an exemplary embodiment of an expansion system.
  • FIG. 14 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expansion and drilling system.
  • FIG. 15 is a graphical illustration of exemplary experimental results obtained during operation of the expansion system of FIG. 7 aa to 7 f.
  • an expandable tubular member 10 is positioned within a wellbore 12 that traverses a subterranean formation 14 .
  • an expansion device 16 is then positioned within the tubular member 10 .
  • the expansion device 16 may be positioned within the tubular member 10 before, during, or after the placement of the tubular member within the wellbore 12 .
  • the expansion device 16 is then operated to radially expand and plastically deform at least a portion of the tubular member 10 into engagement with at least a portion of the interior surface of the wellbore 12 .
  • the expansion device 16 is then further operated to radially expand the remaining portion of the tubular member 10 into engagement with first portions of the interior surface of the wellbore 12 .
  • the expansion device 16 is then further operated to radially expand the remaining portion of the tubular member 10 into engagement with first portions of the interior surface of the wellbore 12 .
  • the tubular member 10 following the operation of the expansion device 16 , the tubular member 10 remains in circumferential compression and the formation 14 surrounding the tubular member remains in circumferential tension. As a result, an interference fit is formed between the tubular member 10 and the surrounding formation 14 .
  • the radial expansion and plastic deformation of the tubular member 10 using the expansion device 16 is provided using one or more of the disclosures of one or more of the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 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.
  • the wellbore casing 10 was radially expanded and plastically deformed into engagement with the interior surface of a wellbore 12 using a fluid powered expansion device 16 .
  • the fluid powered expansion device 16 comprised a conventional solid expansion cone that was displaced upwardly through the casing 10 in a conventional manner using fluid pressure.
  • the operating pressure 100 of the expansion device 16 , the inside diameter 102 of the wellbore 12 at one radial location proximate the expansion device, and the inside diameter 104 of the wellbore at another radial location proximate the expansion device were monitored in a conventional manner using conventional measuring devices.
  • the operating pressure 100 of the expansion device varied inversely with respect to the inside diameters, 102 and 104 , of the wellbore 12 .
  • the geometry of the wellbore 12 may be determined.
  • the material properties and geometry of the formation 14 may also be determined. For example, empirical data may be used to develop and generate a functional relationship between the expansion forces required to radially expand and plastically deform the tubular member 10 and the material properties and geometry of the formation 14 . In this manner, by monitoring the expansion forces required to radially expand and plastically deform the tubular member 10 , a log of the formation 14 may be generated.
  • a pressure test was conducted to determine the degree to which a fluid tight metal to formation seal was created between the tubular member and the interior surface of the wellbore 12 .
  • the fluid tight metal to formation seal generated during the exemplary experimental implementation was capable of withstanding an operating pressure 200 of up to about 2700 psi.
  • the fluid tight metal to formation seal generated during the exemplary experimental implementation was capable of withstanding a tensile load 202 of about 120,000 lbf.
  • an exemplary embodiment of an expansion device assembly 700 includes a tubular support member 702 having an end that is coupled to an end of a locking device 704 .
  • the tubular support member 702 is a conventional drill pipe and the locking device 704 is, for example, a conventional hydraulically actuated locking device suitable for locking onto a tubular member such as, for example, a wellbore casing.
  • Another end of the locking device 704 is coupled to an end of a tubular support member 706 and another end of the tubular support member is coupled to an end of an actuator 708 .
  • the tubular support member 706 is a conventional drill pipe and the actuator 708 is a conventional actuator such as, for example, an hydraulic actuator suitable for displacing one or more elements relative to the actuator.
  • the tubular support member 710 is a conventional drill pipe and the release device 712 is a conventional release device for controllably releasing one or more elements coupled to the release device such, for example, upon the application of a loading condition greater than or equal to a predetermined value.
  • an end of an expansion device 714 having one or more tapered expansion surfaces 714 a is coupled to another end of the release device 712 .
  • the expansion device 714 is a conventional expansion device.
  • an end of an expandable tubular member 716 that receives at least the actuator 708 , the tubular support member 710 , and the release device 712 , is coupled to an supported by the tapered expansion surface 714 a of the end of the expansion device 714 .
  • Another end of the expandable tubular member 716 is coupled to an end of a casing release 718 and another end of the casing release 718 is coupled to an end of an expandable tubular member 720 .
  • the outside diameters of at least one of the expandable tubular member 716 , the casing release 718 , and/or the expandable tubular member 720 are greater than the outside diameter of the expansion device 714 .
  • the casing release 718 includes an outer tubular support member 718 a that defines one or more radial passages 718 aa having an end that is coupled to an end of a tapered tubular member 718 b . Another end of the tapered tubular member 718 b is coupled to an end of the tubular support member 716 .
  • the casing release 718 further includes an inner tubular member 718 c that defines one or more radial passages 718 ca having an end that is coupled to an end of a tapered tubular member 718 d . Another end of the tapered tubular member 718 b is coupled to an end of the tubular support member 716 .
  • the diametrical clearance between the inner and outer tubular members, 718 a and 718 c is a sliding fit.
  • the casing release further includes a conventional shear pin 718 e having ends that mate with and are received within the passages, 718 aa and 718 ca , of the outer and inner tubular members, 718 a and 718 c , respectively.
  • the casing release 718 is adapted to permit the application of radial expansion forces to the casing release without releasing the upper end of the expandable tubular member 716 from the lower end of the expandable tubular member 720 while permitting the upper end of the expandable tubular member 716 to be disengaged from the lower end of the expandable tubular member 720 if a predetermined toque loading is applied to the casing release.
  • the casing release 718 includes may include one or more of the following in addition to, or instead of, the structural features described above: 1) collets; 2) collets with a release sleeve; 3) a threaded connection that may be released by rotation; 4) splines to transfer torque; and/or 5) stress concentrations that permit release after radial expansion, and/or equivalents thereof.
  • the assembly is positioned within a wellbore 740 that traverses a subterranean formation 742 .
  • the wellbore 740 includes a preexisting wellbore casing 744 .
  • the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device.
  • the actuator 708 is then operated to displace the expansion device 714 upwardly relative to the locking device 704 .
  • the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed.
  • at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742 .
  • At least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716 .
  • at least a portion of the lower portion of the expandable tubular member 716 is anchored to the surrounding subterranean formation 742 .
  • the expansion device assembly 700 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716 , the casing release 718 and at least a portion of the expandable tubular member 720 by applying a upward tensile load on an end of the tubular support member 702 .
  • the expansion assembly 700 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716 , the casing release 718 and at least a portion of the expandable tubular member 720 by resetting the actuator 708 and then re-stroking the actuator 708 .
  • an upward tensile load may also be applied to the end of the tubular support member 702 .
  • the release device 712 may be operated to disengage the expansion device 714 from engagement with the release device by, for example, applying a predetermined torque loading to the release device.
  • the expansion device 714 may be released in the event of, for example, an unforeseen operating condition such as when the expansion device becomes stuck within the wellbore 740 .
  • the expansion device 714 may be then removed from the interior of the expandable tubular member 716 by, for example, drilling the expansion device out of the interior of the expandable tubular member.
  • the casing release 718 may be operated to disengage the upper end of the expandable tubular member 716 from the lower end of the expandable tubular member 720 by, for example, applying a predetermined toque loading to the casing release 718 .
  • the expandable tubular member 716 may be released from engagement with the expandable tubular member 720 without having to employ a casing cutter device.
  • the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device.
  • the actuator 708 is then operated to displace the expandable tubular member 716 downwardly relative to the expansion device 714 .
  • the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed.
  • at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742 .
  • at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716 .
  • an expansion and drilling assembly 900 is substantially identical to the expansion assembly 700 except as noted below.
  • the tubular support member 702 , the locking device 704 , the tubular support member 706 , the actuator 708 , the tubular support member 710 , the release device 712 , and the expansion device 714 of the assembly 900 define internal passages, 702 a , 704 a , 706 a , 708 a , 710 a , 712 a , and 714 b , respectively, that are fluidicly coupled to one another.
  • an end of a tubular support member 902 that defines an internal passage 902 a is coupled to the other end of the expansion device 914 .
  • the internal passage 902 a of the tubular support member 902 is fluidicly coupled to the internal passage 714 b of the expansion device 714 .
  • tubular support member 902 is coupled to a conventional fluid powered motor 904 that includes one or more exhaust ports 904 a for exhausting fluidic materials from the motor and an output shaft 904 b.
  • a conventional drilling device 906 is coupled to an end of the output shaft 904 b of the motor 904 .
  • the drilling device 906 may include a conventional underreamer.
  • the assembly is positioned within the wellbore 740 .
  • a fluidic material 920 is injected into the assembly through the passages 702 a , 704 a , 706 a , 708 a , 710 a , 712 a , 714 b , and 902 a to thereby operate the motor 904 .
  • the output shaft 904 b of the motor 904 operates the drilling device 906 thereby extending the size and/or length of the wellbore 740 .
  • the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device.
  • the actuator 708 is then operated to displace the expansion device 714 upwardly relative to the locking device 704 .
  • the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed.
  • at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742 .
  • at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716 .
  • the assembly 900 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716 , the casing release 718 and at least a portion of the expandable tubular member 720 by applying a upward tensile load on an end of the tubular support member 702 .
  • the assembly 900 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716 , the casing release 718 and at least a portion of the expandable tubular member 720 by resetting the actuator 708 and then re-stroking the actuator 708 .
  • an upward tensile load may also be applied to the end of the tubular support member 702 .
  • the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device.
  • the actuator 708 is then operated to displace the expandable tubular member 716 downwardly relative to the expansion device 714 .
  • the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed.
  • at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742 .
  • at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716 .
  • an expansion and drilling assembly 1100 is substantially identical in design and operation to the assembly 900 except that the expansion device 714 is replaced with an expansion device 1102 that defines a passage 1102 a and includes one or more tapered expansion surfaces 1102 b and the tubular support member 902 is replaced with a tubular support member 1104 that defines a passage 1104 a having an end that is coupled to the release device 712 and another end that is coupled to the motor 904 .
  • the passage 1104 a of the tubular support member 1104 is fluidicly coupled to the passages 712 a of the tubular support member and the motor 904 .
  • the inside diameter of the passage 1102 a of the expansion device 1102 is greater than the outside diameters of both the motor 904 and the drilling device 906 thereby permitting both to pass through the passage.
  • the release device 712 may be operated to disengage the release device from the expansion device 1102 thereby permitting the motor 904 and drilling device 906 to be removed from the assembly by lifting the motor and drilling device upwardly through the passage 1102 a defined within the expansion device 1102 .
  • the motor 904 and drilling device 906 may be removed from the assembly after the insertion of the assembly into the wellbore 740 , either before or after the initiation and/or completion of the expansion process.
  • a wellbore casing 1202 is coupled to a wellbore 1204 that traverses a subterranean formation 1206 .
  • the wellbore casing 1202 is radially expanded and plastically deformed into engagement with the surrounding forming 1206 using one or more of the apparatus and methods described above with reference to FIGS. 11 to 11 c.
  • the wellbore 1204 is then in a convention manner using a drilling device and an expansion assembly 1208 is then positioned within the wellbore using a tubular support member 1210 coupled to an end of the expansion assembly.
  • a gripping device 1212 is coupled to the tubular support member 1210 for locking the position of the tubular support member to, for example, the wellbore casing 1202 .
  • the design and operation of the expansion assembly 1208 may include one or more of the apparatus and methods described above with reference to FIGS. 1 to 1 c .
  • the gripping device 1212 may include a conventional commercially available gripping device.
  • the gripping device 1212 is operated to engage the wellbore casing 1202 thereby locking the position of the tubular support member 1210 to the wellbore casing.
  • the expansion assembly 1208 is then operated to radially expand and plastically deform a wellbore casing 1208 a into engagement with the surrounding forming 1206 .
  • the inside diameters of the wellbore casings 1202 and 1208 a are substantially identical. As a result, a mono-diameter wellbore casing is formed within the wellbore.
  • an exemplary embodiment of a drilling device assembly 1300 that in some respects is similar in design and operation to the drilling device assembly 700 , includes a tubular support member 1302 having an end that is coupled to an end of an actuator 1304 .
  • the tubular support member 1302 is a conventional drill pipe and the actuator 1304 is a conventional actuator such as, for example, an hydraulic actuator suitable for displacing one or more elements relative to the actuator.
  • Another end of the actuator 1304 is coupled to an end of a tubular support member 1306 and the other end of the tubular support member is coupled to an end of the release device 712 .
  • An end of the expansion device 714 having one or more tapered expansion surfaces 714 a is coupled to another end of the release device 712 .
  • An end of an expandable tubular member 1308 that receives at least the tubular support member 1306 and the release device 712 , is coupled to an supported by the tapered expansion surface 714 a of the end of the expansion device 714 .
  • Another end of the expandable tubular member 1308 is coupled to a locking assembly 1310 that defines a passage 1310 a that receives the tubular support member 1306 . In this manner, the tubular support member 1308 may be displaced relative to and within the passage 1310 a of the locking assembly 1310 .
  • the locking assembly 1310 may be a conventional commercially available locking assembly. In an exemplary embodiment, the locking assembly 1310 may further include one or more slips for engaging the end of the expandable tubular member 1308 .
  • the assembly is positioned within a wellbore 740 that traverses a subterranean formation 742 .
  • the wellbore 740 includes a preexisting wellbore casing 744 .
  • the locking assembly 1310 engages the end of the expandable tubular member 1308 and the actuator 1304 is operated to displace the tubular support member 1306 and the expansion device 714 upwardly relative to the actuator.
  • the locking assembly 1310 engages the lower end of the actuator 1304 thereby preventing further upward movement of the expandable tubular member 1308 relative to the actuator 1304 .
  • the lower portion of the expandable tubular member 1308 is radially expanded and plastically deformed by the continued upward displacement of the expansion device 714 .
  • At least a portion of the expandable tubular member 1308 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742 . Furthermore, in an exemplary embodiment, as a result at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 1308 , In an exemplary embodiment, as a result, at least a portion of the lower portion of the expandable tubular member 1308 is anchored to the surrounding subterranean formation 742 .
  • the expansion device assembly 1300 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 1308 by applying a upward tensile load on an end of the tubular support member 1302 .
  • the expansion assembly 1300 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 1308 by continuing to operate the actuator 1304 .
  • an upward tensile load may also be applied to the end of the tubular support member 1302 .
  • the tubular support member 1302 defines a passage 1302 a that is fluidicly coupled to a passage 1304 a defined within the actuator 1304 .
  • the tubular support member 1306 defines a passage 1306 a that is fluidicly coupled to the passage 1304 a of the actuator 1304 and the release device 712 defines a passage 712 a that is fluidicly coupled to the passage 1306 a defined within the tubular support member.
  • the expansion device 714 defines a passage 714 b that is fluidicly coupled to the passage 712 a defined within the release device 712 .
  • the passage 1402 a is also fluidicly coupled to the fluid powered motor 904 that includes an exhaust 904 a and an output shaft 904 b .
  • the output shaft 904 b of the motor 904 is coupled to the drilling device 906 .
  • the assembly may be operated to drill out a wellbore and/or to radially expand and plastically deform the expandable tubular member 1308 .
  • Free Expansion 1502 refers to pipe body expansion forces without cladding into and or against formation.
  • Free Conn Expansion 1504 refers to applying expansion forces across connections between adjacent tubulars without cladding into or against formation.
  • EAF Expansion 1506 refers to the forces required or used for pipe body expansion cladding into and or against the formation.
  • EAF Conn Expansion 1508 refers to the forces required or used for expanding the connections between adjacent tubulars while cladding into and or against the formation.
  • Free OvL Expansion 1510 refers to the expansion forces across the overlap which includes pipe against pipe without cement or formation behind the outer pipe.
  • EAF OvL Expansion 1512 refers to expansion forces across an overlap between inner and outer tubulars while cladding into or against the formation.
  • EAF OvL Conn Exp 1514 refers to the expansion forces across the overlap between inner and outer tubulars with two connections between adjacent tubulars overlaying each other while cladding into or against the formation.
  • An expandable tubular member has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
  • a method of coupling a wellbore casing to the interior surface of a wellbore includes positioning a wellbore casing within the wellbore and radially expanding and plastically deforming the wellbore casing into engagement with the wellbore to form a fluid tight seal between the casing and the wellbore.
  • the fluid tight seal between the casing and the wellbore is capable of sealing off fluidic materials having an operating pressure of up to about 2700 psi.
  • the fluid tight seal between the casing and the wellbore is capable of withstanding a tensile load of up to about 180,000 lbf.
  • An apparatus has been described that includes a wellbore; and a wellbore casing positioned within and engaged with the wellbore to form a fluid tight seal between the casing and the wellbore.
  • the fluid tight seal between the casing and the wellbore is capable of sealing off fluidic materials having an operating pressure of up to about 2700 psi.
  • the fluid tight seal between the casing and the wellbore is capable of withstanding a tensile load of up to about 180,000 lbf.
  • a method of determining one or more properties of at least one of a wellbore and a formation traversed by the wellbore includes radially expanding and plastically deforming a tubular member within the wellbore using an expansion device; monitoring one or more operating parameters of the expansion device; and correlating one or more of the operating parameters of the expansion device to one or more of the properties of at least one of the wellbore and the formation.
  • An apparatus for radially expanding and plastically deforming a tubular member includes a support member; a locking device coupled to the support member for controllably locking a position of the tubular member relative to the locking device; an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member; and an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member.
  • an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device.
  • the apparatus further includes a tubular release member for releasably coupling an end of the tubular member to an end of another adjacent tubular member.
  • the tubular release member comprises a frangible element coupled between the tubular member and the other tubular member.
  • the apparatus further comprises a release device for releasably coupling the expansion device to the actuator.
  • the apparatus further includes a drilling device coupled to the support member for drilling a wellbore.
  • the expansion device defines a longitudinal passage; and wherein an internal diameter of the longitudinal passage is greater than an outside diameter of the drilling device.
  • the apparatus further comprises a motor operably coupled to the drilling device for operating the drilling device.
  • the expansion device defines a longitudinal passage; and wherein an internal diameter of the longitudinal passage is greater than an outside diameter of the motor and the drilling device.
  • the expansion device defines a longitudinal passage.
  • An apparatus for radially expanding and plastically deforming a tubular member includes: a support member; a locking device coupled to the support member for controllably locking a position of the tubular member relate to the locking device; an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member; an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member; a release device for releasably coupling the expansion device to the actuator; another tubular member; a tubular release member for releasably coupling an end of the tubular member to an end of the other tubular member; a drilling device coupled to the support member for drilling a wellbore; and a motor operably coupled to the drilling device for operating the drilling device; wherein an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device; wherein the expansion device defines a longitudinal passage; wherein an internal diameter of the longitudinal passage of the expansion
  • a method of radially expanding and plastically deforming a tubular member within a preexisting structure includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further includes: radially expanding and plastically deforming the tubular member into engagement with the preexisting structure.
  • the method further includes: then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: unlocking the position of the tubular member relative to the support member; displacing the support member relative to the tubular member; relocking the position of the tubular member relative to the support member, and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: decoupling the expansion device from the tubular support member; and removing the tubular support member from the tubular member.
  • the tubular member comprises first and second tubular members coupled to one another; and the method further comprises: decoupling the first and second tubular members; and removing one of the first and second tubular members from the preexisting structure.
  • the method further comprises: drilling out the preexisting structure.
  • the method further comprises: drilling out the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: drilling out the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: drilling out the preexisting structure using a drilling device; and removing the drilling device from the preexisting structure.
  • the method further comprises: removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: removing the drilling device from the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the method further comprises: locking a position of the support member to the preexisting structure; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the preexisting structure comprises a wellbore that traverses a subterranean formation.
  • the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • a method of radially expanding and plastically deforming a tubular member within a preexisting structure includes: positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or unlocking the position of the tubular member relative to the support member; displacing the support member relative to the tubular member; relocking the position of the
  • a method of radially expanding and plastically deforming a tubular member within a preexisting structure includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; decoupling the expansion device from the tubular support member; and removing the tubular support member from the tubular member.
  • a method of radially expanding and plastically deforming a tubular member assembly comprising first and second tubular members coupled to one another, within a preexisting structure has been described that includes positioning the tubular member assembly and an expansion device within the preexisting structure using a support member; locking the position of the tubular member assembly relative to the support member; then displacing the expansion device relative to the tubular member assembly to radially expand and plastically deform the tubular member assembly into engagement with the preexisting structure; then further displacing the expansion device relative to the tubular member assembly to further radially expand and plastically deform the tubular member assembly; decoupling the first and second tubular members; and removing one of the first and second tubular members from the preexisting structure.
  • a method of radially expanding and plastically deforming a tubular member within a preexisting structure includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • a method of radially expanding and plastically deforming a tubular member within a preexisting structure includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking a position of the support member to the preexisting structure; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or unlocking the position of the tubular member relative to the support member; displacing the support member relative
  • a system for radially expanding and plastically deforming a tubular member within a preexisting structure includes means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for radially expanding and plastically deforming the tubular member into engagement with the preexisting structure.
  • the system further comprises: means for then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: means for unlocking the position of the tubular member relative to the support member; means for displacing the support member relative to the tubular member; means for relocking the position of the tubular member relative to the support member, and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for decoupling the expansion device from the tubular support member; and means for removing the tubular support member from the tubular member.
  • the tubular member comprises first and second tubular members coupled to one another; and wherein the method further comprises: means for decoupling the first and second tubular members; and means for removing one of the first and second tubular members from the preexisting structure.
  • the system further comprises: means for drilling out the preexisting structure.
  • the system further comprises: means for drilling out the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for drilling out the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for drilling out the preexisting structure using a drilling device; and means for removing the drilling device from the preexisting structure.
  • the system further comprises: means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for removing the drilling device from the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the system further comprises: means for locking a position of the support member to the preexisting structure; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • the preexisting structure comprises a wellbore that traverses a subterranean formation.
  • the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • a system for radially expanding and plastically deforming a tubular member within a preexisting structure includes means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or means for unlocking the position of the tubular member relative to the support member; means for displacing the
  • a system for radially expanding and plastically deforming a tubular member within a preexisting structure includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; means for decoupling the expansion device from the tubular support member; and means for removing the tubular support member from the tubular member.
  • a system for radially expanding and plastically deforming a tubular member assembly comprising first and second tubular members coupled to one another, within a preexisting structure
  • a system for radially expanding and plastically deforming a tubular member within a preexisting structure includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; means for drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • a system for radially expanding and plastically deforming a tubular member within a preexisting structure includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking a position of the support-member to the preexisting structure; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or means for unlocking the
  • a method of forming a wellbore casing system within a wellbore that traverses a subterranean formation includes: radially expanding and plastically deforming a first tubular member within a first portion of the wellbore; and then radially expanding and plastically deforming a second tubular member within a second portion of the wellbore using any one of the methods or apparatus described above.
  • the method further comprises: radially expanding and plastically deforming a first tubular member within a first portion of the wellbore using any one of the methods or apparatus described above.
  • an inside diameter of the first and second tubular members are substantially identical.
  • teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support.
  • 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.
  • 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.

Abstract

Radial expansion of a wellbore casing against a formation.

Description

  • This application is based on U.S. Provisional Application Ser. No. 60/948,890, attorney docket number 14147.105348P2US, filed Jul. 10, 2007; and is a continuation in part of PCT application serial number PCT/US2006/004809, attorney docket number 25791.348.02, filed on Feb. 9, 2006, which claimed priority to U.S. provisional patent application Ser. No. 60/652,564, attorney docket number 25791.348, filed on Feb. 14, 2005, the disclosures of which are incorporated herein by reference.
  • This application is a continuation in part of: (1) U.S. application Ser. No. 10/938,225, which issued into U.S. Pat. No. 7,231,985, attorney docket number 25791.331, filed on Sep. 10, 2004, which is a divisional of U.S. application Ser. No. 10/303,992, attorney docket no. 25791.38.07, filed Nov. 22, 2002, which is the National Stage filing of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. Provisional Application Ser. No. 60/212,359, attorney docket number 25791.38, filed on Jun. 19, 2000, (2) U.S. application Ser. No. 10/952,288, attorney docket no. 25791.332, filed on Sep. 28, 2004, which is a divisional of U.S. application Ser. No. 10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, which is the National Stage of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. Application Ser. No. 60/212,359, filed on Jun. 19, 2000, attorney docket number 25791.38, (3) U.S. application Ser. No. 10/952,416, attorney docket no. 25791.333, filed on Sep. 28, 2004 which is a divisional of U.S. application Ser. No. 10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, which is the National Stage filing of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. provisional Application Ser. No. 60/212,359, filed on Jun. 19, 2000, attorney docket number 25791.38, (4) U.S. application Ser. No. 10/950,749, attorney docket no. 25791.334, filed on Sep. 27, 2004, which is a divisional of U.S. application Ser. No. 10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, which is the National Stage filing of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. provisional Application Ser. No. 60/212,359, filed on Jun. 19, 2000, attorney docket number 25791.38, (5) U.S. application Ser. No. 10/950,869, which issued into U.S. Pat. No. 7,246,667, attorney docket no. 25791.335, filed on Sep. 27, 2004, which is a divisional of U.S. application Ser. No. 10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, which is the National Stage filing of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. Application Ser. No. 60/212,359, filed on Jun. 19, 2000, attorney docket number 25791.38. Applicants incorporate by reference the disclosures of these applications.
  • The present application is a continuation-in-part of the following: (1) PCT patent application serial number PCT/US02/36157, attorney docket number 25791.87.02, filed on Nov. 12, 2002, (2) PCT patent application serial number PCT/US02/36267, attorney docket number 25791.88.02, filed on Nov. 12, 2002, (3) PCT patent application serial number PCT/US03/04837, attorney docket number 25791.95.02, filed on Feb. 29, 2003, (4) PCT patent application serial number PCT/US03/29859, attorney docket no. 25791.102.02, filed on Sep. 22, 2003, (5) PCT patent application serial number PCT/US03/14153, attorney docket number 25791.104.02, filed on Nov. 13, 2003, (6) PCT patent application serial number PCT/US03/18530, attorney docket number 25791.108.02, filed on Jun. 11, 2003, (7) PCT patent application serial number PCT/US03/29858, attorney docket number 25791.112.02, filed on Sep. 22, 2003 (8) PCT patent application serial number PCT/US03/29460, attorney docket number 25791.114.02, filed on Sep. 23, 2003, (9) PCT patent application serial number PCT/US04/07711, attorney docket number 25791.253.02, filed on Mar. 11, 2004, (10) PCT patent application serial number PCT/US04/009434, attorney docket number 25791.260.02, filed on Mar. 26, 2004, (11) PCT patent application serial number PCT/US04/010317, attorney docket number 25791.270.02, filed on Apr. 2, 2004, (12) PCT patent application Ser. No. PCT/US04/010712, attorney docket number 25791.272.02, filed on Apr. 7, 2004, (13) PCT patent application serial number PCT/US04/010762, attorney docket number 25791.273.02, filed on Apr. 6, 2004, (14) PCT patent application serial number PCT/US04/011973, attorney docket number 25791.277.02, filed on Apr. 15, 2004, and (15) U.S. patent application Ser. No. 11/531,041, attorney docket number 25791.214.04, filed Sep. 12, 2006, which is a continuation-in-part of PCT patent application serial number PCT/US04/011973, attorney docket number 25791.277.02, filed on Apr. 15, 2004, and claims priority to U.S. provisional patent application Ser. No. 60/717,391, attorney docket no. 25791.214, filed on Sep. 15, 2005, the disclosures of which are incorporated herein by reference.
  • This application is also a CIP of U.S. application Ser. No. 10/553,094, attorney docket number 25791.193, filed on Apr. 13, 2004, which is the National Stage of the International Application Serial Number PCT/US2004/011177, attorney docket number 25791.193.02, filed on Apr. 14, 2004, which claimed the benefit of the filing dates of U.S. Provisional Patent Application Ser. No. 60/462,750, attorney docket no. 25791.193, filed on Apr. 14, 2003, the disclosure of which is 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. 12, 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. 11, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. Pat. No. 6,640,903 which was filed as U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on 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. provisional patent application Ser. No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on. Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket no. 25791.36.03, which claims priority from provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02, which claims priority from provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, attorney docket no. 25791.38.07, which claims priority from provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. 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No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no. 25791.48.06, which claims priority from provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14.2002, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on. Jun. 13, 2003, attorney docket no. 25791.51.06, which claims priority from provisional patent application Ser. No. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application Ser. 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No. 60/600,679, attorney docket number 25791.194, filed on Aug. 11, 2004; (134) PCT patent application serial number PCT/US2005/027318, attorney docket number 25791.329.02, filed on Jul. 29, 2005; (135) PCT patent application serial number PCT/US2005/028936, attorney docket number 25791.338.02, filed on Aug. 12, 2005; (136) PCT patent application serial number PCT/US2005/028669, attorney docket number 25791.194.02, filed on Aug. 11, 2005; (137) PCT patent application serial number PCT/US2005/028453, attorney docket number 25791.371, filed on Aug. 11, 2005; (138) PCT patent application serial number PCT/US2005/028641, attorney docket number 25791.372, filed on Aug. 11, 2005; (139) PCT patent application serial number PCT/US2005/028819, attorney docket number 25791.373, filed on Aug. 11, 2005; (140) PCT patent application serial number PCT/US2005/028446, attorney docket number 25791.374, filed on Aug. 11, 2005; (141) PCT patent application serial number PCT/US2005/028642, attorney docket number 25791.375, filed on Aug. 11, 2005; (142) PCT patent application serial number PCT/US2005/028451, attorney docket number 25791.376, filed on Aug. 11, 2005, and (143). PCT patent application serial number PCT/US2005/028473, attorney docket number 25791.377, filed on Aug. 11, 2005, (144) U.S. utility patent application Ser. No. 10/546,082, attorney docket number 25791.378, filed on Aug. 16, 2005, (145) U.S. utility patent application Ser. No. 10/546,076, attorney docket number 25791.379, filed on Aug. 16, 2005, (146) U.S. utility patent application Ser. No. 10/545,936, attorney docket number 25791.380, filed on Aug. 16, 2005, (147) U.S. utility patent application Ser. No. 10/546,079, attorney docket number 25791.381, filed on Aug. 16, 2005 (148) U.S. utility patent application Ser. No. 10/545,941, attorney docket number 25791.382, filed on Aug. 16, 2005, (149) U.S. utility patent application Ser. No. 546,078, attorney docket number 25791.383, filed on Aug. 16, 2005, filed on Aug. 11, 2005, (150) U.S. utility patent application Ser. No. 10/545,941, attorney docket number 25791.185.05, filed on Aug. 16, 2005, (151) U.S. utility patent application Ser. No. 11/249,967, attorney docket number 25791.384, filed on Oct. 13, 2005, (152) U.S. provisional patent application Ser. No. 60/734,302, attorney docket number 25791.24, filed on Nov. 7, 2005, (153) U.S. provisional patent application Ser. No. 60/725,181, attorney docket number 25791.184, filed on Oct. 11, 2005, (154), PCT patent application serial number PCT/US2005/023391, attorney docket number 25791.299.02 filed Jun. 29, 2005 which claims priority from U.S. provisional patent application Ser. No. 60/585,370, attorney docket number 25791.299, filed on Jul. 2, 2004, (155) U.S. provisional patent application Ser. No. 60/721,579, attorney docket number 25791.327, filed on Sep. 28, 2005, (156) U.S. provisional patent application Ser. No. 60/717,391, attorney docket number 25791.214, filed on Sep. 15, 2005, (157) U.S. provisional patent application Ser. No. 60/702,935, attorney docket number 25791.133, filed on Jul. 27, 2005, (158) U.S. provisional patent application Ser. No. 60/663,913, attorney docket number 25791.32, filed on Mar. 21, 2005, (159) U.S. provisional patent application Ser. No. 60/652,564, attorney docket number 25791.348, filed on Feb. 14, 2005, (160) U.S. provisional patent application Ser. No. 60/645,840, attorney docket number 25791.324, filed on Jan. 21, 2005, (161) PCT patent application serial number PCT/US2005/043122, attorney docket number 25791.326.02, filed on Nov. 29, 2005 which claims priority from U.S. provisional patent application Ser. No. 60/631,703, attorney docket number 25791.326, filed on Nov. 30, 2004, and (162) U.S. provisional patent application Ser. No. 60/752,787, attorney docket number 25791.339, filed on Dec. 22, 2005, the disclosures of which are incorporated herein by reference.
    • BACKGROUND OF THE INVENTION
  • This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
    • BRIEF DESCRIPTION OF THE DRAWINGS
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a wellbore that traverses a subterranean formation.
  • 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.
  • 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 at least a portion of the expandable tubular member into engagement with at least a portion of the interior surface of the wellbore.
  • FIG. 4 is a fragmentary cross sectional view of the expandable tubular member of FIG. 3 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member into engagement with at least another portion of the interior surface of the wellbore.
  • FIG. 5 is a graphical illustration of the operating pressure of the expansion device and the inside diameter of the wellbore during an exemplary experimental radial expansion and plastic deformation of the tubular member.
  • FIG. 6 is a graphical illustration of an exemplary experimental implementation of a pressure test and a pull test following an exemplary experimental radial expansion and plastic deformation of the tubular member.
  • FIG. 7 aa is a fragmentary cross sectional illustration of an exemplary embodiment of an expansion device assembly.
  • FIG. 7 ab is a fragmentary cross-sectional illustration of an exemplary embodiment of the casing release of the expansion device assembly of FIG. 7 aa.
  • FIG. 7 b is a fragmentary cross-sectional illustration of the placement of the expansion device assembly of FIG. 7 aa within a wellbore that traverses a subterranean formation.
  • FIG. 7 c is a fragmentary cross-sectional illustration of the operation of the expansion device assembly of FIG. 7 b within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 7 d is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 c within the wellbore to further radially expand and plastically deform the tubular member.
  • FIG. 7 e is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 c within the wellbore in which the expansion cone is released by the release device.
  • FIG. 7 f is a fragmentary cross-sectional illustration of the further operation of the expansion device assembly of FIG. 7 e within the wellbore in which the casing release is operated.
  • FIG. 8 is a fragmentary cross-sectional illustration of an alternative embodiment of the operation of the expansion device assembly of FIG. 7 b within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 9 aa and 9 ab are fragmentary cross sectional illustrations of an exemplary embodiment of an expansion and drilling device assembly.
  • FIG. 9 b is a fragmentary cross-sectional illustration of the placement of the expansion and drilling device assembly of FIG. 9 a within a wellbore that traverses a subterranean formation.
  • FIG. 9 c is a fragmentary cross-sectional illustration of the operation of the expansion and drilling device assembly of FIG. 9 b to drill within the wellbore.
  • FIG. 9 d is a fragmentary cross-sectional illustration of the operation of the expansion and device assembly of FIG. 9 c within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 9 e is a fragmentary cross-sectional illustration of the further operation of the expansion and drilling device assembly of FIG. 9 d within the wellbore to further radially expand and plastically deform the tubular member.
  • FIG. 10 is a fragmentary cross-sectional illustration of an alternative embodiment of the operation of the expansion and drilling device assembly of FIG. 9 d within the wellbore to radially expand and plastically deform a lower portion of a tubular member.
  • FIG. 11 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expansion and drilling sub-assembly.
  • FIGS. 11 b and 11 c are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of the expansion and drilling sub-assembly of FIG. 11 a.
  • FIGS. 12 a to 12 c are fragmentary cross-sectional illustrations of an exemplary embodiment of the operation of an expansion system for forming a mono-diameter wellbore casing.
  • FIGS. 13 a to 13 d are fragmentary cross-sectional illustrations of an exemplary embodiment of an expansion system.
  • FIG. 14 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expansion and drilling system.
  • FIG. 15 is a graphical illustration of exemplary experimental results obtained during operation of the expansion system of FIG. 7 aa to 7 f.
    • DETAILED DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS
  • Referring initially to FIG. 1, an expandable tubular member 10 is positioned within a wellbore 12 that traverses a subterranean formation 14.
  • As illustrated in FIG. 2, an expansion device 16 is then positioned within the tubular member 10. In several exemplary embodiments, the expansion device 16 may be positioned within the tubular member 10 before, during, or after the placement of the tubular member within the wellbore 12.
  • As illustrated in FIG. 3, the expansion device 16 is then operated to radially expand and plastically deform at least a portion of the tubular member 10 into engagement with at least a portion of the interior surface of the wellbore 12.
  • As illustrated in FIG. 4, the expansion device 16 is then further operated to radially expand the remaining portion of the tubular member 10 into engagement with first portions of the interior surface of the wellbore 12. In an exemplary embodiment, as a result of the operation of the
  • In an exemplary embodiment, following the operation of the expansion device 16, the tubular member 10 remains in circumferential compression and the formation 14 surrounding the tubular member remains in circumferential tension. As a result, an interference fit is formed between the tubular member 10 and the surrounding formation 14.
  • In several exemplary embodiments, the radial expansion and plastic deformation of the tubular member 10 using the expansion device 16 is provided using one or more of the disclosures of one or more of the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 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. 6,575,249, 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. 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  • In an exemplary experimental implementation, the wellbore casing 10 was radially expanded and plastically deformed into engagement with the interior surface of a wellbore 12 using a fluid powered expansion device 16. In the exemplary experimental implementation, the fluid powered expansion device 16 comprised a conventional solid expansion cone that was displaced upwardly through the casing 10 in a conventional manner using fluid pressure.
  • As illustrated in FIG. 5, during the exemplary experimental implementation, the operating pressure 100 of the expansion device 16, the inside diameter 102 of the wellbore 12 at one radial location proximate the expansion device, and the inside diameter 104 of the wellbore at another radial location proximate the expansion device were monitored in a conventional manner using conventional measuring devices.
  • As illustrated in FIG. 5, during the exemplary experimental implementation, the operating pressure 100 of the expansion device varied inversely with respect to the inside diameters, 102 and 104, of the wellbore 12. Thus, by monitoring the expansion forces required to radially expand and plastically deform the tubular member 10, the geometry of the wellbore 12 may be determined. Furthermore, by monitoring the expansion forces required to radially expand and plastically deform the tubular member 10, the material properties and geometry of the formation 14 may also be determined. For example, empirical data may be used to develop and generate a functional relationship between the expansion forces required to radially expand and plastically deform the tubular member 10 and the material properties and geometry of the formation 14. In this manner, by monitoring the expansion forces required to radially expand and plastically deform the tubular member 10, a log of the formation 14 may be generated.
  • As illustrated in FIG. 6, in an exemplary experimental implementation, following the completion of the radial expansion and plastic deformation of the tubular member 10, a pressure test was conducted to determine the degree to which a fluid tight metal to formation seal was created between the tubular member and the interior surface of the wellbore 12.
  • As illustrated in FIG. 6, the fluid tight metal to formation seal generated during the exemplary experimental implementation was capable of withstanding an operating pressure 200 of up to about 2700 psi.
  • As also illustrated in FIG. 6, in an exemplary experimental implementation, following the completion of the radial expansion and plastic deformation of the tubular member 10, a pull test was conducted to determine the degree to which a fluid tight metal to formation seal was created between the tubular member and the interior surface of the wellbore 12.
  • As illustrated in FIG. 6, the fluid tight metal to formation seal generated during the exemplary experimental implementation was capable of withstanding a tensile load 202 of about 120,000 lbf.
  • The experimental results, and observations derived therefrom, illustrated and described above with reference to FIGS. 5 and 6 were unexpected results.
  • Referring now to FIG. 7 aa and 7 ab, an exemplary embodiment of an expansion device assembly 700 includes a tubular support member 702 having an end that is coupled to an end of a locking device 704. In an exemplary embodiment, the tubular support member 702 is a conventional drill pipe and the locking device 704 is, for example, a conventional hydraulically actuated locking device suitable for locking onto a tubular member such as, for example, a wellbore casing.
  • Another end of the locking device 704 is coupled to an end of a tubular support member 706 and another end of the tubular support member is coupled to an end of an actuator 708. In an exemplary embodiment, the tubular support member 706 is a conventional drill pipe and the actuator 708 is a conventional actuator such as, for example, an hydraulic actuator suitable for displacing one or more elements relative to the actuator.
  • Another end of the actuator 708 is coupled to an end of a tubular support member 710 and another end of the tubular support member is coupled to an end of a release device 712. In an exemplary embodiment, the tubular support member 710 is a conventional drill pipe and the release device 712 is a conventional release device for controllably releasing one or more elements coupled to the release device such, for example, upon the application of a loading condition greater than or equal to a predetermined value.
  • An end of an expansion device 714 having one or more tapered expansion surfaces 714 a is coupled to another end of the release device 712. In an exemplary embodiment, the expansion device 714 is a conventional expansion device.
  • An end of an expandable tubular member 716, that receives at least the actuator 708, the tubular support member 710, and the release device 712, is coupled to an supported by the tapered expansion surface 714 a of the end of the expansion device 714. Another end of the expandable tubular member 716 is coupled to an end of a casing release 718 and another end of the casing release 718 is coupled to an end of an expandable tubular member 720. In an exemplary embodiment, the outside diameters of at least one of the expandable tubular member 716, the casing release 718, and/or the expandable tubular member 720 are greater than the outside diameter of the expansion device 714.
  • Referring now to FIG. 7 ab, in an exemplary embodiment, the casing release 718 includes an outer tubular support member 718 a that defines one or more radial passages 718 aa having an end that is coupled to an end of a tapered tubular member 718 b. Another end of the tapered tubular member 718 b is coupled to an end of the tubular support member 716.
  • The casing release 718 further includes an inner tubular member 718 c that defines one or more radial passages 718 ca having an end that is coupled to an end of a tapered tubular member 718 d. Another end of the tapered tubular member 718 b is coupled to an end of the tubular support member 716.
  • In an exemplary embodiment, the diametrical clearance between the inner and outer tubular members, 718 a and 718 c, is a sliding fit.
  • The casing release further includes a conventional shear pin 718 e having ends that mate with and are received within the passages, 718 aa and 718 ca, of the outer and inner tubular members, 718 a and 718 c, respectively.
  • In an exemplary embodiment, the casing release 718 is adapted to permit the application of radial expansion forces to the casing release without releasing the upper end of the expandable tubular member 716 from the lower end of the expandable tubular member 720 while permitting the upper end of the expandable tubular member 716 to be disengaged from the lower end of the expandable tubular member 720 if a predetermined toque loading is applied to the casing release.
  • In several exemplary embodiments, the casing release 718 includes may include one or more of the following in addition to, or instead of, the structural features described above: 1) collets; 2) collets with a release sleeve; 3) a threaded connection that may be released by rotation; 4) splines to transfer torque; and/or 5) stress concentrations that permit release after radial expansion, and/or equivalents thereof.
  • Referring now to FIG. 7 b, in an exemplary embodiment, during the operation of the expansion device assembly 700, the assembly is positioned within a wellbore 740 that traverses a subterranean formation 742. In an exemplary embodiment, at least a portion of the wellbore 740 includes a preexisting wellbore casing 744.
  • Referring now to FIG. 7 c, in an exemplary embodiment, during the operation of the expansion device assembly 700, the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device. In an exemplary embodiment, the actuator 708 is then operated to displace the expansion device 714 upwardly relative to the locking device 704. As a result, the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed. Furthermore, in an exemplary embodiment, as a result, at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742. Furthermore, in an exemplary embodiment, as a result, at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716. In an exemplary embodiment, as a result, at least a portion of the lower portion of the expandable tubular member 716 is anchored to the surrounding subterranean formation 742.
  • Referring now to FIG. 7 d, in an exemplary embodiment, the expansion device assembly 700 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716, the casing release 718 and at least a portion of the expandable tubular member 720 by applying a upward tensile load on an end of the tubular support member 702.
  • In an alternative embodiment, the expansion assembly 700 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716, the casing release 718 and at least a portion of the expandable tubular member 720 by resetting the actuator 708 and then re-stroking the actuator 708. In an alternative embodiment, during the re-stroking of the actuator 708, an upward tensile load may also be applied to the end of the tubular support member 702.
  • Referring to FIG. 7 e, in an exemplary embodiment, during operation of the expansion device assembly 700, the release device 712 may be operated to disengage the expansion device 714 from engagement with the release device by, for example, applying a predetermined torque loading to the release device. In this manner, the expansion device 714 may be released in the event of, for example, an unforeseen operating condition such as when the expansion device becomes stuck within the wellbore 740. The expansion device 714 may be then removed from the interior of the expandable tubular member 716 by, for example, drilling the expansion device out of the interior of the expandable tubular member.
  • Referring to FIG. 7 f, in an exemplary embodiment, during operation of the expansion device assembly 700, the casing release 718 may be operated to disengage the upper end of the expandable tubular member 716 from the lower end of the expandable tubular member 720 by, for example, applying a predetermined toque loading to the casing release 718. In this manner, the expandable tubular member 716 may be released from engagement with the expandable tubular member 720 without having to employ a casing cutter device.
  • Referring to FIG. 8, in an alternative embodiment, during the operation of the expansion device assembly 700, the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device. In an exemplary embodiment, the actuator 708 is then operated to displace the expandable tubular member 716 downwardly relative to the expansion device 714. As a result, the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed. Furthermore, in an exemplary embodiment, as a result, at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742. Furthermore, in an exemplary embodiment, as a result, at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716.
  • Referring to FIG. 9 aa and 9 ab, in an exemplary embodiment, an expansion and drilling assembly 900 is substantially identical to the expansion assembly 700 except as noted below.
  • In an exemplary embodiment, the tubular support member 702, the locking device 704, the tubular support member 706, the actuator 708, the tubular support member 710, the release device 712, and the expansion device 714 of the assembly 900 define internal passages, 702 a, 704 a, 706 a, 708 a, 710 a, 712 a, and 714 b, respectively, that are fluidicly coupled to one another.
  • In an exemplary embodiment, an end of a tubular support member 902 that defines an internal passage 902 a is coupled to the other end of the expansion device 914. In an exemplary embodiment, the internal passage 902 a of the tubular support member 902 is fluidicly coupled to the internal passage 714 b of the expansion device 714.
  • In an exemplary embodiment, another end of the tubular support member 902 is coupled to a conventional fluid powered motor 904 that includes one or more exhaust ports 904 a for exhausting fluidic materials from the motor and an output shaft 904 b.
  • In an exemplary embodiment, a conventional drilling device 906 is coupled to an end of the output shaft 904 b of the motor 904. In an exemplary embodiment, the drilling device 906 may include a conventional underreamer.
  • In an exemplary embodiment, during operation of the assembly 900, as illustrated in FIG. 9 b, the assembly is positioned within the wellbore 740.
  • In an exemplary embodiment, during further operation of the assembly 900, as illustrated in FIG. 9 c, a fluidic material 920 is injected into the assembly through the passages 702 a, 704 a, 706 a, 708 a, 710 a, 712 a, 714 b, and 902 a to thereby operate the motor 904. As a result, the output shaft 904 b of the motor 904 operates the drilling device 906 thereby extending the size and/or length of the wellbore 740.
  • Referring now to FIG. 9 d, in an exemplary embodiment, during the continued operation of the assembly 900, the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device. In an exemplary embodiment, the actuator 708 is then operated to displace the expansion device 714 upwardly relative to the locking device 704. As a result, the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed. Furthermore, in an exemplary embodiment, as a result, at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742. Furthermore, in an exemplary embodiment, as a result, at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716.
  • Referring now to FIG. 9 e, in an exemplary embodiment, the assembly 900 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716, the casing release 718 and at least a portion of the expandable tubular member 720 by applying a upward tensile load on an end of the tubular support member 702.
  • In an alternative embodiment, the assembly 900 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 716, the casing release 718 and at least a portion of the expandable tubular member 720 by resetting the actuator 708 and then re-stroking the actuator 708. In an alternative embodiment, during the re-stroking of the actuator 708, an upward tensile load may also be applied to the end of the tubular support member 702.
  • Referring to FIG. 10, in an alternative embodiment, during the operation of the assembly 900, the locking device 704 is operated to engage and lock the position of the expandable tubular member 716 relative to the locking device. In an exemplary embodiment, the actuator 708 is then operated to displace the expandable tubular member 716 downwardly relative to the expansion device 714. As a result, the lower portion of the expandable tubular member 716 is thereby radially expanded and plastically deformed. Furthermore, in an exemplary embodiment, as a result, at least a portion of the expandable tubular member 716 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742. Furthermore, in an exemplary embodiment, as a result, at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 716.
  • Referring to FIG. 11 a, in an alternative embodiment, an expansion and drilling assembly 1100 is substantially identical in design and operation to the assembly 900 except that the expansion device 714 is replaced with an expansion device 1102 that defines a passage 1102 a and includes one or more tapered expansion surfaces 1102 b and the tubular support member 902 is replaced with a tubular support member 1104 that defines a passage 1104 a having an end that is coupled to the release device 712 and another end that is coupled to the motor 904. In an exemplary embodiment, the passage 1104 a of the tubular support member 1104 is fluidicly coupled to the passages 712 a of the tubular support member and the motor 904. In an exemplary embodiment, the inside diameter of the passage 1102 a of the expansion device 1102 is greater than the outside diameters of both the motor 904 and the drilling device 906 thereby permitting both to pass through the passage.
  • In an exemplary embodiment, during the operation of the assembly 1100, as illustrated in FIGS. 11 b and 11 c, the release device 712 may be operated to disengage the release device from the expansion device 1102 thereby permitting the motor 904 and drilling device 906 to be removed from the assembly by lifting the motor and drilling device upwardly through the passage 1102 a defined within the expansion device 1102.
  • In an exemplary embodiment, during the operation of the assembly 1100, the motor 904 and drilling device 906 may be removed from the assembly after the insertion of the assembly into the wellbore 740, either before or after the initiation and/or completion of the expansion process.
  • Referring now to FIG. 12 a, in an exemplary embodiment, a wellbore casing 1202 is coupled to a wellbore 1204 that traverses a subterranean formation 1206. In an exemplary embodiment, the wellbore casing 1202 is radially expanded and plastically deformed into engagement with the surrounding forming 1206 using one or more of the apparatus and methods described above with reference to FIGS. 11 to 11 c.
  • In an exemplary embodiment, as illustrated in FIG. 12 b, the wellbore 1204 is then in a convention manner using a drilling device and an expansion assembly 1208 is then positioned within the wellbore using a tubular support member 1210 coupled to an end of the expansion assembly. In an exemplary embodiment, a gripping device 1212 is coupled to the tubular support member 1210 for locking the position of the tubular support member to, for example, the wellbore casing 1202.
  • In an exemplary embodiment, the design and operation of the expansion assembly 1208 may include one or more of the apparatus and methods described above with reference to FIGS. 1 to 1 c. In an exemplary embodiment, the gripping device 1212 may include a conventional commercially available gripping device.
  • In an exemplary embodiment, after positioning the expansion assembly 1208 at a predetermined position within the wellbore 1204, the gripping device 1212 is operated to engage the wellbore casing 1202 thereby locking the position of the tubular support member 1210 to the wellbore casing.
  • In an exemplary embodiment, as illustrated in FIG. 12 c, the expansion assembly 1208 is then operated to radially expand and plastically deform a wellbore casing 1208 a into engagement with the surrounding forming 1206.
  • In an exemplary embodiment, the inside diameters of the wellbore casings 1202 and 1208 a are substantially identical. As a result, a mono-diameter wellbore casing is formed within the wellbore.
  • Referring now to FIG. 13 a, an exemplary embodiment of a drilling device assembly 1300, that in some respects is similar in design and operation to the drilling device assembly 700, includes a tubular support member 1302 having an end that is coupled to an end of an actuator 1304. In an exemplary embodiment, the tubular support member 1302 is a conventional drill pipe and the actuator 1304 is a conventional actuator such as, for example, an hydraulic actuator suitable for displacing one or more elements relative to the actuator.
  • Another end of the actuator 1304 is coupled to an end of a tubular support member 1306 and the other end of the tubular support member is coupled to an end of the release device 712. An end of the expansion device 714 having one or more tapered expansion surfaces 714 a is coupled to another end of the release device 712.
  • An end of an expandable tubular member 1308, that receives at least the tubular support member 1306 and the release device 712, is coupled to an supported by the tapered expansion surface 714 a of the end of the expansion device 714. Another end of the expandable tubular member 1308 is coupled to a locking assembly 1310 that defines a passage 1310 a that receives the tubular support member 1306. In this manner, the tubular support member 1308 may be displaced relative to and within the passage 1310 a of the locking assembly 1310.
  • In an exemplary embodiment, the locking assembly 1310 may be a conventional commercially available locking assembly. In an exemplary embodiment, the locking assembly 1310 may further include one or more slips for engaging the end of the expandable tubular member 1308.
  • Referring now to FIG. 13 b, in an exemplary embodiment, during the operation of the expansion device assembly 1300, the assembly is positioned within a wellbore 740 that traverses a subterranean formation 742. In an exemplary embodiment, at least a portion of the wellbore 740 includes a preexisting wellbore casing 744.
  • Referring now to FIG. 13 c, in an exemplary embodiment, during the operation of the expansion device assembly 1308, the locking assembly 1310 engages the end of the expandable tubular member 1308 and the actuator 1304 is operated to displace the tubular support member 1306 and the expansion device 714 upwardly relative to the actuator. As a result, the locking assembly 1310 engages the lower end of the actuator 1304 thereby preventing further upward movement of the expandable tubular member 1308 relative to the actuator 1304. As a result, the lower portion of the expandable tubular member 1308 is radially expanded and plastically deformed by the continued upward displacement of the expansion device 714. Furthermore, in an exemplary embodiment, as a result, at least a portion of the expandable tubular member 1308 is radially expanded and plastically deformed into engagement with the surrounding subterranean formation 742. Furthermore, in an exemplary embodiment, as a result at least a portion of the surrounding subterranean formation 742 is elastically deformed following the radial expansion and plastic deformation of the lower portion of the expandable tubular member 1308, In an exemplary embodiment, as a result, at least a portion of the lower portion of the expandable tubular member 1308 is anchored to the surrounding subterranean formation 742.
  • Referring now to FIG. 13 d, in an exemplary embodiment, the expansion device assembly 1300 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 1308 by applying a upward tensile load on an end of the tubular support member 1302.
  • In an alternative embodiment, the expansion assembly 1300 may be further operated to radially expand and plastically deform the remaining portion of the expandable tubular member 1308 by continuing to operate the actuator 1304. In an alternative embodiment, during the operation of the actuator 1304, an upward tensile load may also be applied to the end of the tubular support member 1302.
  • Referring now to FIG. 14 a, an exemplary embodiment of an expansion and drilling assembly 1400 will now be described that includes various aspects of the design and operation of the expansion assembly 1300. In particular, the tubular support member 1302 defines a passage 1302 a that is fluidicly coupled to a passage 1304 a defined within the actuator 1304.
  • The tubular support member 1306 defines a passage 1306 a that is fluidicly coupled to the passage 1304 a of the actuator 1304 and the release device 712 defines a passage 712 a that is fluidicly coupled to the passage 1306 a defined within the tubular support member. The expansion device 714 defines a passage 714 b that is fluidicly coupled to the passage 712 a defined within the release device 712.
  • An end of a tubular support member 1402 that defines a passage 1402 a that is fluidicly coupled to the passage 714 b defined within the expansion device. The passage 1402 a is also fluidicly coupled to the fluid powered motor 904 that includes an exhaust 904 a and an output shaft 904 b. The output shaft 904 b of the motor 904 is coupled to the drilling device 906.
  • During operation of the assembly 1400, the assembly may be operated to drill out a wellbore and/or to radially expand and plastically deform the expandable tubular member 1308.
  • Referring now to FIG. 15, in an exemplary experimental implementation of the expansion assembly 700, the following graphical data 1500 was observed: Free Expansion 1502, Free Conn Expansion 1504, EAF Expansion 0.1506, EAF Conn Expansion 1508, Free OvL Expansion 1510, EAF OvL Expansion 1512, and EAF OvL Conn Exp 1514.
  • Free Expansion 1502 refers to pipe body expansion forces without cladding into and or against formation.
  • Free Conn Expansion 1504 refers to applying expansion forces across connections between adjacent tubulars without cladding into or against formation.
  • EAF Expansion 1506 refers to the forces required or used for pipe body expansion cladding into and or against the formation.
  • EAF Conn Expansion 1508 refers to the forces required or used for expanding the connections between adjacent tubulars while cladding into and or against the formation.
  • Free OvL Expansion 1510 refers to the expansion forces across the overlap which includes pipe against pipe without cement or formation behind the outer pipe.
  • EAF OvL Expansion 1512 refers to expansion forces across an overlap between inner and outer tubulars while cladding into or against the formation.
  • EAF OvL Conn Exp 1514 refers to the expansion forces across the overlap between inner and outer tubulars with two connections between adjacent tubulars overlaying each other while cladding into or against the formation.
  • An expandable tubular member has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body.
  • A method of coupling a wellbore casing to the interior surface of a wellbore has been described that includes positioning a wellbore casing within the wellbore and radially expanding and plastically deforming the wellbore casing into engagement with the wellbore to form a fluid tight seal between the casing and the wellbore. In an exemplary embodiment, the fluid tight seal between the casing and the wellbore is capable of sealing off fluidic materials having an operating pressure of up to about 2700 psi. In an exemplary embodiment, the fluid tight seal between the casing and the wellbore is capable of withstanding a tensile load of up to about 180,000 lbf.
  • An apparatus has been described that includes a wellbore; and a wellbore casing positioned within and engaged with the wellbore to form a fluid tight seal between the casing and the wellbore. In an exemplary embodiment, the fluid tight seal between the casing and the wellbore is capable of sealing off fluidic materials having an operating pressure of up to about 2700 psi. In an exemplary embodiment, the fluid tight seal between the casing and the wellbore is capable of withstanding a tensile load of up to about 180,000 lbf.
  • A method of determining one or more properties of at least one of a wellbore and a formation traversed by the wellbore has been described that includes radially expanding and plastically deforming a tubular member within the wellbore using an expansion device; monitoring one or more operating parameters of the expansion device; and correlating one or more of the operating parameters of the expansion device to one or more of the properties of at least one of the wellbore and the formation.
  • An apparatus for radially expanding and plastically deforming a tubular member has been described that includes a support member; a locking device coupled to the support member for controllably locking a position of the tubular member relative to the locking device; an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member; and an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member. In an exemplary embodiment, an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device. In an exemplary embodiment, the apparatus further includes a tubular release member for releasably coupling an end of the tubular member to an end of another adjacent tubular member. In an exemplary embodiment, the tubular release member comprises a frangible element coupled between the tubular member and the other tubular member. In an exemplary embodiment, the apparatus further comprises a release device for releasably coupling the expansion device to the actuator. In an exemplary embodiment, the apparatus further includes a drilling device coupled to the support member for drilling a wellbore. In an exemplary embodiment, the expansion device defines a longitudinal passage; and wherein an internal diameter of the longitudinal passage is greater than an outside diameter of the drilling device. In an exemplary embodiment, the apparatus further comprises a motor operably coupled to the drilling device for operating the drilling device. In an exemplary embodiment, the expansion device defines a longitudinal passage; and wherein an internal diameter of the longitudinal passage is greater than an outside diameter of the motor and the drilling device. In an exemplary embodiment, the expansion device defines a longitudinal passage.
  • An apparatus for radially expanding and plastically deforming a tubular member has been described that includes: a support member; a locking device coupled to the support member for controllably locking a position of the tubular member relate to the locking device; an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member; an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member; a release device for releasably coupling the expansion device to the actuator; another tubular member; a tubular release member for releasably coupling an end of the tubular member to an end of the other tubular member; a drilling device coupled to the support member for drilling a wellbore; and a motor operably coupled to the drilling device for operating the drilling device; wherein an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device; wherein the expansion device defines a longitudinal passage; wherein an internal diameter of the longitudinal passage of the expansion device is greater than an outside diameter of the motor and the drilling device; and wherein the tubular release member comprises a frangible element coupled between the tubular member and the other tubular member.
  • A method of radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further includes: radially expanding and plastically deforming the tubular member into engagement with the preexisting structure. In an exemplary embodiment, the method further includes: then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: unlocking the position of the tubular member relative to the support member; displacing the support member relative to the tubular member; relocking the position of the tubular member relative to the support member, and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: decoupling the expansion device from the tubular support member; and removing the tubular support member from the tubular member. In an exemplary embodiment, the tubular member comprises first and second tubular members coupled to one another; and the method further comprises: decoupling the first and second tubular members; and removing one of the first and second tubular members from the preexisting structure. In an exemplary embodiment, the method further comprises: drilling out the preexisting structure. In an exemplary embodiment, the method further comprises: drilling out the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: drilling out the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: drilling out the preexisting structure using a drilling device; and removing the drilling device from the preexisting structure. In an exemplary embodiment, the method further comprises: removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: removing the drilling device from the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method further comprises: locking a position of the support member to the preexisting structure; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the preexisting structure comprises a wellbore that traverses a subterranean formation. In an exemplary embodiment, the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • A method of radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes: positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or unlocking the position of the tubular member relative to the support member; displacing the support member relative to the tubular member; relocking the position of the tubular member relative to the support member and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • A method of radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; decoupling the expansion device from the tubular support member; and removing the tubular support member from the tubular member.
  • A method of radially expanding and plastically deforming a tubular member assembly, comprising first and second tubular members coupled to one another, within a preexisting structure has been described that includes positioning the tubular member assembly and an expansion device within the preexisting structure using a support member; locking the position of the tubular member assembly relative to the support member; then displacing the expansion device relative to the tubular member assembly to radially expand and plastically deform the tubular member assembly into engagement with the preexisting structure; then further displacing the expansion device relative to the tubular member assembly to further radially expand and plastically deform the tubular member assembly; decoupling the first and second tubular members; and removing one of the first and second tubular members from the preexisting structure.
  • A method of radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • A method of radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes positioning the tubular member and an expansion device within the preexisting structure using a support member; locking a position of the support member to the preexisting structure; locking the position of the tubular member relative to the support member; then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: unlocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or unlocking the position of the tubular member relative to the support member; displacing the support member relative to the tubular member; relocking the position of the tubular member relative to the support member; and then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; and wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • A system for radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for radially expanding and plastically deforming the tubular member into engagement with the preexisting structure. In an exemplary embodiment, the system further comprises: means for then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, then further displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member comprises: means for unlocking the position of the tubular member relative to the support member; means for displacing the support member relative to the tubular member; means for relocking the position of the tubular member relative to the support member, and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for decoupling the expansion device from the tubular support member; and means for removing the tubular support member from the tubular member. In an exemplary embodiment, the tubular member comprises first and second tubular members coupled to one another; and wherein the method further comprises: means for decoupling the first and second tubular members; and means for removing one of the first and second tubular members from the preexisting structure. In an exemplary embodiment, the system further comprises: means for drilling out the preexisting structure. In an exemplary embodiment, the system further comprises: means for drilling out the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for drilling out the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for drilling out the preexisting structure using a drilling device; and means for removing the drilling device from the preexisting structure. In an exemplary embodiment, the system further comprises: means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for removing the drilling device from the preexisting structure after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the system further comprises: means for locking a position of the support member to the preexisting structure; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the preexisting structure comprises a wellbore that traverses a subterranean formation. In an exemplary embodiment, the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • A system for radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or means for unlocking the position of the tubular member relative to the support member; means for displacing the support member relative to the tubular member; means for relocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • A system for radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; means for decoupling the expansion device from the tubular support member; and means for removing the tubular support member from the tubular member.
  • A system for radially expanding and plastically deforming a tubular member assembly, comprising first and second tubular members coupled to one another, within a preexisting structure has been described that includes: means for positioning the tubular member assembly and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member assembly relative to the support member; means for then displacing the expansion device relative to the tubular member assembly to radially expand and plastically deform the tubular member assembly into engagement with the preexisting structure; means for then further displacing the expansion device relative to the tubular member assembly to further radially expand and plastically deform the tubular member assembly; means for decoupling the first and second tubular members; and means for removing one of the first and second tubular members from the preexisting structure.
  • A system for radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; means for drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • A system for radially expanding and plastically deforming a tubular member within a preexisting structure has been described that includes: means for positioning the tubular member and an expansion device within the preexisting structure using a support member; means for locking a position of the support-member to the preexisting structure; means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member; wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of: means for unlocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or means for unlocking the position of the tubular member relative to the support member; means for displacing the support member relative to the tubular member; means for relocking the position of the tubular member relative to the support member; and means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; and wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
  • A method of forming a wellbore casing system within a wellbore that traverses a subterranean formation has been described that includes: radially expanding and plastically deforming a first tubular member within a first portion of the wellbore; and then radially expanding and plastically deforming a second tubular member within a second portion of the wellbore using any one of the methods or apparatus described above. In an exemplary embodiment, the method further comprises: radially expanding and plastically deforming a first tubular member within a first portion of the wellbore using any one of the methods or apparatus described above. In an exemplary embodiment, an inside diameter of the first and second tubular members are substantially identical.
  • 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.
  • 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.

Claims (29)

1. A method of coupling a wellbore casing to the interior surface of a wellbore, comprising:
positioning a wellbore casing within the wellbore; and
radially expanding and plastically deforming the wellbore casing into direct contact with the wellbore to form a fluid tight seal between the casing and the wellbore.
2. An apparatus, comprising:
a wellbore;
a wellbore casing positioned within and engaged with the wellbore to form a fluid tight seal between the casing and the wellbore.
3. A method of determining one or more properties of at least one of a wellbore and a formation traversed by the wellbore, comprising:
radially expanding and plastically deforming a tubular member within the wellbore using an expansion device;
monitoring one or more operating parameters of the expansion device; and
correlating one or more of the operating parameters of the expansion device to one or more of the properties of at least one of the wellbore and the formation.
4. An apparatus for radially expanding and plastically deforming a tubular member, comprising:
a support member;
a locking device coupled to the support member for controllably locking a position of the tubular member relative to the locking device;
an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member; and
an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member.
5. An apparatus for radially expanding and plastically deforming a tubular member, comprising:
a support member;
a locking device coupled to the support member for controllably locking a position of the tubular member relative to the locking device;
an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member;
an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member;
a release device for releasably coupling the expansion device to the actuator;
another tubular member;
a tubular release member for releasably coupling an end of the tubular member to an end of the other tubular member;
a drilling device coupled to the support member for drilling a wellbore; and
a motor operably coupled to the drilling device for operating the drilling device;
wherein an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device;
wherein the expansion device defines a longitudinal passage;
wherein an internal diameter of the longitudinal passage of the expansion device is greater than an outside diameter of the motor and the drilling device and
wherein the tubular release member comprises a frangible element coupled between the tubular member and the other tubular member.
6. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking the position of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
7. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking the position of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of:
unlocking the position of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or
unlocking the position of the tubular member relative to the support member;
displacing the support member relative to the tubular member;
relocking the position of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
8. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking the position of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
decoupling the expansion device from the tubular support member; and
removing the tubular support member from the tubular member.
9. A method of radially expanding and plastically deforming a tubular member assembly, comprising first and second tubular members coupled to one another, within a preexisting structure, comprising:
positioning the tubular member assembly and an expansion: device within the preexisting structure using a support member;
locking the position of the tubular member assembly relative to the support member;
then displacing the expansion device relative to the tubular member assembly to radially expand and plastically deform the tubular member assembly into engagement with the preexisting structure;
then further displacing the expansion device relative to the tubular member assembly to further radially expand and plastically deform the tubular member assembly;
decoupling the first and second tubular members; and
removing one of the first and second tubular members from the preexisting structure.
10. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking the position of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and
removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
11. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking a position of the support member to the preexisting structure;
locking the position of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of:
unlocking the position of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or
unlocking the position of the tubular member relative to the support member;
displacing the support member relative to the tubular member;
relocking the position of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; and
wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and
wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
12. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking the position of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
13. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking the position of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of:
means for unlocking the position of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or
means for unlocking the position of the tubular member relative to the support member;
means for displacing the support member relative to the tubular member;
means for relocking the position of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
14. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking the position of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
means for decoupling the expansion device from the tubular support member; and
means for removing the tubular support member from the tubular member.
15. A system for radially expanding and plastically deforming a tubular member assembly, comprising first and second tubular members coupled to one another, within a preexisting structure, comprising:
means for positioning the tubular member assembly and an expansion device within the preexisting structure using a support member;
means for locking the position of the tubular member assembly relative to the support member;
means for then displacing the expansion device relative to the tubular member assembly to radially expand and plastically deform the tubular member assembly into engagement with the preexisting structure;
means for then further displacing the expansion device relative to the tubular member assembly to further radially expand and plastically deform the tubular member assembly;
means for decoupling the first and second tubular members; and
means for removing one of the first and second tubular members from the preexisting structure.
16. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking the position of the tubular member relative to the support member; means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
means for drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and
means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
17. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking a position of the support member to the preexisting structure;
means for locking the position of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member comprises one or more of:
means for unlocking the position of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; or
means for unlocking the position of the tubular member relative to the support member;
means for displacing the support member relative to the tubular member;
means for relocking the position of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; and
wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and
wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
18. An apparatus for radially expanding and plastically deforming a tubular member, comprising:
a support member;
an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member;
an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member; and
a locking device coupled to the tubular member for limiting displacement of the tubular member relative to the actuator.
19. An apparatus for radially expanding and plastically deforming a tubular member, comprising:
a support member;
an expansion device coupled to the support member for radially expanding and plastically deforming the tubular member;
an actuator coupled to the support member and the expansion device for displacing the expansion device relative to the tubular member;
a locking device coupled to the tubular member for limiting displacement of the tubular member relative to the actuator;
a release device for releasably coupling the expansion device to the actuator;
a drilling device coupled to the support member for drilling a wellbore; and
a motor operably coupled to the drilling device for operating the drilling device;
wherein an outside diameter of the expansion device is less than or equal to an outside diameter of a bottom end of the tubular member proximate the expansion device;
wherein the expansion device defines a longitudinal passage; and
wherein an internal diameter of the longitudinal passage of the expansion device is greater than an outside diameter of the motor and the drilling device.
20. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
limiting displacement of the tubular member relative to the support member; and
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
21. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
limiting displacement of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member.
22. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
limiting displacement of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
decoupling the expansion device from the tubular support member; and
removing the tubular support member from the tubular member.
23. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
limiting displacement of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and
removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
24. A method of radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
positioning the tubular member and an expansion device within the preexisting structure using a support member;
locking a position of the support member to the preexisting structure;
limiting displacement of the tubular member relative to the support member;
then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and
wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
25. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for limiting displacement of the tubular member relative to the support member; and
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
26. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for limiting displacement of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member.
27. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for limiting displacement of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
means for decoupling the expansion device from the tubular support member; and
means for removing the tubular support member from the tubular member.
28. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for limiting displacement of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure;
means for drilling out the preexisting structure prior to or after displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member using a drilling device; and
means for removing the drilling device from the preexisting structure prior to displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
29. A system for radially expanding and plastically deforming a tubular member within a preexisting structure, comprising:
means for positioning the tubular member and an expansion device within the preexisting structure using a support member;
means for locking a position of the support member to the preexisting structure;
means for limiting displacement of the tubular member relative to the support member;
means for then displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member into engagement with the preexisting structure; and
means for then further displacing the expansion device relative to the tubular member to further radially expand and plastically deform the tubular member;
wherein the preexisting structure comprises a wellbore that traverses a subterranean formation; and
wherein the preexisting structure further comprises a wellbore casing positioned within the wellbore that is coupled to the subterranean formation.
US11/838,782 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation Abandoned US20080142213A1 (en)

Priority Applications (2)

Application Number Priority Date Filing Date Title
US11/838,782 US20080142213A1 (en) 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation
US12/170,880 US7823659B2 (en) 2007-07-10 2008-07-10 Apparatus and methods for drilling and lining a wellbore

Applications Claiming Priority (28)

Application Number Priority Date Filing Date Title
PCT/US2002/036267 WO2003042487A2 (en) 2001-11-12 2002-11-12 Mono diameter wellbore casing
PCT/US2002/036157 WO2003042486A2 (en) 2001-11-12 2002-11-12 Collapsible expansion cone
US10/303,992 US7270188B2 (en) 1998-11-16 2002-11-22 Radial expansion of tubular members
PCT/US2003/004837 WO2003078785A2 (en) 2002-03-13 2003-02-19 Collapsible expansion cone
US46275003P 2003-04-14 2003-04-14
PCT/US2003/014153 WO2003093623A2 (en) 2002-05-06 2003-05-06 Mono diameter wellbore casing
PCT/US2003/018530 WO2003106130A2 (en) 2002-06-12 2003-06-12 Collapsible expansion cone
PCT/US2003/029858 WO2004027204A2 (en) 2002-09-20 2003-09-22 Cutter for wellbore casing
PCT/US2003/029859 WO2004027205A2 (en) 2002-09-20 2003-09-22 Mono diameter wellbore casing
PCT/US2003/029460 WO2004027200A2 (en) 2002-09-20 2003-09-22 Bottom plug for forming a mono diameter wellbore casing
PCT/US2004/007711 WO2004081346A2 (en) 2003-03-11 2004-03-11 Apparatus for radially expanding and plastically deforming a tubular member
PCT/US2004/009434 WO2004085790A2 (en) 2003-03-27 2004-03-26 Apparatus for radially expanding and plastically deforming a tubular member
PCT/US2004/010317 WO2004089608A2 (en) 2003-04-02 2004-04-02 Apparatus for radially expanding and plastically deforming a tubular member
PCT/US2004/010712 WO2004092527A2 (en) 2003-04-08 2004-04-06 Apparatus for radially expanding and plastically deforming a tubular member
PCT/US2004/010762 WO2004092528A2 (en) 2003-04-07 2004-04-06 Apparatus for radially expanding and plastically deforming a tubular member
PCT/US2004/011177 WO2004092530A2 (en) 2003-04-14 2004-04-13 Radially expanding casing and driling a wellbore
PCT/US2004/011973 WO2004094766A2 (en) 2003-04-17 2004-04-15 Apparatus for radially expanding and plastically deforming a tubular member
US10/938,225 US7231985B2 (en) 1998-11-16 2004-09-10 Radial expansion of tubular members
US10/950,869 US7246667B2 (en) 1998-11-16 2004-09-27 Radial expansion of tubular members
US10/950,749 US7299881B2 (en) 1998-11-16 2004-09-27 Radial expansion of tubular members
US10/952,288 US7275601B2 (en) 1998-11-16 2004-09-28 Radial expansion of tubular members
US10/952,416 US7357190B2 (en) 1998-11-16 2004-09-28 Radial expansion of tubular members
US65256405P 2005-02-14 2005-02-14
US71739105P 2005-09-15 2005-09-15
PCT/US2006/004809 WO2006088743A2 (en) 2005-02-14 2006-02-09 Radial expansion of a wellbore casing against a formation
US11/531,041 US20070227730A1 (en) 2005-09-15 2006-09-12 Apparatus for radially expanding and plastically deforming a tubular member
US94889007P 2007-07-10 2007-07-10
US11/838,782 US20080142213A1 (en) 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation

Related Parent Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2006/004809 Continuation-In-Part WO2006088743A2 (en) 2002-11-12 2006-02-09 Radial expansion of a wellbore casing against a formation

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/170,880 Continuation US7823659B2 (en) 2007-07-10 2008-07-10 Apparatus and methods for drilling and lining a wellbore

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US20080142213A1 true US20080142213A1 (en) 2008-06-19

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US11/838,782 Abandoned US20080142213A1 (en) 2002-11-12 2007-08-14 Radial expansion of a wellbore casing against a formation

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US20090126944A1 (en) * 2007-11-16 2009-05-21 Enventure Global Technology, Llc System for Radially Expanding and Plastically Deforming a Wellbore Casing
US20090151930A1 (en) * 2007-12-17 2009-06-18 Richard Lee Giroux Mechanical expansion system
US20100257913A1 (en) * 2009-04-13 2010-10-14 Enventure Global Technology, Llc Resilient Anchor
US20110094753A1 (en) * 2009-10-22 2011-04-28 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable members
US20110220356A1 (en) * 2010-03-11 2011-09-15 Halliburton Energy Services, Inc. Multiple stage cementing tool with expandable sealing element
US20120152565A1 (en) * 2010-12-21 2012-06-21 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable member
WO2012149241A2 (en) * 2011-04-28 2012-11-01 Enventure Global Technology, Llc Downhole release joint
US8695699B2 (en) 2010-12-21 2014-04-15 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable member
US8899336B2 (en) 2010-08-05 2014-12-02 Weatherford/Lamb, Inc. Anchor for use with expandable tubular
US11585178B2 (en) 2018-06-01 2023-02-21 Winterhawk Well Abandonment Ltd. Casing expander for well abandonment
US11634967B2 (en) 2021-05-31 2023-04-25 Winterhawk Well Abandonment Ltd. Method for well remediation and repair

Cited By (22)

* Cited by examiner, † Cited by third party
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US7789140B2 (en) * 2007-11-16 2010-09-07 Enventure Global Technology, Llc System and method for radially expanding and plastically deforming a wellbore casing
US20090126944A1 (en) * 2007-11-16 2009-05-21 Enventure Global Technology, Llc System for Radially Expanding and Plastically Deforming a Wellbore Casing
US7992644B2 (en) * 2007-12-17 2011-08-09 Weatherford/Lamb, Inc. Mechanical expansion system
US20090151930A1 (en) * 2007-12-17 2009-06-18 Richard Lee Giroux Mechanical expansion system
US20100257913A1 (en) * 2009-04-13 2010-10-14 Enventure Global Technology, Llc Resilient Anchor
WO2010120677A2 (en) * 2009-04-13 2010-10-21 Enventure Global Technology, Llc Resilient anchor
WO2010120677A3 (en) * 2009-04-13 2011-01-13 Enventure Global Technology, Llc Resilient anchor
US8225877B2 (en) * 2009-10-22 2012-07-24 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable members
US20110094753A1 (en) * 2009-10-22 2011-04-28 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable members
US8230926B2 (en) 2010-03-11 2012-07-31 Halliburton Energy Services Inc. Multiple stage cementing tool with expandable sealing element
US20110220356A1 (en) * 2010-03-11 2011-09-15 Halliburton Energy Services, Inc. Multiple stage cementing tool with expandable sealing element
US8899336B2 (en) 2010-08-05 2014-12-02 Weatherford/Lamb, Inc. Anchor for use with expandable tubular
US8499840B2 (en) * 2010-12-21 2013-08-06 Enventure Global Technology, Llc Downhole release joint with radially expandable member
US8695699B2 (en) 2010-12-21 2014-04-15 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable member
US20120152565A1 (en) * 2010-12-21 2012-06-21 Enventure Global Technology, L.L.C. Downhole release joint with radially expandable member
EP2655788A4 (en) * 2010-12-21 2016-08-17 Enventure Global Technology Downhole release joint with radially expandable member
WO2012149241A2 (en) * 2011-04-28 2012-11-01 Enventure Global Technology, Llc Downhole release joint
WO2012149241A3 (en) * 2011-04-28 2013-01-31 Enventure Global Technology, Llc Downhole release joint
US8657001B2 (en) 2011-04-28 2014-02-25 Enventure Global Technology, L.L.C. Downhole release joint
EP2702224A4 (en) * 2011-04-28 2016-11-16 Richard Murray Whiddon Downhole release joint
US11585178B2 (en) 2018-06-01 2023-02-21 Winterhawk Well Abandonment Ltd. Casing expander for well abandonment
US11634967B2 (en) 2021-05-31 2023-04-25 Winterhawk Well Abandonment Ltd. Method for well remediation and repair

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