WO2004083594A2 - Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool - Google Patents

Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool Download PDF

Info

Publication number
WO2004083594A2
WO2004083594A2 PCT/US2004/008171 US2004008171W WO2004083594A2 WO 2004083594 A2 WO2004083594 A2 WO 2004083594A2 US 2004008171 W US2004008171 W US 2004008171W WO 2004083594 A2 WO2004083594 A2 WO 2004083594A2
Authority
WO
WIPO (PCT)
Prior art keywords
filed
attorney docket
patent application
application serial
tubular member
Prior art date
Application number
PCT/US2004/008171
Other languages
French (fr)
Other versions
WO2004083594B1 (en
WO2004083594A3 (en
Inventor
Mark Shuster
Scott Costa
Original Assignee
Enventure Global Technology
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
Application filed by Enventure Global Technology filed Critical Enventure Global Technology
Priority to US10/546,903 priority Critical patent/US20070034383A1/en
Priority to GB0518252A priority patent/GB2415004B/en
Priority to CA002517524A priority patent/CA2517524A1/en
Publication of WO2004083594A2 publication Critical patent/WO2004083594A2/en
Publication of WO2004083594A3 publication Critical patent/WO2004083594A3/en
Publication of WO2004083594B1 publication Critical patent/WO2004083594B1/en

Links

Classifications

    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02Subsoil filtering
    • E21B43/10Setting of casings, screens, liners or the like in wells
    • E21B43/103Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105Expanding tools specially adapted therefor
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B23/00Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
    • EFIXED CONSTRUCTIONS
    • E21EARTH DRILLING; MINING
    • E21BEARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02Subsoil filtering
    • E21B43/10Setting of casings, screens, liners or the like in wells
    • E21B43/103Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like

Definitions

  • patent number 6,568,471 which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50)
  • Patent Number 6,497,289 which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no.
  • 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 relatively large borehole diameter is required at the upper part of the wellbore.
  • Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings.
  • increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.
  • the present invention is directed to overcoming one or more of the limitations of the existing procedures for forming and/or repairing wellbore casings.
  • an apparatus for radially expanding and plastically deforming a tubular member includes a tubular support member defining a first passage, a tubular expansion cone defining a second passage coupled to the tubular support member, a fluid driven motor coupled to the tubular expansion cone comprising an inlet, and a rotary expansion device coupled to the output shaft of the fluid driven motor.
  • the first passage is operably coupled to the second passage, and the second passage is operably coupled to the inlet of the fluid driven motor.
  • an apparatus for radially expanding and plastically deforming a tubular member includes a first expansion device for controllably straining the tubular member, and a second expansion device coupled to the first expansion device for controllably stressing the tubular member.
  • a method of radially expanding and plastically deforming a tubular member includes controllably straining the tubular member, and then controllably stressing the tubular member.
  • an apparatus for radially expanding and plastically deforming a tubular member includes means for controllably straining the tubular member, and means for controllably stressing the tubular member after controllably straining the tubular member.
  • an apparatus for radially expanding and plastically deforming a tubular member includes a first expansion device for radially expanding the tubular member, and a second expansion device coupled to the first expansion device for further radially expanding the tubular member.
  • a method of radially expanding and plastically deforming a tubular member includes radially expanding a portion of the tubular member, and then further radially expanding the portion of the tubular member.
  • a system for radially expanding and plastically deforming a tubular member includes means for radially expanding a portion of the tubular member, and means for then further radially expanding the portion of the tubular member.
  • a method of radially expanding and plastically deforming a tubular member includes controllably stressing the tubular member; and then controllably straining the tubular member.
  • an apparatus for radially expanding and plastically deforming a tubular member includes means for controllably stressing the tubular member; and means for controllably straining the tubular member after controllably stressing the tubular member.
  • FIG. 1 is a fragmentary cross sectional illustration of an exemplary embodiment of an apparatus for radially expanding a tubular member.
  • an exemplary embodiment of an apparatus 100 for radially expanding a tubular member includes a tubular support member 102 that defines a passage
  • An end of an expansion mandrel 104 that defines a passage 104a, a chamber 104b, and a passage 104c is coupled to an end of the tubular support member 102 that includes a tapered outer surface 104d.
  • a conventional mud motor 106 is positioned within the chamber 104b of the mandrel
  • the inlet of the mud motor 106 is fluidicly coupled to the passage
  • a conventional rotary expansion tool 108 is coupled to an end of the shaft 106a that may be any number of conventional commercially available rotary expansion devices such as, for example, the rotary expansion devices commercially available from Weatherford International or as described in one or more of the following: U.S. 6,457,532 and/or WO 02/081863 A1, the disclosures of which are incorporated herein by reference.
  • the rotary expansion tool 108 includes one or more circumferentially and/or axially spaced apart roller expansion elements 108a.
  • the mandrel 104, the mud motor 106, and the rotary expansion tool 108 are housed within a tubular launcher assembly 110 that includes a shoe 110a, a tubular section 110b, and a tapered tubular section 110c.
  • the tubular section 110b of the tubular launcher assembly 110 mates with the mandrel 104 and the rotary expansion tool 108.
  • An end of an expandable tubular 112 is coupled to the tapered tubular section
  • the apparatus is initially positioned within a borehole 116 that traverses a subterranean formation 118. Fluidic materials 120 are then injected into the apparatus 100 through the passages, 102a and 104a. The fluidic materials 120 are then conveyed into and through the mud motor 106 and out of the mandrel 104 through the passage 104c. As a result, the mud motor 106 is operated to thereby rotate the shaft 106a and the rotary expansion tool 108.
  • the interior portion of the launcher 110 below the mandrel 104 is pressurized thereby causing the mandrel, mud motor 106, and the rotary expansion tool 108 to be displaced upwardly relative to the launcher 110.
  • the tapered surface 104d of the expansion mandrel 104 provides the majority of the radial expansion and plastic deformation of the tapered tubular section 110c of the launcher 110 and the expandable tubular member 112.
  • the outside diameter of the rotary expansion tool 108 is adjustable and thereby permits the rotary expansion tool 108 to radially expand and plastically deform the expandable tubular member 112 into intimate contact with the walls of the borehole 114. As a result, the formation surrounding the expandable tubular member 112 may be compressed and, after the completion of the radial expansion and plastic deformation of the expandable tubular member, held in compression.
  • the expansion mandrel 104 applies radial forces to contiguous circumferential interior surfaces of the tubular launcher assembly 110 and/or the expandable tubular member 112, and the rotary expansion tool 108 applies radial forces to discrete noncontiguous interior surfaces of the tubular launcher assembly and/or the expandable tubular member.
  • the expansion mandrel 104 provides a strain controlled radial expansion process
  • the rotary expansion tool 108 provides a stress controlled radial expansion process.
  • the final inside diameter of the expandable tubular member 112 provided by operation of the expansion mandrel 104 is controlled by the shape and geometry of the expansion mandrel and should be constant.
  • the final inside diameter of the expandable tubular member provided by operation of the rotary expansion tool 108 may, or may not, be constant depending upon the shape of the wellbore 116.
  • the amount of strain of the expandable tubular member 112 provided by the rotary expansion tool 108 is not controlled.
  • the amount of stress applied to the expandable tubular member 112 by the rotary expansion tool 108 is controlled by controlling the compliance of the roller expansion elements 108a. Consequently, in an exemplary embodiment, the operation of the rotary expansion tool 108 will cause the outside diameter of the expandable tubular member 112 to engage and thereby match the inside diametrical shape of the wellbore 116.
  • a strain controlled radial expansion process is typically capable of providing more radial expansion and plastic deformation than a stress controlled radial expansion process.
  • a stress controlled radial expansion process is typically more capable of expanding a tubular member into engagement with an irregularly shaped wellbore 116. Consequently, the combination of a strain controlled expansion process with a stress controlled expansion process provides the benefits of both in one radial expansion process.
  • the tubular support member 102, mandrel 104, and/or mud motor 106 are also rotated during the radial expansion and plastic deformation of the expandable tubular member 112.
  • the rotary expansion tool 108 is not rotated relative to the mandrel 104.
  • the expansion mandrel 104 is pulled upwardly relative to the tubular member 112 in combination with, or in substitution for, the injection of the fluidic material 120 during at least a portion of the radial expansion and plastic deformation of the tubular member.
  • the annulus defined between the cup seals 114 and the expansion mandrel 104 within the expandable tubular member 112 is pressurized such that the resulting axial force applied to the cup seals pulls the expansion mandrel 104 and the rotary expansion device 108 through the tubular launcher assembly 110 and/or the expandable tubular member 112.
  • the order and/or orientation of the expansion mandrel 104 and/or rotary expansion tool 108 may be reversed.
  • a conventional hydro-forming device may be substituted for, or used in addition to, the expansion mandrel 104.
  • the expansion mandrel 104 and/or the rotary expansion tool 108 are adjustable in size.
  • a conventional rotary expansion tool such as, for example, as described in U.S. 6,457,532 and/or WO 02/081863 A1 , the disclosures of which are incorporated herein by reference, or any one of the commercially available rotary expansion tools available from Weatherford International, Inc. may be substituted for, or used in combination with, the expansion mandrel 104.
  • exemplary embodiments of Fig. 1 are implemented using the methods and/or apparatus disclosed one or more of the following: (1)
  • Patent Number 6,497,289 which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01 , attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no.
  • patent number 6,568,471 which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50)
  • Patent Number 6,497,289 which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no.
  • An apparatus for radially expanding and plastically deforming a tubular member includes a tubular support member defining a first passage, a tubular expansion cone defining a second passage coupled to the tubular support member, a fluid driven motor coupled to the tubular expansion cone comprising an inlet, and a rotary expansion device coupled to the output shaft of the fluid driven motor.
  • the first passage is operably coupled to the second passage, and the second passage is operably coupled to the inlet of the fluid driven motor.
  • An apparatus for radially expanding and plastically deforming a tubular member includes a first expansion device for controllably straining the tubular member, and a second expansion device coupled to the first expansion device for controllably stressing the tubular member.
  • the apparatus further includes a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
  • a method of radially expanding and plastically deforming a tubular member includes controllably straining the tubular member, and then controllably stressing the tubular member.
  • An apparatus for radially expanding and plastically deforming a tubular member includes means for controllably straining the tubular member, and means for controllably stressing the tubular member after controllably straining the tubular member.
  • An apparatus for radially expanding and plastically deforming a tubular member includes a first expansion device for radially expanding the tubular member, and a second expansion device coupled to the first expansion device for further radially expanding the tubular member.
  • the apparatus further includes a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
  • a method of radially expanding and plastically deforming a tubular member includes radially expanding a portion of the tubular member, and then further radially expanding the portion of the tubular member.
  • radially expanding the portion of the tubular member includes applying forces to a continuous circumferential portion of the interior surface of the tubular member.
  • further radially expanding the portion of the tubular member includes applying forces to one or more discrete portions of the interior surface of the tubular member.
  • a system for radially expanding and plastically deforming a tubular member includes means for radially expanding a portion of the tubular member, and means for then further radially expanding the portion of the tubular member.
  • the means for radially expanding the portion of the tubular member includes means for applying forces to a continuous circumferential portion of the interior surface of the tubular member.
  • the means for further radially expanding the portion of the tubular member includes means for applying forces to one or more discrete portions of the interior surface of the tubular member.
  • a method of radially expanding and plastically deforming a tubular member includes controllably stressing the tubular member; and then controllably straining the tubular member.
  • An apparatus for radially expanding and plastically deforming a tubular member includes means for controllably stressing the tubular member; and means for controllably straining the tubular member after controllably stressing the tubular member.
  • teachings of the present disclosure may incorporate one or more features or operational aspects of conventional hydro-forming tools.

Abstract

An apparatus and method for radially expanding a wellbore casing (112) using an expansion mandrel (104) and a rotary expansion tool (108).

Description

APPARATUS AND METHOD FOR RADIALLY EXPANDING A WELLBORE CASING
USING AN EXPANSION MANDREL AND A ROTARY EXPANSION TOOL
Cross Reference To Related Applications
[001] The present application claims the benefit of the filing date of U.S. provisional patent application serial no. 60/454,896, attorney docket no. 25791.236, filed on March 14, 2003, the disclosure of which is incorporated herein by reference.
[002] The present application is related to the following: (1) U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional application
60/111 ,293, filed on 12/7/98, (2) U.S. patent application serial no. 09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application
60/121 ,702, filed on 2/25/99, (3) U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application
60/119,611 , filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed as U.S. Patent
Application serial number 09/440,338, attorney docket number 25791.9.02, filed on
11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (5)
U.S. patent application serial no. 10/169,434, attorney docket no. 25791.10.04, filed on
7/1/02, which claims priority from provisional application 60/183,546, filed on 2/18/00, (6)
U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (7)
U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (8) U.S. patent number 6,575,240, which was filed as patent application serial no. 09/511 ,941, attorney docket no. 25791.16.02, filed on
2/24/2000, which claims priority from provisional application 60/121 ,907, filed on 2/26/99, (9)
U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial no. 09/981 ,916, attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (11) U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on
4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99,
(12) U.S. patent application serial no. 10/030,593, attorney docket no. 25791.25.08, filed on
1/8/02, which claims priority from provisional application 60/146,203, filed on 7/29/99, (13)
U.S. provisional patent application serial no. 60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent application serial no. 10/111 ,982, attorney docket no. 25791.27.08, filed on 4/30/02, which claims priority from provisional patent application serial no. 60/162,671 , attorney docket no. 25791.27, filed on 11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047, attorney docket no. 25791.29, filed on 9/16/1999, (16) U.S. provisional patent application serial no. 60/438,828, attorney docket no. 25791.31, filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as application serial no. 09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority from provisional patent application serial no. 60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on 3/27/02, attorney docket no. 25791.36.03, which claims priority from provisional patent application serial no. 60/159,039, attorney docket no. 25791.36, filed on 10/12/1999, (19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (20) U.S. patent application serial no. 10/303,992, filed on 11/22/02, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on 6/19/2000, (21) U.S. provisional patent application serial no. 60/165,228, attorney docket no. 25791.39, filed on 11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051, attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on 6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711 , attorney docket no. 25791.44, filed on 7/6/01 , (24) U.S. patent application serial no. 10/311 ,412, filed on 12/12/02, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221 ,443, attorney docket no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/, filed on 12/18/02, attorney docket no. 25791.46.07, which claims priority from provisional patent application serial no. 60/221 ,645, attorney docket no. 25791.46, filed on 7/28/2000, (26) U.S. patent application serial no. 10/322,947, filed on 1/22/03, attorney docket no. 25791.47.03, which claims priority from provisional patent application serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial no. 10/406,648, filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000, (28) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 , (29) U.S. patent application serial no. 10/465,835, filed on 6/13/03, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51 , filed on 1/17/2001 , (30) U.S. patent application serial no. 10/465,831 , filed on 6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (31) U.S. provisional patent application serial no. 60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent number 6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (33) U.S. patent number 6,561 ,227, which was filed as patent application serial number 09/852,026 , filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (34) U.S. patent application serial number 09/852,027, filed on 5/9/01 , attorney docket no. 25791.57, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01 , attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional patent application serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001 , (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S. provisional patent application serial no. 60/303,740, attorney docket no. 25791.61 , filed on 7/6/2001 , (39) U.S. patent application serial no. 09/962,469, filed on 9/25/01 , attorney docket no. 25791.62, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01, attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (41) U.S. patent application serial no. 09/962,471 , filed on 9/25/01 , attorney docket no. 25791.64, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (42) U.S. patent application serial no. 09/962,467, filed on 9/25/01 , attorney docket no. 25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent application serial no. 09/962,468, filed on 9/25/01 , attorney docket no. 25791.66, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001 , and U.S. provisional patent application serial no.
60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001 , (45) PCT application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket no. 25791.68, filed on 12/27/2001 , (46) U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (47) U.S. utility patent application serial no.
10/516,467, attorney docket no. 25791.70, filed on 12/10/01 , which is a continuation application of U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001 , which is a continuation-in-part application of U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372 , attorney docket no. 25791.71 , filed on 2/15/02, (49) U.S. patent application serial no. 10/074,703, attorney docket no. 25791.74, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which is a divisional of
U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (51) U.S. patent application serial no. 10/076,660, attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841, filed on 2/26/99, (52) U.S. patent application serial no. 10/076,661 , attorney docket no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471, which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (54) U.S. patent application serial no. 10/078,928, attorney docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (55) U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (56) U.S. patent application serial no. 10/078,921, attorney docket no. 25791.81 , filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (57) U.S. patent application serial no. 10/261,928, attorney docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276 , attorney docket no.
25791.83, filed on 2/20/02, wh ich is a divisional of U.S. patent number 6,568,471 , which was filed as patent application ser iial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims prior ϊity from provisional application 60/121,841, filed on 2/26/99,
(59) U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481 , attorney docket no. 25791.85, filed on 3/7/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (61) U.S. patent application serial no.
10/261 ,926, attorney docket no. 25791.86, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157, filed on 11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application serial no. 60/338,996, attorney docket no. 25791.87, filed on 11/12/01 , (63) PCT application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application serial no. 60/339,013, attorney docket no.
25791.88, filed on 11/12/01, (64) PCT application US 03/11765, filed on 4/16/03, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application serial no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT application US
03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application serial no. 60/391 ,703, attorney docket no. 25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket no.
25791.92.02, which claims priority from U.S. provisional patent application serial no.
60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT application US
03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application serial no. 60/372,048, attorney docket no. 25791.93, filed on
4/12/02, (68) U.S. patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02, which is a divisional U.S. patent application serial no. 09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69)
PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no. 10/261 ,927, attorney docket no. 25791.97, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney docket no.
25791.98, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72)
U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (74) PCT application US 03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims priority from
U.S. provisional patent application serial no. 60/372,632, attorney docket no. 25791.101 , filed on 4/15/02, (75) U.S. provisional patent application serial no. 60/412,542, attorney docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153, filed on 5/6/03, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application serial no. 60/380,147, attorney docket no. 25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application serial no. 60/397,284, attorney docket no.
25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6/10/02, (79) PCT application
US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims priority from
U.S. provisional patent application serial no. 60/387,961 , attorney docket no. 25791.108, filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney docket no.
25791.110.02, which claims priority from U.S. provisional patent application serial no.
60/398,061 , attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US
03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111 , filed on
7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no.
25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no.
10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a continuation of
U.S. patent number 6,470,966, which was filed as patent application serial number
09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S.
Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no.
60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on
8/23/02, (88) U.S. provisional patent application serial no. 60/405,394, attorney docket no.
25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial no. 60/412,544, attorney docket no. 25791.121 , filed on 9/20/02, (90) PCT application PCT/US03/24779, filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application serial no. 60/407,442, attorney docket no. 25791.125, filed on
8/30/02, (91) U.S. provisional patent application serial no. 60/423,363, attorney docket no.
25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial no. 60/412,196, attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent application serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94) U.S. provisional patent application serial no. 60/412,371 , attorney docket no. 25791.129, filed on 9/20/02,
(95) U.S. patent application serial no. 10/382,325, attorney docket no. 25791.145, filed on
3/5/03, which is a continuation of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent application serial no. 10/624,842, attorney docket no. 25791.151 , filed on 7/22/03, which is a divisional of U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611 , filed on
2/11/99, (97) U.S. provisional patent application serial no. 60/431 ,184, attorney docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial no. 60/448,526, attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent application serial no. 60/461 ,539, attorney docket no. 25791.186, filed on 4/9/03, (100) U.S. provisional patent application serial no. 60/462,750, attorney docket no. 25791.193, filed on 4/14/03,
(101) U.S. provisional patent application serial no. 60/436,106, attorney docket no.
25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial no. 60/442,942, attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent application serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104) U.S. provisional patent application serial no. 60/418,687, attorney docket no. 25791.228, filed on 4/18/03,
(105) U.S. provisional patent application serial no. 60/454,896, attorney docket no.
25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no. 10/421 ,682, attorney docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S. provisional patent application serial no. 60/457,965, attorney docket no. 25791.260, filed on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney docket no.
25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821 , which was filed as patent application serial no. 09/811 ,734, filed on 3/19/01 , (114) U.S. patent application serial no.
10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a continuation of U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131,106, filed on 4/26/99, (115) U.S. provisional patent application serial no. 60/459,776, attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent application serial no. 60/461 ,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S. provisional patent application serial no. 60/461 ,038, attorney docket no. 25791.273, filed on 4/7/03,
(118) U.S. provisional patent application serial no. 60/463,586, attorney docket no.
25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial no. 60/472,240, attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application serial no.
10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on
10/3/2001 , which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number
25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (121) U.S. utility patent application serial no. 10/418,688, attorney docket no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (122) PCT patent application serial no. , attorney docket no. 25791.238.02, filed on ,
(123) PCT patent application serial no. , attorney docket no. 25791.253.02, filed on , and (124) PCT patent application serial no. , attorney docket no.
25791.40.02, filed on , the disclosures of which are incorporated herein by reference.
Background of the Invention
[003] This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
[004] Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.
[005] The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming and/or repairing wellbore casings.
Summary of the Invention
[006] According to one aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided that includes a tubular support member defining a first passage, a tubular expansion cone defining a second passage coupled to the tubular support member, a fluid driven motor coupled to the tubular expansion cone comprising an inlet, and a rotary expansion device coupled to the output shaft of the fluid driven motor. The first passage is operably coupled to the second passage, and the second passage is operably coupled to the inlet of the fluid driven motor.
[007] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided that includes a first expansion device for controllably straining the tubular member, and a second expansion device coupled to the first expansion device for controllably stressing the tubular member.
[008] According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular member is provided that includes controllably straining the tubular member, and then controllably stressing the tubular member.
[009] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided thai includes means for controllably straining the tubular member, and means for controllably stressing the tubular member after controllably straining the tubular member.
[0010] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided that includes a first expansion device for radially expanding the tubular member, and a second expansion device coupled to the first expansion device for further radially expanding the tubular member.
[0011] According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular member is provided that includes radially expanding a portion of the tubular member, and then further radially expanding the portion of the tubular member.
[0012] According to another aspect of the present invention, a system for radially expanding and plastically deforming a tubular member is provided that includes means for radially expanding a portion of the tubular member, and means for then further radially expanding the portion of the tubular member.
[0013] According to another aspect of the present invention, a method of radially expanding and plastically deforming a tubular member is provided that includes controllably stressing the tubular member; and then controllably straining the tubular member.
[0014] According to another aspect of the present invention, an apparatus for radially expanding and plastically deforming a tubular member is provided that includes means for controllably stressing the tubular member; and means for controllably straining the tubular member after controllably stressing the tubular member.
Brief Description of the Drawings
[0015] Fig. 1 is a fragmentary cross sectional illustration of an exemplary embodiment of an apparatus for radially expanding a tubular member.
Detailed Description of the Illustrative Embodiments
[0016] Referring to Fig. 1, an exemplary embodiment of an apparatus 100 for radially expanding a tubular member includes a tubular support member 102 that defines a passage
102a. An end of an expansion mandrel 104 that defines a passage 104a, a chamber 104b, and a passage 104c is coupled to an end of the tubular support member 102 that includes a tapered outer surface 104d.
[0017] A conventional mud motor 106 is positioned within the chamber 104b of the mandrel
104 that includes an rotable output shaft 106a that extends out of the mandrel. In an exemplary embodiment, the inlet of the mud motor 106 is fluidicly coupled to the passage
104a of the mandrel, and the outlet of the mud motor is fluidicly coupled to the passage 104c of the mandrel. In this manner, the mud motor 106 may be operated to rotate the shaft 106a upon pumping fluidic materials into and through the mud motor. A conventional rotary expansion tool 108 is coupled to an end of the shaft 106a that may be any number of conventional commercially available rotary expansion devices such as, for example, the rotary expansion devices commercially available from Weatherford International or as described in one or more of the following: U.S. 6,457,532 and/or WO 02/081863 A1, the disclosures of which are incorporated herein by reference. In an exemplary embodiment, the rotary expansion tool 108 includes one or more circumferentially and/or axially spaced apart roller expansion elements 108a.
[0018] The mandrel 104, the mud motor 106, and the rotary expansion tool 108 are housed within a tubular launcher assembly 110 that includes a shoe 110a, a tubular section 110b, and a tapered tubular section 110c. In an exemplary embodiment, the tubular section 110b of the tubular launcher assembly 110 mates with the mandrel 104 and the rotary expansion tool 108. An end of an expandable tubular 112 is coupled to the tapered tubular section
110c of the launcher assembly 110. In an exemplary embodiment, one or more cup seals
114 are coupled to the exterior of the tubular support 102 for sealingly engaging the interior surface of the expandable tubular member 112.
[0019] In an exemplary embodiment, the apparatus is initially positioned within a borehole 116 that traverses a subterranean formation 118. Fluidic materials 120 are then injected into the apparatus 100 through the passages, 102a and 104a. The fluidic materials 120 are then conveyed into and through the mud motor 106 and out of the mandrel 104 through the passage 104c. As a result, the mud motor 106 is operated to thereby rotate the shaft 106a and the rotary expansion tool 108. Also, as a result, the interior portion of the launcher 110 below the mandrel 104 is pressurized thereby causing the mandrel, mud motor 106, and the rotary expansion tool 108 to be displaced upwardly relative to the launcher 110.
[0020] The upward displacement of the mandrel 104, mud motor 106, and rotary expansion tool 108 then radially expands and plastically deforms at least the tubular section 110b and the tapered tubular section 110c of the launcher 110 and the expandable tubular member
112. In an exemplary embodiment, the tapered surface 104d of the expansion mandrel 104 provides the majority of the radial expansion and plastic deformation of the tapered tubular section 110c of the launcher 110 and the expandable tubular member 112. In an exemplary embodiment, the outside diameter of the rotary expansion tool 108 is adjustable and thereby permits the rotary expansion tool 108 to radially expand and plastically deform the expandable tubular member 112 into intimate contact with the walls of the borehole 114. As a result, the formation surrounding the expandable tubular member 112 may be compressed and, after the completion of the radial expansion and plastic deformation of the expandable tubular member, held in compression. In an exemplary embodiment, during the operation of the apparatus 100, the expansion mandrel 104 applies radial forces to contiguous circumferential interior surfaces of the tubular launcher assembly 110 and/or the expandable tubular member 112, and the rotary expansion tool 108 applies radial forces to discrete noncontiguous interior surfaces of the tubular launcher assembly and/or the expandable tubular member.
[0021] During the operation of the apparatus 100, in an exemplary embodiment, the expansion mandrel 104 provides a strain controlled radial expansion process, and the rotary expansion tool 108 provides a stress controlled radial expansion process. For example, the final inside diameter of the expandable tubular member 112 provided by operation of the expansion mandrel 104 is controlled by the shape and geometry of the expansion mandrel and should be constant. However, the final inside diameter of the expandable tubular member provided by operation of the rotary expansion tool 108 may, or may not, be constant depending upon the shape of the wellbore 116. In particular, the amount of strain of the expandable tubular member 112 provided by the rotary expansion tool 108 is not controlled.
Rather, the amount of stress applied to the expandable tubular member 112 by the rotary expansion tool 108 is controlled by controlling the compliance of the roller expansion elements 108a. Consequently, in an exemplary embodiment, the operation of the rotary expansion tool 108 will cause the outside diameter of the expandable tubular member 112 to engage and thereby match the inside diametrical shape of the wellbore 116. A strain controlled radial expansion process is typically capable of providing more radial expansion and plastic deformation than a stress controlled radial expansion process. However, a stress controlled radial expansion process is typically more capable of expanding a tubular member into engagement with an irregularly shaped wellbore 116. Consequently, the combination of a strain controlled expansion process with a stress controlled expansion process provides the benefits of both in one radial expansion process.
[0022] In several alternative embodiments, during the operation of the apparatus 100, the tubular support member 102, mandrel 104, and/or mud motor 106 are also rotated during the radial expansion and plastic deformation of the expandable tubular member 112. In several alternative embodiments, during the operation of the apparatus 100, the rotary expansion tool 108 is not rotated relative to the mandrel 104.
[0023] In an alternative embodiment, the expansion mandrel 104 is pulled upwardly relative to the tubular member 112 in combination with, or in substitution for, the injection of the fluidic material 120 during at least a portion of the radial expansion and plastic deformation of the tubular member.
[0024] In several exemplary embodiments, the interface between the expansion mandrel
104 and the tubular launcher assembly 110 and/or the expandable tubular member 112 is not fluid tight. As a result, the annulus defined between the cup seals 114 and the expansion mandrel 104 within the expandable tubular member 112 is pressurized such that the resulting axial force applied to the cup seals pulls the expansion mandrel 104 and the rotary expansion device 108 through the tubular launcher assembly 110 and/or the expandable tubular member 112.
[0025] In several alternative embodiments, the order and/or orientation of the expansion mandrel 104 and/or rotary expansion tool 108 may be reversed.
[0026] In several alternative embodiments, a conventional hydro-forming device may be substituted for, or used in addition to, the expansion mandrel 104.
[0027] In several alternative embodiments, the expansion mandrel 104 and/or the rotary expansion tool 108 are adjustable in size.
[0028] In several alternative embodiments, a conventional rotary expansion tool such as, for example, as described in U.S. 6,457,532 and/or WO 02/081863 A1 , the disclosures of which are incorporated herein by reference, or any one of the commercially available rotary expansion tools available from Weatherford International, Inc. may be substituted for, or used in combination with, the expansion mandrel 104.
[0029] In several alternative embodiments, the exemplary embodiments of Fig. 1 are implemented using the methods and/or apparatus disclosed one or more of the following: (1)
U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (2) U.S. patent application serial no.
09/510,913, attorney docket no. 25791.7.02, filed on 2/23/2000, which claims priority from provisional application 60/121 ,702, filed on 2/25/99, (3) U.S. patent application serial no.
09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611 , filed on 2/11/99, (4) U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number
25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (5) U.S. patent application serial no. 10/169,434, attorney docket no.
25791.10.04, filed on 7/1/02, which claims priority from provisional application 60/183,546, filed on 2/18/00, (6) U.S. patent application serial no. 09/523,468, attorney docket no.
25791.11.02, filed on 3/10/2000, which claims priority from provisional application
60/124,042, filed on 3/11/99, (7) U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (8) U.S. patent number 6,575,240, which was filed as patent application serial no. 09/511,941 , attorney docket no. 25791.16.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,907, filed on 2/26/99, (9) U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (10) U.S. patent application serial no. 09/981 ,916, attorney docket no. 25791.18, filed on 10/18/01 as a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent
Application serial number 09/440,338, attorney docket number 25791.9.02, filed on
11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98,
(11) U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application 60/131 ,106, filed on 4/26/99, (12) U.S. patent application serial no. 10/030,593, attorney docket no. 25791.25.08, filed on 1/8/02, which claims priority from provisional application 60/146,203, filed on 7/29/99, (13) U.S. provisional patent application serial no.
60/143,039, attorney docket no. 25791.26, filed on 7/9/99, (14) U.S. patent application serial no. 10/111,982, attorney docket no. 25791.27.08, filed on 4/30/02, which claims priority from provisional patent application serial no. 60/162,671 , attorney docket no. 25791.27, filed on
11/1/1999, (15) U.S. provisional patent application serial no. 60/154,047, attorney docket no.
25791.29, filed on 9/16/1999, (16) U.S. provisional patent application serial no. 60/438,828, attorney docket no. 25791.31 , filed on 1/9/03, (17) U.S. patent number 6,564,875, which was filed as application serial no. 09/679,907, attorney docket no. 25791.34.02, on 10/5/00, which claims priority from provisional patent application serial no. 60/159,082, attorney docket no. 25791.34, filed on 10/12/1999, (18) U.S. patent application serial no. 10/089,419, filed on 3/27/02, attorney docket no. 25791.36.03, which claims priority from provisional patent application serial no. 60/159,039, attorney docket no. 25791.36, filed on 10/12/1999,
(19) U.S. patent application serial no. 09/679,906, filed on 10/5/00, attorney docket no.
25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (20) U.S. patent application serial no.
10/303,992, filed on 11/22/02, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on
6/19/2000, (21) U.S. provisional patent application serial no. 60/165,228, attorney docket no.
25791.39, filed on 11/12/1999, (22) U.S. provisional patent application serial no. 60/455,051 , attorney docket no. 25791.40, filed on 3/14/03, (23) PCT application US02/2477, filed on
6/26/02, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711, attorney docket no. 25791.44, filed on 7/6/01 , (24) U.S. patent application serial no. 10/311 ,412, filed on 12/12/02, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221 ,443, attorney docket no. 25791.45, filed on 7/28/2000, (25) U.S. patent application serial no. 10/, filed on
12/18/02, attorney docket no. 25791.46.07, which claims priority from provisional patent application serial no. 60/221 ,645, attorney docket no. 25791.46, filed on 7/28/2000, (26) U.S. patent application serial no. 10/322,947, filed on 1/22/03, attorney docket no. 25791.47.03, which claims priority from provisional patent application serial no. 60/233,638, attorney docket no. 25791.47, filed on 9/18/2000, (27) U.S. patent application serial no. 10/406,648, filed on 3/31/03, attorney docket no. 25791.48.06, which claims priority from provisional patent application serial no. 60/237,334, attorney docket no. 25791.48, filed on 10/2/2000,
(28) PCT application US02/04353, filed on 2/14/02, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application serial no. 60/270,007, attorney docket no. 25791.50, filed on 2/20/2001 , (29) U.S. patent application serial no. 10/465,835, filed on
6/13/03, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51 , filed on 1/17/2001 , (30) U.S. patent application serial no. 10/465,831 , filed on 6/13/03, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application serial no. 60/259,486, attorney docket no. 25791.52, filed on 1/3/2001 , (31) U.S. provisional patent application serial no.
60/452,303, filed on 3/5/03, attorney docket no. 25791.53, (32) U.S. patent number
6,470,966, which was filed as patent application serial number 09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no.
25791.03.02, filed on 12/3/1999, which claims priority from provisional application
60/111 ,293, filed on 12/7/98, (33) U.S. patent number 6,561 ,227, which was filed as patent application serial number 09/852,026 , filed on 5/9/01 , attorney docket no. 25791.56, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (34) U.S. patent application serial number 09/852,027, filed on 5/9/01 , attorney docket no. 25791.57, as a divisional application of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on 8/13/02, which claims priority from provisional application 60/318,021 , filed on 9/7/01 , attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on 8/1/02, which claims priority from U.S. provisional patent application serial no. 60/313,453, attorney docket no. 25791.59, filed on 8/20/2001 , (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on 9/19/02, which claims priority from U.S. provisional patent application serial no. 60/326,886, attorney docket no. 25791.60, filed on 10/3/2001 , (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on 6/26/02, which claims priority from U.S. provisional patent application serial no. 60/303,740, attorney docket no. 25791.61 , filed on 7/6/2001 , (39) U.S. patent application serial no. 09/962,469, filed on 9/25/01 , attorney docket no. 25791.62, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (40) U.S. patent application serial no. 09/962,470, filed on 9/25/01 , attorney docket no. 25791.63, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99,
(41) U.S. patent applicati on serial no. 09/962,471 , filed on 9/25/01 , attorney docket no. 25791.64, which is a div sional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, fi led on 3/10/2000, which claims priority from provisional application
60/124,042, filed on 3/11/99, (42) U.S. patent application serial no. 09/962,467, filed on
9/25/01 , attorney docket no. 25791.65, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (43) U.S. patent application serial no. 09/962,468, filed on 9/25/01 , attorney docket no. 25791.66, which is a divisional of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on
3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99,
(44) PCT application US 02/25727, filed on 8/14/02, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application serial no. 60/317,985, attorney docket no. 25791.67, filed on 9/6/2001 , and U.S. provisional patent application serial no. 60/318,386, attorney docket no. 25791.67.02, filed on 9/10/2001 , (45) PCT application US
02/39425, filed on 12/10/02, attorney docket no. 25791.68.02, which claims priority from
U.S. provisional patent application serial no. 60/343,674 , attorney docket no. 25791.68, filed on 12/27/2001 , (46) U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on 10/3/2001, which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (47) U.S. utility patent application serial no.
10/516,467, attorney docket no. 25791.70, filed on 12/10/01 , which is a continuation application of U.S. utility patent application serial no. 09/969,922, attorney docket no.
25791.69, filed on 10/3/2001 , which is a continuation-in-part application of U.S. patent no.
6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number 25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (48) PCT application US 03/00609, filed on 1/9/03, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application serial no. 60/357,372 , attorney docket no. 25791.71 , filed on 2/15/02, (49) U.S. patent application serial no. 10/074,703, attorney docket no. 25791.74, filed on 2/12/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (50) U.S. patent application serial no. 10/074,244, attorney docket no. 25791.75, filed on 2/12/02, which is a divisional of
U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (51) U.S. patent application serial no. 10/076,660, attorney docket no. 25791.76, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (52) U.S. patent application serial no. 10/076,661 , attorney docket no. 25791.77, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841, filed on 2/26/99, (53) U.S. patent application serial no. 10/076,659, attorney docket no. 25791.78, filed on 2/15/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841, filed on 2/26/99, (54) U.S. patent application serial no. 10/078,928, attorney docket no. 25791.79, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (55) U.S. patent application serial no. 10/078,922, attorney docket no. 25791.80, filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841, filed on 2/26/99, (56) U.S. patent application serial no. 10/078,921, attorney docket no. 25791.81 , filed on 2/20/02, which is a divisional of U.S. patent number
6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no.
25791.12.02, filed on 2/24/2000, which claims priority from provisional application
60/121 ,841 , filed on 2/26/99, (57) U.S. patent application serial no. 10/261 ,928, attorney docket no. 25791.82, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (58) U.S. patent application serial no. 10/079,276 , attorney docket no.
25791.83, filed on 2/20/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no. 09/512,895, attorney docket no. 25791.12.02, filed on
2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99,
(59) U.S. patent application serial no. 10/262,009, attorney docket no. 25791.84, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (60) U.S. patent application serial no. 10/092,481 , attorney docket no. 25791.85, filed on 3/7/02, which is a divisional of U.S. patent number 6,568,471 , which was filed as patent application serial no.
09/512,895, attorney docket no. 25791.12.02, filed on 2/24/2000, which claims priority from provisional application 60/121 ,841 , filed on 2/26/99, (61) U.S. patent application serial no.
10/261 ,926, attorney docket no. 25791.86, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (62) PCT application US 02/36157, filed on 11/12/02, attorney docket no. 25791.87.02, which claims priority from U.S. provisional patent application serial no. 60/338,996, attorney docket no. 25791.87, filed on 11/12/01 , (63) PCT application US 02/36267, filed on 11/12/02, attorney docket no. 25791.88.02, which claims priority from U.S. provisional patent application serial no. 60/339,013, attorney docket no.
25791.88, filed on 11/12/01 , (64) PCT application US 03/11765, filed on 4/16/03, attorney docket no. 25791.89.02, which claims priority from U.S. provisional patent application serial no. 60/383,917, attorney docket no. 25791.89, filed on 5/29/02, (65) PCT application US 03/15020, filed on 5/12/03, attorney docket no. 25791.90.02, which claims priority from U.S. provisional patent application serial no. 60/391 ,703, attorney docket no. 25791.90, filed on
6/26/02, (66) PCT application US 02/39418, filed on 12/10/02, attorney docket no.
25791.92.02, which claims priority from U.S. provisional patent application serial no.
60/346,309, attorney docket no. 25791.92, filed on 1/7/02, (67) PCT application US
03/06544, filed on 3/4/03, attorney docket no. 25791.93.02, which claims priority from U.S. provisional patent application serial no. 60/372,048, attorney docket no. 25791.93, filed on
4/12/02, (68) U.S. patent application serial no. 10/331 ,718, attorney docket no. 25791.94, filed on 12/30/02, which is a divisional U.S. patent application serial no. 09/679,906, filed on
10/5/00, attorney docket no. 25791.37.02, which claims priority from provisional patent application serial no. 60/159,033, attorney docket no. 25791.37, filed on 10/12/1999, (69)
PCT application US 03/04837, filed on 2/29/03, attorney docket no. 25791.95.02, which claims priority from U.S. provisional patent application serial no. 60/363,829, attorney docket no. 25791.95, filed on 3/13/02, (70) U.S. patent application serial no. 10/261 ,927, attorney docket no. 25791.97, filed on 10/1/02, which is a divisional of U.S. patent number
6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no.
25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (71) U.S. patent application serial no. 10/262,008, attorney docket no.
25791.98, filed on 10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on
6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (72)
U.S. patent application serial no. 10/261 ,925, attorney docket no. 25791.99, filed on
10/1/02, which is a divisional of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (73) U.S. patent application serial no. 10/199,524, attorney docket no. 25791.100, filed on 7/19/02, which is a continuation of U.S. Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (74) PCT application US
03/10144, filed on 3/28/03, attorney docket no. 25791.101.02, which claims priority from
U.S. provisional patent application serial no. 60/372,632, attorney docket no. 25791.101 , filed on 4/15/02, (75) U.S. provisional patent application serial no. 60/412,542, attorney docket no. 25791.102, filed on 9/20/02, (76) PCT application US 03/14153, filed on 5/6/03, attorney docket no. 25791.104.02, which claims priority from U.S. provisional patent application serial no. 60/380,147, attorney docket no. 25791.104, filed on 5/6/02, (77) PCT application US 03/19993, filed on 6/24/03, attorney docket no. 25791.106.02, which claims priority from U.S. provisional patent application serial no. 60/397,284, attorney docket no. 25791.106, filed on 7/19/02, (78) PCT application US 03/13787, filed on 5/5/03, attorney docket no. 25791.107.02, which claims priority from U.S. provisional patent application serial no. 60/387,486 , attorney docket no. 25791.107, filed on 6/10/02, (79) PCT application
US 03/18530, filed on 6/11/03, attorney docket no. 25791.108.02, which claims priority from
U.S. provisional patent application serial no. 60/387,961, attorney docket no. 25791.108, filed on 6/12/02, (80) PCT application US 03/20694, filed on 7/1/03, attorney docket no.
25791.110.02, which claims priority from U.S. provisional patent application serial no.
60/398,061 , attorney docket no. 25791.110, filed on 7/24/02, (81) PCT application US
03/20870, filed on 7/2/03, attorney docket no. 25791.111.02, which claims priority from U.S. provisional patent application serial no. 60/399,240, attorney docket no. 25791.111 , filed on
7/29/02, (82) U.S. provisional patent application serial no. 60/412,487, attorney docket no.
25791.112, filed on 9/20/02, (83) U.S. provisional patent application serial no. 60/412,488, attorney docket no. 25791.114, filed on 9/20/02, (84) U.S. patent application serial no.
10/280,356, attorney docket no. 25791.115, filed on 10/25/02, which is a continuation of
U.S. patent number 6,470,966, which was filed as patent application serial number
09/850,093, filed on 5/7/01 , attorney docket no. 25791.55, as a divisional application of U.S.
Patent Number 6,497,289, which was filed as U.S. Patent Application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, which claims priority from provisional application 60/111 ,293, filed on 12/7/98, (85) U.S. provisional patent application serial no.
60/412,177, attorney docket no. 25791.117, filed on 9/20/02, (86) U.S. provisional patent application serial no. 60/412,653, attorney docket no. 25791.118, filed on 9/20/02, (87) U.S. provisional patent application serial no. 60/405,610, attorney docket no. 25791.119, filed on
8/23/02, (88) U.S. provisional patent application serial no. 60/405,394, attorney docket no.
25791.120, filed on 8/23/02, (89) U.S. provisional patent application serial no. 60/412,544, attorney docket no. 25791.121 , filed on 9/20/02, (90) PCT application PCT/US03/24779, filed on 8/8/03, attorney docket no. 25791.125.02, which claims priority from U.S. provisional patent application serial no. 60/407,442, attorney docket no. 25791.125, filed on
8/30/02, (91) U.S. provisional patent application serial no. 60/423,363, attorney docket no.
25791.126, filed on 12/10/02, (92) U.S. provisional patent application serial no. 60/412,196, attorney docket no. 25791.127, filed on 9/20/02, (93) U.S. provisional patent application serial no. 60/412,187, attorney docket no. 25791.128, filed on 9/20/02, (94) U.S. provisional patent application serial no. 60/412,371 , attorney docket no. 25791.129, filed on 9/20/02,
(95) U.S. patent application serial no. 10/382,325, attorney docket no. 25791.145, filed on
3/5/03, which is a continuation of U.S. patent number 6,557,640, which was filed as patent application serial no. 09/588,946, attorney docket no. 25791.17.02, filed on 6/7/2000, which claims priority from provisional application 60/137,998, filed on 6/7/99, (96) U.S. patent application serial no. 10/624,842, attorney docket no. 25791.151, filed on 7/22/03, which is a divisional of U.S. patent application serial no. 09/502,350, attorney docket no. 25791.8.02, filed on 2/10/2000, which claims priority from provisional application 60/119,611 , filed on
2/11/99, (97) U.S. provisional patent application serial no. 60/431,184, attorney docket no.
25791.157, filed on 12/5/02, (98) U.S. provisional patent application serial no. 60/448,526, attorney docket no. 25791.185, filed on 2/18/03, (99) U.S. provisional patent application serial no. 60/461 ,539, attorney docket no. 25791.186, filed on 4/9/03, (100) U.S. provisional patent application serial no. 60/462,750, attorney docket no. 25791.193, filed on 4/14/03,
(101) U.S. provisional patent application serial no. 60/436,106, attorney docket no.
25791.200, filed on 12/23/02, (102) U.S. provisional patent application serial no. 60/442,942, attorney docket no. 25791.213, filed on 1/27/03, (103) U.S. provisional patent application serial no. 60/442,938, attorney docket no. 25791.225, filed on 1/27/03, (104) U.S. provisional patent application serial no. 60/418,687, attorney docket no. 25791.228, filed on 4/18/03,
(105) U.S. provisional patent application serial no. 60/454,896, attorney docket no.
25791.236, filed on 3/14/03, (106) U.S. provisional patent application serial no. 60/450,504, attorney docket no. 25791.238, filed on 2/26/03, (107) U.S. provisional patent application serial no. 60/451 ,152, attorney docket no. 25791.239, filed on 3/9/03, (108) U.S. provisional patent application serial no. 60/455,124, attorney docket no. 25791.241 , filed on 3/17/03,
(109) U.S. provisional patent application serial no. 60/453,678, attorney docket no.
25791.253, filed on 3/11/03, (110) U.S. patent application serial no. 10/421 ,682, attorney docket no. 25791.256, filed on 4/23/03, which is a continuation of U.S. patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (111) U.S. provisional patent application serial no. 60/457,965, attorney docket no. 25791.260, filed on 3/27/03,
(112) U.S. provisional patent application serial no. 60/455,718, attorney docket no.
25791.262, filed on 3/18/03, (113) U.S. patent number 6,550,821 , which was filed as patent application serial no. 09/811 ,734, filed on 3/19/01 , (114) U.S. patent application serial no.
10/436,467, attorney docket no. 25791.268, filed on 5/12/03, which is a continuation of U.S. patent number 6,604,763, which was filed as application serial no. 09/559,122, attorney docket no. 25791.23.02, filed on 4/26/2000, which claims priority from provisional application
60/131 ,106, filed on 4/26/99, (115) U.S. provisional patent application serial no. 60/459,776, attorney docket no. 25791.270, filed on 4/2/03, (116) U.S. provisional patent application serial no. 60/461 ,094, attorney docket no. 25791.272, filed on 4/8/03, (117) U.S. provisional patent application serial no. 60/461 ,038, attorney docket no. 25791.273, filed on 4/7/03,
(118) U.S. provisional patent application serial no. 60/463,586, attorney docket no.
25791.277, filed on 4/17/03, (119) U.S. provisional patent application serial no. 60/472,240, attorney docket no. 25791.286, filed on 5/20/03, (120) U.S. patent application serial no.
10/619,285, attorney docket no. 25791.292, filed on 7/14/03, which is a continuation-in-part of U.S. utility patent application serial no. 09/969,922, attorney docket no. 25791.69, filed on
10/3/2001 , which is a continuation-in-part application of U.S. patent no. 6,328,113, which was filed as U.S. Patent Application serial number 09/440,338, attorney docket number
25791.9.02, filed on 11/15/99, which claims priority from provisional application 60/108,558, filed on 11/16/98, (121) U.S. utility patent application serial no. 10/418,688, attorney docket no. 25791.257, which was filed on 4/18/03, as a division of U.S. utility patent application serial no. 09/523,468, attorney docket no. 25791.11.02, filed on 3/10/2000, which claims priority from provisional application 60/124,042, filed on 3/11/99, (122) PCT patent application serial no. PCT/US04/ , attorney docket no. 25791.238.02, filed on
2/26/04, (123) PCT patent application serial no. PCT/US04/ , attorney docket no.
25791.253.02, filed on 3/11/04, and (124) PCT patent application serial no.
PCT/US04/ , attorney docket no. 25791.40.02, filed on 3/15/04, the disclosures of which are incorporated herein by reference.
[0030] An apparatus for radially expanding and plastically deforming a tubular member has been described that includes a tubular support member defining a first passage, a tubular expansion cone defining a second passage coupled to the tubular support member, a fluid driven motor coupled to the tubular expansion cone comprising an inlet, and a rotary expansion device coupled to the output shaft of the fluid driven motor. The first passage is operably coupled to the second passage, and the second passage is operably coupled to the inlet of the fluid driven motor.
[0031] An apparatus for radially expanding and plastically deforming a tubular member has been described that includes a first expansion device for controllably straining the tubular member, and a second expansion device coupled to the first expansion device for controllably stressing the tubular member. In an exemplary embodiment, the apparatus further includes a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
[0032] A method of radially expanding and plastically deforming a tubular member has been described that includes controllably straining the tubular member, and then controllably stressing the tubular member.
[0033] An apparatus for radially expanding and plastically deforming a tubular member has been described that includes means for controllably straining the tubular member, and means for controllably stressing the tubular member after controllably straining the tubular member.
[0034] An apparatus for radially expanding and plastically deforming a tubular member has been described that includes a first expansion device for radially expanding the tubular member, and a second expansion device coupled to the first expansion device for further radially expanding the tubular member. In an exemplary embodiment, the apparatus further includes a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
[0035] A method of radially expanding and plastically deforming a tubular member has been described that includes radially expanding a portion of the tubular member, and then further radially expanding the portion of the tubular member. In an exemplary embodiment, radially expanding the portion of the tubular member includes applying forces to a continuous circumferential portion of the interior surface of the tubular member. In an exemplary embodiment, further radially expanding the portion of the tubular member includes applying forces to one or more discrete portions of the interior surface of the tubular member.
[0036] A system for radially expanding and plastically deforming a tubular member has been described that includes means for radially expanding a portion of the tubular member, and means for then further radially expanding the portion of the tubular member. In an exemplary embodiment, the means for radially expanding the portion of the tubular member includes means for applying forces to a continuous circumferential portion of the interior surface of the tubular member. In an exemplary embodiment, the means for further radially expanding the portion of the tubular member includes means for applying forces to one or more discrete portions of the interior surface of the tubular member.
[0037] A method of radially expanding and plastically deforming a tubular member has been described that includes controllably stressing the tubular member; and then controllably straining the tubular member.
[0038] An apparatus for radially expanding and plastically deforming a tubular member has been described that includes means for controllably stressing the tubular member; and means for controllably straining the tubular member after controllably stressing the tubular member.
[0039] 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 teachings of the present disclosure may incorporate one or more features or operational aspects of conventional hydro-forming tools.
[0040] 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

ClaimsWhat is claimed is:
1. An apparatus for radially expanding and plastically deforming a tubular member, comprising: a tubular support member defining a first passage; a tubular expansion cone defining a second passage coupled to the tubular support member; a fluid driven motor coupled to the tubular expansion cone comprising an inlet; and a rotary expansion device coupled to the output shaft of the fluid driven motor; wherein the first passage is operably coupled to the second passage; wherein the second passage is operably coupled to the inlet of the fluid driven motor.
2. An apparatus for radially expanding and plastically deforming a tubular member, comprising: a first expansion device for controllably straining the tubular member; and a second expansion device coupled to the first expansion device for controllably stressing the tubular member.
3. The apparatus of claim 2, further comprising a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
4. A method of radially expanding and plastically deforming a tubular member, comprising: controllably straining the tubular member; and then controllably stressing the tubular member.
5. An apparatus for radially expanding and plastically deforming a tubular member, comprising: means for controllably straining the tubular member; and means for controllably stressing the tubular member after controllably straining the tubular member.
6. An apparatus for radially expanding and plastically deforming a tubular member, comprising: a first expansion device for radially expanding the tubular member; and a second expansion device coupled to the first expansion device for further radially expanding the tubular member.
7. The apparatus of claim 6, further comprising a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.
8. A method of radially expanding and plastically deforming a tubular member, comprising: radially expanding a portion of the tubular member; and then further radially expanding the portion of the tubular member.
9. The method of claim 8, wherein radially expanding the portion of the tubular member comprises: applying forces to a continuous circumferential portion of the interior surface of the tubular member.
10. The method of claim 8, wherein further radially expanding the portion of the tubular member comprises: applying forces to one or more discrete portions of the interior surface of the tubular member.
11. A system for radially expanding and plastically deforming a tubular member, comprising: means for radially expanding a portion of the tubular member; and means for then further radially expanding the portion of the tubular member.
12. The system of claim 11 , wherein means for radially expanding the portion of the tubular member comprises: means for applying forces to a continuous circumferential portion of the interior surface of the tubular member.
13. The system of claim 11 , wherein means for further radially expanding the portion of the tubular member comprises: means for applying forces to one or more discrete portions of the interior surface of the tubular member.
14. A method of radially expanding and plastically deforming a tubular member, comprising: controllably stressing the tubular member; and then controllably straining the tubular member.
15. An apparatus for radially expanding and plastically deforming a tubular member, comprising: means for controllably stressing the tubular member; and means for controllably straining the tubular member after controllably stressing the tubular member.
PCT/US2004/008171 2003-03-14 2004-03-15 Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool WO2004083594A2 (en)

Priority Applications (3)

Application Number Priority Date Filing Date Title
US10/546,903 US20070034383A1 (en) 2003-03-14 2004-03-15 Apparatus and method for radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool
GB0518252A GB2415004B (en) 2003-03-14 2004-03-15 Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool
CA002517524A CA2517524A1 (en) 2003-03-14 2004-03-15 Apparatus and method for radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
US45489603P 2003-03-14 2003-03-14
US60/454,896 2003-03-14

Publications (3)

Publication Number Publication Date
WO2004083594A2 true WO2004083594A2 (en) 2004-09-30
WO2004083594A3 WO2004083594A3 (en) 2005-05-19
WO2004083594B1 WO2004083594B1 (en) 2005-07-07

Family

ID=33029926

Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/US2004/008171 WO2004083594A2 (en) 2003-03-14 2004-03-15 Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool

Country Status (4)

Country Link
US (1) US20070034383A1 (en)
CA (1) CA2517524A1 (en)
GB (3) GB2415004B (en)
WO (1) WO2004083594A2 (en)

Cited By (12)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7367389B2 (en) 2003-06-16 2008-05-06 Weatherford/Lamb, Inc. Tubing expansion
US7384981B2 (en) 2001-11-14 2008-06-10 N.V. Nutricia Preparation for improving the action of receptors
WO2009017939A1 (en) * 2007-07-30 2009-02-05 Baker Hughes Incorporated Tubular expander
US7665532B2 (en) 1998-12-07 2010-02-23 Shell Oil Company Pipeline
US7712522B2 (en) 2003-09-05 2010-05-11 Enventure Global Technology, Llc Expansion cone and system
US7740076B2 (en) 2002-04-12 2010-06-22 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger
US7739917B2 (en) 2002-09-20 2010-06-22 Enventure Global Technology, Llc Pipe formability evaluation for expandable tubulars
US7775290B2 (en) 2003-04-17 2010-08-17 Enventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
US7793721B2 (en) 2003-03-11 2010-09-14 Eventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
US7819185B2 (en) 2004-08-13 2010-10-26 Enventure Global Technology, Llc Expandable tubular
US7886831B2 (en) 2003-01-22 2011-02-15 Enventure Global Technology, L.L.C. Apparatus for radially expanding and plastically deforming a tubular member
US7918284B2 (en) 2002-04-15 2011-04-05 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger

Families Citing this family (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
AU2001269810B2 (en) * 1998-11-16 2005-04-07 Shell Oil Company Radial expansion of tubular members
GB2344606B (en) * 1998-12-07 2003-08-13 Shell Int Research Forming a wellbore casing by expansion of a tubular member
US7100685B2 (en) * 2000-10-02 2006-09-05 Enventure Global Technology Mono-diameter wellbore casing
US20050166387A1 (en) * 2003-06-13 2005-08-04 Cook Robert L. Method and apparatus for forming a mono-diameter wellbore casing
GB0525410D0 (en) * 2005-12-14 2006-01-25 Weatherford Lamb Expanding Multiple Tubular Portions

Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2627891A (en) * 1950-11-28 1953-02-10 Paul B Clark Well pipe expander
US3785193A (en) * 1971-04-10 1974-01-15 Kinley J Liner expanding apparatus
US3818734A (en) * 1973-05-23 1974-06-25 J Bateman Casing expanding mandrel
US20030024711A1 (en) * 2001-04-06 2003-02-06 Simpson Neil Andrew Abercrombie Tubing expansion
US6543552B1 (en) * 1998-12-22 2003-04-08 Weatherford/Lamb, Inc. Method and apparatus for drilling and lining a wellbore

Family Cites Families (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US6820687B2 (en) * 2002-09-03 2004-11-23 Weatherford/Lamb, Inc. Auto reversing expanding roller system
US6907937B2 (en) * 2002-12-23 2005-06-21 Weatherford/Lamb, Inc. Expandable sealing apparatus
US7140428B2 (en) * 2004-03-08 2006-11-28 Shell Oil Company Expander for expanding a tubular element

Patent Citations (5)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US2627891A (en) * 1950-11-28 1953-02-10 Paul B Clark Well pipe expander
US3785193A (en) * 1971-04-10 1974-01-15 Kinley J Liner expanding apparatus
US3818734A (en) * 1973-05-23 1974-06-25 J Bateman Casing expanding mandrel
US6543552B1 (en) * 1998-12-22 2003-04-08 Weatherford/Lamb, Inc. Method and apparatus for drilling and lining a wellbore
US20030024711A1 (en) * 2001-04-06 2003-02-06 Simpson Neil Andrew Abercrombie Tubing expansion

Cited By (14)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US7665532B2 (en) 1998-12-07 2010-02-23 Shell Oil Company Pipeline
US7384981B2 (en) 2001-11-14 2008-06-10 N.V. Nutricia Preparation for improving the action of receptors
US7740076B2 (en) 2002-04-12 2010-06-22 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger
US7918284B2 (en) 2002-04-15 2011-04-05 Enventure Global Technology, L.L.C. Protective sleeve for threaded connections for expandable liner hanger
US7739917B2 (en) 2002-09-20 2010-06-22 Enventure Global Technology, Llc Pipe formability evaluation for expandable tubulars
US7886831B2 (en) 2003-01-22 2011-02-15 Enventure Global Technology, L.L.C. Apparatus for radially expanding and plastically deforming a tubular member
US7793721B2 (en) 2003-03-11 2010-09-14 Eventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
US7775290B2 (en) 2003-04-17 2010-08-17 Enventure Global Technology, Llc Apparatus for radially expanding and plastically deforming a tubular member
US7367389B2 (en) 2003-06-16 2008-05-06 Weatherford/Lamb, Inc. Tubing expansion
US7712522B2 (en) 2003-09-05 2010-05-11 Enventure Global Technology, Llc Expansion cone and system
US7819185B2 (en) 2004-08-13 2010-10-26 Enventure Global Technology, Llc Expandable tubular
GB2466885A (en) * 2007-07-30 2010-07-14 Baker Hughes Inc Tubular expander
WO2009017939A1 (en) * 2007-07-30 2009-02-05 Baker Hughes Incorporated Tubular expander
GB2466885B (en) * 2007-07-30 2012-02-08 Baker Hughes Inc Tubular expander

Also Published As

Publication number Publication date
GB2415004A (en) 2005-12-14
CA2517524A1 (en) 2004-09-30
GB0613406D0 (en) 2006-08-16
GB2427886B (en) 2007-10-10
GB0613405D0 (en) 2006-08-16
GB2415004B (en) 2006-12-13
GB2427885A (en) 2007-01-10
GB0518252D0 (en) 2005-10-19
GB2427886A (en) 2007-01-10
US20070034383A1 (en) 2007-02-15
WO2004083594B1 (en) 2005-07-07
WO2004083594A3 (en) 2005-05-19
GB2427885B (en) 2007-05-16

Similar Documents

Publication Publication Date Title
EP1549823B1 (en) Bottom plug for forming a mono diameter wellbore casing
US7360591B2 (en) System for radially expanding a tubular member
US7168496B2 (en) Liner hanger
EP1549824B1 (en) Mono diameter wellbore casing
EP1485567B1 (en) Mono-diameter wellbore casing
WO2004083594A2 (en) Apparatus and method radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool
CA2563259A1 (en) Expandable tubular member
US7363984B2 (en) System for radially expanding a tubular member
WO2003104601A2 (en) Mono-diameter wellbore casing
AU3826301A (en) Expanding a tubular member
US20060272826A1 (en) Apparatus and method for radially expanding a wellbore casing using and adaptive expansion system
WO2004092530A2 (en) Radially expanding casing and driling a wellbore
WO2004011776A2 (en) Method of forming a mono diameter wellbore casing
WO2004083593A2 (en) Radial expansion and milling of expandable tubulars
WO2002066783A1 (en) Mono-diameter wellbore casing
AU2002240366A1 (en) Mono-diameter wellbore casing
WO2004003337A1 (en) System for radially expanding a tubular member
GB2437879A (en) Radially expanding a wellbore casing using an expansion mandrel and a rotary expansion cone
GB2437880A (en) Radially expanding a wellbore casing using an expansion mandrel and a rotary expansion cone
GB2440858A (en) Fluid expansion of liner into contact with existing tubular
GB2443098A (en) Expansion cone with stepped or curved gradient
GB2440693A (en) Fabrication of an expandable tubular

Legal Events

Date Code Title Description
AK Designated states

Kind code of ref document: A2

Designated state(s): AE AG AL AM AT AU AZ BA BB BG BR BW BY BZ CA CH CN CO CR CU CZ DE DK DM DZ EC EE EG ES FI GB GD GE GH GM HR HU ID IL IN IS JP KE KG KP KR KZ LC LK LR LS LT LU LV MA MD MG MK MN MW MX MZ NA NI NO NZ OM PG PH PL PT RO RU SC SD SE SG SK SL SY TJ TM TN TR TT TZ UA UG US UZ VC VN YU ZA ZM ZW

AL Designated countries for regional patents

Kind code of ref document: A2

Designated state(s): BW GH GM KE LS MW MZ SD SL SZ TZ UG ZM ZW AM AZ BY KG KZ MD RU TJ TM AT BE BG CH CY CZ DE DK EE ES FI FR GB GR HU IE IT LU MC NL PL PT RO SE SI SK TR BF BJ CF CG CI CM GA GN GQ GW ML MR NE SN TD TG

121 Ep: the epo has been informed by wipo that ep was designated in this application
DPEN Request for preliminary examination filed prior to expiration of 19th month from priority date (pct application filed from 20040101)
B Later publication of amended claims

Effective date: 20050413

WWE Wipo information: entry into national phase

Ref document number: 2517524

Country of ref document: CA

ENP Entry into the national phase

Ref document number: 0518252

Country of ref document: GB

Kind code of ref document: A

Free format text: PCT FILING DATE = 20040315

122 Ep: pct application non-entry in european phase
WWE Wipo information: entry into national phase

Ref document number: 2007034383

Country of ref document: US

Ref document number: 10546903

Country of ref document: US

WWP Wipo information: published in national office

Ref document number: 10546903

Country of ref document: US