WO2005079186A2 - Crépine de forme tubulaire expansible - Google Patents

Crépine de forme tubulaire expansible Download PDF

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Publication number
WO2005079186A2
WO2005079186A2 PCT/US2004/028888 US2004028888W WO2005079186A2 WO 2005079186 A2 WO2005079186 A2 WO 2005079186A2 US 2004028888 W US2004028888 W US 2004028888W WO 2005079186 A2 WO2005079186 A2 WO 2005079186A2
Authority
WO
WIPO (PCT)
Prior art keywords
tubular
tubular member
expansion device
lubricant
expansion
Prior art date
Application number
PCT/US2004/028888
Other languages
English (en)
Other versions
WO2005079186B1 (fr
WO2005079186A3 (fr
Inventor
Mark Shuster
Malcolm Gray
Grigory Greenburg
Scott Costa
Matt Shade
Alla Petlyuk
Original Assignee
Enventure Global Technology, Llc
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, Llc filed Critical Enventure Global Technology, Llc
Priority to GB0603996A priority Critical patent/GB2420810A/en
Priority to PCT/US2004/028888 priority patent/WO2005079186A2/fr
Priority to US10/571,041 priority patent/US20070215360A1/en
Publication of WO2005079186A2 publication Critical patent/WO2005079186A2/fr
Publication of WO2005079186A3 publication Critical patent/WO2005079186A3/fr
Publication of WO2005079186B1 publication Critical patent/WO2005079186B1/fr
Priority to NO20061503A priority patent/NO20061503L/no

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/08—Tube expanders
    • B21D39/20—Tube expanders with mandrels, e.g. expandable
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
    • B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
    • B21D39/08—Tube expanders
    • B21D39/20—Tube expanders with mandrels, e.g. expandable
    • B21D39/203—Tube expanders with mandrels, e.g. expandable expandable by fluid or elastic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B30—PRESSES
    • B30B—PRESSES IN GENERAL
    • B30B7/00—Presses characterised by a particular arrangement of the pressing members
    • B30B7/04—Presses characterised by a particular arrangement of the pressing members wherein pressing is effected in different directions simultaneously or in turn
    • C—CHEMISTRY; METALLURGY
    • C21—METALLURGY OF IRON
    • C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
    • C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
    • C21D9/08—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for tubular bodies or pipes
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
    • E21B17/042—Threaded
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
    • E21B17/02—Couplings; joints
    • E21B17/08—Casing joints
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
    • E21B29/10—Reconditioning of well casings, e.g. straightening
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/08—Screens or liners
    • E21B43/084—Screens comprising woven materials, e.g. mesh or cloth
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/105—Expanding tools specially adapted therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/106—Couplings or joints therefor
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/02—Subsoil filtering
    • E21B43/10—Setting of casings, screens, liners or the like in wells
    • E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
    • E21B43/108—Expandable screens or perforated liners
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/14—Obtaining from a multiple-zone well
    • E—FIXED CONSTRUCTIONS
    • E21—EARTH DRILLING; MINING
    • E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
    • E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
    • E21B43/30—Specific pattern of wells, e.g. optimizing the spacing of wells
    • E21B43/305—Specific pattern of wells, e.g. optimizing the spacing of wells comprising at least one inclined or horizontal well
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16L—PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL
    • F16L55/00—Devices or appurtenances for use in, or in connection with, pipes or pipe systems
    • F16L55/16—Devices for covering leaks in pipes or hoses, e.g. hose-menders
    • F16L55/162—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe
    • F16L55/163—Devices for covering leaks in pipes or hoses, e.g. hose-menders from inside the pipe a ring, a band or a sleeve being pressed against the inner surface of the pipe
    • F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
    • F16N—LUBRICATING
    • F16N7/00—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated
    • F16N7/30—Arrangements for supplying oil or unspecified lubricant from a stationary reservoir or the equivalent in or on the machine or member to be lubricated the oil being fed or carried along by another fluid
    • F16N7/32—Mist lubrication
    • F16N7/34—Atomising devices for oil
    • G—PHYSICS
    • G01—MEASURING; TESTING
    • G01N—INVESTIGATING OR ANALYSING MATERIALS BY DETERMINING THEIR CHEMICAL OR PHYSICAL PROPERTIES
    • G01N17/00—Investigating resistance of materials to the weather, to corrosion, or to light
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T29/00—Metal working
    • Y10T29/49—Method of mechanical manufacture
    • Y10T29/49826—Assembling or joining
    • Y10T29/49908—Joining by deforming
    • Y10T29/49938—Radially expanding part in cavity, aperture, or hollow body
    • Y10T29/4994—Radially expanding internal tube

Definitions

  • 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)
  • 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 60/1 37,998, filed on 6/7/99, (73)
  • provisional patent application serial no. 60/387,486 attorney docket no. 25791.107, filed on 6/10/02
  • 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
  • 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.
  • PCT/US2004/009434 attorney docket number 25791.260.02, filed on 3/26/2004
  • PCT patent application serial number PCT/US2004/010317, attorney docket number
  • PCT/US2004/010712 attorney docket number 25791.272.02, filed on 4/06/2004, (130)
  • PCT patent application serial number PCT/US2004/010762 attorney docket number
  • This invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration. Summary Of The Invention
  • a method of forming a tubular liner within a preexisting structure includes positioning a tubular assembly within the preexisting structure; and radially expanding and plastically deforming the tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member that includes a steel alloy including: 0.065 % C, 1.44 % Mn, 0.01 % P, 0.002 %
  • an expandable tubular member that includes a steel alloy including: 0.18 % C, 1.28 % Mn, 0.017 % P, 0.004 %
  • an expandable tubular member that includes a steel alloy including: 0.08 % C, 0.82 % Mn, 0.006 % P, 0.003 %
  • an expandable tubular member that includes a steel alloy including: 0.02 % C, 1.31 % Mn, 0.02 % P, 0.001 % S,
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 40 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48.
  • an expandable tubular member wherein the yield point of the expandable tubular member is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the expandable tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation.
  • an expandable tubular member wherein the yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 28 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34.
  • an expandable tubular member wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92.
  • an expandable tubular member is provided, wherein the yield point of the expandable tubular member, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi.
  • an expandable tubular member wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12.
  • an expandable tubular member is provided, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
  • an expandable tubular member is provided, wherein the tubular member has a higher ductility and a lower yield point prior to a radial expansion and plastic deformation than after the radial expansion and plastic deformation.
  • a method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member.
  • a system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member includes means for radially expanding the tubular assembly within a preexisting structure; and means for using less power to radially expand each unit length of the first tubular member than required to radially expand each unit length of the second tubular member.
  • a method of manufacturing a tubular member includes processing a tubular member until the tubular member is characterized by one or more intermediate characteristics; positioning the tubular member within a preexisting structure; and processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics.
  • an apparatus that includes an expandable tubular assembly; and an expansion device coupled to the expandable tubular assembly; wherein a predetermined portion of the expandable tubular assembly has a lower yield point than another portion of the expandable tubular assembly.
  • an expandable tubular member wherein a yield point of the expandable tubular member after a radial expansion and plastic deformation is at least about 5.8 % greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
  • a method of determining the expandability of a selected tubular member includes determining an anisotropy value for the selected tubular member, determining a strain hardening value for the selected tubular member; and multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member.
  • a method of radially expanding and plastically deforming tubular members includes selecting a tubular member; determining an anisotropy value for the selected tubular member; determining a strain hardening value for the selected tubular member; multiplying the anisotropy value times the strain hardening value to generate an expandability value for the selected tubular member; and if the anisotropy value is greater than 0.12, then radially expanding and plastically deforming the selected tubular member.
  • a radially expandable tubular member apparatus includes a first tubular member; a second tubular member engaged with the first tubular member forming a joint; and a sleeve overlapping and coupling the first and second tubular members at tine joint; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a radially expandable tubular member apparatus includes: a first tubular member; a second tubular member engaged with the first tubular member forming a joint; a sleeve overlapping and coupling the first and second tubular members at the joint; the sleeve having opposite tapered ends and a flange engaged in a recess formed in an adjacent tubular member; and one of the tapered ends being a surface formed on the flange; wherein, prior to a radial expansion and plastic deformation of the apparatus, a predetermined portion of the apparatus has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; provid ing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • a method of joining radial ly expandable tubular members includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; provi ing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a su rface formed on the flange; mounting the sleeve for overlapping and coupling the first and second tubular members at the joint, wherein the flange is engaged in a recess formed in an adjacent one of the tubular members; wherein the first tubular member, the second tubular member, and the sleeve define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular assembly includes a first tubular member; a second tubular member coupled to the first tubular member; a first threaded connection for coupling a portion of the first and second tubular members; a second threaded connection spaced apart from the first threaded connection for coupling another portion of the first and second tubular members; a tubular sleeve coupled to and receiving end portions of the first and second tubular members; and a sealing element positioned between the first and second spaced apart threaded connections for sealing an interface between the first and second tubular member; wherein the sealing element is positioned within an annulus defined between the first and second tubular members; and wherein, prior to a radial expansion and plastic deformation of the assembly, a predetermined portion of the assembly has a lower yield point than another portion of the apparatus.
  • a method of joining radially expandable tubular members includes: providing a first tubular member; providing a second tubular member; providing a sleeve; mounting the sleeve for overlapping and coupling the first and second tubular members; threadably coupling the first and second tubular members at a first location; threadably coupling the first and second tubular members at a second location spaced apart from the first location; sealing an interface between the first and second tubular members between the first and second locations usinga compressible sealing element, wherein the first tubular member, second tubular member, sleeve, and the sealing element define a tubular assembly; and radially expanding and plastically deforming the tubular assembly; wherein, prior to the radial expansion and plastic deformation, a predetermined portion of the tubular assembly has a lower yield point than another portion of the tubular assembly.
  • an expandable tubular member is provided, wherein the carbon content of the tubular member is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.21.
  • an expandable tubular member is provided, wherein the carbon content of the tubular member is greater than 0.12 percent; and wherein the carbon equivalent value for the tubular member is less than 0.36.
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is less than or equal to 0.12 percent and the carbon equivalent value for the selected tubular member is less than
  • a method of selecting tubular members for radial expansion and plastic deformation includes selecting a tubular member from a collection of tubular member; determining a carbon content of the selected tubular member; determining a carbon equivalent value for the selected tubular member; and if the carbon content of the selected tubular member is greater than 0.12 percent and the carbon equivalent value for the selected tubular member is less than 0.36, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
  • an expandable tubular member that includes a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body.
  • a method of manufacturing an expandable tubular member includes: providing a tubular member;
  • the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
  • a system for radially expanding and plastically deforming a tubular member that includes an expansion device positioned in the tubular member, wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than
  • a method of radially expanding and plastically deforming a tubular member includes positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08.
  • a system for radially expanding and plastically deforming a tubular member includes means for positioning an expansion device having a first tapered end and a second end at least partially within the tubular member and means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes at least eight components selected from the group consisting of: a base oil; metal deactivator; antioxidants; sulfurized natural oils; phosphate ester; phosphoric acid; viscosity modifier; pour-point depressant; defoamer; and carboxylic acid soaps.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes 77.81% canola oil; 0.04% tolyltriazole; 1.0% phenolic antioxidant; 10% sulfurized natural oil or sulferized lard oil; 9% phosphate ester; 1% phosphoric acid; 0.8% styrene hydrocarbon polymer; 0.3% alkyl ester copolymer; and 0.05% silicon based antifoam agent.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • canola oil 0.05% tolyltriazole; 1.0% aminic antioxidant; 2.0% phenolic antioxidant,
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • canola oil 90.89% canola oil; 0.02% tolyltriazole; 0.5% phenolic antioxidant; 4% sulfurized natural oil or sulferized lard oil; 4% phosphate ester; 0.4% phosphoric acid; 0.08% styrene hydrocarbon polymer; 0.1% alkyl ester copolymer; and 0.01% silicon based antifoam agent.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • canola oil 80.68% canola oil; 0.04% tolyltriazole; 1 % phenolic antioxidant; 8% sulfurized natural oil or sulferized lard oil; 9% phosphate ester; 1% phosphoric acid; 0.1% styrene hydrocarbon polymer; 0.1% alkyl ester copolymer; and 0.08% silicon based antifoam agent.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes:
  • canola oil 80.31 % canola oil; 0.04% tolyltriazole; 1.1% phenolic antioxidant; 9% sulfurized natural oil or sulferized lard oil; 8% phosphate ester; 0.8% phosphoric acid; 0.4% styrene hydrocarbon polymer; 0.3% alkyl ester copolymer; and 0.05% silicon based antifoam agent.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes: at least 10% Graphite.
  • a lubricant for injecting in an interface between a tubular member and an expansion device includes: at least 10% Molybedenum Disulfide in a thickener in with a dropping point above 350-400F.
  • an expansion device for radially expanding and plastically deforming the tubular member includes one or more expansion surfaces on the expansion device for engaging the interior surface of the tubular member during the radial expansion and plastic deformation of the tubular member; and a lubrication device operably coupled to the expansion surface for injecting lubricant into an interface between the expansion surface and the tubular member during the radial expansion and plastic deformation of the tubular member when a predetermined pressure for lubrication is reached.
  • a method for radially expanding and plastically deforming the tubular member includes positioning an expansion device having one or more expansion surfaces in the interior surface of the tubular member, displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and operating a lubrication device to inject lubricant into an interface between the expansion surface and the tubular member when a predetermined lubricant pressure is reached.
  • a lubricant delivery assembly for radially expanding and plastically deforming a tubular member that includes an expansion cone having a tapered portion with an outer surface, at least one reservoir for housing a lubricant, at least one circumferential groove on the outer surface fluidicly connected to the reservoir, and a lubricant injection mechanism to force lubricant into the at least one circumferential groove while radially expanding and plastically deforming the tubular member when a predetermined lubricant pressure is reached.
  • an expansion device for radially expanding and plastically deforming a tubular member includes a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal -flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes -a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; a tapered portion with an outer surface internal flow passage in the tapered portion and at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member.
  • an expansion cone-: for radially expanding and plastically deforming a tubular member that includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow pas sage in the tapered portion, and at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at lea st one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the second sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member from the internal flow passage, a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion.
  • a method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than 0.08 includes altering at least one of the elements selected from the group consisting of: expansion device geometry, expansion device composition, expansion device surface roughness, expansion device texture, expansion device coating, lubricant composition, lubricant environmental issues, lubricant frictional modifiers, tubular member roughness, and tubular member coating.
  • a method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than or equal to 0.05 includes altering at least one of the elements selected from the group consisting of: expansion device geometry, expansion device composition, expansion device surface roughness, expansion device texture, expansion device coating, lubricant composition, lubricant environmental issues, lubricant frictional modifiers, tubular member roughness, and tubular member coating.
  • a method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than or equal to 0.02 includes altering at least one of the elements selected from the group consisting of: expansion device geometry, expansion device composition, expansion device surface roughness, expansion device texture, expansion device coating, lubricant composition, lubricant environmental issues, lubricant frictional modifiers, tubular member roughness, and tubular member coating.
  • a lubrication system for lubricating an interface between a first element and a second elements includes a vaporizer proximate to the interface for vaporizing a lubricant to inject the lubricant in the interface.
  • a method for lubricating an interface between a first element and a second elements includes vaporizing a lubricant proximate to the interface to inject the lubricant in the interface.
  • a system for lubricating an interface between a first element and a second elements includes means for vaporizing a lubricant proximate to the interface to inject the lubricant in the interface.
  • a system for radially expanding and plastically deforming a tubular member includes an expansion device positioned in the tubular member, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08 and wherein lubricant is stored in a reservoir with a magnetic coil in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when current runs through the magnetic coil.
  • a system for radially expanding and plastically deforming a tubular member includes an expansion device positioned in the tubular member, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08 and wherein lubricant is stored in a reservoir and injected through at least a portion of the expansion device between the tubular member and the expansion device when vaporized.
  • a method of radially expanding and plastically deforming a tubular member includes positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and injecting a lubricant stored in a reservoir with a magnetic coil in the expansion device through at least a portion of the expansion device between the tubular member and the expansion device when current runs through the magnetic coil, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than
  • a method of radially expanding and plastically deforming a tubular member includes positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and vaporizing a lubricant stored in a reservoir in the expansion device and injecting it through at least a portion of the expansion device between the tubular member and the expansion device, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08.
  • a system for radially expanding and plastically deforming a tubular member includes means for positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08 and wherein lubricant is stored in a reservoir and injected through at least a portion of the expansion device between the tubular member and the expansion device when vaporized.
  • a system for radially expanding and plastically deforming a tubular member includes means for positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member; and wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08 and wherein lubricant is stored in a reservoir with a magnetic coil in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when current runs through the magnetic coil.
  • a system for radially expanding and plastically deforming a tubular member includes means for positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and means for vaporizing lubricant stored in a reservoir and injecting it through at least a portion of the expansion device between the tubular member and the expansion device, wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08.
  • a system for radially expanding and plastically deforming a tubular member includes means for positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, and means for vaporizing lubricant stored in a reservoir and injecting it through at least a portion of the expansion device between the tubular member and the expansion device, wherein the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08 and wherein means for vaporizes comprises a magnetic coil in the reservoir operably connected to a power source.
  • an expansion device for radially expanding and plastically deforming the tubular member includes one or more expansion surfaces on the expansion device for engaging the interior surface of the tubular member during the radial expansion and plastic deformation of the tubular member; and a lubrication device operably coupled to the expansion surface for injecting lubricant into an interface between the expansion surface and the tubular member during the radial expansion and plastic deformation of the tubular member when a predetermined lubricant pressure is reached, wherein lubricant is stored in a reservoir in the lubrication device and injected through at least a portion of the expansion device between the tubular member and the expansion device when vaporized.
  • an expansion device for radially expanding and plastically deforming the tubular member includes one or more expansion surfaces on the expansion device for engaging the interior surface of the tubular member during the radial expansion and plastic deformation of the tubular member, and a lubrication device operably coupled to the expansion surface for injecting lubricant into an interface between the expansion surface and the tubular member during the radial expansion and plastic deformation of the tubular member when a predetermined lubricant pressure is reached, and wherein lubricant is stored in a reservoir with a magnetic coil in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when current runs through the magnetic coil.
  • a method for radially expanding and plastically deforming the tubular member includes positioning an expansion device having one or more expansion surfaces in the interior surface of the tubular member, displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, operating a lubrication device to inject lubricant into an interface between the expansion surface and the tubular member when a predetermined lubricant pressure is reached, and wherein lubricant is stored in a reservoir in the lubrication device and injected through at least a portion of the expansion device between the tubular member and the expansion device when vaporized.
  • a method for radially expanding and plastically deforming the tubular member includes positioning an expansion device having one or more expansion surfaces in the interior surface of the tubular member; displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member, operating a lubrication device to inject lubricant into an interface between the expansion surface and the tubular member when a predetermined lubricant pressure is reached, and wherein lubricant is stored in a reservoir with a magnetic coil in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when current runs through the magnetic coil.
  • a lubricant delivery assembly for radially expanding and plastically deforming a tubular member that includes an expansion cone having a tapered portion with an outer surface, at least one reservoir for housing a lubricant, at least one circumferential groove on the outer surface fluidicly connected to the reservoir and a lubricant injection mechanism to force lubricant into the at least one circumferential groove while radially expanding and plastically deforming the tubular member when a predetermined lubricant pressure is reached.
  • an expansion device for radially expanding and plastically deforming a tubular member includes a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion and at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member from the internal flow passage, a tapered portion with an outer surface, internal flow passage in the tapered portion, at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion.
  • a method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than 0.08 includes altering at least one of the elements selected from the group consisting of: expansion device geometry, expansion device composition, expansion device surface roughness, expansion device texture, expansion device coating, lubricant composition, lubricant environmental issues, lubricant frictional modifiers, tubular member roughness, and tubular member coating.
  • a system for radially expanding and plastically deforming a tubular member having a non-uniform wall thickness includes an expansion device having one or more expansion surfaces and a tapered portion having a tapered faceted polygonal outer expansion surface in the interior surface of the tubular member.
  • a method of radially expanding and plastically deforming a tubular member having a non-uniform wall thickness includes positioning an expansion device having a first tapered end and a second end at least partially within the tubular member, and displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • an expansion device for radially expanding and plastically deforming a tubular member includes a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the sliding angle is less than or equal to 30 degrees; and wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface; internal flow passage in the tapered portion; and at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion; and at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion, and wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion, and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees, wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member, a tapered portion with an outer surface, internal flow passage in the tapered portion; and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees., wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and is injected through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges.
  • an expansion cone for radially expanding and plastically deforming a tubular member includes a leading portion with an outer surface, internal flow passage in the leading portion, at least one circumferential groove on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member from the internal flow passage, a tapered portion with an outer surface, internal flow passage in the tapered portion; and at least one circumferential groove having a first edge and a second edge with a second predetermined sliding angle on the outer surface of the tapered portion fluidicly coupled to the internal flow passage for receiving lubricant during radial expansion and plastic deformation of the tubular member; wherein the second sliding angle is less than or equal to 30 degrees, wherein the lubricant in the leading portion is at pressure different from the lubricant in the tapered portion, and wherein lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the
  • a system for radially expanding and plastically deforming a tubular member having non-uniform wall thickness includes means for positioning an expansion device having one or more expansion surfaces and a tapered portion having a tapered faceted polygonal outer expansion surface in the interior surface of the tubular member; and means for displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member.
  • FIG. 1 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 2 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 1 after positioning an expansion device within the expandable tubular member.
  • FIG. 3 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 4 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 5 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 1-4.
  • Fig. 6 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 1-
  • Fig. 7 is a fragmentary cross sectional illustration of an embodiment of a series of overlapping expandable tubular members.
  • Fig. 8 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • FIG. 9 is a fragmentary cross sectional view of the expandable tubular member of
  • Fig. 10 is a fragmentary cross sectional view of the expandable tubular member of Fig. 9 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • Fig. 11 is a fragmentary cross sectional view of the expandable tubular member of Fig. 10 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • Fig. 12 is a graphical illustration of exemplary embodiments of the stress/strain curves for several portions of the expandable tubular member of Figs. 8-11.
  • Fig. 13 is a graphical illustration of an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member of Figs. 8-
  • FIG. 14 is a fragmentary cross sectional view of an exemplary embodiment of an expandable tubular member positioned within a preexisting structure.
  • Fig. 15 is a fragmentary cross sectional view of the expandable tubular member of Fig. 14 after positioning an expansion device within the expandable tubular member.
  • Fig. 16 is a fragmentary cross sectional view of the expandable tubular member of Fig. 15 after operating the expansion device within the expandable tubular member to radially expand and plastically deform a portion of the expandable tubular member.
  • Fig. 17 is a fragmentary cross sectional view of the expandable tubular member of Fig. 16 after operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member.
  • Fig. 18 is a flow chart illustration of an exemplary embodiment of a method of processing an expandable tubular member.
  • Fig. 19 is a graphical illustration of the an exemplary embodiment of the yield strength vs. ductility curve for at least a portion of the expandable tubular member during the operation of the method of Fig. 18.
  • Fig. 20 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • Fig. 21 is a graphical illustration of stress/strain curves for an exemplary embodiment of an expandable tubular member.
  • Fig. 22 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, an embodiment of a tubular sleeve supported by the end portion of the first tubular member, and a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member and engaged by a flange of the sleeve.
  • the sleeve includes the flange at one end for increasing axial compression loading.
  • FIG. 23 is a fragmentary cross-sectional view illustrating an embodiment of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial tension loading.
  • Fig. 24 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends for increasing axial compression/tension loading.
  • FIG. 25 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes flanges at opposite ends having sacrificial material thereon.
  • Fig. 26 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a thin walled cylinder of sacrificial material.
  • Fig. 27 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a variable thickness along the length thereof.
  • Fig. 28 is a fragmentary cross-sectional illustration of the radial expansion and plastic deformation of a portion of a first tubular member having an internally threaded connection at an end portion, a second tubular member having an externally threaded portion coupled to the internally threaded portion of the first tubular member, and an embodiment of a tubular sleeve supported by the end portion of both tubular members.
  • the sleeve includes a member coiled onto grooves formed in the sleeve for varying the sleeve thickness.
  • Fig. 29 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • Figs. 30a-30c are fragmentary cross-sectional illustrations of exemplary embodiments of expandable connections.
  • Fig. 31 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • FIGs. 32a and 32b are fragmentary cross-sectional illustrations of the formation of an exemplary embodiment of an expandable connection.
  • Fig. 33 is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable connection.
  • Figs. 34a, 34b and 34c are fragmentary cross-sectional illustrations of an exemplary embodiment of an expandable connection.
  • Fig. 35a is a fragmentary cross-sectional illustration of an exemplary embodiment of an expandable tubular member.
  • Fig. 35b is a graphical illustration of an exemplary embodiment of the variation in the yield point for the expandable tubular member of Fig. 35a.
  • Fig. 36a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 36b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 36c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 37a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 37b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 37c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 38a is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 38b is an illustration of the microstructure of an exemplary embodiment of a tubular member prior to thermal processing.
  • Fig. 38c is an illustration of the microstructure of an exemplary embodiment of a tubular member after thermal processing.
  • Fig. 39a is an illustration of exemplary tribological elements in a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 39b is a fragmentary cross-sectional illustration of the lubrication of the interface between an expansion cone and a tubular member during the radial expansion process.
  • Fig. 40 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 41 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 42 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 43 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 44 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 45 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 46 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 47 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 48 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 49 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 50 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 51 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 52 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 53 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 54 is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 55 is a cross-sectional illustration of a circumferential groove suitable for use with the expansion cones of Figs. 40 - 54.
  • Fig. 56 is an illustration of the groove of Fig. 55.
  • Fig. 57 is an illustration of an alternate embodiment of the circumferential grove of the expansion cones of Figs. 40 - 57.
  • Fig. 58a is an elevational view of an embodiment of an expansion cone including a system for lubricating lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member utilizing a groove designed in accordance with Figure 57.
  • Fig. 58b is a top view of the expansion cone of Fig. 58a.
  • Fig. 58c is an enlarged section of the expansion cone of Fig. 58a.
  • Fig. 59a is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 59b is a top view of the expansion cone of Fig. 59a.
  • Fig. 60a is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 60b is a top view of the expansion cone in Fig. 60a.
  • Fig. 60c is a fragmentary cross-sectional illustration of the expansion cone in
  • Fig. 60a in a tubular member.
  • Figs. 61a and 61 b are cross-sectional illustrations of an alternate embodiment of tubular member and an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Figs. 61c and 61 d are cross-sectional illustrations of an alternate embodiment of an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 61 e is cross-sectional illustrations of an alternate embodiment of an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member having non-uniform wall thickness during the radial expansion and plastic deformation of the tubular member.
  • Fig. 62a, 62b, and 62c are an illustrations of an alternate embodiment of an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 62d, 62e, and 62f are an illustrations of an alternate embodiment of an expansion cone including a system for lubricating the interface between the expansion cone having a tapered faceted polygonal outer expansion surface and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 63 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 64 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 65 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 66 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • FIG. 67 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 68 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 69 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 70 is a cross-sectional illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Figs. 71a, 71b, 71c, 71 d and 71 e are graphical illustrations of example expansion cone materials characteristics.
  • Fig. 72 is a flow chart illustration of an exemplary embodiment of a method for processing a tubular member.
  • Fig. 73a is a fragmentary cross-sectional illustration of example frictional forces in a system including an expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 73b is a fragmentary cross-sectional illustration of an example components in a system including an expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member that contribute to the frictional forces.
  • Figs. 73c and 73d are fragmentary cross-sectional illustrations of example expansion cone surface roughness and texture characteristics in a system including an expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member that contribute to the frictional forces.
  • Fig. 74 is a graphical illustration of a coefficient of friction versus expansion force in an exemplary system for radially expanding a tubular member.
  • Fig. 75 is a graphical logarithmic illustration of the coefficient of friction versus expansion force (in pounds per square inch) in an exemplary system for radially expanding a tubular member.
  • Fig. 76 is a graphical logarithmic illustration of the coefficient of friction versus expansion force (in pounds) in an exemplary system for radially expanding a tubular member.
  • Fig. 77 is a graphical illustration of the expansion forces in an exemplary system for radially expanding a tubular member over time.
  • Fig. 78 is a graphical illustration the range of coefficients of friction for exemplary systems for radially expanding a tubular member.
  • Fig. 79a and 79b are photo-micrograph illustrations of the microstructure of an exemplary embodiments of expansion cones.
  • Figs. 80a and 80b are photo-micrograph illustrations of the microstructure of the exemplary embodiments of expansion cones shown in Figs. 79a and 79b, respectively.
  • Figs. 81a and 81 b are graphical illustrations of the x-profile of the exemplary embodiments of expansion cones shown in Figs. 79a and 79b, respectively.
  • Figs. 82a and 82b are graphical illustrations of the bearing ratio of the exemplary embodiments of expansion cones shown in Figs. 79a and 79b, respectively.
  • Figs. 83a and 83b are photo-micrograph illustrations of the microstructure of an exemplary embodiments of expansion cones.
  • Figs. 84a and 84b are photo-micrograph illustrations of the microstructure of the exemplary embodiments of expansion cones shown in Figs. 83a and 83b, respectively.
  • Figs. 85a and 85b are graphical illustrations of the x-profile of the exemplary embodiments of expansion cones shown in Figs. 83a and 83b, respectively.
  • Figs. 86a and 86b are graphical illustrations of the bearing ratio of the exemplary embodiments of expansion cones shown in Figs. 83a and 83b, respectively.
  • Fig. 87 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 88 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 89 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 90 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 91 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 92 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 93 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 94 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 95 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 96 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 97 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 98 is a graphical illustration ranges of expansion forces associated with exemplary systems for radially expanding a tubular member.
  • Fig. 99a is an illustration of an embodiment of an expansion cone including a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • Fig. 99b are photo-micrograph illustrations of the microstructure of an exemplary embodiments of expansion cones.
  • Fig. 99c is an illustration of an embodiment of a system for lubricating the interface between the expansion cone and a tubular member during the radial expansion and plastic deformation of the tubular member.
  • an exemplary embodiment of an expandable tubular assembly 10 includes a first expandable tubular member 12 coupled to a second expandable tubular member 14.
  • the ends of the first and second expandable tubular members, 12 and 14, are coupled using, for example, a conventional mechanical coupling, a welded connection , a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first expandable tubular member 12 has a plastic yield point YP-
  • the second expandable tubular member 14 has a plastic yield point YP 2 .
  • the expandable tubular assembly 10 is positioned within a preexisting structure such as, for example, a wellbore 16 that traverses a subterranean formation 18.
  • an expansion device 20 may then be positioned within the second expandable tubular member 14.
  • the expansion device 20 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
  • the expansion device 20 is positioned within the second expandable tubular member 14 before, during, or after the placement of the expandable tubular assembly 10 within the preexisting structure 16.
  • the expansion device 20 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 14 and at least a portion of the first expandable tubular member 12.
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 12 and 14, are radially expanded into intimate contact with the interior surface of the preexisting structure 16.
  • the plastic yield point YP 1 is greater than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand the second expandable tubular member 14 is less than the amount of power and/or energy required to radially expand the first expandable tubular member 12.
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • the amount of power and/or energy required to radially expand each unit length of the first and/or second expandable tubular members, 12 and 14, is reduced. Furthermore, because the YS AE is greater than YS PE , the collapse strength of the first expandable tubular member 12 and/or the second expandable tubular member 14 is increased after the radial expansion and plastic deformation process. [00225] In an exemplary embodiment, as illustrated in Fig. 7, following the completion of the radial expansion and plastic deformation of the expandable tubular assembly 10 described above with reference to Figs. 1-4, at least a portion of the second expandable tubular member 14 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 12.
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 14.
  • Another expandable tubular assembly 22 that includes a first expandable tubular member 24 and a second expandable tubular member 26 may then be positioned in overlapping relation to the first expandable tubular assembly 10 and radially expanded and plastically deformed using the methods described above with reference to Figs. 1-4.
  • at least a portion of the second expandable tubular member 26 has an inside diameter that is greater than at least the inside diameter of the first expandable tubular member 24.
  • a bell-shaped section is formed using at least a portion of the second expandable tubular member 26.
  • a mono- diameter tubular assembly is formed that defines an internal passage 28 having a substantially constant cross-sectional area and/or inside diameter.
  • an exemplary embodiment of an expandable tubular assembly 100 includes a first expandable tubular member 102 coupled to a tubular coupling 104.
  • the tubular coupling 104 is coupled to a tubular coupling 106.
  • the tubular coupling 106 is coupled to a second expandable tubular member 108.
  • the tubular couplings, 104 and 106 provide a tubular coupling assembly for coupling the first and second expandable tubular members, 102 and 108, together that may include, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • the first and second expandable tubular members 12 have a plastic yield point YP-i, and the tubular couplings, 104 and 106, have a plastic yield point YP 2 .
  • the expandable tubular assembly 100 is positioned within a preexisting structure such as, for example, a wellbore 110 that traverses a subterranean formation 112. [00227] As illustrated in Fig. 9, an expansion device 114 may then be positioned within the second expandable tubular member 108.
  • the expansion device 114 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services,
  • the expansion device 114 is positioned within the second expandable tubular member 108 before, during, or after the placement of the expandable tubular assembly 100 within the preexisting structure 110.
  • the expansion device 114 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 108 to form a bell-shaped section.
  • the expansion device 114 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 108, the tubular couplings, 104 and 106, and at least a portion of the first expandable tubular member 102.
  • At least a portion of at least a portion of at least one of the first and second expandable tubular members, 102 and 108, are radially expanded into intimate contact with the interior surface of the preexisting structure 110.
  • the plastic yield point YP- is less than the plastic yield point YP 2 .
  • the amount of power and/or energy required to radially expand each unit length of the first and second expandable tubular members, 102 and 108 is less than the amount of power and/or energy required to radially expand each unit length of the tubular cou plings, 104 and 106.
  • the first expandable tubular member 12 and/or the second expandable tubular member 14 have a ductility D PE and a yield strength YS PE prior to radial expansion and plastic deformation, and a ductility D AE and a yield strength YS AE after radial expansion and plastic deformation.
  • D PE is greater than D AE
  • YS AE is greater than YS PE . I n this manner, the first expandable tubular member 12 and/or the second expandable tubular member 14 are transformed during the radial expansion and plastic deformation process.
  • an exemplary embodiment of an expandable tubular assembly 200 includes a first expandable tubular member 202 coupled to a second expandable tubular member 204 that defines radial openings 204a, 204b, 204c, and 204d.
  • the ends of the first and second expandable tubular members, 202 and 204 are coupled using, for example, a conventional mechanical coupling, a welded connection, a brazed connection, a threaded connection, and/or an interference fit connection.
  • one or more of the radial openings, 204a, 204b, 204c, and 204d have circular, oval, square, and/or irregular cross sections and/or include portions that extend to and interrupt either end of the second expandable tubular member 204.
  • the expandable tubular assembly 200 is positioned within a preexisting structure such as, for example, a wellbore 206 that traverses a subterranean formation 208.
  • an expansion device 210 may then be positioned within the second expandable tubular member 204.
  • the expansion device 210 may include, for example, one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; d) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L-L.C.
  • the expansion device 210 is positioned within the second expandable tubular member 204 before, during, or after the placement of the expandable tubular assembly 200 within the preexisting structure 206.
  • the expansion device 210 may then be operated to radially expand and plastically deform at least a portion of the second expandable tubular member 204 to form a bell-shaped section.
  • the expansion device 20 may then be operated to radially expand and plastically deform the remaining portion of the second expandable tubular member 204 and at least a portion of the first expandable tubular member 202.
  • the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204 is greater than 1.
  • the second expandable tubular member 204 had an anisotropy ratio AR greater than 1 , and the radial expansion and plastic deformation of the second expandable tubular member did not result in any of the openings, 204a, 204b, 204c, and 204d, splitting or otherwise fracturing the remaining portions of the second expandable tubular member. This was an unexpected result.
  • thermo-mechanical processing 302 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to an intermediate state.
  • the tubular member is then further thermo-mechanically processed in step 304.
  • the thermo-mechanical processing 304 includes one or more heat treating and/or mechanical forming processes.
  • the tubular member is transformed to a final state.
  • the tubular member has a ductility D PE and a yield strength YS PE prior to the final thermo-mechanical processing in step 304, and a ductility D AE and a yield strength YS AE after final thermo-mechanical processing.
  • D PE is greater than D AE
  • YS AE is greater than YS PE .
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have the following characteristics:
  • the strain hardening exponent for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.
  • the expandability coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 0.12.
  • a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient.
  • a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 are steel alloys having one of the following compositions:
  • a sample of an expandable tubular member composed of Alloy A exhibited a yield point before radial expansion and plastic deformation YP ⁇ E , a yield point after radial expansion and plastic deformation of about 16 % YP AE ⁇ 6% , and a yield point after radial expansion and plastic deformation of about 24 % YP AE2 % .
  • a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
  • a sample of an expandable tubular member composed of Alloy B exhibited a yield point before radial expansion and plastic deformation YP B E, a yield point after radial expansion and plastic deformation of about 16 % YP AE ⁇ 6% , and a yield point after radial expansion and plastic deformation of about 24 % YP AE2 % -
  • YP AE2 % > YP AEI 6% > YP BE .
  • the ductility of the sample of the expandable tubular member composed of Alloy B also exhibited a higher ductility prior to radial expansion and plastic deformation than after radial expansion and plastic deformation. These were unexpected results.
  • a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
  • samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation:
  • one or more o the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.
  • the carbon equivalent value C e for tubular members having a carbon content less than or equal to 0.12% (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.21.
  • the carbon equf valent value C e for tubular members having greater than 0.12% carbon content (by weight), for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is less than 0.36.
  • a first tubular member 2210 includes an internally threaded connection 2212 at an end portion 2214.
  • the end portion 2214 of the first tubular member 2210 abuts one side of the internal flange 2218 of the tubular sleeve 2216, and the internal diameter of the internal flange 2218 of the tubular sleeve 2216 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 2212 of the end portion 2214 of the first tubular member
  • An externally threaded connection 2224 of an end portion 2226 of a second tubular member 2228 having an annular recess 2230 is then positioned within the tubular sleeve
  • the internal flange 2214 of the first tubular member 2210.
  • the internal flange 2214 of the first tubular member 2210.
  • tubular sleeve 2216 mates with and is received within the annular recess 2230 of the end portion 2226 of the second tubular member 2228.
  • the tubular sleeve 2216 is coupled to and surrounds the external surfaces of the first and second tubular members,
  • the internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection
  • the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection.
  • the internal diameter of the tubular sleeve 2216 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 2210 and 2228. In this manner, during the threaded coupling of the first and second tubular members, 2210 and 2228, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • tubular sleeve 2216 may be positioned within another structure 2232 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members.
  • a conventional expansion device 2234 within and/or through the interiors of the first and second tubular members.
  • tubular sleeve 2216 facilitates the insertion and movement of the first and second tubular members within and through the structure 2232, and the movement of the expansion device 2234 through the interiors of the first and second tubular members,
  • tubular sleeve 2216 may be, for example, from top to bottom or from bottom to top.
  • the tubular sleeve 2216 is also radially expanded and plastically deformed.
  • the tubular sleeve 2216 may be maintained in circumferential tension and the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, may be maintained in circumferential compression.
  • Sleeve 2216 increases the axial compression loading of the connection between tubular members 2210 and 2228 before and after expansion by the expansion device 2234.
  • Sleeve 2216 may, for example, be secured to tubular members 2210 and
  • first and second tubular members are first and second tubular members
  • 2210 and 2228 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 2216 during (a) the coupling of the first tubular member 2210 to the second tubular member 2228, (b) the placement of the first and second tubular members in the structure 2232, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 2216 protects the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, during handling and insertion of the tubular members within the structure 2232. In this manner, damage to the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members, 2210 and 2228, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
  • tubular sleeve 2216 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 2228 to the first tubular member 2210. In this manner, misalignment that could result in damage to the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, may be avoided.
  • the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled.
  • tubular sleeve 2216 can be easily rotated, that would indicate that the first and second tubular members, 2210 and 2228, are not fully threadably coupled and in intimate contact with the internal flange 2218 of the tubular sleeve.
  • the tubular sleeve 2216 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 2214 and 2226, of the first and second tubular members may be limited in severity or eliminated all together.
  • the tubular sleeve 2216 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 2216 and the exterior surfaces of the end portions, 2214 and 2226, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 2212 and 2224, of the first and second tubular members, 2210 and 2228, into the annulus between th e first and second tubular members and the structure 2232. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 may be maintained in circumferential tension and the end portions,
  • first and second tubular members, 2210 and 2228 may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 2210 and 2228, and the tubular sleeve 2216 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a first tubular me-mber 210 includes an internally threaded connection 2312 at an end portion 2314.
  • a first end of a tubular sleeve 2316 includes an internal flange 2318 and a tapered portion 2320.
  • ⁇ second end of the sleeve 2316 includes an internal flange 2321 and a tapered portion 2322.
  • the first tubular member 2310 includes a recess 2331.
  • the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members
  • the internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection
  • the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection.
  • the internal diameter of the tubular sleeve 2316 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2310 and 2328. In this manner, during the threaded coupling of the first and second tubular members 2310 and 2328, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2310 and 2328, and the tubular sleeve 2316 may then be positioned within another structure 2332 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2334 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2320 and 2322, of the tubular sleeve 2316 facilitates the insertion and movement of the first and second tubular members within and through the structure 2332, and the displacement of the expansion device 2334 through the interiors of the first and second tubular members 2310 and 2328, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2316 is also radially expanded and plastically deformed.
  • the tubular sleeve 2316 may be maintained in circumferential tension and the end portions 2314 and 2326, of the first and second tubular members 2310 and 2328, may be maintained in circumferential compression.
  • Sleeve 2316 increases the axial tension loading of the connection between tubular members 2310 and 2328 before and after expansion by the expansion device 2334.
  • Sleeve 2316 may be secured to tubular members 2310 and 2328 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2310 and 2328, and the tubular sleeve 2316 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a 2410 includes an internally threaded connection 2412 at an end portion 2414.
  • a first end of a tubular sleeve 2416 includes an internal flange 2418 and a tapered portion 2420.
  • a second end of the sleeve 2416 includes an internal flange 2421 and a tapered portion 2422.
  • the first tubular member 2410 includes a recess
  • the internal flange 2421 mates with and is received within the annular recess 2431.
  • the sleeve 2416 is coupled to and surrounds the external surfaces of the first and second tubular members 2410 and 2428.
  • the internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection
  • the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection.
  • the internal diameter of the tubular sleeve 2416 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2410 and 2428. In this manner, during the threaded coupling of the first and second tubular members 2410 and 2428, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2410 and 2428, and the tubular sleeve 2416 may then be positioned within another structure 2432 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2434 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2420 and 2422, of the tubular sleeve 2416 facilitate the insertion and movement of the first and second tubular members within and through the structure 2432, and the displacement of the expansion device 2434 through the interiors of the first and second tubular members, 2410 and 2428, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2416 is also radially expanded and plastically deformed.
  • the tubular sleeve 2416 may be maintained in circumferential tension and the end portions, 2414 and 2426, of the first and second tubular members, 2410 and 2428, may be maintained in circumferential compression.
  • the sleeve 2416 increases the axial compression and tension loading of the connection between tubular members 2410 and 2428 before and after expansion by expansion device 2424.
  • Sleeve 2416 may be secured to tubular members 2410 and 2428 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2410 and 2428, and the tubular sleeve 2416 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a 2510 includes an internally threaded connection 2512 at an end portion 2514.
  • a first end of a tubular sleeve 2516 includes an internal flange 2518 and a relief 2520.
  • a second end of the sleeve 2516 includes an internal flange 2521 and a relief 2522.
  • An externally threaded connection 2524 of an end portion 2526 of a second tubular member 2528 having an annular recess 2530 is then positioned within the tubular sleeve 2516 and threadably coupled to the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510.
  • the internal flange 2518 of the sleeve 2516 mates with and is received within the annular recess 2530.
  • the first tubular member 2510 includes a recess 2531.
  • the internal flange 2521 mates with and is received within the annular recess 2531.
  • the sleeve 2516 is coupled to and surrounds the external surfaces of the first and second tubular members 2510 and 2528.
  • the internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection
  • the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection.
  • the internal diameter of the tubular sleeve 2516 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2510 and 2528. In this manner, during the threaded coupling of the first and second tubular members 2510 and 2528, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2510 and 2528, and the tubular sleeve 2516 may then be positioned within another structure 2532 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2534 through and/or within the interiors of the first and second tubular members.
  • the reliefs 2520 and 2522 are each filled with a sacrificial material 2540 including a tapered surface 2542 and 2544, respectively.
  • the material 2540 may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2510 and 2528, through the structure 2532.
  • the displacement of the expansion device 2534 through the interiors of the first and second tubular members 2510 and 2528 may, for example, be from top to bottom or from bottom to top.
  • the tubular sleeve 2516 is also radially expanded and plastically deformed.
  • the tubular sleeve 2516 may be maintained in circumferential tension and the end portions 2514 and 2526, of the first and second tubular members, 2510 and 2528, may be maintained in circumferential compression.
  • sacrificial material 2540 provided on sleeve 2516, avoids stress risers on the sleeve 2516 and the tubular member 2510.
  • the tapered surfaces 2542 and 2544 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2516.
  • Sleeve 2516 may be secured to tubular members 2510 and 2528 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2510 and 2528, and the tubular sleeve 2516 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 2610 includes an internally threaded connection 2612 at an end portion 2614.
  • a first end of a tubular sleeve 2616 includes an internal flange 2618 and a tapered portion 2620.
  • a second end of the sleeve 2616 includes an internal flange 2621 and a tapered portion 2622.
  • the first tubular member 2610 includes a recess 2631.
  • the internal flange 2631 includes a recess 2631.
  • the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members
  • the internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection
  • the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection.
  • the internal diameter of the tubular sleeve 2616 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2610 and 2628. In this manner, during the threaded coupling of the first and second tubular members 2610 and 2628, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2610 and 2628, and the tubular sleeve 2616 may then be positioned within another structure 2632 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2634 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2620 and 2622, of the tubular sleeve 2616 facilitates the insertion and movement of the first and second tubular members within and through the structure 2632, and the displacement of the expansion device 2634 through the interiors of the first and second tubular members 2610 and 2628, may, for example, be from top to bottom or from bottom to top.
  • tubular sleeve 2616 is also radially expanded and plastically deformed.
  • the tubular sleeve 2616 may be maintained in circumferential tension and the end portions 2614 and 2626, of the first and second tubular members 2610 and 2628, may be maintained in circumferential compression.
  • Sleeve 2616 is covered by a thin walled cylinder of sacrificial material 2640.
  • Spaces 2623 and 2624, adjacent tapered portions 2620 and 2622, respectively, are also filled with an excess of the sacrificial material 2640.
  • the material may be a metal or a synthetic, and is provided to facilitate the insertion and movement of the first and second tubular members 2610 and 2628, through the structure 2632.
  • sacrificial material 2640 provided on sleeve 2616, avoids stress risers on the sleeve 2616 and the tubular member 2610.
  • the excess of the sacrificial material 2640 adjacent tapered portions 2620 and 2622 are intended to wear or even become damaged, thus incurring such wear or damage which would otherwise be borne by sleeve 2616.
  • Sleeve 2616 may be secured to tubular members 2610 and 2628 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2610 and 2628, and the tubular sleeve 2616 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • FIG. 2710 includes an internally threaded connection 2712 at an end portion 2714.
  • a first end of a tubular sleeve 2716 includes an internal flange 2718 and a tapered portion 2720.
  • a second end of the sleeve 2716 includes an internal flange 2721 and a tapered portion 2722.
  • An externally threaded connection 2724 of an end portion 2726 of a second tubular member 2728 having an annular recess 2730 is then positioned within the tubular sleeve 2716 and threadably coupled to the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710.
  • the internal flange 2718 of the sleeve 2716 mates with and is received within the annular recess 2730.
  • the first tubular member 2710 includes a recess 2731.
  • the internal flange 2731 includes a recess 2731.
  • the sleeve 2716 is coupled to and surrounds the external surfaces of the first and second tubular members 2710 and 2728.
  • the internally threaded connection 2712 of the end portion 2714 of the first tubular member 2710 is a box connection
  • the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection.
  • the internal diameter of the tubular sleeve 2716 is at least approximately .020" greater than the outside diameters of the first and second tubular members 2710 and 2728. In this manner, during the threaded coupling of the first and second tubular members 2710 and 2728, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • the first and second tubular members 2710 and 2728, and the tubular sleeve 2716 may then be positioned within another structure 2732 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 2734 through and/or within the interiors of the first and second tubular members.
  • the tapered portions 2720 and 2722, of the tubular sleeve 2716 facilitates the insertion and movement of the first and second tubular members within and through the structure 2732, and the displacement of the expansion device 2734 through the interiors of the first and second tubular members 2710 and 2728, may be from top to bottom or from bottom to top.
  • the tubular sleeve 2716 is also radially expanded and plastically deformed.
  • the tubular sleeve 2716 may be maintained in circumferential tension and the end portions 2714 and 2726, of the first and second tubular members 2710 and 2728, may be maintained in circumferential compression.
  • Sleeve 2716 has a variable thickness due to one or more reduced thickness portions 2790 and/or increased thickness portions 2792.
  • Varying the thickness of sleeve 2716 provides the ability to control or induce stresses at selected positions along the length of sleeve 2716 and the end portions 2724 and 2726.
  • Sleeve 2716 may be secured to tubular members 2710 and 2728 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 2710 and 2728, and the tubular sleeve 2716 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a member 2740 which may be coiled onto the grooves 2739 formed in sleeve 2716, thus varying the thickness along the length of sleeve 2716.
  • 2910 includes an internally threaded connection 2912 and an internal annular recess 2914 at an end portion 2916.
  • a first end of a tubular sleeve 2918 includes an internal flange 2920, and a second end of the sleeve 2916 mates with and receives the end portion 2916 of the first tubular member 2910.
  • An externally threaded connection 2922 of an end portion 2924 of a second tubular member 2926 having an annular recess 2928, is then positioned within the tubular sleeve 2918 and threadably coupled to the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910.
  • the internal flange 2920 of the sleeve 2918 mates with and is received within the annular recess 2928.
  • the internally threaded connection 2912 of the end portion 2916 of the first tubular member 2910 is a box connection, and the externally threaded connection 2922 of the end portion 2924 of the second tubular member 2926 is a pin connection.
  • the internal diameter of the tubular sleeve 2918 is at least approximately .020" greater than the outside diameters of the first tubular member 2910.
  • fluidic materials within the first and second tubular members may be vented from the tubular members.
  • 2918 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the tubular sleeve 2918 is also radially expanded and plastically deformed.
  • the tubular sleeve 2918 may be maintained in circumferential tension and the end portions 2916 and 2924, of the first and second tubular members 2910 and 2926, respectively, may be maintained in circumferential compression.
  • the sealing element 2930 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 2910 and 2926, the first tubular member and the tubular sleeve 2918, and/or the second tubular member and the tubular sleeve.
  • the metal to metal seal is both fluid tight and gas tight.
  • 2930 have one or more of the material properties of one or more of the tubular members 12,
  • 3010 includes internally threaded connections 3012a and 3012b, spaced apart by a cylindrical internal surface 3014, at an end portion 3016. Externally threaded connections
  • a sealing element 3026 is received within an annulus defined between the internal cylindrical surface 3014 of the first tubular member 3010 and the external cylindrical surface 3020 of the second tubular member 3024.
  • the sealing element 3026 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3010 and 3024 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3026 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 3010 and 3024, the first tubular member and the sealing element 3026, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3026 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3010 and 3024, the sealing element 3026 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 3030 includes internally threaded connections 3032a and 3032b, spaced apart by an undulating approximately cylindrical internal surface 3034, at an end portion 3036.
  • Externally threaded connections 3038a and 3038b, spaced apart by a cylindrical external surface 3040, of an end portion 3042 of a second tubular member 3044 are threadably coupled to the internally threaded connections, 3032a and 3032b, respectively, of the end portion 3036 of the first tubular member 3030.
  • a sealing element 3046 is received within an annulus defined between the undulating approximately cylindrical internal surface 3034 of the first tubular member 3030 and the external cylindrical surface 3040 of the second tubular member 3044.
  • the sealing element 3046 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3030 and 3044 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3046 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members 3030 and 3044, the first tubular member and the sealing element 3046, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3046 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3030 and 3044, the sealing element 3046 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • 3050 includes internally threaded connections 3052a and 3052b, spaced apart by a cylindrical internal surface 3054 including one or more square grooves 3056, at an end portion 3058.
  • Externally threaded connections 3060a and 3060b, spaced apart by a cylindrical external surface 3062 including one or more square grooves 3064, of an end portion 3066 of a second tubular member 3068 are threadably coupled to the internally threaded connections, 3052a and 3052b, respectively, of the end portion 3058 of the first tubular member 3050.
  • a sealing element 3070 is received within an annulus defined between the cylindrical internal surface 3054 of the first tubular member 3050 and the external cylindrical surface 3062 of the second tubular member 3068.
  • the sealing element 3070 is an elastomeric and/or metallic sealing element.
  • the first and second tubular members 3050 and 3068 may be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • the sealing element 3070 seals the interface between the first and second tubular members.
  • a metal to metal seal is formed between at least one of: the first and second tubular members, the first tubular member and the sealing element 3070, and/or the second tubular member and the sealing element.
  • the metal to metal seal is both fluid tight and gas tight.
  • the sealing element 3070 is omitted, and during and/or after the radial expansion and plastic deformation of the first and second tubular members 950 and 968, a metal to metal seal is formed between the first and second tubular members.
  • one or more portions of the first and second tubular members, 3050 and 3068, the sealing element 3070 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204.
  • 3110 includes internally threaded connections, 3112a and 3112b, spaced apart by a non- threaded internal surface 3114, at an end portion 3116.
  • Externally threaded connections, 3118a and 3118b, spaced apart by a non-threaded external surface 3120, of an end portion 3122 of a second tubular member 3124 are threadably coupled to the internally threaded connections, 3112a and 3112b, respectively, of the end portion 3122 of the first tubular member 3124.
  • First, second, and/or third tubular sleeves, 3126, 3128, and 3130 are coupled the external surface of the first tubular member 3110 in opposing relation to the threaded connection formed by the internal and external threads, 3112a and 3118a, the interface between the non-threaded surfaces, 3114 and 3120, and the threaded connection formed by the internal and external threads, 3112b and 3118b, respectively.
  • first and second tubular members 3110 and 3124, and the tubular sleeves 3126, 3128, and/or 3130 may then be positioned within another structure 3132 such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device 3134 through and/or within the interiors of the first and second tubular members.
  • tubular sleeves 3126, 3128 and/or 3130 are also radially expanded and plastically deformed.
  • the tubular sleeves 3126, 3128, and/or 3130 are maintained in circumferential tension and the end portions 3116 and 3122, of the first and second tubular members 3110 and 3124, may be maintained in circumferential compression.
  • the sleeves 3126, 3128, and/or 3130 may, for example, be secured to the first tubular member 3110 by a heat shrink fit.
  • one or more portions of the first and second tubular members, 3110 and 3124, and the sleeves, 3126, 3128, and 3130 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102,
  • 3210 includes an internally threaded connection 3212 at an end portion 3214.
  • An externally threaded connection 3216 of an end portion 3218 of a second tubular member 3220 are threadably coupled to the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210.
  • the internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection
  • the externally threaded connection 3216 of the end portion 3218 of the second tubular member 3220 is a pin connection.
  • a tubular sleeve 3222 including internal flanges 3224 and 3226 is positioned proximate and surrounding the end portion 3214 of the first tubular member 3210. As illustrated in Fig. 32b, the tubular sleeve 3222 is then forced into engagement with the external surface of the end portion 3214 of the first tubular member 3210 in a conventional manner. As a result, the end portions, 3214 and 3218, of the first and second tubular members, 3210 and 3220, are upset in an undulating fashion.
  • 3222 may then be positioned within another structure such as, for example, a wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating an expansion device through and/or within the interiors of the first and second tubular members.
  • tubular sleeve 3222 is also radially expanded and plastically deformed.
  • the tubular sleeve 3222 is maintained in circumferential tension and the end portions 3214 and 3218, of the first and second tubular members 3210 and 3220, may be maintained in circumferential compression.
  • one or more portions of the first and second tubular members, 3210 and 3220, and the sleeve 3222 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 02, 104, 106,
  • 3310 includes an internally threaded connection 3312 and an annular projection 3314 at an end portion 3316.
  • the end portion 3316 of the first tubular member 3310 abuts one side of the internal flange 3320 of the tubular sleeve 3318 and the annular projection 3314 of the end portion of the first tubular member mates with and is received within the annular recess 3324 of the internal flange of the tubular sleeve, and the internal diameter of the internal flange 3320 of the tubular sleeve 3318 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310.
  • tubular sleeve 3318 is then positioned within the tubular sleeve 3318 and threadably coupled to the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310.
  • the internal flange 3332 of the tubular sleeve 3318 mates with and is received within the annular recess 3332 of the end portion 3328 of the second tubular member 3330.
  • the tubular sleeve 3318 is coupled to and surrounds the external surfaces of the first and second tubular members, 3310 and 3328.
  • the internally threaded connection 3312 of the end portion 3316 of the first tubular member 3310 is a box connection
  • the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection.
  • the internal diameter of the tubular sleeve 3318 is at least approximately .020" greater than the outside diameters of the first and second tubular members, 3310 and 3330. In this manner, during the threaded coupling of the first and second tubular members, 3310 and 3330, fluidic materials within the first and second tubular members may be vented from the tubular members.
  • tubular sleeve 3318 may be positioned within another structure 3334 such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • a conventional expansion device 3336 within and/or through the interiors of the first and second tubular members.
  • tubular sleeve 3318 facilitates the insertion and movement of the first and second tubular members within and through the structure 3334, and the movement of the expansion device 3336 through the interiors of the first and second tubular members,
  • 3310 and 3330 may, for example, be from top to bottom or from bottom to top.
  • tubular sleeve 3318 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3318 may be maintained in circumferential tension and the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, may be maintained in circumferential compression.
  • Sleeve 3316 increases the axial compression loading of the connection between tubular members 3310 and 3330 before and after expansion by the expansion device 3336.
  • Sleeve 3316 may be secured to tubular members 3310 and 3330, for example, by a heat shrink fit.
  • first and second tubular members are identical to each other.
  • 3310 and 3330 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 3318 during (a) the coupling of the first tubular member 3310 to the second tubular member 3330, (b) the placement of the first and second tubular members in the structure 3334, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3318 protects the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, during handling and insertion of the tubular members within the structure 3334. In this manner, damage to the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members, 3310 and 3330, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations.
  • tubular sleeve 3318 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3330 to the first tubular member 3310. In this manner, misalignment that could result in damage to the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, may be avoided.
  • the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled.
  • tubular sleeve 3318 can be easily rotated, that would indicate that the first and second tubular members, 3310 and 3330, are not fully threadably coupled and in intimate contact with the internal flange 3320 of the tubular sleeve. Furthermore, the tubular sleeve 3318 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3316 and 3328, of the first and second tubular members may be limited in severity or eliminated all together.
  • the tubular sleeve 3318 may provide a fluid tight metal-to-metal seal between interior surface of the tubular sleeve 3318 and the exterior surfaces of the end portions, 3316 and 3328, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3312 and 3326, of the first and second tubular members, 3310 and 3330, into the annulus between the first and second tubular members and the structure 3334. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the tubular sleeve 33 8 may be maintained in circumferential tension and the end portions,
  • first and second tubular members, 3310 and 3330 may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • one or more portions of the first and second tubular members, 3310 and 3330, and the sleeve 3318 have one or more of the material properties of one or more of the tubular members 12, 14, 24, 26, 102, 104, 106,
  • a first tubular member 3410 includes an internally threaded connection 1312 and one or more external grooves 3414 at an end portion 3416.
  • the end portion 3416 of the first tubular member 3410 abuts one side of the internal flange 3420 of the tubular sleeve 3418, and the internal diameter of the internal flange 3420 of the tubular sleeve 3416 is substantially equal to or greater than the maximum internal diameter of the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410.
  • tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432.
  • first and second tubular members 3418 may be positioned within another structure such as, for example, a cased or uncased wellbore, and radially expanded and plastically deformed, for example, by displacing and/or rotating a conventional expansion device within and/or through the interiors of the first and second tubular members.
  • the tapered portions, 3422 and 3424, of the tubular sleeve 3418 facilitate the insertion and movement of the first and second tubular members within and through the structure, and the movement of the expansion device through the interiors of the first and second tubular members, 3410 and 3432, may be from top to bottom or from bottom to top.
  • tubular sleeve 3418 is also radially expanded and plastically deformed. As a result, the tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression.
  • Sleeve 3416 increases the axial compression loading of the connection between tubular members 3410 and 3432 before and after expansion by the expansion device. The sleeve 3418 may be secured to tubular members 3410 and 3432, for example, by a heat shrink fit.
  • the grooves 3414 and/or 3434 and/or the openings 3426 provide stress concentrations that in turn apply added stress forces to the mating threads of the threaded connections, 3412 and 3428.
  • the mating threads of the threaded connections, 3412 and 3428 are maintained in metal to metal contact thereby providing a fluid and gas tight connection.
  • the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another.
  • the grooves 3414 and/or 3434 are helical grooves.
  • first and second tubular members are identical to first and second tubular members
  • 3410 and 3432 are radially expanded and plastically deformed using other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global
  • tubular sleeve 3418 The use of the tubular sleeve 3418 during (a) the coupling of the first tubular member 3410 to the second tubular member 3432, (b) the placement of the first and second tubular members in the structure, and (c) the radial expansion and plastic deformation of the first and second tubular members provides a number of significant benefits.
  • the tubular sleeve 3418 protects the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, during handling and insertion of the tubular members within the structure.
  • tubular sleeve 3418 provides an alignment guide that facilitates the insertion and threaded coupling of the second tubular member 3432 to the first tubular member 3410. In this manner, misalignment that could result in damage to the threaded connections, 3412 and 3428, of the first and second tubular members, 3410 and 3432, may be avoided.
  • the tubular sleeve 3416 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the tubular sleeve 3418 can be easily rotated, that would indicate that the first and second tubular members, 3410 and 3432, are not fully threadably coupled and in intimate contact with the internal flange 3420 of the tubular sleeve. Furthermore, the tubular sleeve 3418 may prevent crack propagation during the radial expansion and plastic deformation of the first and second tubular members, 3410 and
  • 3418 may provide a fluid and gas tight metal-to-metal seal between interior surface of the tubular sleeve 3418 and the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members. In this manner, fluidic materials are prevented from passing through the threaded connections, 3412 and 3430, of the first and second tubular members,
  • tubular sleeve 3418 may be maintained in circumferential tension and the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, may be maintained in circumferential compression, axial loads and/or torque loads may be transmitted through the tubular sleeve.
  • the first and second tubular members described above with reference to Figs. 1 to 34c are radially expanded and plastically deformed using the expansion device in a conventional manner and/or using one or more of the methods and apparatus disclosed in one or more of the following:
  • the present application is related to the following: (1) U.S. patent application serial no. 09/454,139, attorney docket no. 25791.03.02, filed on 12/3/1999, (2) U.S. patent application serial no.
  • an exemplary embodiment of an expandable tubular member 3500 includes a first tubular region 3502 and a second tubular portion 3504.
  • the material properties of the first and second tubular regions, 3502 and 3504, are different.
  • the yield points of the first and second tubular regions, 3502 and 3504, are different.
  • the yield point of the first tubular region 3502 is less than the yield point of the second tubular region 3504.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 incorporate the tubular member 3500.
  • the yield point within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 vary as a function of the radial position within the expandable tubular member.
  • the yield point increases as a function of the radial position within the expandable tubular member 3502.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a linear relationship.
  • the relationship between the yield point and the radial position within the expandable tubular member 3502 is a non-linear relationship.
  • the yield point increases at different rates within the first and second tubular regions, 3502a and 3502b, as a function of the radial position within the expandable tubular member 3502.
  • the functional relationship, and value, of the yield points within the first and second tubular regions, 3502a and 3502b, of the expandable tubular member 3502 are modified by the radial expansion and plastic deformation of the expandable tubular member.
  • one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202, 204 and/or 3502, prior to a radial expansion and plastic deformation include a microstructure that is a combination of a hard phase, such as martensite, a soft phase, such as ferrite, and a transitionary phase, such as retained austentite.
  • a hard phase such as martensite
  • a soft phase such as ferrite
  • a transitionary phase such as retained austentite.
  • the hard phase provides high strength
  • the soft phase provides ductility
  • the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation.
  • the yield point of the tubular member increases as a result of the radial expansion and plastic deformation.
  • the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation.
  • the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1 % C, 1.2% Mn, and 0.3% Si.
  • an expandable tubular member 3602a is provided that is a steel alloy having following material composition (by weight percentage): 0.065% C, 1.44% Mn, 0.01 % P, 0.002% S,
  • the expandable tubular member 3602a provided in step 3602 has a yield strength of 45 ksi, and a tensile strength of 69 ksi.
  • the expandable tubular member 3602a includes a microstructure that includes martensite, pearlite, and V, Ni, and/or Ti carbides.
  • the expandable tubular member 3602a is then heated at a temperature of 790 °C for about 10 minutes in step 3604. [00364] ⁇ In an exemplary embodiment, the expandable tubular member 3602a is then quenched in water in step 3606.
  • the expandable tubular member 3602a includes a microstructure that includes new ferrite, grain pearlite, martensite, and ferrite.
  • the expandable tubular member 3602a has a yield strength of 67 ksi, and a tensile strength of 95 ksi.
  • the expandable tubular member 3602a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 95 ksi.
  • an expandable tubular member 3702a is provided that is a steel alloy having following material composition (by weight percentage): 0.18% C, 1.28% Mn, 0.017% P, 0.004% S,
  • the expandable tubular member 3702a provided in step 3702 has a yield strength of 60 ksi, and a tensile strength of 80 ksi.
  • the expandable tubular member 3702a includes a microstructure that includes pearlite and pearlite striation.
  • the expandable tubular member 3702a is then heated at a temperature of 790 °C for about 10 minutes in step 3704.
  • the expandable tubular member 3702a is then quenched in water in step 3706.
  • the expandable tubular member 3702a includes a microstructure that includes ferrite, martensite, and bainite.
  • the expandable tubular member 3702a has a yield strength of 82 ksi, and a tensile strength of 130 ksi.
  • the expandable tubular member 3702a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 130 ksi.
  • an expandable tubular member 3802a is provided that is a steel alloy having following material composition (by weight percentage): 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.06% Cu, 0.05% Ni, 0.05% Cr, 0.03% V, 0.03%Mo, 0.01% Nb, and 0.01% Ti.
  • the expandable tubular member 3802a provided in step 3802 has a yield strength of 56 ksi, and a tensile strength of 75 ksi.
  • step 38b in step
  • the expandable tubular member 3802a includes a microstructure that includes grain pearlite, widmanstatten martensite and carbides of V, Ni, and/or Ti.
  • the expandable tubular member 3802a is then heated at a temperature of 790 °C for about 10 minutes in step 3804. [00376] In an exemplary embodiment, the expandable tubular member 3802a is then quenched in water in step 3806.
  • the expandable tubular member 3802a includes a microstructure that includes bainite, pearlite, and new ferrite.
  • the expandable tubular member 3802a has a yield strength of 60 ksi, and a tensile strength of 97 ksi.
  • the expandable tubular member 3802a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above.
  • the yield strength of the expandable tubular member is about 97 ksi.
  • a system for reducing the friction between an expansion cone and a tubular member during the expansion process there may be at least three elements contributing to friction; an expansion device 4002, a lubricant 4004, and a tubular member 4006.
  • Elements in the expansion device 4002 that may contribute to friction comprise the following: composition 4008; geometry 4010; surface roughness 4012; texture; 4014 and coating 4016.
  • Elements in the lubricant 4004 that may contribute to friction comprise the following: composition 4018; environmental issues 4020; and friction modifiers.
  • Element in the tubular member 4006 that may contribute to friction comprise the following: inside diameter roughness 4022; and coating 4024.
  • Each element may be adjusted in the manner described below to reduce the friction between an expansion cone and a tubular member during the expansion process.
  • an expansion cone 5000 radially expands a tubular member 5005 by moving in an axial direction 5010 relative to the tubular member 5005.
  • the interface between the outer surface 5010 of the tapered portion 5015 of the expansion cone 5000 and the inner surface 5020 of the tubular member 5005 includes a leading edge portion 5025 and a trailing edge portion 5030.
  • leading edge portion 5025 may be lubricated by the presence of lubricating fluids provided ahead of the expansion cone 5000.
  • an expansion cone 5100 having a front end 5100a and a rear end 5100b, includes a tapered portion 5105 having an outer surface 3110, one or more circumferential grooves 5115a and 5115b, and one more internal flow passages 5120a and
  • the circumferential grooves 5115 are fluidicly coupled to the internal flow passages 5120.
  • lubricating fluids are transmitted from the area ahead of the front 5100a of the expansion cone 5100 into the circumferential grooves 5115 from a lubricant source, such as, for example, from reservoir 5122 utilizing pump 5124.
  • a lubricant source such as, for example, from reservoir 5122 utilizing pump 5124.
  • the expansion cone 5100 includes a plurality of circumferential grooves 51 15.
  • the expansion cone 5100 includes circumferential grooves 5115 concentrated about the axial midpoint of the tapered portion 5105 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5100 and a tubular member during the radial expansion process.
  • the circumferential grooves 5115 are equally spaced along the trailing edge portion of the expansion cone 51 00 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5100 and a tubular member during the radial expansion process.
  • the expansion cone 5100 includes a plurality of flow passages 5120 coupled to each of the circumferential grooves 5115.
  • the cross sectional area of the circumferential grooves 5115 is greater than the cross sectional area of the flow passage 5120 in order to minimize resistance to fluid flow.
  • an expansion cone 5200 having a front end 5200a and a rear end 5200b, includes a tapered portion 5205 having an outer surface 5210, one or more circumferential grooves 5215a and 5215b, and one or more axial grooves 5220a and 5220b.
  • the circumferential grooves 5215 are fluidicly coupled to the axial groves 5220.
  • lubricating fluids are transmitted from the area ahead of the front 5200a of the expansion cone 5200 into the circumferential grooves 5215.
  • the trailing edge portion of the interface between the expansion cone 5200 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the axial grooves 5220 are provided with lubricating fluid using a supply of lubricating fluid positioned proximate the front end 5200a of the expansion cone 5200.
  • the circumferential grooves 3215 are concentrated about the axial midpoint of the tapered portion 5205 of the expansion cone 5200 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5200 and a tubular member during the radial expansion process.
  • the circumferential grooves 5215 are equally spaced along the trailing edge portion of the expansion cone 5200 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5200 and a tubular member during the radial expansion process.
  • the expansion cone 5200 includes a plurality of circumferential grooves 5215.
  • the expansion cone 5200 includes a plurality of axial grooves 5220 coupled to each of the circumferential grooves 5215.
  • the cross sectional area of the circumferential grooves 5215 is greater than the cross sectional area of the axial grooves 5220 in order to minimize resistance to fluid flow.
  • the axial groves 5220 are spaced apart in the circumferential direction by at least about 3 inches in order to provide lubrication during the radial expansion process.
  • an expansion cone 5300 having a front end 5300a and a rear end 5300b, includes a tapered portion 5305 having an outer surface 5310, one or more circumferential grooves 5315a and 5315b, and one or more internal flow passages 5320a and 5320b.
  • the circumferential grooves 5315 are fluidicly coupled to the internal flow passages 5320. In this manner, during the radial expansion process, lubricating fluids are transmitted from the areas in front of the front 5300a and/or behind the rear 5300b of the expansion cone 5300 into the circumferential grooves 5315.
  • the trailing edge portion of the interface between the expansion cone 5300 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the lubricating fluids also pass to the area in front of the expansion cone. In this manner, the area adjacent to the front 5300a of the expansion cone 5300 is cleaned of foreign materials.
  • the lubricating fluids are injected into the internal flow passages
  • the expansion cone 5300 includes a plurality of circumferential grooves 5315.
  • the expansion cone 5300 includes circumferential grooves 5315 that are concentrated about the axial midpoint of the tapered portion 5305 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5300 and a tubular member during the radial expansion process.
  • the circumferential grooves 5315 are equally spaced along the trailing edge portion of the expansion cone 5300 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5300 and a tubular member during the radial expansion process.
  • the expansion cone 5300 includes a plurality of flow passages 5320 coupled to each of the circumferential grooves 5315.
  • the flow passages 5320 fluidicly coupled the front end 5300a and the rear end
  • the cross sectional area of the circumferential grooves 5315 is greater than the cross-sectional area of the flow passages 5320 in order to minimize resistance to fluid flow.
  • an expansion cone 5400 having a front end 5400a and a rear end 5400b, includes a tapered portion 5405 having an outer surface 5410, one or more circumferential grooves 5415a and 5415b, and one or more axial grooves 5420a and 5420b.
  • the circumferential grooves 5415 are fluidicly coupled to the axial grooves 5420.
  • lubricating fluids are transmitted from the areas in front of the front 5400a and/or behind the rear 5400b of the expansion cone 5400 into the circumferential grooves 5415.
  • the trailing edge portion of the interface between the expansion cone 5400 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand the tubular member.
  • pressurized lubricating fluids pass from the fluid passages 5420 to the area in front of the front 5400a of the expansion cone 5400.
  • the area adjacent to the front 5400a of the expansion cone 5400 is cleaned of foreign materials.
  • the lubricating fluids are injected into the internal flow passages 5420 by pressurizing the area behind the rear 5400b expansion cone 5400 during the radial expansion process.
  • the expansion cone 5400 includes a plurality of circumferential grooves 5415.
  • the expansion cone 5400 includes circumferential grooves 54 5 that are concentrated about the axial midpoint of the tapered portion 5405 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5400 and a tubular member during the radial expansion process.
  • the circumferential grooves 5415 are equally spaced along the trailing edge portion of the expansion cone 5400 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone
  • the expansion cone 5400 includes a plurality of axial grooves 5420 coupled to each of the circumferential grooves 5415.
  • the axial grooves 5420 fluidicly coupled the front end and the rear end of the expansion cone 5400.
  • the cross sectional area of the circumferential grooves 5415 is greater than the cross sectional area of the axial grooves
  • the axial grooves 5420 are spaced apart in the circumferential direction by at least about 3 inches in order to provide lubrication during the radial expansion process.
  • an expansion cone 5500 having a front end 5500a and a rear end 5500b, includes a tapered portion 5505 having an outer surface 5510, one or more circumferential grooves 5515a and 5515b, and one or more axial grooves 5520a and 5520b.
  • the circumferential grooves 5515 are fluidicly coupled to the axial grooves 5520.
  • lubricating fluids are transmitted from the area ahead of the front 5500a of the expansion cone 5500 into the circumferential grooves 5515.
  • the trailing edge portion of the interface between the expansion cone 5500 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand the tubular member.
  • the lubricating fluids are injected into the axial grooves 5520 using a fluid conduit that is coupled to the tapered end 3205 of the expansion cone 3200.
  • the expansion cone 5500 includes a plurality of circumferential grooves 5515.
  • the expansion cone 5500 includes circumferential grooves 5515 that are concentrated about the axial midpoint of the tapered portion 5505 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5500 and a tubular member during the radial expansion process.
  • the circumferential grooves 5515 are equally spaced along the trailing edge portion of the expansion cone 5500 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5500 and a tubular member du ring the radial expansion process.
  • the expansion cone 5500 includes a plurality of axial grooves 5520 coupled to each of the circumferential grooves 5515.
  • the axial grooves 5520 intersect each of the circumferential groves 5515 at an acute angle.
  • the cross sectional area of the circumferential grooves 5515 is greater than the cross sectional area of the axial grooves 5520.
  • the axial grooves 5520 are spaced apart in the circu mferential direction by at least about 3 inches in order to provide lubrication during the radial expansion process.
  • an expansion cone 5600 having a front end 5600a and a rear end 5600b, includes a tapered portion 5605 having an outer surface 5610, a spiral circumferential groove 5615, and one or more internal flow passages 5620.
  • the circumferential groove 5615 is fluidicly coupled to the internal flow passage 5620.
  • lubricating fluids are transmitted from the area ahead of the front 5600a of the expansion cone 5600 into the circumferential groove 5615, such as, for example, from reservoir 5622 utilizing pump 5624.
  • the trailing edge portion of the interface between the expansion cone 5600 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the lubricating fluids are injected into the internal flow passage 5620 using a fluid conduit that is coupled to the tapered end 5605 of the expansion cone 5600.
  • the expansion cone 5600 includes a plurality of spiral circumferential grooves 5615.
  • the expansion cone 5600 includes circumferential grooves 5615 that are concentrated about the axial midpoint of the tapered portion 5605 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5600 and a tubular member during the radial expansion process.
  • the circumferential grooves 561 5 are equally spaced along the trailing edge portion of the expansion cone 5600 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5600 and a tubular member during the radial expansion process.
  • the expansion cone 5600 includes a plurality of flow passages 5620 coupled to each of the circumferential grooves 5615.
  • the cross sectional area of the circumferential groove 5615 is greater than the cross sectional area of the flow passage 5620 in order to minimize resistance to fluid flow.
  • an expansion cone 5700 having a front end 5700a and a rear end 5700b, includes a tapered portion 5705 having an outer surface 5710, a spiral circumferential groove 5715, and one or more axial grooves 5720a, 5720b and 5720c.
  • the circumferential groove 5715 is fluidicly coupled to the axial grooves 5720.
  • lubricating fluids are transmitted from the area ahead of the front 5700a of the expansion cone 5700 into the circumferential groove 5715.
  • the trailing edge portion of the interface between the expansion cone 5700 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the lubricating fluids are injected into the axial grooves 5720 using a fluid conduit that is coupled to the tapered end 5705 of the expansion cone 5700.
  • the expansion cone 5700 includes a plurality of spiral circumferential grooves 5715.
  • the expansion cone 5700 includes circumferential grooves 5715 concentrated about the axial midpoint of the tapered portion 5705 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5700 and a tubular member during the radial expansion process.
  • the circumferential grooves 5715 are equally spaced along the trailing edge portion of the expansion cone 5700 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5700 and a tubular member during the radial expansion process.
  • the expansion cone 5700 includes a plurality of axial grooves 5720 coupled to each of the circumferential grooves 5715.
  • the axial grooves 5720 intersect the circumferential grooves 5715 in a perpendicular manner.
  • the cross sectional area of the circumferential groove 5715 is greater than the cross sectional area of the axial grooves
  • the circumferential spacing of the axial grooves is greater than about 3 inches in order to provide lubrication during the radial expansion process.
  • the axial grooves 5720 intersect the longitudinal axis of the expansion cone at an angle greater than the angle of attack of the tapered portion 5705 in order to provide lubrication during the radial expansion process.
  • an expansion cone 5800 having a front end 5800a and a rear end 5800b, includes a tapered portion 5805 having an outer surface 5810, a circumferential groove 5815, a first axial groove 5820, and one or more second axial grooves 5825a, 5825b, 5825c and 5825d.
  • the circumferential groove 5815 is fluidicly coupled to the axial grooves 5820 and 5825. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area behind the back 5800b of the expansion cone 5800 into the circumferential groove 5815. Thus, the trailing edge portion of the interface between the expansion cone 5800 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the lubricating fluids are injected into the first axial groove 5820 by pressurizing the region behind the back 5800b of the expansion cone 5800.
  • the lubricant is further transmitted into the second axial grooves 5825 where the lubricant preferably cleans foreign materials from the tapered portion 5805 of the expansion cone 5800.
  • the expansion cone 5800 includes a plurality of circumferential grooves 5815.
  • the expansion cone 5800 includes circumferential grooves 5815 concentrated about the axial midpoint of the tapered portion 5805 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5800 and a tubular member during the radial expansion process.
  • the circumferential grooves 5815 are equally spaced along the trailing edge portion of the expansion cone 5800 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5800 and a tubular member during the radial expansion process.
  • the expansion cone 5800 includes a plurality of first axial grooves 5820 coupled to each of the circumferential grooves 5815.
  • the first axial grooves 5820 extend from the back 5800b of the expansion cone 5800 and intersect the circumferential groove 5815.
  • the first axial groove 5820 intersects the circumferential groove 5815 in a perpendicular manner.
  • the cross sectional area of the circumferential groove 5815 is greater than the cross sectional area of the first axial groove
  • the circumferential spacing of the first axial grooves 5820 is greater than about 3 inches in order to provide lubrication during the radial expansion process.
  • the expansion cone 5800 includes a plurality of second axial grooves 5825 coupled to each of the circumferential grooves 5815.
  • the second axial grooves 5825 extend from the front 5800a of the expansion cone 5800 and intersect the circumferential groove 5815.
  • the second axial grooves 5825 intersect the circumferential groove 5815 in a perpendicular manner.
  • the cross sectional area of the circumferential groove 5815 is greater than the cross sectional area of the second axial grooves 5825 in order to minimize resistance to fluid flow.
  • the circumferential spacing of the second axial grooves 5825 is greater than about 3 inches in order to provide lubrication during the radial expansion process.
  • the second axial grooves 5825 intersect the longitudinal axis of the expansion cone 5800 at an angle greater than the angle of attack of the tapered portion 5805 in order to provide lubrication during the radial expansion process.
  • an expansion cone 5900 having a front end 5900a and a rear end 5900b, includes a tapered portion 5905 having an outer surface 5910, one or more circumferential grooves 5915a and 5915b, one or more radial passageways 5916 and one more internal flow passages 5920.
  • the circumferential groove 5915a is fluidicly coupled to the internal flow passages 5920.
  • lubricating fluids are transmitted from the area ahead of the front 5900a of the expansion cone 5900 into the circumferential grooves 5915, such as, for example, from reservoir 5922 utilizing pump 5924.
  • the trailing edge portion of the interface between the expansion cone 5900 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the expansion cone 5900 includes a plurality of circumferential grooves 5915a.
  • the expansion cone 5900 includes circumferential grooves 5915a concentrated about the axial midpoint of the tapered portion 5905 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 590O and a tubular member during the radial expansion process.
  • the circumferential grooves 5915 are equally spaced along the trailing edge portion of the expansion cone 5900 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 5900 and a tubular member during the radial expansion process.
  • the expansion cone 5900 includes a plurality of flow passages coupled to each of the circumferential grooves 5915a.
  • circumferential groove 5915b which is not fluidicly coupled to the internal flow passages, may also be included.
  • an expansion cone 6000 having a front end 6000a and a rear end 6000b, includes a tapered portion 6005 having an outer surface 6010, one or more circumferential grooves 6015, one or more radial passageways 6016 and one or more internal flow passages 6020.
  • the circumferential grooves 6015 are fluidicly coupled to the internal flow passages 6020.
  • lubricating fluids are transmitted from the area ahead of the front 6000a of the expansion cone 6000 into the circumferential grooves 6015, such as, for example, from reservoir 6022 utilizing pump 6024.
  • the trailing edge portion of the interface between the expansion cone 6000 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the expansion cone 6000 includes a plurality of circumferential grooves 6015.
  • the expansion cone 6000 includes circumferential grooves 6015 concentrated about the axial midpoint of the tapered portion 6005 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6000 and a tubular member during the radial expansion process.
  • the circumferential grooves 6015 are equally spaced along the trailing edge portion of the expansion cone 6000 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6000 and a tubular member during the radial expansion process.
  • the expansion cone 6000 includes a plurality of flow passages coupled to each of the circumferential grooves 6015.
  • an expansion cone 6100 having a front end 6100a and a rear end 6100b, includes a tapered portion 6105 having an outer surface 6110, one or more circumferential grooves 6115a and 6115b, one or more radial passageways 6116 and one more internal flow passages 6120.
  • the circumferential groove 6115a is fluidicly coupled to the internal flow passages 6120.
  • lubricating fluids are transmitted from the area ahead of the front 6100a of the expansion cone 6100 into the circumferential grooves 6115, such as, for example, from reservoir 6122 utilizing pump 6124.
  • the trailing edge portion of the interface between the expansion cone 6100 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the expansion cone 6100 includes a plurality of circumferential grooves 6115a.
  • the expansion cone 6100 includes circumferential grooves 6115a concentrated about the axial midpoint of the tapered portion 6105 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6100 and a tubular member during the radial expansion process.
  • the circumferential grooves 6115a are equally spaced along the trailing edge portion of the expansion cone 6100 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6100 and a tubular member during the radial expansion process.
  • the expansion cone 6100 includes a plurality of flow passages coupled to each of the circumferential grooves 6115a.
  • circumferential groove 6115b which is not fluidicly coupled to the internal flow passages, may also be included.
  • an expansion cone 6200 having a front end 6200a and a rear end 6200b, includes a tapered portion 6205 having an outer surface 6210, circumferential grooves 6215 arranged in a helical crisscrossing pattern, one or more radial passageways 6216 and one or more internal flow passages 6220.
  • the circumferential grooves 6215 are fluidicly coupled to each other and to the internal flow passages 6220. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front
  • the trailing edge portion of the interface between the expansion cone 6200 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the expansion cone 6200 includes a plurality of circumferential grooves 6215 arranged in a pinecone design.
  • the expansion cone 6200 includes circumferential grooves 6215 concentrated about the axial midpoint of the tapered portion 6205 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6200 and a tubular member during the radial expansion process.
  • the circumferential grooves 6215 are equally spaced along the trailing edge portion of the expansion cone 6200 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone
  • an expansion cone 6200 having a front end 6200a and a rear end 6200b, includes a tapered portion 6205 having an outer surface 6210, circumferential grooves 6215 arranged in a helical crisscrossing pattern over the entire outer surface 6210, one or more radial passageways 6216 and one or more internal flow passages 6220.
  • the circumferential grooves 6218 are fluidicly coupled to each other and to the internal flow passages 6220. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front 6200a of the expansion cone 6200 into the circumferential grooves 6218, such as, for example, from reservoir 6222 utilizing pump 6224.
  • the trailing edge portion of the interface between the expansion cone 6200 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • a second circumferential groove 6226 is fluidicly coupled to the circumferential grooves 6218.
  • an expansion cone 6300 having a front end 6300a and a rear end 6300b, includes a tapered portion 6305 having an outer surface 6310, circumferential grooves 6315 arranged in a helical crisscrossing pattern, one or more radial passageways 6316 and one or more internal flow passages 6320.
  • the circumferential grooves 6315 are fluidicly coupled to each other and one more internal flow passages 6320. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front
  • the trailing edge portion of the interface between the expansion cone 6300 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the lubricating fluids are injected into the axial grooves 6320 using a fluid conduit that is coupled to the tapered end 6305 of the expansion cone 6300.
  • the expansion cone 6300 includes a plurality of spiral circumferential grooves 6315.
  • the expansion cone 6300 includes circumferential grooves 6315 concentrated about the axial midpoint of the tapered portion 6305 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6300 and a tubular member during the radial expansion process.
  • the circumferential grooves 6315 are equally spaced along the trailing edge portion of the expansion cone 6300 in order to provide lubrication to the trailing edge portion of the interface between the expansion cone 6300 and a tubular member during the radial expansion process.
  • the axial grooves 6320 intersect each other in a perpendicular manner.
  • an expansion cone 6300 having a front end 6300a and a rear end 6300b, includes a tapered portion 6305 having an outer surface 6310, circumferential grooves 6315 arranged in a helical crisscrossing pattern over the substantially all of the outer surface 6310, one or more radial passageways 63 6 and one more internal flow passages 6320.
  • the circumferential grooves 6318 are fluidicly coupled to each other and to the internal flow passages 6320. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front
  • the trailing edge portion of the interface between the expansion cone 6300 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • a second circumferential groove 6326 is fluidicly coupled to the circumferential grooves 6318.
  • 6415 may be utilized on the outer surfaces 5101 , 5210, 5310, 5410, 5510, 5610, 5710,
  • circumferential groove 6415 is positioned in tapered portion
  • first edge 6430 on outer surface 6410a having a first radius of curvature
  • second edge 6434 on outer surface 6410b having a second radius of curvature.
  • the radius on the trailing edge 6434 may be much larger than the radius on the leading edge 6430 to assist lubricant delivery.
  • outer surfaces 6410a and 6410b are exemplary embodiments.
  • 6410b of tapered portion 6405 are tapered at angle ⁇ .
  • the angle that is generated by radius of curvature of second edge 6434 and the tubular member is the sliding angle, which may be important for adequate delivery of lubricant. If the sliding angle is too large or too small, then the trailing edge may act as a wiper, which may remove lubricant form the working area.
  • the radius of curvature of second edge 6434 and the sliding angle are at least dependent on the lubricant viscosity, pipe diameter and friction between the expansion cone and the tubular member.
  • Each cone surface channel design may be empirically design by testing cones in stages to determine the optimum friction-reducing configuration.
  • outer surfaces 6410a and 6410b of tapered portion 6405 are tapered at angle ⁇ .
  • the angle ⁇ may range from 8.5 degrees to 12.5 degrees, such as, for example, 10 degrees.
  • the width 6442 of circumferential groove 6415 may be as small as possible to maximize the area of outer surfaces 6410a and 641 Ob in contact with the inner surface of the tubular member for radial expansion.
  • the radius of curvature 6446 of second edge 6434 which may be defined as the perpendicular to the tangent 6448 at the point where vertical projection line 6450 intersects second edge 6434, may be positioned relative to the bottom of circumferential groove at angle ⁇ , the sliding angle.
  • angle ⁇ may be less than or eq ual to 30 degrees, such as, for example 10 degrees, causing lubricant in the circumferential groove 6415to be drawn efficiently on to the inner surface of the tubular member during radial expansion.
  • tapered portions, 6505a and 6505b are at the same angle ⁇ .
  • Width y of circumferential groove 6518 from lip 6515 to the location where taper portion 6505b is at the same angle ⁇ tapered portion 6505a may be wide enough to supply sufficient lubricant to the tubular member, thereby reducing the amount of feree required to radially expand the tubular member.
  • Vertical portion 6520 in tapered portion 6505a having width x exists to reduce the mechanical stress at corner 6552 due to corner loading.
  • the vertical portion 6520 is not critical to the operation of the circumferential groove 6518 and hence the width x of the vertical portion 6520 is not critical. However, width x of vertical portion 6520 may be small enough to maximize the amount of contact between the expansion cone and the tubular member during radial expansion, yet large enough to reduce the mechanical stress at corner 6552. In determining the width x of the vertical portion 6520 and width y of the circumferential groove 6518 under lip 6515, the following factors may be addressed: the size of the expansion cone; the viscosity of the lubricant; and the lubrication injection pressure. Width y of the circumferential groove 6518 may be as small possible to maximize the area of outer surfaces, 6510a and 6510b, in contact with the surface of the tubular member for radial expansion.
  • expansion cone 6600 having a front end 6600a and a rear end 6600b, includes a tapered portions 6605a and 6605b and lip 6615.
  • the circumferential groove 6618 under lip 6615 is fluidicly coupled to the internal flow passages 6660 through port 6662.
  • lubricating fluids are transmitted from the area ahead of the front end 6600a of the expansion cone 6600 under lip 6615.
  • the trailing edge portion of the interface between the expansion cone 6600 and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • exemplary relative dimensions of the elements of Figs. 58a, 58b and 58c are as follows: 1. taper angle ⁇ of tapered portions 6605a and 6605b - 10 degrees; 2. width x - 0.125; 3. radius of curvature of the top edge 6670 - 0.500; 4. radius of curvature of the first edge 6650 - 0.02; 5. width of the circumferential groove 6618 under lip 6615 - 0.020 - .060; 6. height of the cone 6672 - 1.887; 7. height 6682 of the expansion cone beneath the tapered portion 6605b - 0.895; 8. diameter 6678 of the cone at front end 6600a - 1.380. 9.
  • an expansion cone 6700 having a front end 6700a and a rear end 6700b, includes a tapered portion 6705 having an outer surface 6710, internal flow passage 6730 and one or more axial grooves 6720.
  • the axial grooves 6720 may be fluidicly coupled to the area ahead of the front end 6700a of the expansion cone 6700 to receive lubricant.
  • the trailing edge portion of the interface between the expansion cone and a tubular member is provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand the tubular member.
  • the axial grooves 6720 are provided with lubricating fluid using a supply of lubricating fluid positioned proximate the front end 6700a of the expansion cone 6700.
  • example relative dimensions of the elements of in Figs. 59a and 59b are as follows: 1. taper angle ⁇ of tapered portion 6605 - 10 degrees; 2. channel 6720 depth - 0.020; 3. channel 6720 diameter - 0.040; 4. radius of curvature of the bottom of taper portion 6705 - 0.500; 5. number of axial grooves 6720 - 8; 6. height of the expansion cone 6700 - 1.678; 7. height of the expansion cone 6700 beneath the tapered portion 6705 - 0.895; 8. diameter 6778 of the expansion cone 6700 at front end 6600a - 1.380; and 9. diameter 6776 of the expansion cone 6700 at rear end 6600b - 1.656.
  • an expansion cone 6800 having a front end 6800a and a rear end 6800b, includes a tapered portion 6805 having an outer surface 6810, which includes a tapered faceted polygonal outer expansion surface 6802.
  • Tapered faceted polygonal outer expansion surface 6802 includes circumferential spaced apart contact points 6810 that may be in contact with the inside surface of a tubular member during radial expansion and recesses 6912.
  • lubricant gaps 6822 may act as a high-pressure lubrication channel.
  • Internal passageway 6804 is fluidicly connected to radial ports 6806, which may supply lubricant to lubricant gaps.
  • an expansion cone 6900 includes circumferential spaced apart contact points 6910, recesses 6912 around the perimeter of the expansion cone, internal passage 6930 for drilling fluid, internal passages
  • Figs. 61c and 61 d illustrate expansion cone 6900 in contact with tubular member 6920 at circumferential spaced apart contact points 6910 around the perimeter of expansion cone 6900.
  • Lubricant gaps 6922 exist between recesses 6912 and tubular member 6920 and are fluidicly coupled to internal passages 6914 to act as a high-pressure lubrication channels to increased supply of lubricant, thereby reducing the amount of feree required to radially expand tubular member 6920.
  • Lubricant gaps 6922 provide additional high-pressure lubrication channels, which may assist in lubricating the tubular member where needed most, at the high load contact edge.
  • an expansion cone having a tapered faceted polygonal outer expansion surface with contact points may compensate for non-uniform wall thickness tubular member 6940, by applying localized higher loads at the polygon contact points.
  • expansion cone 6900 having tapered faceted polygonal outer expansion surface in contact with tubular member 6940 having a non-uniform wall thickness is shown.
  • the high load circumferential spaced apart contact points may radially expand and plastically deform the thick wall areas T2 as well as the thin wall areas T1 , instead of taking the path of least resistance, which may assist in maintaining a proportional wall thickness during the radial expansion and plastic deformation process.
  • the number of circumferential spaced apart contact points, 6810 and 6910, having width (W) around the circumference of an expansion cone may vary for different sizes of expandable tubular members. Several factors may be considered when determining the appropriate number contact points, 6810 and 6910, such as, for example, the coefficient of friction between the expansion cone and the expandable tubular member, pipe quality, and data from lubrication tests. For the ideal tubular member with uniform thickness, the number of circumferential spaced apart contact points may be infinity. Thus, the dimensions of the final design of an expansion cone may ultimately be refined by performing an empirical study.
  • the following equations may be used to make a preliminary calculation of the optimum number of circumferential spaced apart contact points, 6810 and 6910, on an expansion cone, 6800 and 6900, having a tapered faceted polygonal outer expansion surface for expanding an expandable tubular member having an original inside diameter of 4.77" to an inside diameter of 5.68" utilizing an expansion cone, including a lubricant gap depth of .06":
  • U ! Original tubular member inside diameter
  • D eXp Expanded tubular member inside diameter
  • H Gap between gap surface and tubular member inside diameter
  • R Radius of polygon at midpoint of expansion cone
  • ⁇ Angle between circumferential spaced apart contact points of polygon
  • N Number of polygon flat surfaces.
  • the theoretical number (N) of circumferential spaced apart contact points, 6810 and 6910, on an expansion cone having a tapered faceted polygonal outer expansion surface is 15, but the actual number that may result from an empirical analysis may depend on tubular member quality, coefficient of friction, and data from lubrication tests.
  • a range for the actual number (N) of circumferential spaced apart contact points necessary to expand an expandable tubular member having an original inside diameter of 4.77" to an inside diameter of 5.68" I.D. may range from 12-15.
  • an expansion cone 7000 having a front end 7000a and a rear end 7000b, includes a tapered portion 7005, contact surfaces 7010, recesses 7012, internal passage 7030 for drilling fluid, internal passages 7014 for lubricating fluids, and radial passageways 7016.
  • the width 7020 of contact surfaces 7010 of expansion cone 7000 may be constant for the length of the cone, resulting in trapezoidal shaped lubricant gap 7022 between each contact surface 7010.
  • K is between 3 to 5 for an expandable tubular member having an original inside diameter of 4.77" and an expanded inside diameter of 5.68" may range from 12-15.
  • K is 4.2.
  • an expansion cone 7100 having a front end 7100a and a rear end 7100b, includes a tapered portion 7105, contact surfaces 7110, recesses 7112, internal passage 7130 for drilling fluid, internal passages 7114 for lubricating fluids, and radial passageways 7116.
  • the width 7120 of contact surfaces 7110 of expansion cone 7100 may vary the length of the cone.
  • width 7120 of contact surfaces 7110 may be larger at the front end 7100a W1 and become smaller toward the rear end 7100b W2.
  • tapered faceted polygonal outer expansion surface of an expansion cone may be implemented in any expansion cone, including one or more of expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800,
  • 6800, 6900, 7000 and 7100 may be dependant on the amount of friction between the tapered portion of the expansion cone and the inside diameter of the tubular member.
  • a cone angle of 8.5° to 12.5° was shown to be sufficient to expand an expandable tubular member having an original inside diameter of
  • the optimum cone angle may be determined after testing the lubricant system to determine the exact coefficient of friction.
  • a cone angle greater than 10° may be required to minimize the effect of thinning the tubular member wall during expansion and may potentially reduce failures related to collapsing.
  • 6700, 6800, 6900, 7000 and 7100 may or may not have internal passages.
  • a plurality of inserts having internal flow passages may be provided in the expansion cone internal flow passages, The internal flow passages of each insert may vary in size.
  • a expansion cone flow passage may be machined to a standard size, and the lubricant supply may be varied by using different inserts having different sized internal flow passages.
  • Each insert may include a filter for filtering particles and other foreign materials from the lubricant that passes into the flow passage. In this manner, the foreign materials are prevented from clogging the flow passage and other flow passages.
  • expansion cones 5100, 5200, 5300, 5400, 5500, 5600 including, for example, expansion cones 5100, 5200, 5300, 5400, 5500, 5600,
  • lubricants utilized in the systems may be provided to the system in various manners.
  • lubricating fluids are provided to the internal flow passages or axial groove in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000,
  • lubricating fluids may provided to the internal flow passages or axial groove in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200,
  • the lubricating fluids may be injected into any internal flow passages in expansion cones 5100, 5200, 5300, 5400, 5500,
  • an expansion cone 7202 includes a body
  • 7218a, 7218b, and 7218c fluidicly coupled to the longitudinal passage 7214b, and includes a front end face 7220, a rear end face 7222, and a tapered external expansion surface 7224 including spaced apart external grooves, 7224a, 7224b, and 7224c, that are fluidicly coupled to the radial passages, 7214a, 7216a, 7214b, 7216b, 7214c, and 7216c, respectively.
  • Spring-biased check valves, 7226a and 7226b are received within, mate with, and are operably coupled to, the longitudinal passages, 7214a and 7214b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7228 that defines a longitudinal passage 7228a and radial passages, 7228b and 7228c, that are fluidicly coupled to the internal annular recess 7208 of the expansion cone 7202 is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7206 of the expansion cone.
  • the expansion cone 7202 is positioned within, and displaced relative to, an expandable tubular member 7230 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7202 is displaced relative to the expandable tubular member 7230 by injecting a pressurized fluidic material 7232 into and through the passage 7228a of the tubular member 7228.
  • the fluidic material 7232 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7202 and the expandable tubular member 7230 during the radial expansion process.
  • the fluidic material 7232 is conveyed through the radial passages, 7228b and
  • the pressurized fluidic material 7232 is then conveyed into the external grooves, 7224a, 7224b, and 7224c, through the longitudinal passages, 7214a and 7214b, and the radial passages, 7216a, 7216b, 7216c,
  • the rate of injection of the fluidic material 7232 into the external grooves, 7224a, 7224b, and 7224c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7232 may be injected into the external grooves, 7224a, 7224b, and 7224c only when required, or as desired.
  • the trailing edge portion of the interface between the tapered external expansion surface 7224 of the expansion cone 7202 and the expandable tubular member 7230 may be provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand and plastically deform the expandable tubular member.
  • 7226b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • an expansion cone 7302 includes a body
  • a tubular member 7328 that defines a longitudinal passage 7328a and radial passages, 7328b and 7328c, that are fluidicly coupled to the internal annular recess 7308 of the expansion cone 7302, is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7306 of the expansion cone.
  • a tubular piston 7340 defines a passageway 7340a that receives, mates with and is slidably coupled to the tubular member 7328 and is received within, mates with and is slidably coupled to internal annular recess 7332, of the expansion cone.
  • the expansion cone 7302 is positioned within, and displaced relative to, an expandable tubular member 7330 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7302 is displaced relative to the expandable tubular member 7330 by injecting a pressurized fluidic material 7332 into and through the passage 7328a of the tubular member 7328.
  • the fluidic material 7332 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7302 and the expandable tubular member 7330 during the radial expansion process.
  • the fluidic material 7332 is conveyed through the radial passages, 7328b and
  • a second fluidic material 7344 may be housed in the annular chamber 7336 below tubular piston 7342.
  • the second fluidic material 7344 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7302 and the expandable tubular member 7330 during the radial expansion process.
  • the fluidic material 7344 is then conveyed through the radial passages, 7328b and 7328c, into an annular chamber 7336 defined between the external annular recess 7310 of the expansion cone 7302 and the expandable tubular member 7330.
  • a predetermined value which may vary as a function of the operating characteristics the tubular piston 7340
  • the tubular piston 7340 is displaced within the annular chamber 7336 thereby pumping the pressurized fluidic material 7344 into the external grooves, 7324a, 7324b, and 7324c, through the longitudinal passages, 7314a and
  • the rate of injection of the fluidic material 7344 into the external grooves, 7324a, 7324b, and 7324c depends on the operating pressure of the fluidic material 7232 and the operating characteristics of the tubular piston 7340.
  • the tubular piston 7340 pumps second fluidic material 7344 when the input pressure of the fluidic material 7332 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member 7330 the length of the tubular member 7330 and the desired amount of lubricant to be dispensed.
  • the fluidic material 7344 may be controllably injected and pumped into the interface between the tapered external expansion surface 7324 of the expansion cone 7302 and the expandable tubular member 7330 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7332 may be injected into the external grooves, 7324a, 7324b, and 7324c only when required, or as desired .
  • the trailing edge portion of the interface between the tapered external expansion surface 7324 of the expansion cone 7302 and the expandable tubular member 7330 may be provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand and plastically deform the expandable tubular member.
  • the second fluidic material 7344 in the annular chamber 7336 below tubular piston 7340 may be preloaded into expansion cone 7300 prior to being used to expand tubular member 7330.
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7300.
  • an expansion cone 7402 includes a body
  • 7418a, 7418b, and 7418c fluidicly coupled to the longitudinal passage 7414b, and includes a front end face 7420, a rear end face 7422, and a tapered external expansion surface 7424 including spaced apart external grooves, 7424a, 7424b, and 7424c, that are fluidicly coupled to the radial passages, 7414a, 7416a, 7414b, 7416b, 7414c, and 7416c, respectively.
  • Spring-biased check valves, 7426a and 7426b are received within, mate with, and are operably coupled to, the longitudinal passages, 7414a and 7414b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7428 that defines a longitudinal passage 7428a and radial passages, 7428b and 7428c, that are fluidicly coupled to the internal annular recess 7408 of the expansion cone 7402 is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7406 of the expansion cone.
  • a tubular piston 7440 defines a passageway 7440a that receives, mates with and is slidably coupled to the tubular member 7428 and is received within, mates with and is slidably coupled to internal annular recess 7432 of the expansion cone 7400.
  • the expansion cone 7402 is positioned within, and displaced relative to, an expandable tubular member 7430 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7402 is displaced relative to the expandable tubular member 7430 by injecting a pressurized fluidic material 7432 into and through the passage 7428a of the tubular member 7428. As a result, the expansion cone
  • the fluidic material 7432 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7402 and the expandable tubular member 7430 during the radial expansion process.
  • the fluidic material 7432 is conveyed through the radial passages, 7428b and
  • a second fluidic material 7444 may be housed in the annular chamber 7434 below tubular piston 7442 and in an annular chamber 7436 defined between the external annular recess 7410 of the expansion cone 7402 and the expandable tubular member 7430.
  • the fluidic material 7444 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7402 and the expandable tubular member 7430 during the radial expansion process.
  • the pressurized fluidic material 7444 is then conveyed into the external grooves, 7424a, 7424b, and 7424c, through the longitudinal passages, 7414a and 7414b, and the radial passages, 7416a, 7416b, 7416c, 7418a, 7418b, and 7418c, into the interface between the expansion cone 7402 and the expandable tubular member 7430.
  • the rate of injection of the fluidic material 7444 into the external grooves, 7424a, 7424b, and 7424c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7444 may be controllably injected and metered into the interface between the tapered external expansion surface 7424 of the expansion cone 7402 and the expandable tubular member 7430 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7444 may be injected into the external grooves, 7424a, 7424b, and 7424c only when required, or as desired.
  • 7430 may be provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand and plastically deform the expandable tubular member.
  • valves 7426a and 7426b permits lubricant flow when the input pressure of the fluidic material 7432 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member, the length of the tubular member and the desired amount of lubricant to be dispensed.
  • tubular piston 7440 pumps the fluidic material 7444 into the annular chamber 7736, based on the input pressure of the fluidic material 7432, such as, for example, when the input pressure of the fluidic material
  • a predetermined pressure limit which may be a factor of diameter of the tubular member 7430, the length of the tubular member 7430 and the desired amount of lubricant to be injected.
  • the second fluidic material 7444 in annular chambers, 7434 and 7436 below tubular piston 7440 may be preloaded into expansion cone
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 74O0.
  • tubular piston 7440 and spring-biased check valves, 7426a and 7426b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • an expansion cone 7502 includes a body
  • 7518a, 7518b, and 7518c fluidicly coupled to the longitudinal passage 7514b, and includes a front end face 7520, a rear end face 7522, and a tapered external expansion surface 7524 including spaced apart external grooves, 7524a, 7524b, and 7524-c, that are fluidicly coupled to the radial passages, 7514a, 7516a, 7514b, 7516b, 7514c, and 7516c, respectively.
  • Spring-biased check valves, 7526a and 7526b are received within, mate with, and are operably coupled to, the longitudinal passages, 7514a and 7514b , respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7528 that defines a longitudinal passage 7528a and radial passages, 7528b and 7528c, that are fluidicly coupled to the internal annular recess 7508 of the expansion cone 7502 is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7506 of the expansion cone.
  • a conventional pressure enhancer 7550 is received within, mates with and is slidably coupled to external annular recess 7510, of the expansion cone.
  • the expansion cone 7502 is positioned within, and displaced relative to, an expandable tubular member 7530 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7502 is displaced relative to the expandable tubular member 7530 by injecting a pressurized fluidic material 7532 into and through the passage 7528a of the tubular member 7528.
  • the fluidic material 7532 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone " 7502 and the expandable tubular member 7530 during the radial expansion process.
  • the fluidic material 7532 is conveyed through the radial passages, 7528b and
  • the pressure enhancer 7550 increases the pressure on the fluidic material. If the operating pressure of the fluidic material 7532 exceeds a predetermined val ue, which will vary as a function of the operating characteristics of the check valves, 7526 a and 7526b, the fluidic material is then conveyed through the longitudinal passages, 7512a and 7512b, into an annular chamber 7536 defined between the external annular rece ss 7510 of the expansion cone 7502 and the expandable tubular member 7530. The pressurized fluidic material 7532 is then conveyed into the external grooves, 7524a, 7524b, and 7524c, through the longitudinal passages, 7514a and 7514b, and the radial passages, 7516a, 7516b, 7516c,
  • the rate of injection of the fluidic material 7532 into the external grooves, 7524a, 7524b, and 7524c depends on the operating pressure of the fluidic material and the operating characteristics of the pressure enhancer 7550 and of the spring-biased check valves, 7526a and 7526b. In this manner, during the radial expansion process, the fluidic material 7532 may be controllably injected and metered into the interface between the tapered external expansion surface 7524 of the expansion cone
  • the fluidic material 7532 may be injected into the external grooves, 7524a, 7524b, and 7524c only when required, or as desired.
  • the trailing edge portion of the interface between the tapered external expansion surface 7524 of the expansion cone 7502 and the expandable tubular member 7530 may be provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand and plastically deform the expandable tubular member.
  • the pressure enhancer 7550 which any type of pressure enhancing device, such as, for example, a piston or a diaphragm, may be omitted, and/or used in combination with other types of flow enhancing devices or pressure increasing devices, such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices, such as, for example, a high-pressure lubricator.
  • an expansion cone 7602 includes a body
  • 7618a, 7618b, and 7618c fluidicly coupled to the longitudinal passage 7614b, and includes a front end face 7620, a rear end face 7622, and a tapered external expansion surface 7624 including spaced apart external grooves, 7624a, 7624b, and 7624c, that are fluidicly coupled to the radial passages, 7614a, 7616a, 7614b, 7616b, 7614c, and 7616c, respectively.
  • Spring-biased check valves, 7626a and 7626b are received within, mate with, and are operably coupled to, the longitudinal passages, 7614a and 7614b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7628 that defines a longitudinal passage 7628a and radial passages, 7628b an d 7628c, that are fluidicly coupled to the internal annular recess 7608 of the expansion cone 7 * 602 is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7606 of the expansion cone.
  • a tubular piston 7640 defines a passageway 7642 triat receives, mates with and is slidably coupled to the tubular member 7628 and is receive within, mates with and is slidably coupled to internal annular recess 7632, of the expansion cone.
  • a conventional pressure enhancer 7650 is received within, mates with and is slidably coupled to external annular recess 7610, of the expansion cone 7630.
  • the expansion cone 7602 is positioned within, and displaced relative to, an expandable tubular member 7630 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7602 is displaced relative to the expandable tubular member 7630 by injecting a pressurized fluidic material 7632 into and through the passage 7628a of the tubular member 7628. A-s a result, the expansion cone
  • the fluidic material 7632 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7602 and the expandable tubular member 7630 during the radial expansion process.
  • the fluidic material 7632 is conveyed through the radial passages, 7628b and
  • a second fluidic material 7644 may be housed in the annular chamber 7634 below tubular piston 7642 and in an annular chamber 7636 defined between the external annular recess 7610 of the expansion cone 7602 and the expandable tubular member 7630.
  • the fluidic material 7644 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7602 and the expandable tubular member 7630 during the radial expansion process.
  • the tubular piston is displaced within annular chamber 7634, thereby pumping the second fluidic material through the longitudinal passages, 7612a and
  • the pressure enhancer 7650 increases the pressure on the second fluidic material 7644.
  • the pressurized fluidic material 7644 is then conveyed into the external grooves, 7624a, 7624b, and 7624c, througtn the longitudinal passages,
  • the rate of injection of the fluidic material 7644 into the external grooves, 7624a, 7624b, and 7624c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7644 may be controllably injected and metered into the interface between the tapered external expansion surface 7624 of the expansion cone 7602 and the expandable tubular member 7630 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7644 may be injected into the external grooves, 7624a,
  • the trailing edge portion of the interface between the tapered external expansion surface 7624 of the expansion cone 7602 and the expandable tubular member 7630 may be provided with an increased supply of lubricant, thereby reducing the amount of feree required to radially expand and plastically deform the expandable tubular member.
  • valves 7626a and 7626b permits lubricant flow when the input pressure of the fluidic material 7632 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member, the length of the tubular member and the desired amount of lubricant to be dispensed.
  • tubular piston 7640 pumps the fluidic material 7644 into the annular chamber 7636, based on the input pressure of the fluidic material 7632, such as, for example, when the input pressure of the fluidic material
  • a predetermined pressure limit which may be a factor of diameter of the tubular member 7630, the length of the tubular member 7630 and the desired amount of lubricant to be injected.
  • the second fluidic material 7644 in an annular chamber 7636 below tubular piston 7640 may be preloaded into expansion cone 7600 prior to being used to expand tubular member 7602.
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7600.
  • tubular piston 7640 and spring-biased check valves, 7626a and 7626b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • the pressure enhancer 7550 which any type of pressure enhancing device, such as, for example, a piston or a diaphragm, may be omitted, and/or used in combination with other types of flow enhancing devices or pressure increasing devices, such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices, such as, for example, a high-pressure lubricator.
  • an expansion cone 7702 includes a body
  • 7704 that defines a centrally positioned longitudinal passage 7706, an internal annular recess 7708, an internal annular recess 7709, an external annular recess 7710, longitudinal passages, 7712a and 7712b, fluidicly coupled between the internal and external annular recesses, longitudinal passages, 7714a and 7714b, fluidicly coupled to the external annular recess, radial passages, 7716a, 7716b, and 7716c, fluidicly coupled to the longitudinal passage 7714a, and radial passages, 7718a, 7718b, and 7718c, fluidicly coupled to the longitudinal passage 7714b, and includes a front end face 7720, a rear end face 7722, and a tapered external expansion surface 7724 including spaced apart external grooves, 7724a,
  • 7724b, and 7724c that are fluidicly coupled to the radial passages, 7714a, 7716a, 7714b,
  • Spring-biased check valves, 7726a and 7726b are received within, mate with, and are operably coupled to, the longitudinal passages, 7714a and 7714b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7728 that defines a longitudinal passage 7728a and radial passages, 7728b and
  • a tubular piston 7740 defines a passageway 7740a that receives, mates with and is slidably coupled to the tubular member 7728 and is received within, mates with and is slidably coupled to internal annular recess 7732, of the expansion cone.
  • a capacitor bank 7750 is received within the internal annular chamber 7709 and is electrically coupled to power source 7760 through connectors 7756. Electrodes 7754a and
  • 7754b are received within external annular recess 7732 and are electrically coupled to capacitor bank 7750 through connectors 7758.
  • the expansion cone 7702 is positioned within, and displaced relative to, an expandable tubular member 7730 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7702 is displaced relative to the expandable tubular member 7730 by injecting a pressurized fluidic material 7732 into and through the passage 7728a of the tubular member 7728. As a result, the expansion cone
  • the fluidic material 7732 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7702 and the expandable tubular member 7730 during the radial expansion process.
  • the fluidic material 7732 is conveyed through the radial passages, 7728b and 7728c, of the tubular member 7728 into a annular chamber 7734 defined between the internal annular recess 7708 of the expansion cone 7702 and the tubular member 7728.
  • a second fluidic material 7744 may be housed in the annular chamber 7734 below tubular piston 7742 and in an annular chamber 7736 defined between the external annular recess 7710 of the expansion cone 7702 and the expandable tubular member 7730.
  • the fluidic material 7744 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7702 and the expandable tubular member 7730 during the radial expansion process.
  • the pressurized fluidic material 7744 is then conveyed into the external grooves, 7724a, 7724b, and 7724c, through the longitudinal passages, 7714a and 7714b, and the radial passages, 7716a, 7716b, 7716c, 7718a, 7718b, and 7718c, into the interface between the expansion cone 7702 and the expandable tubular member 7730.
  • the pressure on the fluidic material 7744 in annular recess 7736 may be increased by the introduction of an electric pulse into the fluidic material
  • the rate of injection of the fluidic material 7744 into the external grooves, 7724a, 7724b, and 7724c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7744 may be controllably injected and metered into the interface between the tapered external expansion surface 7724 of the expansion cone 7702 and the expandable tubular member 7730 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7744 may be injected into the external grooves, 7724a, 7724b, and 7724c only when required, or as desired.
  • 7730 may be provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand and plastically deform the expandable tubular member.
  • valves 7726a and 7726b permits lubricant flow when the input pressure of the fluidic material 7732 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member, the length of the tubular member and the desired amount of lubricant to be dispensed.
  • tubular piston 7740 pumps the fluidic material 7744 into the annular chamber 7736, based on the input pressure of the fluidic material 7732, such as, for example, when the input pressure of the fluidic material 7744 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member 7730, the length of the tubular member 7730 and the desired amount of lubricant to be injected.
  • a predetermined pressure limit which may be a factor of diameter of the tubular member 7730, the length of the tubular member 7730 and the desired amount of lubricant to be injected.
  • the second fluidic material 7744 in an annular chamber 7736 below tubular piston 7740 may be preloaded into expansion cone 7700 prior to being used to expand tubular member 7702.
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7700.
  • the tubular piston 7740 and spring-biased check valves, 7726a and 7726b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • the introduction of electrodes 7754a and 7754b that are electrically coupled via connectors 7758 to bank of capacitor 7750 to trigger a high- pressure gaseous expansion within an enclosed volume of lubricant in annular chamber 7736 when bank of capacitors 7750 discharge may increase the lubricant pressure.
  • the discharge expansion may create a pressure impulse allowing more lubricant to flow between the expansion cone 7700 and tubular member 7730, thereby reducing the friction.
  • the expansion may create a pressure impulse in annular recess 7736 of approximately 15ksi, allowing more lubricant to flow between expansion cone 7700 and tubular member 7702 and thereby reducing the friction, which may reduce the working pressure behind the expansion cone 7700.
  • a discharge may occur between electrodes 7754a and 7754b in the lubricant stored in external annular recess 7732 that acts as a dielectric when capacitor bank 7750 discharge current through connectors 7756 to electrodes 7754a and 7754b.
  • capacitor bank 7750 discharge current through connectors 7756 to electrodes 7754a and 7754b.
  • thermodynamic properties due to the non-ideal nature of a vaporized dielectric medium, the following equations may be utilized to determining the properties of a system for lubricating the interface between expansion cone 7700 and a tubular member 7702 during the expansion process implementing a mechanism to trigger a high-pressure gaseous expansion.
  • Van der Waals equation may be manipulated to express pressure as a function of the ratio of dielectric medium density, average molar mass, and the dielectric's boiling point as follows: where: P - Pressure [psi] V - Volume of Vaporized Lubricant T - Temperature [K] n - Moles of Lubricant [mols] R - 1.206 [L-psi/K-mol] a - Experimental Proportionality Constant b - Experimental Constant Relating to Molecular Volume
  • Molar mass of the dielectric may need to be calculated experimentally or mathematically if all the components of the dielectric medium are known.
  • the constants 'a' and 'b' may be experimentally determined or may be available in engineering tables based on the choice of lubricant.
  • the effective discharge energy (E effect i ve ) of back of capacitor 7750 is proportionately related to the calculated discharge energy of back of capacitor 7750 by an experimentally determined an "energy efficiency factor".
  • the mass 'm' of vaporized lubricant will depend on the geometry of the electrodes and of the discharge volume.
  • oils have high dielectric strengths, on the order of about 10-50 kV/mm. In an exemplary embodiment, a dielectric strength on the low end of that range may be desired.
  • the resistance consists of several components, internal resistance of bank of capacitors 7752, resistance added by the designer, and line impedance. Line impedance may play an important role since the system will not be in steady state and may need to be determined empirically.
  • Synthetic oils which generally have higher heats of vaporization, generally have film strengths exceeding 3000 psi.
  • Mineral-based oils have film strengths of about 400 psi.
  • neither synthetic oils nor mineral based oils may be sufficient for the expected pressures of 10ksi-15ksi. It seems that a hard lubricant with a higher tolerance for pressure, such as graphite or molybdenum disulfide, may work better.
  • the heat of vaporization of a hard lubricant may be significantly higher than that of a liquid lubricant.
  • the electrodes 7754a and 7754b and the surrounding liquid dielectric may be insulated to prevent any permanent dielectric breakdown in such a hard lubricants.
  • the use of a system for lubricating the interface between an expansion cone and a tubular member during the expansion process implementing a mechanism to trigger a high-pressure gaseous expansion may be also advantageous because it allows more flexibility in the choice of the dielectric medium.
  • capacitor bank 7750 be located as close to the electrodes 7754a and 7754b as possible.
  • any commercial capacitor for high-power pulsing applications that uses charging voltages in the tens of kV, can retain several kJ of energy, and is able to deliver current on the order of 100 kA may be used in capacitor bank 7750.
  • the selected capacitor should be able to tolerate significant voltage reversal.
  • high power capacitors such as those manufactured by Passoni Villa that have built in switches, may be used to achieve more control of the discharge frequency.
  • capacitors suitable for capacitor bank 7750 include the following: Passoni Villa (www.passoni-villa.com (Capacitors)); Aerovox (www.aerovox.com (Capacitors)); Richardson Electronics (www.industrial.rell.com (Ignitrons)); Darrah Electric (www.darrahelectric.com (Power Semiconductors)); Magnet-Physik (www.magnet-physik.de (EMF Forming)) and Magneform (www.magneform.com (EMF Forming)).
  • Passoni Villa www.passoni-villa.com (Capacitors)
  • Aerovox www.aerovox.com (Capacitors)
  • Richardson Electronics www.industrial.rell.com (Ignitrons)
  • Darrah Electric www.darrahelectric.com (Power Semiconductors)
  • Magnet-Physik www.magnet-physik.de (EMF Forming)
  • Magneform www.magneform.
  • capacitor bank 7750 may include one capacitor or a plurality of capacitors.
  • a solid-state amplifier located near the capacitor bank 7750 may be utilized instead of a high-voltage transformer due to size considerations.
  • Example manufacturers of such devices are as follows: Richardson Electronics (www.industrial.rell.com (Ignitrons)); Darrah Electric (www.darrahelectric.com (Power Semiconductors)); Magnet-Physik (www.magnet-physik.de (EMF Forming)); and Magneform (www.magneform.com (EMF Forming)).
  • the work done on tubular member 7702 by the Shockwave created by the electric discharge may be constrained to be less than the amount of work required to deform the tube.
  • the work done on the tubular member 7702 can be calculated using the tubular member 7702 material properties and its cylindrical geometry.
  • the mechanical constant B is defined by the following equation.
  • E - Deformation Intensity r 0 - Original Radius r - Final Radius The radius referred to is the inner radius of the tubular member 7702.
  • the total work of deformation is a function of the specific work of deformation and the volume of the tubular member 7702 material deformed.
  • the work done by the discharge on the tubular member must be no greater than the work required to expand the tubular member 7702 to its final radius and is defined as follows: W D ⁇ a s V w (23) where: a s - Specific Work of Deformation V w - Volume of Deformed Material W D - Work Due to Discharge [00507]
  • An expression relating the maximum amount of work may be constructed by assuming a discharge volume of axial length ⁇ , and an outer radius r 0 (the outer radius being equal to the inner radius of the unexpanded tubular member 7702). The final outer radius will be designated by r.
  • the deformation intensity (E) is 0.191 , assuming that the axial length of discharge volume ( ⁇ ) is 0.04m and produces a volume of deformation material (V w ) of 0.005809 m 3 and true strain (m m ) of 0.182.
  • yield strength ( ⁇ b ) range for En-80 steel tubes is approximately 48.26x10 7 N/m 2 (70 ksi) to 65.50x10 7 N/m 2 (95 ksi) and mechanical constant (B) is found to range from 48.69 x10 7 N/m 2 to 66.08 x10 7 N/m 2 .
  • the specific work (a s ) of deformation ranges from 5.82 x10 7 N/m 2 to 7.90 x10 7
  • the amount of work required to expand the tubular member 7702 is on the order of 460 kJ to 340 kJ.
  • the work done on the tubular member 7702 due to the discharge may not exceed 340 kJ.
  • the expected energy of the discharge is far lower.
  • the pressure produced by the discharge may also be limited.
  • the yield strength of En-80 steel is 70-95ksi. The pressure produced by the discharge can therefore not exceed 70ksi. Again, the expected maximum pressure due to the discharge will be approximately 15ksi. However, should the stated constraints be exceeded, the results would be unpredictable, and control over the process could be lost.
  • an apparatus for testing a system for lubricating the interface between an expansion cone and a tubular member implementing a mechanism to trigger a high-pressure gaseous expansion during the expansion process may consider the following: (1 ) the determination of the specific capacitances of capacitor bank
  • Piezoelectric sensors are small, may withstand extremely high pressures, and produce electric outputs that are easily digitized and quantified for analysis.
  • There are also several possible ways to regulate the power at power source 7760 in a testing apparatus including for example, regulation of system resistance using potentiometers as an effective way to regulate the discharge power.
  • the capacitor bank 7750 may also be designed to enable quick removal or addition of capacitors.
  • a digital oscilloscope may be connected to the transmission line via a voltage divider to monitor system voltage. Finally, the current may be measured with a Rogowski coil, which uses the Hall effect to measure high currents.
  • an expansion cone 7802 includes a body
  • 7818a, 7818b, and 7818c fluidicly coupled to the longitudinal passage 7814b, and includes a front end face 7820, a rear end face 7822, and a tapered external expansion surface 7824 including spaced apart external grooves, 7824a, 7824b, and 7824c, that are fluidicly coupled to the radial passages, 7814a, 7816a, 7814b, 7816b, 7814c, and 7816c, respectively.
  • Spring-biased check valves, 7826a and 7826b are received within, mate with, and are operably coupled to, the longitudinal passages, 7814a and 7814b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular member 7828 that defines a longitudinal passage 7828a and radial passages, 7828b and 7828c, that are fluidicly coupled to the internal annular recess 7808 of the expansion cone 7802 is received within, mates with, and is coupled to the centrally positioned longitudinal passage 7806 of the expansion cone.
  • a tubular piston 7840 defines a passageway 7840a that receives, mates with and is slidably coupled to the tubular member 7828 and is received within, mates with and is slidably coupled to internal annular recess 7732, of the expansion cone.
  • 7854 is received within external annular recess 7752 and is electrically coupled to power source 7860 via connectors, 7756a and 7756b.
  • the expansion cone 7802 is positioned within, and displaced relative to, an expandable tubular member 7830 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7802 is displaced relative to the expandable tubular member 7830 by injecting a pressurized fluidic material 7832 into and through the passage 7828a of the tubular member 7828.
  • the fluidic material 7832 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7802 and the expandable tubular member 7830 during the radial expansion process.
  • the fluidic material 7832 is conveyed through the radial passages, 7828b and
  • a second fluidic material 7844 may be housed in the annular chamber 7834 below tubular piston 7842 and in an annular chamber 7836 defined between the external annular recess 7810 of the expansion cone 7802 and the expandable tubular member 7830.
  • the fluidic material 7844 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7802 and the expandable tubular member 7830 during the radial expansion process.
  • magnetic coil 7854 may trigger a high-pressure impulse in volume of fluidic material in annular recess 7836 from a magnetic field created in magnetic coil 7854 and thereby increase the pressure in the fluidic material.
  • the pressurized fluidic material 7844 is then conveyed into the external grooves, 7824a, 7824b, and 7824c, through the longitudinal passages, 7814a and 7814b, and the radial passages, 7816a, 7816b, 7816c,
  • the rate of injection of the fluidic material 7844 into the external grooves, 7824a, 7824b, and 7824c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7844 may be controllably injected and metered into the interface between the tapered external expansion surface 7824 of the expansion cone 7802 and the expandable tubular member 7830 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7844 may be injected into the external grooves, 7824a, 7824b, and 7824c only when required, or as desired.
  • 7830 may be provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand and plastically deform the expandable tubular member.
  • valves 7826a and 7826b permits lubricant flow when the input pressure of the fluidic material 7832 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member, the length of the tubular member and the desired amount of lubricant to be dispensed.
  • tubular piston 7840 pumps the fluidic material 7844 into the annular chamber 7836, based on the input pressure of the fluidic material 7832, such as, for example, when the input pressure of the fluidic material
  • a predetermined pressure limit which may be a factor of diameter of the tubular member 7830, the length of the tubular member 7830 and the desired amount of lubricant to be injected.
  • the second fluidic material 7844 in an annular chamber 7836 below tubular piston 7840 may be preloaded into expansion cone 7800 prior to being used to expand tubular member 7802.
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7800.
  • tubular piston 7840 and spring-biased check valves, 7826a and 7826b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • magnetic coil 7854 triggers a high-pressure impulse in the lubricant in annular recess 7836 by means of a magnetic field created by in magnetic coil 7854 when current is generated by power source 7860 and run through magnetic coil 7854. In an exemplary embodiment, when current generated by power source
  • 7856b may be used to provide power to the magnetic coils 7854 that may generate the magnetic field.
  • an expansion cone 7902 includes a body
  • 7928c and 79 28d and includes a front end face 7920, a rear end face 7922, and a tapered external expansion surface 7924 including spaced apart external grooves, 7924a, 7924b, and 7924c, that are fluidicly coupled to the radial passages, 7914a, 7916a, 7914b, 7916b,
  • Spring-biased check valves, 7926a and 7926b are received within, mate with, and are operably coupled to, the longitudinal passages, 7914a and 7914b, respectively, for controlling the flow of fluidic materials therethrough.
  • a tubular piston 7940 defines a passageway 7940a that receives, mates with and is slidably coupled to the tubular member 7928 and is received within, mates with and is slidably coupled to internal annular recess 7932, of the expansion cone.
  • the expansion cone 7902 is positioned within, and displaced relative to, an expandable tubular member 7930 thereby radially expanding and plastically deforming the expandable tubular member.
  • the expansion cone 7902 is displaced relative to the expandable tubular member 7930 by injecting a pressurized fluidic material 7932 into and through the passage 7928a of the tubular member 7928.
  • the expansion cone 7902 is displaced relative to the expandable tubular member 7930 by injecting a pressurized fluidic material 7932 into and through the passage 7928a of the tubular member 7928.
  • the fluidic material 7932 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7902 and the expandable tubular member 7930 during the radial expansion process.
  • the fluidic material 7932 is conveyed through the radial passages, 7928b and
  • a second fluidic material 7944 may be housed in the annular chamber 7934 below tubular piston 7942 and in an annular chamber 7936 defined between the external annular recess 7910 of the expansion cone 7902 and the expandable tubular member 7930.
  • the fluidic material 7944 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 7902 and the expandable tubular member 7930 during the radial expansion process.
  • the pressurized fluidic material 7944 is then conveyed into the external grooves, 7924a, 7924b, and 7924c, through the longitudinal passages, 7914a and 7914b, and the radial passages, 7916a, 7916b, 7916c, 7918a, 7918b, and 7918c, into the interface between the expansion cone 7902 and the expandable tubular member 7930.
  • the fluidic material 7932 is conveyed through the radial passages, 7928d and 7928e, of the tubular member 7928 and through radial passages, 7917a and 7917b, into a passageway 7952 defined between the expansion cone 7902 and the tubular member 7930.
  • the rate of injection of the fluidic material 7944 into the external grooves, 7924a, 7924b, and 7924c depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves,
  • the fluidic material 7944 may be controllably injected and metered into the interface between the tapered external expansion surface 7924 of the expansion cone 7902 and the expandable tubular member 7930 continuously during the radial expansion and plastic deformation of the tubular member.
  • the fluidic material 7944 may be injected into the external grooves, 7924a, 7924b, and 7924c only when required, or as desired.
  • 7930 may be provided with an increased supply of lubricant, thereby reducing the amount of force required to radially expand and plastically deform the expandable tubular member.
  • the rate of injection of fluidic material 7932 into passageway 7952 between expansion cone 7900 and tubular member 7902 depends on the input pressure of the fluidic material 7932. Since, the rate of injection of the second fluidic material 7944 into the external grooves, 7924a, 7924b, and 7924c, depends on the operating pressure of the fluidic material and the operating characteristics of the spring-biased check valves, 7926a and
  • 7952 may be at a different pressure than the pressure of the fluidic material 7932 injected into passageway 7952 between expansion cone 7900 and tubular member 7902.
  • valves 7926a and 7926b permits lubricant flow when the input pressure of the fluidic material 7932 exceeds a predetermined pressure limit, which may be a factor of diameter of the tubular member, the length of the tubular member and the desired amount of lubricant to be dispensed.
  • tubular piston 7940 pumps the fluidic material 7944 into the annular chamber 7936, based on the input pressure of the fluidic material 7932, such as, for example, when the input pressure of the fluidic material
  • a predetermined pressure limit which may be a factor of diameter of the tubular member 7930, the length of the tubular member 7930 and the desired amount of lubricant to be injected.
  • the second fluidic material 7944 in an annular chamber 7936 below tubular piston 7940 may be preloaded into expansion cone 7900 prior to being used to expand tubular member 7902.
  • the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7900.
  • tubular piston 7940 and spring-biased check valves, 7926a and 7926b may be omitted, and/or used in combination with other types of flow metering devices such as, for example, passive flow control devices, active flow control devices, fixed orifices, and/or variable orifices.
  • valve may not be used in the expansion cone.
  • only one or a plurality of lubricant reservoirs may be utilized in the expansion cone.
  • Lubricants [00526]
  • the lubricant may be any media that may assist in reducing the friction between the expansion cone and a tubular member, including any fluidic material. Several factors may be considered, including the coefficient of friction between the expansion cone and tubular member, the size and complexity of the expansion cone, and the lubricant injection pressure, length of the tubular member and the amount of lubricant to be dispersed.
  • the lubricant may include wet lubricants and/or solid lubricants. It is expected that the lubricant typically need to withstand at least 5000 psi of pressure.
  • the lubricants for a system for lubricating the interface between an expansion cone and a tubular member during the expansion process may include, conventional commercial lubricants (natural and synthetic), working hydraulic fluid mud currently used in expandable tubular systems, and working hydraulic fluid mud blended with solid lubricants to improve lubricity.
  • a lithium based (non-synthetic) multipurpose grease combined with a solid lubricant may be used as the lubricant.
  • a grease lubricant for this application may be composed of a solid lubricant in a moderately high temperature resistant thickener.
  • the lubricant may have at least 10% Graphite or 10% Molybdenum Disulfide in a thickener with a dropping point above 350-400F.
  • two lubricants which meet the requirements state above, and their respective suppliers, are as follows:
  • Exemplary embodiments of lubricants that may be used in a system for lubricating the interface between an expansion cone and a tubular member may consist of the following component in the weight percentages indicated:
  • the lubricant may optionally contain various other additives, or mixture thereof, in order to improve the basic properties.
  • these further additives may include other antioxidants, metal deactivators, viscosity improvers, extreme-pressure additives, pour-point depressants, antifoam agents, dispersants, detergents, corrosion inhibitors, emulsifiers, demulsifiers and friction modifiers.
  • H1 , H2, H3, H4, H5, H6, and H7 identified by the specified components in the weight percentages and the component manufactures and/or distributors indicated may perform in a system for lubricating the interface between an expansion cone and a tubular member:
  • Expansion Cone Material When selecting the material for an expansion cone to reduce the coefficient of friction between an expansion cone and a tubular member in a system for lubricating the interface between an expansion cone and a tubular member during the expansion process, several factors may be considered, including, among other things, the coefficient of friction between the expansion cone and the tubular member, the size and complexity of the expansion cone, material hardness, compressive strength, wear resistance, corrosion resistance, toughness, surface finish ability and coatings.
  • example expansion cone materials include, high chrome, high carbon and molybdenum based tool steels, as well as a few powdered materials.
  • the following commercially available expansion cone materials may be used in a system for lubricating the interface between an expansion cone and a tubular member: DC53, D2, D5, D7, M2, M4, CPM M4, 10V AND 3V.
  • Figs. 71a, 71 b, 71c, and 71 d the hardness, toughness, relative wear resistance and temper temperature characteristics are shown for each of the cone materials listed in the table above, respectively.
  • Fig. 71 e shows some hardness characteristics for some of the additional cone materials not listed above.
  • Example expansion cone material manufactures and/or distributors are as follows: 1. International Mold Steel, Inc., of Florence, Kentucky distributes DC53 material; and 2. Crucible Materials Corporation of Syracuse, New York distributes D2, CPM M4, 10V AND 3V materials. The characteristics of each material are specified below.
  • an example of a DC53 material has the following characteristics: Higher hardness (62-63 HRc) than D2 after heat treatment; Twice the toughness of D2 with superior wear resistance; 20% higher fatigue strength than D2; Smaller primary carbides than D2 protect the die from chipping and cracking; Secondary refining process (DLF) reduces impurities; Machines and grinds up to 40% faster than D2; and Less residual stress after wire EDMing.
  • an example of a DC53 material has the following Coefficient of Thermal Expansion (x10-6/C°):
  • an example of a DC53 material has the following Coefficient of Thermal Conductivity (cal/cm sec°C):
  • an example of a DC53 material has the following physical data:
  • an example of a DC53 material can be hardened to 62-63 HRc in the same manner as D2, and when tempered at high temperatures (520° to 530°C), it assumes excellent properties. Even when tempered at lower temperatures (180° to 200°C), its performance is equivalent to or better than that of D2. This improved hardenability makes heat treatment easier and reduces hardness problems due to vacuum heat treatment, which uses gas cooling.
  • an example of a DC53 material displays superior wear-resistance to D2 when tempered at high temperatures (520°C) and equal wear resistance to D2 when tempered at low temperatures.
  • High resistance to temper softening minimizes seizing and galling on the die surface.
  • DC53 is ideal for dies needing to maintain high surface hardness against frictional heat between the die surface and the worked materials.
  • an example of a D2 material is, AISI Type D2 Tool Steel that is air-quenched from 1010°C and tempered at 450°C, which falls into the following subcategories: cold work steel; high carbon steel; metal; and tool steel.
  • the AISI Type D2 Tool Steel has the following properties: Mechanical Properties Metric English Comments - Hardness, Knoop 682 Converted from Rockwell C hardness; Hardness, Rockwell C 58; Hardness, Vickers 661 ; Izod Impact, Unnotched 63 J 46.5 ft-lb; and Thermal Properties - CTE, linear 20°C 10.5 ⁇ m/m-°C 5.83 ⁇ in/in-°F 20 - 100°C; CTE, linear 250°C 11.8 ⁇ m/m-°C 6.56 ⁇ in/in-°F from 0-300°C (68-570°F); and CTE, linear 500°C 12.5 ⁇ m/m-°C 6.94 ⁇ in/in-°F from 0-500°C (68-930°F). [00540] In an exemplary embodiment, the AISI Type D2 Tool Steel has the following material composition:
  • an example of a D3 material is, AISI Type D3 Tool Steel that is oil-quenched from 980°C (1800°F) and tempered at 450°C, which falls into the following subcategories: cold work steel; high carbon steel; metal; and tool steel.
  • the AISI Type D3 Tool Steel has the following properties: Mechanical Properties Metric English Comments - Hardness, Knoop 682 682 Converted from Rockwell C hardness; Hardness, Rockwell C 58 58; Hardness, Vickers 661 661 ; Izod Impact, Unnotched 29 J 21.4 ft-lb; and Thermal Properties - CTE, linear 20°C 10.7 ⁇ m/m-°C 5.94 ⁇ in/in-°F 20 - 100°C; CTE, linear 250°C 12.1 ⁇ m/m-°C 6.72 ⁇ in/in-°F from 0-300°C (68-570°F); and CTE, linear 500°C 12.8 ⁇ m/m-°C 7.11 ⁇ in/in-°F from 0-500°C (68-930°F). [00542] In an exemplary embodiment, the AISI Type D3 Tool Steel has the following material composition:
  • an example of a D5 material has the following characteristics:
  • an example of a D5 material has the following material composition:
  • an example of a D5 material has the following physical data:
  • an example of a D7 material has the following characteristics:
  • an example of a D7 material has the following material composition:
  • an example of a D7 material has the following
  • an example of a M2 material is, Allegheny Ludlum M2 Tool Steel, UNS T11302, which falls into the following subcategories: metal; tool steel.
  • the Allegheny Ludlum M2 Tool Steel has the following material composition:
  • an example of a M4 has the following material composition:
  • an example of a M4 material has the following characteristics:
  • an example of a M4 material has the following physical data:
  • Expansion Cone Coating and Polish [00554] Several expansion cone finish techniques may be used to reduce the surface roughness of the an expansion cone, including for example applying coating, polishing the surface, chrome plating, cryogenics and REM® Isotropic Finishing (available from Taylor Race Engineering, Piano, Texas).
  • coating polishing the surface
  • chrome plating chrome plating
  • cryogenics cryogenics
  • REM® Isotropic Finishing available from Taylor Race Engineering, Piano, Texas.
  • the coefficient of friction between an expansion cone and a tubular member several factors may be considered, including the coefficient of friction between an expansion cone and a tubular member, cone material hardness, cone wear resistance, surface finish and the compatibility of the coating to the cone material.
  • the following coatings with specified characteristics may be utilized as a coating for an expansion cone in a tubular member during the expansion process:
  • At least two thin film deposition processes may be used as coatings for an expansion cone in a tubular member during the expansion process; Chemical Vapor Deposition (CVD) and Physical Vapor Deposition (PVD). Both processes may yield hard coatings with high lubricity for forming and cutting. Each coating is very thin, such as, for example, in the order of microns, and the bond to the expansion cone substrate surface is a metallurgical bond. These two features of vapor deposition coatings are very conducive for high load and shear application. Thin film coatings are typically used with a cone material to support the coating. Referring to Fig. 71 e, a comparison of the hardness of a few thin film coatings and cone materials is presented.
  • CVD coatings are processed at temperature above 500C, which may have an impact on the expansion cone material hardness. Re-hardening is available for the expansion cone material in the event that hardness is lost during the CVD coating process. However, for many metals, the dimensional tolerance of the component may change during the re-hardening process and may need to be accounted for.
  • a low process temperature Diamond Like Carbon (DLC) coating may be used as a coating for an expansion cone in a tubular member during the expansion process.
  • PVD coatings are well suited to function as a coating for an expansion cone in a tubular member during the expansion process.
  • the PVD thin film coatings are typically processed at temperature below 400 C, which may not effect the hardness of the expansion cone material. PVD typically produce well bonded, high hardness coatings.
  • either a Titanium Nitride or Titanium Carbonitride coating may be used as a coating for an expansion cone in a tubular member during the expansion process.
  • the thermal spray coating process typically requires a soft expansion cone material for a high strength coating bond, which may be important during the tubular member expansion process due to the potential for high shear forces on the expansion cone.
  • a high strength bond with an expansion cone may be obtained with a very high velocity thermal spray equipment.
  • Post-coating work such as for example, machining or grinding, may be utilized after the application of a thermal spray coating to an expansion cone to achieve the desired surface.
  • the REM® Isotropic Finishing process for an expansion cone involves two steps.
  • the first step involves a chemical interaction on the surface of the expansion cone.
  • a soft, thin (one micron) film is formed on the surface of the expansion cone.
  • the expansion cone interacts with the ceramic media in a special vibratory tub, this film is physically removed from the peaks of the processed part and the valleys are unaffected.
  • the chemically induced film re-forms only at the peaks that are interacting with the vibratory media, and the process repeats itself. Over time, the peaks are removed, leaving only the valleys, producing the improved micro finish on the expansion cone.
  • the second step is the burnish process. After the required micro finish is achieved, a mild alkaline mixture is introduced. After a relatively short period a polished, chrome-like finish is produced. In addition to the polishing effects, this step effectively removes all traces of the film formation on the expansion cone from the refinement process.
  • Fig. 72 an example method 7880 for radially expanding a tubular member is described.
  • the expansion cone and tubular member are placed in a wellbore, step 7880.
  • Lubrication is introduced into the interface between the expansion cone and the tubular member, step 7884.
  • Tubular member is radially expanded by the expansion cone using one or more conventional methods in step
  • lubricant delivery systems 7200, 7300, 7400, 7500, 7600, 7700, 7800 and 7900 are incorporated into the method 7880 and apparatus for expanding tubular members described above with reference to Fig. 72.
  • one or more of the lubricants described above are incorporated into the method 7880 and apparatus for expanding tubular members described above with reference to Fig. 72.
  • one or more of the cone materials described above are incorporated into the method 7880 and apparatus for expanding tubular members described above with reference to Fig. 72.
  • one or more of the cone finish techniques described above are incorporated into the method 7880 and apparatus for expanding tubular members described above with reference to Fig. 72.
  • one or more of the lubrication systems and lubricants described above are incorporated into the methods and apparatus for expanding tubular members described above with reference to Figs. 1-30.
  • lubricant delivery systems 7200, 7300, 6600, 6700, 6800, 6900, 7000 and 7100 are incorporated into the methods and apparatus for expanding tubular members described above with reference to Figs. 1-99.
  • one or more of the lubrication systems, lubricants, lubricant delivery systems, expansion cone materials and cone finish techniques described above may be incorporated into one or more of the following conventional expansion devices: a) an expansion cone; b) a rotary expansion device; c) a hydroforming expansion device; d) an impulsive force expansion device; e) any one of the expansion devices commercially available from, or disclosed in any of the published patent applications or issued patents, of Weatherford International, Baker Hughes, Halliburton Energy Services, Shell Oil Co., Schlumberger, and/or Enventure Global Technology L.L.C.
  • a tubular members may be radially expanded and plastically deformed using one or more of the lubrication systems, lubricants, lubricant delivery systems, expansion cone materials and cone finish techniques described above in conjunction with other conventional methods for radially expanding and plastically deforming tubular members such as, for example, internal pressurization, hydroforming, and/or roller expansion devices and/or any one or combination of the conventional commercially available expansion products and services available from Baker Hughes, Weatherford International, and/or Enventure Global Technology L.L.C.
  • many of the lubricants specified above were tested with different types of expansion cones in tubular member in different conditions to determine the expansion forces necessary to expand the respective tubular members.
  • Fig. 73a illustrates the forces on expansion cone 8000 in tubular member 8002 during the expansion process. It is apparent from the equations listed directly above that the load on the expansion cone surface may be an important parameter in system and that the exemplary embodiments of structures of the surfaces of the systems; mechanisms for delivering lubricating fluid to the surfaces of the systems; lubricating fluids delivered to the system; different compositions of the system; and compositions of the tubular member described above have an im pact on that load.
  • Fig. 73b illustrates example elements in a system for lubricating the interface between an expansion cone and a tubular member during the expansion process that may have an impact on the effective friction forces of the system.
  • Such elements include, the surface 8102 of the tubular member 8100, the coating 8104 on the surface 8102 such as, for example, a low friction soft coating, the surface 8106 of the expansion cone 8108, the coating 8110 on the expansion cone 8108 such as, for example, a self-lubricating hard film, and the lubricant 8112 such as, for example, oil or grease and lubricated mud located between the tubular membe r 8100 and the expansion cone 8108.
  • both the surface roughness, such as, for example, a rough or polished finish, and the texture, such as, for example, a pattern in the surface may play a role in contributing to the overall friction of the system.
  • Figs. 73c and 73d illustrations of a smoother expansion cone finish and a rougher expans ion cone finish, respectively, will now be described.
  • roughness refers to the roughness 8O10 of the planar part of the surface.
  • texture refers to the patter in the surface, such as, for example, the holes 8012 in the surface.
  • the holes may represent oil pockets will capture oil that in turn acts as a liquid ball bearing and thus may increase the lubricity of the surface of the expansion cone.
  • a range of roughness for an expansion cone that may decrease the coefficient of friction between an expansion cone and a tubular member during radial expansion and plastic deformation is 0.02 - 0.1 micrometers.
  • the system was modeled for static and dynamic conditions.
  • the tool velocity in the system allowed for static kinematic calculations with static and dynamic coefficients of friction.
  • a preliminary evaluation shows that up to 25% of input pressure may be required to compensate for dynamic frictional effects and that the effective force on the cone could exceed 5000 psi during tubular member expansion.
  • a tubular member may withstand a finite amount of expansion pressure from an expansion cone, the maximum acceptable expansion pressure, beyond which tubular member failure may occur, including fracturing and splitting. Laboratory tests have shown that the maximum acceptable expansion pressure for an 5 1 / " LSX-80 tubular member having a 0.3" wall thickness is approximately 5000psi. Referring to Fig. 74, a chart illustrates a curve depicting the pressure (y-axis) versus coefficient of friction (x-axis) for an 5 V ⁇ " LSX-80 tubular member having a 0.3" wall thickness.
  • Figs. 75 and 76 charts illustrate information similar to that shown in Fig. 74 on a logarithmic scale; one showing pressure in terms of pounds per square inch and the other showing pressure in terms of pounds. As illustrated in Figs. 74, 75 and 76, as the coefficient of friction increases, the expansion pressure increases.
  • Fig. 77 a chart depicting the results in an exemplary experimental embodiment that shows the expansion forces in pounds per square inch over time applied to a 6" LSX80 tubular member coated with a Gear Kote coating, which is a graphite based coating distributed by Commercial Coating Services International, Ltd.
  • the expansion process began with no lubricant between the expansion cone and the tubular member, period 8900. A steady increase in expansion force was observed. After the introduction of oil between the expansion cone and the tubular member at point 8902, the expansion force decreased significantly over the period 8904 suggesting that expansion force is related to the coefficient of friction between the expansion cone and the tubular member.
  • Sample 7 also produce a low coefficient of friction in the order of approximately 0,05 EGT MS - 9075 is a Teflon based coating (polytetrafluoroethylene or PTFE), distributed by Enventure Global Technology, L.L.C, Houston Texas, is shown.
  • Phygen film is a chrome nitride coating and is distributed by Phygen, Inc., Minneapolis, Minnesota.
  • Fig. 79a a three dimensional photograph having a 5X magnification and a field of the view 1.20 X 0.90 mm of the surface of an expansion cone made of D2 material is shown.
  • the expansion cone made of D2 material has the following surface characteristics:
  • Ra is the roughness average, is the arithmetic average of the absolute values of the surface height deviations measured from the best fitting plane, cylinder or sphere;
  • Rz is the average maximum height of the surface;
  • Rpk - is the reduced peak height, a measure of the peak height above the nominal/core roughness;
  • Rvk is the reduced valley depth, which is a measure of the valley depth below the nominal /core roughness;
  • Rk is the core roughness depth which is a measure of the nominal or "core” roughness (peak-to-valley) of the surface with the predominant peaks and valleys removed.
  • FIG. 79b a three dimensional photograph having a 5X magnification and a field of the view 1.20 X 0.90 mm of the surface of an expansion cone made of DC53 material having a Phygen film and REM polish is shown.
  • the expansion cone made of DC53 material has the following surface characteristics:
  • FIGs. 80a and 80b photo micrographs of the expansion cone made of D2 material shown in Fig. 79a and the expansion cone made of DC53 material shown in Fig. 79b are shown, respectively.
  • D2 material shown in Fig. 79a and the expansion cone made of DC53 shown in Fig. 81 b are shown, respectively.
  • a hole pocket 9000 in surface the expansion cone made of DC53 exists, which may create an oil pocket.
  • Hole pockets may be desirable and may enhance the reduction of the effect of friction on the expansion system.
  • Hole pockets may collect oil, act as a liquid ball bearings when in contact with a tubular member and may increase the lubricity of the system by introducing more lubricant in the interface between the expansion cone and the tubular member.
  • Figs. 82a and 82b the bearing ratio for the expansion cone made of D2 shown in Fig. 79a and the expansion cone made of DC53 shown in Fig. 79b are shown, respectively.
  • the bearing ratio represents the length of material surface (expressed as a percentage of the evaluation length L) at a depth below the highest peak.
  • Fig. 83a a three dimensional photograph having a 50X magnification and a field of the view 1.20 X 0.90 mm of the surface of an expansion cone made of D2 material is shown.
  • the expansion cone made of D2 material has the following surface characteristics:
  • FIG. 83b three dimensional photographs having a 50X magnification and a field of the view 1.20 X 0.90 mm of the surface of an expansion cone made of DC53 material having a Phygen film and REM polish is shown.
  • the expansion cone made of DC53 material has the following surface characteristics:
  • FIG. 84a and 84b photo micrographs of the expansion cone made of D2 material shown in Fig. 83a and the expansion co ne made of DC53 material shown in Fig. 83b are shown, respectively.
  • FIGs. 85a and 85b an x-profile of the expansion cone made of

Abstract

La présente invention a trait à un système de réduction du coefficient de frottement entre un dispositif de dilatation et la crépine de forme tubulaire lors de la dilatation radiale.
PCT/US2004/028888 2003-09-05 2004-09-07 Crépine de forme tubulaire expansible WO2005079186A2 (fr)

Priority Applications (4)

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GB0603996A GB2420810A (en) 2003-09-05 2004-09-07 Expandable tubular
PCT/US2004/028888 WO2005079186A2 (fr) 2003-09-05 2004-09-07 Crépine de forme tubulaire expansible
US10/571,041 US20070215360A1 (en) 2003-09-05 2004-09-07 Expandable Tubular
NO20061503A NO20061503L (no) 2003-09-05 2006-04-03 Utvidbart, rorformet element

Applications Claiming Priority (7)

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US50043503P 2003-09-05 2003-09-05
US60/500,435 2003-09-05
US58537004P 2004-07-02 2004-07-02
US60/585,370 2004-07-02
US60067904P 2004-08-11 2004-08-11
US60/600,679 2004-08-11
PCT/US2004/028888 WO2005079186A2 (fr) 2003-09-05 2004-09-07 Crépine de forme tubulaire expansible

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PCT/US2004/029025 WO2005028803A2 (fr) 2003-09-05 2004-09-07 Element tubulaire extensible
PCT/US2004/028889 WO2005024171A2 (fr) 2003-09-05 2004-09-07 Element tubulaire expansible
PCT/US2004/028831 WO2005024170A2 (fr) 2003-09-05 2004-09-07 Systeme d'expansion radiale
PCT/US2004/028888 WO2005079186A2 (fr) 2003-09-05 2004-09-07 Crépine de forme tubulaire expansible

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PCT/US2004/028831 WO2005024170A2 (fr) 2003-09-05 2004-09-07 Systeme d'expansion radiale

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JP (1) JP2007521430A (fr)
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WO2005028803A2 (fr) 2005-03-31
GB0802113D0 (en) 2008-03-12
GB2432384A (en) 2007-05-23
RU2006110933A (ru) 2007-10-10
GB2442645A (en) 2008-04-09
GB0624394D0 (en) 2007-01-17
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GB2432384A8 (en) 2007-06-12
US20070266756A1 (en) 2007-11-22
WO2005028803A3 (fr) 2012-12-13
GB2420811B (en) 2008-03-19
JP2007521430A (ja) 2007-08-02
GB2443124B (en) 2008-07-02
GB2432384B (en) 2008-04-09
WO2005024170A2 (fr) 2005-03-17
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GB2432383A (en) 2007-05-23
GB0604359D0 (en) 2006-04-12
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GB0603996D0 (en) 2006-04-05
US20070205001A1 (en) 2007-09-06
WO2005028803A9 (fr) 2005-05-26
GB2427212B (en) 2008-04-23
WO2005024170A3 (fr) 2006-02-16
WO2005024171A2 (fr) 2005-03-17
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GB2420811A (en) 2006-06-07
GB0604360D0 (en) 2006-04-12
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GB2421262B (en) 2008-04-09
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GB0623634D0 (en) 2007-01-03
NO20061503L (no) 2006-05-12
WO2005079186A3 (fr) 2005-11-17
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US20070215360A1 (en) 2007-09-20
GB2442645B (en) 2008-06-11

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