US20100024348A1 - Method of expansion - Google Patents

Method of expansion Download PDF

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Publication number
US20100024348A1
US20100024348A1 US11/573,485 US57348505A US2010024348A1 US 20100024348 A1 US20100024348 A1 US 20100024348A1 US 57348505 A US57348505 A US 57348505A US 2010024348 A1 US2010024348 A1 US 2010024348A1
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United States
Prior art keywords
tubular
plastic deformation
filed
radial expansion
yield point
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Abandoned
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US11/573,485
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English (en)
Inventor
David Paul Brisco
Brock Wayne Watson
Mark Shuster
Malcolm Gray
Grigoriy Grinberg
Scott Costa
Russell Wasson
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Enventure Global Technology Inc
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Enventure Global Technology Inc
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Priority to US11/573,485 priority Critical patent/US20100024348A1/en
Assigned to ENVENTURE GLOBAL TECHNOLOGY L.L.C. reassignment ENVENTURE GLOBAL TECHNOLOGY L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WASSON, RUSSELL, BRISCO, DAVID PAUL, SHUSTER, MARK, WATSON, BROCK WAYNE, GRAY, MALCOLM, GRINBERG, GRIGORIY, COSTA, SCOTT
Assigned to ENVENTURE GLOBAL TECHNOLOGY, L.L.C. reassignment ENVENTURE GLOBAL TECHNOLOGY, L.L.C. ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: WASSON, RUSSELL, BRISCO, DAVID PAUL, SHUSTER, MARK, WATSON, BROCK WAYNE, GRAY, MALCOLM, GRINBERG, GRIGORIY, COSTA, SCOTT
Publication of US20100024348A1 publication Critical patent/US20100024348A1/en
Abandoned legal-status Critical Current

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    • 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
    • C—CHEMISTRY; METALLURGY
    • C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
    • C22C—ALLOYS
    • C22C38/00—Ferrous alloys, e.g. steel alloys
    • 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
    • E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
    • E21B23/04—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells operated by fluid means, e.g. actuated by explosion
    • 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
    • E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
    • E21B23/08—Introducing or running tools by fluid pressure, e.g. through-the-flow-line tool systems
    • 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
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • 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
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/10—Reconditioning of well casings, e.g. straightening
    • 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
    • E21B43/08—Screens or liners
    • 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
    • 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
    • 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
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T436/00—Chemistry: analytical and immunological testing
    • Y10T436/23—Carbon containing

Definitions

  • This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • 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 a portion of the expandable tubular member.
  • FIG. 4 is a fragmentary cross sectional view of the expandable tubular member of FIG. 3 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 1-4 .
  • FIG. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 1-4 .
  • FIG. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.
  • FIG. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 9 is a fragmentary cross sectional view of the expandable tubular member of FIG. 8 after positioning an expansion device within the expandable tubular member.
  • FIG. 10 is a fragmentary cross sectional view of the expandable tubular member of FIG. 9 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • FIG. 11 is a fragmentary cross sectional view of the expandable tubular member of FIG. 10 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of FIGS. 8-11 .
  • FIG. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of FIGS. 8-11 .
  • FIG. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 15 is a fragmentary cross sectional view of the expandable tubular member of FIG. 14 after positioning an expansion device within the expandable tubular member.
  • FIG. 16 is a fragmentary cross sectional view of the expandable tubular member of Fig. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • FIG. 17 is a fragmentary cross sectional view of the expandable tubular member of Fig. 16 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • FIG. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.
  • FIG. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of FIG. 18 .
  • FIG. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • FIG. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • FIG. 35 a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.
  • FIG. 35 b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of FIG. 35 a.
  • FIG. 36 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 36 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 36 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • FIG. 37 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 37 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 37 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • FIG. 38 a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • FIG. 38 b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • FIG. 38 c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14 .
  • the ends of the first and second expandable tubular members, 12 and 14 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first expandable tubular member 12 has a plastic yield point YP 1
  • the second expandable tubular member 14 has a plastic yield point YP 2 .
  • the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18 .
  • an expansion device 20 may then be positioned within the second expandable tubular member 14 .
  • the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16 .
  • the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 14 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12 .
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14 are radially expanded into intimate contact with the interior surface of the preexisting structure 16 .
  • the plastic yield point YP 1 is greater than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12 .
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14 is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
  • At least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12 .
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 14 .
  • Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to FIGS. 1-4 .
  • At least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24 .
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 26 .
  • a mono-diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter.
  • an exemplary embodiment of an expandable tubular assembly 100 includes a first expandable tubular member 102 coupled to a tubular coupling 104 .
  • the tubular coupling 104 is coupled to a tubular coupling 106 .
  • the tubular coupling 106 is coupled to a second expandable tubular member 108 .
  • the tubular couplings, 104 and 106 provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108 , together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first and second expandable tubular members 12 have a plastic yield point YP 1
  • the tubular couplings, 104 and 106 have a plastic yield point YP 2
  • the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112 .
  • an expansion device 114 may then be positioned within the second expandable tubular member 108 .
  • the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110 .
  • the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.
  • the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108 , the tubular couplings, 104 and 106 , and at least a portion of the first expandable tubular member 102 .
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108 are radially expanded into intimate contact with the interior surface of the preexisting structure 110 .
  • the plastic yield point YP 1 is less than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108 is less than the amount of power and/or energy required to radially expand each unit length of the tubular couplings, 104 and 106 .
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14 is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process.
  • an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204 a , 204 b , 204 c , and 204 d .
  • the ends of the first and second expandable tubular members, 202 and 204 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • one or more of the radial openings, 204 a , 204 b , 204 c , and 204 d have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204 .
  • the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore 206 that traverses a subterranean formation 208 .
  • an expansion device 210 may then be positioned within the second expandable tubular member 204 .
  • the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206 .
  • the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202 .
  • the anisotropy ratio AR for the first and second expandable tubular members is defined by the following equation:
  • WT f final wall thickness of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member
  • WT i initial wall thickness of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member
  • D f final inside diameter of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member
  • D i initial inside diameter of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member.
  • the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204 is greater than 1.
  • the second expandable tubular member 204 had an anisotropy ratio AR greater than 1, and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204 a , 204 b , 204 c , and 204 d , splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 are processed using a method 300 in which a tubular member in an initial state is thermo-mechanically processed in step 302 .
  • the thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to an intermediate state.
  • the tubular member is then further thermo-mechanically processed in step 304 .
  • the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to a final state.
  • the tubular member has a ductility D PE and a yield strength YS PE prior to the final thermo-mechanical processing in step 304 , and a ductility D AE and a yield strength YS AE after final thermo-mechanical processing.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of energy and/or power required to transform the tubular member, using mechanical forming processes, during the final thermo-mechanical processing in step 304 is reduced.
  • the YS AE is greater than YS PE , the collapse strength of the tubular member is increased after the final thermo-mechanical processing in step 304 .
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 have the following characteristics:
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 are characterized by an expandability coefficient f:
  • the anisotropy coefficient for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 1.
  • the strain hardening exponent for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 0.12.
  • the expandability coefficient for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is greater than 0.12.
  • a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient. In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 are steel alloys having one of the following compositions:
  • a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16% YP AE16 %, and a yield point after radial expansion and plastic deformation of about 24% YP AE24 %.
  • YP AE24 %>YP AE16 %>YP BE Furthermore, in an exemplary experimental embodiment, the ductility of the sample of the expandable tubular member composed of Alloy A also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation.
  • a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
  • a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YP BE , a yield point after radial expansion and plastic deformation of about 16% YP AE16 %, and a yield point after radial expansion and plastic deformation of about 24% YP AE24 %.
  • YP AE24 %>YP AE16 %>YP BE the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation.
  • a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
  • samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation:
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.
  • the carbon equivalent C e for tubular members having a carbon content (by weight percentage) less than or equal to 0.12%, is given by the following expression:
  • Mn manganese percentage by weight
  • V vanadium percentage by weight
  • g. Nb niobium percentage by weight
  • Ni nickel percentage by weight
  • the carbon equivalent value C e for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is less than 0.21.
  • the carbon equivalent C e for tubular members having more than 0.12% carbon content (by weight), is given by the following expression:
  • Si silicon percentage by weight
  • Ni nickel percentage by weight
  • V vanadium percentage by weight
  • the carbon equivalent value C e for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 is less than 0.36.
  • the first and second tubular members described above with reference to FIGS. 1 to 21 are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following:
  • the present application is related to the following: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent application Ser.
  • an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504 .
  • the material properties of the first and second tubular regions, 3502 and 3504 are different.
  • the yield points of the first and second tubular regions, 3502 and 3504 are different.
  • the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504 .
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 and/or 204 incorporate the tubular member 3500 .
  • the yield point within the first and second tubular regions, 3502 a and 3502 b, of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member.
  • the yield point increases as a function of the radial position within the expandable tubular member 3502 .
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship.
  • the yield point increases at different rates within the first and second tubular regions, 3502 a and 3502 b , as a function of the radial position within the expandable tubular member 3502 .
  • the functional relationship, and value, of the yield points within the first and second tubular regions, 3502 a and 3502 b , of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 prior to a radial expansion and plastic deformation, include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite.
  • the hard phase provides high strength
  • the soft phase provides ductility
  • the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation.
  • the yield point of the tubular member increases as a result of the radial expansion and plastic deformation. Further, in this manner, the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation.
  • the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3600 , in which, in step 3602 , an expandable tubular member 3602 a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3602 a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
  • the expandable tubular member 3602 a includes a microstructure that includes martensite, pearlite, and V, Ni, and/or Ti carbides.
  • the expandable tubular member 3602 a is then heated at a temperature of 790° C. for about 10 minutes in step 3604 .
  • the expandable tubular member 3602 a is then quenched in water in step 3606 .
  • the expandable tubular member 3602 a includes a microstructure that includes new ferrite, grain pearlite, martensite, and ferrite.
  • the expandable tubular member 3602 a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.
  • the expandable tubular member 3602 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 95 ksi.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3700 , in which, in step 3702 , an expandable tubular member 3702 a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti.
  • the expandable tubular member 3702 a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
  • the expandable tubular member 3702 a includes a microstructure that includes pearlite and pearlite striation.
  • the expandable tubular member 3702 a is then heated at a temperature of 790° C. for about 10 minutes in step 3704 .
  • the expandable tubular member 3702 a is then quenched in water in step 3706 .
  • the expandable tubular member 3702 a includes a microstructure that includes ferrite, martensite, and bainite.
  • the expandable tubular member 3702 a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
  • the expandable tubular member 3702 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 130 ksi.
  • one or more of the expandable tubular members, 12 , 14 , 24 , 26 , 102 , 104 , 106 , 108 , 202 , 204 and/or 3502 are processed in accordance with a method 3800 , in which, in step 3802 , an expandable tubular member 3802 a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03% Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3802 a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
  • the expandable tubular member 3802 a includes a microstructure that includes grain pearlite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
  • the expandable tubular member 3802 a is then heated at a temperature of 790° C. for about 10 minutes in step 3804 .
  • the expandable tubular member 3802 a is then quenched in water in step 3806 .
  • the expandable tubular member 3802 a includes a microstructure that includes bainite, pearlite, and new ferrite. In an exemplary experimental embodiment, following the completion of step 3806 , the expandable tubular member 3802 a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
  • the expandable tubular member 3802 a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 97 ksi.
  • teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, the disclosure of which is incorporated herein by reference.
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly.
  • the method further includes positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly.
  • the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly.
  • the predetermined portion of the tubular assembly includes an end portion of the tubular assembly.
  • the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings.
  • the tubular couplings include the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly.
  • one or more of the tubular couplings include the predetermined portions of the tubular assembly.
  • one or more of the tubular members include the predetermined portions of the tubular assembly.
  • the predetermined portion of the tubular assembly defines one or more openings.
  • one or more of the openings include slots.
  • the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1.
  • the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly is a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.48.
  • the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.04.
  • the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.92.
  • the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is about 1.34.
  • the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.48.
  • the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.04.
  • the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly.
  • the tubular assembly includes a wellbore casing, a pipeline, or a structural support.
  • the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21.
  • the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36.
  • a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly.
  • 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.
  • the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body.
  • the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
  • the tubular assembly prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure.
  • the hard phase structure comprises martensite.
  • the soft phase structure comprises ferrite.
  • the transitional phase structure comprises retained austentite.
  • the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite.
  • the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • the tubular member includes a wellbore casing, a pipeline, or a structural support.
  • 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.
US11/573,485 2004-08-11 2005-08-11 Method of expansion Abandoned US20100024348A1 (en)

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PCT/US2005/028453 WO2006033720A2 (fr) 2004-08-11 2005-08-11 Procede d'expansion

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US11/573,485 Abandoned US20100024348A1 (en) 2004-08-11 2005-08-11 Method of expansion
US11/573,482 Active 2027-12-13 US8196652B2 (en) 2004-08-11 2005-08-11 Radial expansion system
US11/573,465 Abandoned US20080257542A1 (en) 2004-08-11 2005-08-11 Low Carbon Steel Expandable Tubular
US11/573,066 Abandoned US20080035251A1 (en) 2004-08-11 2005-08-11 Method of Manufacturing a Tubular Member
US11/573,467 Abandoned US20080236230A1 (en) 2004-08-11 2005-08-11 Hydroforming Method and Apparatus

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US11/573,465 Abandoned US20080257542A1 (en) 2004-08-11 2005-08-11 Low Carbon Steel Expandable Tubular
US11/573,066 Abandoned US20080035251A1 (en) 2004-08-11 2005-08-11 Method of Manufacturing a Tubular Member
US11/573,467 Abandoned US20080236230A1 (en) 2004-08-11 2005-08-11 Hydroforming Method and Apparatus

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EP (3) EP1792043A4 (fr)
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US20080236230A1 (en) 2008-10-02
US20080257542A1 (en) 2008-10-23
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EP1792043A4 (fr) 2010-01-20
CN101133229A (zh) 2008-02-27
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EP1792044A2 (fr) 2007-06-06
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US20080000645A1 (en) 2008-01-03
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US20080035251A1 (en) 2008-02-14
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