PRESSURE CYCLING TO CONTROL THE MATERIAL PROPERTIES OF A TUBULAR MEMBER

Abstract

A method of controlling the material properties of a tubular member including positioning a pressure source within the tubular member; and operating the pressure source to generate a pressure cycle signal.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of the filing date of U.S. provisional patent application Ser. No. 60/761,324, attorney docket number 25791.340, filed on Jan. 23, 2006, the disclosure of which is incorporated herein by reference.

This application is a continuation-in-part of U.S. patent application Ser. No. 10/030,593, attorney docket number 25791.25.08, filed on Jan. 8, 2002, which was the National Stage for PCT application serial number PCT/US00/18635, attorney docket number 25791.25.02, filed on Jul. 7, 2000, which claimed the benefit of U.S. provisional patent application Ser. No. 60/137,998, filed on Jun. 7, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/588,946, attorney docket number 25791.17.02, filed on Jun. 7, 2000, (now U.S. Pat. No. 6,557,640 which issued May 6, 2003) which claimed the benefit of U.S. provisional patent application Ser. No. 60/137,998, filed on Jun. 7, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/559,122, attorney docket number 25791.23.02, filed on Apr. 26, 2000, (now U.S. Pat. No. 6,604,763 which issued Aug. 12, 2003) which claimed the benefit of U.S. provisional patent application Ser. No. 60/131,106, filed on Apr. 26, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/523,460, attorney docket number 25791.11.02, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003) which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/124,042, filed on Mar. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/510,913, attorney docket number 25791.7.02, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/121,702, filed on Feb. 25, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/502,350, attorney docket number 25791.8.02, filed on Feb. 10, 2000, (now U.S. Pat. No. 6,823,937 which issued Nov. 30, 2004) which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/119,611, attorney docket number 25791.8, filed on Feb. 11, 1999, which was a continuation-in-part of U.S. patent application Ser. No. 09/454,139, attorney docket number 25791.3.02, filed on Dec. 3, 1999, (now U.S. Pat. 6,497,289 which issued Dec. 24, 2002) which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/111,293, filed on Dec. 7, 1998.

This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. 11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claims priority from provisional application 60/183,546, filed on Feb. 18, 2000, (6) U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121, 907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. 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No. 60/455,051, attorney docket no. 25791.40, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application Ser. No. 60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no. 25791.45.07, which claims priority from provisional patent application Ser. No. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (25) U.S. patent application Ser. No. 10/, filed on Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priority from provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, attorney docket no. 25791.47.03, which claims priority from provisional patent application Ser. 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BACKGROUND OF THE INVENTION

The present disclosure relates to the material properties of tubing and/or casing located in a borehole traversing a subterranean formation.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an illustration of a conventional method for drilling a borehole in a subterranean formation.

FIG. 2 is an illustration of a device for coupling an expandable tubular member to an existing tubular member.

FIG. 3 is an illustration of a hardenable fluidic sealing material being pumped down the device of FIG. 2.

FIG. 4 is an illustration of the expansion of an expandable tubular member using the expansion device of FIG. 2.

FIG. 5 is an of the completion of the radial expansion and plastic deformation of an expandable tubular member.

FIG. 6 is an illustration of a pressure source inside an expandable tubular member.

FIG. 7 is a graphical illustration of an sinusoidal pressure cycle signal.

FIG. 8 is a graphical illustration of a square wave pressure cycle signal.

FIG. 9 is a graphical illustration of a triangular pressure cycle signal.

FIG. 10 is a graphical illustration of the spectral content of a pressure cycle signal.

FIG. 11 is a graphical illustration of varying the collapse strength of a tubular member by varying the spectral content of the pressure cycle signal.

FIG. 12 is a graphical illustration of varying the collapse strength of a tubular member by varying the maximum magnitude of the pressure of the pressure cycle signal.

FIG. 13 is a graphical illustration of varying the collapse strength of a tubular member by varying the number of cycles of the pressure cycle signal.

FIG. 14 is a graphical illustration of varying the burst strength of a tubular member by varying the spectral content of the pressure cycle signal.

FIG. 15 is a graphical illustration of varying the burst strength of a tubular member by varying the maximum magnitude of the pressure of the pressure cycle signal.

FIG. 16 is a graphical illustration of varying the burst strength of a tubular member by varying the number of cycles of the pressure cycle signal.

FIG. 17 is a graphical illustration of varying the yield strength of a tubular member by varying the spectral content of the pressure cycle signal.

FIG. 18 is a graphical illustration of varying the yield strength of a tubular member by varying the maximum magnitude of the pressure of the pressure cycle signal.

FIG. 19 is a graphical illustration of varying the yield strength of a tubular member by varying the number of cycles of the pressure cycle signal.

FIG. 20 is a graphical illustration of varying the wall thickness of a tubular member by varying the spectral content of the pressure cycle signal.

FIG. 21 is a graphical illustration of varying the wall thickness of a tubular member by varying the maximum magnitude of the pressure of the pressure cycle signal.

FIG. 22 is a graphical illustration of varying the wall thickness of a tubular member by varying the number of cycles of the pressure cycle signal.

FIG. 23 is an illustration of a partially expanded expandable tubular member.

DETAILED DESCRIPTION

Referring initially to FIG. 1, a conventional device 100 for drilling a borehole 102 in a subterranean formation 104 is shown. The borehole 102 may be lined with a casing 106 at the top portion of its length. An annulus 108 formed between the casing 106 and the formation 104 may be filled with a sealing material 110, such as, for example, cement. In an exemplary embodiment, the device 100 may be operated in a conventional manner to extend the length of the borehole 102 beyond the casing 106.

Referring now to FIG. 2, a device 200 for coupling an expandable tubular member 202 to an existing tubular member, such as, for example, the existing casing 106 , is shown. The device 200 includes a shoe 206 that defines a centrally positioned valveable passage 206 a adapted to receive, for example, a ball, plug or other similar device for closing the passage. An end of the shoe 206b is coupled to a lower tubular end 208a of a tubular launcher assembly 208 that includes the lower tubular end, an upper tubular end 208b, and a tapered tubular transition member 208c. The lower tubular end 208a of the tubular launcher assembly 208 has a greater inside diameter than the inside diameter of the upper tubular end 208b. The tapered tubular transition member 208c connects the lower tubular end 208a and the upper tubular end 208b. The upper tubular end 208b of the tubular launcher assembly 208 is coupled to an end of the expandable tubular member 202. One or more seals 210 are coupled to the outside surface of the other end of the expandable tubular member 202.

An expansion device 212 is centrally positioned within and mates with the tubular launcher assembly 208. The expansion device 212 defines a centrally positioned fluid pathway 212a, and includes a lower section 212b, a middle section 212c, and an upper section 212d. The lower section 212b of the expansion device 212 defines an inclined expansion surface 212ba that supports the tubular launcher assembly 208 by mating with the tapered tubular transition member 208c of the tubular launcher assembly. The upper section 212d of the expansion device 212 is coupled to an end of a tubular member 218 that defines a fluid pathway 218a. The fluid pathway 218a of the tubular member 218 is fluidicly coupled to the fluid pathway 212a defined by the expansion device 212. One or more spaced apart cup seals 220 and 222 are coupled to the outside surface of the tubular member 218 for sealing against the interior surface of the expandable tubular member 202. In an exemplary embodiment, cup seal 222 is positioned near a top end of the expandable tubular member 202. A top fluid valve 224 is coupled to the tubular member 218 above the cup seal 222 and defines a fluid pathway 226 that is fluidicly coupled to the fluid pathway 218a.

During operation of the device 200, as illustrated in FIG. 2, the device 200 is initially lowered into the borehole 102. In an exemplary embodiment, during the lowering of the device 200 into the borehole 102, a fluid 228 within the borehole 102 passes upwardly through the device 200 through the valveable passage 206a into the fluid pathway 212a and 218a and out of the device 200 through the fluid pathway 226 defined by the top fluid valve 224.

Referring now to FIG. 3, in an exemplary embodiment, a hardenable fluidic sealing material 300, such as, for example, cement, is then pumped down the fluid pathway 218a and 212a and out through the valveable passage 206a into the borehole 102 with the top fluid valve 224 in a closed position. The hardenable fluidic sealing material 300 thereby fills an annular space 302 between the borehole 102 and the outside diameter of the expandable tubular member 102.

Referring now to FIG. 4, a plug 402 is then injected with a fluidic material 404. The plug thereby fits into and closes the valveable passage 206a to further fluidic flow. Continued injection of the fluidic material 404 then pressurizes a chamber 406 defined by the shoe 206, the bottom of the expansion device 212, and the walls of the launcher assembly 208 and the expandable tubular member 202. Continued pressurization of the chamber 406 then displaces the expansion device 212 in an upward direction 408 relative to the expandable tubular member 202 thereby causing radial expansion and plastic deformation of the launcher assembly 208 and the expandable tubular member.

In an exemplary embodiment, the pressure in chamber 406 is cycled between a minimum P_min and maximum pressure P_max over a length 410 of the expandable tubular member 202, during operation of the device 200.

Referring now to FIG. 5, the radial expansion and plastic deformation of the expandable tubular member 202 is then completed and the expandable tubular member is coupled to the existing casing 106. The hardenable fluidic sealing material 300, such as, for example, cement fills the annulus 302 between the expandable tubular member 202 and the borehole 102. The device 200 has been withdrawn from the borehole and a conventional device 100 for drilling the borehole 102 may then be utilized to drill out the shoe 206 and continue drilling the borehole 102, if desired.

Referring now to FIG. 6, in an exemplary embodiment, the interior of the expandable tubular member 202 is pressure cycled using a pressure source 602 positioned within and/or operably coupled to the interior of the expandable tubular member, to generate a pressure cycle signal 604. In an exemplary embodiment, the pressure source 602 may comprise a hydraulic, pneumatic, or impulse type pressure source. In an exemplary embodiment, a controller 606 is coupled to the pressure source 602 for controlling the operation of the pressure source. In an exemplary embodiment, the controller 606 operates the pressure source 602 to generate a pressure cycle signal 604 to control one or more of the following material properties: collapse strength, burst strength, yield strength, and wall thickness of the expandable tubular member 202.

Referring now to FIG. 7, in an exemplary embodiment, the controller 606 operates the pressure source 602 to generate a sinusoidal pressure cycle signal 700 within the expandable tubular member 202. In an exemplary embodiment, the sinusoidal pressure cycle signal 700 varies from a maximum value P_max to a minimum value P_min over time.

Referring now to FIG. 8, in an exemplary embodiment, the controller 606 operates the pressure source 602 to generate a square wave pressure cycle signal 800 within the expandable tubular member 202. In an exemplary embodiment, the square wave pressure cycle signal 800 varies from a maximum value P_max to a minimum value P_min over time.

Referring now to FIG. 9, in an exemplary embodiment, the controller 606 operates the pressure source 602 to generate a triangular pressure cycle signal 900 within the expandable tubular member 202. In an exemplary embodiment, the triangular pressure cycle signal 900 varies from a maximum value P_max to a minimum value P_min over time.

In an exemplary embodiment, the controller 606 may operate the pressure source 602 to generate a pressure cycle signal 604 that includes one or more of the pressure cycle signals 700, 800, and 900.

Referring now to FIG. 10, in an exemplary embodiment, the spectral content of the pressure cycle signals of 700, 800, or 900 include one or more center frequencies CF within the spectral content 1000 of the pressure signal.

Referring now to FIG. 11, in an exemplary embodiment, the collapse strength of the expandable tubular member 202 varies as a function of the spectral content 1100 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the spectral content 1100 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical center frequencies C_F for maximizing the collapse strength C-S_max of the expandable tubular member 202.

Referring now to FIG. 12, in an exemplary embodiment, the collapse strength of the expandable tubular member 202 varies as a function of the maximum magnitude of the pressure 1200 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the maximum magnitude of the pressure 1200 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical pressures, P-C₁ and P-C₂, for maximizing the collapse strength C-S_max of the expandable tubular member 202.

Referring now to FIG. 13, in an exemplary embodiment, the collapse strength of the expandable tubular member 202 varies as a function of the number of cycles 1300 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the number of cycles 1300 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more number of critical cycles, C₁ and C₂, for maximizing the collapse strength C-S_max of the expandable tubular member 202.

Referring now to FIG. 14, in an exemplary embodiment, the burst strength of the expandable tubular member 202 varies as a function of the spectral content 1400 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the spectral content 1400 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical center frequencies C_F for maximizing the burst strength B-S_max of the expandable tubular member 202.

Referring now to FIG. 15, in an exemplary embodiment, the burst strength of the expandable tubular member 202 varies as a function of the maximum magnitude of the pressure 1500 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the maximum magnitude of the pressure 1500 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical pressures, P-C₁ and P-C₂, for maximizing the burst strength B-S_max of the expandable tubular member 202.

Referring now to FIG. 16, in an exemplary embodiment, the burst strength of the expandable tubular member 202 varies as a function of the number of cycles 1600 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the number of cycles 1600 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more number of critical cycles, C₁ and C₂, for maximizing the burst strength B-S_max of the expandable tubular member 202.

Referring now to FIG. 17, in an exemplary embodiment, the yield strength of the expandable tubular member 202 varies as a function of the spectral content 1700 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the spectral content 1700 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical center frequencies C_F for maximizing the yield strength Y-S_max of the expandable tubular member 202.

Referring now to FIG. 18, in an exemplary embodiment, the yield strength of the expandable tubular member 202 varies as a function of the maximum magnitude of the pressure 1800 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the maximum magnitude of the pressure 1800 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical pressures, P-C₁ and P-C₂, for maximizing the yield strength Y-S_max of the expandable tubular member 202.

Referring now to FIG. 19, in an exemplary embodiment, the yield strength of the expandable tubular member 202 varies as a function of the number of cycles 1900 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the number of cycles 1900 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more number of critical cycles, C₁ and C₂, for maximizing the yield strength Y-S_max of the expandable tubular member 202.

Referring now to FIG. 20, in an exemplary embodiment, the wall thickness of the expandable tubular member 202 varies as a function of the spectral content 2000 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the spectral content 2000 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical center frequencies C_F for maximizing the wall thickness W-T_max of the expandable tubular member 202.

Referring now to FIG. 21, in an exemplary embodiment, the wall thickness of the expandable tubular member 202 varies as a function of the maximum magnitude of the pressure 2100 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the maximum magnitude of the pressure 2100 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more critical pressures, P-C₁ and P-C₂, for maximizing the wall thickness W-T_max of the expandable tubular member 202.

Referring now to FIG. 22, in an exemplary embodiment, the wall thickness of the expandable tubular member 202 varies as a function of the number of cycles 2200 of the pressure cycle signal 604 generated by the pressure source 602. In an exemplary embodiment, the number of cycles 2200 of the pressure cycle signal 604 generated by the pressure source 602 includes one or more number of critical cycles, C₁ and C₂, for maximizing the wall thickness W-T_max of the expandable tubular member 202.

In an exemplary embodiment, the critical parameters of the pressure cycle signal 604 including: one or more critical center frequencies C_F; one or more critical pressures P-C; and one or more number of critical cycles, C₁ and C₂; for maximizing the collapse strength, burst strength, yield strength, and wall thickness of the expandable tubular member 202, may be empirically determined.

Referring now to FIG. 23, a non-expanded end of an expandable tubular member 2100 defines a non-expanded interior diameter ID_pre and outer diameter OD_pre. The other expanded end of the expandable tubular member 2100 defines an interior diameter lD_post and outer diameter OD_post.

In an exemplary embodiment, the maximization of a material property of the expandable tubular member 202 may result in the decrease in another material property, for example, maximization of the collapse strength of the expandable tubular 202 member may result in a decrease in the yield strength of the expandable tubular member. Additionally, different combinations of material properties may be achieved by adjusting the parameters of the pressure cycle signal 604. In an exemplary embodiment, the teaching of the present disclosure may be used to determine the empirical relationship between one or more of the following material properties of the expandable tubular member 202 including: collapse strength, burst strength, yield strength and wall thickness; and one or more of the parameters of the pressure cycle signal 604 generated by the pressure source 602 including spectral content, maximum magnitude of the pressure, and number of cycles.

A generalized vector equation may represent the modification of the material properties of the tubular member by the operation of a pressure source within the tubular member to generate a pressure cycle signal 604, as follows: $\left[\begin{array}{c}{\mathrm{MP}}_i\\ ⋮\\ {\mathrm{MP}}_M\end{array}\right]=\left[\begin{array}{c}{f}_i\left({\mathrm{PCS}}_j\dots {\mathrm{PCS}}_N\right)\\ ⋮\\ f_M\left({\mathrm{PCS}}_j\dots {\mathrm{PCS}}_N\right)\end{array}\right]$
where:

• • MP_i=particular material property of the tubular member, e.g. collapse strength, burst strength, yield strength, and wall thickness;

PCS_J=pressure cycle signal parameter, e.g, spectral content, maximum magnitude of pressure, and number of cycles;

• • i=1 to M
  • j=1 to N

A method of controlling the material properties of a tubular member has been described that includes positioning a pressure source within the tubular member. The tubular member is located in a borehole traversing a subterranean formation and the tubular member comprises a plastically deformed tubular member. The pressure source is operated to generate a pressure cycle signal comprising; a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value P_max to a minimum value P_min over time.

An apparatus has been described that includes a tubular member; wherein the tubular member is located in a borehole traversing a subterranean formation and the tubular member comprises a plastically deformed tubular member; a pressure source operably coupled to the interior of the tubular member; and a controller adapted to control the operation of the pressure source to generate a pressure cycle signal. The pressure cycle signal includes a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value P_max to a minimum value P_min over time.

A method of determining the optimum pressure cycle signal parameter, parameters including spectral content, pressure, and number of cycles, at which to control the material properties of a tubular member, including collapse strength, burst strength, yield strength and wall thickness, has been described that includes: (a) positioning a pressure source within a tubular member; and operating the pressure source to generate a pressure cycle signal having pressure cycle parameters comprising a first spectral content, a maximum magnitude of pressure, and a number of cycles; (b) determining the material properties of the tubular member in which the pressure source was operated to generate a pressure cycle signal having pressure cycle parameters comprising the first spectral content, the maximum magnitude of pressure, and the number of cycles; (c) incrementing one of the pressure cycle signal parameters and holding the other parameters constant and operating the pressure source to generate a pressure cycle signal comprising the incremented pressure cycle parameter; (d) determining the material properties of the tubular member in which the pressure source was operated to generate a pressure signal comprising the incremented pressure cycle parameter; and repeating the procedure (a)-(d) above until the last increment of pressure cycle parameter is reached. Comparing the material properties of the tubular members for each increment of the pressure cycle parameter; determining what is the optimum material property and what is the corresponding increment of the pressure cycle parameter; and operating at that pressure cycle parameter.

A method of determining one or more pressure cycle signal parameters at which to operate a pressure source that generates a pressure cycle signal within a tubular member to control the material properties of a tubular member has been described that includes the pressure cycle signal parameter as a function of the following factors:

• • ID_pre=internal diameter of the unexpanded tubular member;
  • OD_pre=outside diameter of the unexpanded tubular member;
  • ID_post=internal diameter of the expanded tubular member; and
  • OD_post=outside diameter of the expanded tubular member.

A method of coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation has been described that includes: installing a tubular liner and an expansion device in the borehole; overlapping the tubular liner with an existing tubular member; injecting fluidic material into the borehole; pressurizing a portion of an interior region of the tubular liner; radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device; positioning a pressure source within the liner; and operating the pressure source to generate a pressure cycle signal. The pressure cycle signal includes: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value P_max to a minimum value P_min over time.

A method of coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation has been described that includes: means for installing a tubular liner and an expansion device in the borehole; means for overlapping the tubular liner with an existing tubular member; means for injecting fluidic material into the borehole; means for pressurizing a portion of an interior region of the tubular liner; means for radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device; means for positioning a pressure source within the liner; and means for operating the pressure source to generate a pressure cycle signal. The pressure cycle signal includes: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value P_max to a minimum value P_min over time.

Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features, and some steps of the present invention may be executed without a corresponding execution of other steps. Accordingly, all such modifications, changes and substitutions are intended to be included within the scope of this invention as defined in the following claims, and it is appropriate that the claims be construed broadly and in a manner consistent with the scope of the invention. In the claims, means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures.

Claims

1. A method of controlling the material properties of a tubular member, comprising:

positioning a pressure source within the tubular member; and

operating the pressure source to generate a pressure cycle signal.

2. The method of claim 1, wherein the tubular member is located in a borehole traversing a subterranean formation.

3. The method of claim 2, wherein the tubular member comprises a plastically deformed tubular member.

4. The method of claim 1, wherein operating the pressure source to generate a pressure cycle signal comprises one or more of the following:

operating the pressure source to generate a pressure cycle signal comprising a predetermined spectral content;

operating the pressure source to generate a pressure cycle signal that varies between a maximum and a minimum pressure; and

operating the pressure source to generate a pressure cycle signal comprising a predetermined number of cycles.

5. The method of claim 1, wherein the pressure source is operated to generate a pressure cycle signal comprising one or more of the following:

a spectral content selected to control the collapse strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the collapse strength of the expanded tubular member;

a number of cycles selected to control the collapse strength of the expanded tubular member;

a spectral content selected to control the burst strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the burst strength of the expanded tubular member;

a number of cycles selected to control the burst strength of the expanded tubular member;

a spectral content selected to control the yield strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the yield strength of the expanded tubular member;

a number of cycles selected to control the yield strength of the expanded tubular member;

a spectral content selected to control the wall thickness of the expanded tubular member;

a maximum magnitude of pressure selected to control the wall thickness of the expanded tubular member;

a number of cycles selected to control the wall thickness of the expanded tubular member;

a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time;

a square wave signal that varies from a maximum value Pmax to a minimum value Pmin over time; and

a triangular signal that varies from a maximum value Pmax to a minimum value Pmin over time.

6. A method of controlling the material properties of a tubular member located in a borehole traversing a subterranean formation, the tubular member comprising a plastically deformed tubular member, the method comprising:

positioning a pressure source within the tubular member; and

operating the pressure source to generate a pressure cycle signal comprising: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time.

7. An apparatus, comprising:

a tubular member;

a pressure source operably coupled to the interior of the tubular member; and

a controller adapted to control the operation of the pressure source to generate a pressure cycle signal.

8. The apparatus of claim 7, wherein the tubular member is located in a borehole traversing a subterranean formation.

9. The apparatus of claim 8, wherein the tubular member comprises a plastically deformed tubular member.

10. The apparatus of claim 7, wherein the pressure cycle signal comprises one or more of the following:

a predetermined spectral content;

a maximum and a minimum pressure; and

a predetermined number of cycles.

11. The apparatus of claim 7, wherein the pressure cycle signal comprises one or more of the following:

a spectral content selected to control the collapse strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the collapse strength of the expanded tubular member;

a number of cycles selected to control the collapse strength of the expanded tubular member;

a spectral content selected to control the burst strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the burst strength of the expanded tubular member;

a number of cycles selected to control the burst strength of the expanded tubular member;

a spectral content selected to control the yield strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the yield strength of the expanded tubular member;

a number of cycles selected to control the yield strength of the expanded tubular member;

a spectral content selected to control the wall thickness of the expanded tubular member;

a maximum magnitude of pressure selected to control the wall thickness of the expanded tubular member;

a number of cycles selected to control the wall thickness of the expanded tubular member;

a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time;

a square wave signal that varies from a maximum value Pmax to a minimum value Pmin over time; and

a triangular signal that varies from a maximum value Pmax to a minimum value Pmin over time.

12. An apparatus, comprising:

a tubular member adapted to be located in a borehole traversing a subterranean formation, the tubular member comprising a plastically deformed tubular member;

a pressure source operably coupled to the interior of the tubular member; and

a controller adapted to control the operation of the pressure source to generate a pressure cycle signal;

wherein the pressure cycle signal comprises: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time.

13. A method of determining optimum pressure cycle signal parameter at which to control the material properties of a tubular member, the parameters comprising spectral content, maximum magnitude of pressure and number of cycles, the material properties comprising collapse strength, burst strength, yield strength and wall thickness, the method comprising:

positioning a pressure source within a tubular member;

a) operating the pressure source to generate a pressure cycle signal having pressure cycle parameters comprising a first spectral content, a maximum magnitude of pressure, and a number of cycles;

b) determining the material properties of the tubular member in which the pressure source was operated to generate a pressure cycle signal having pressure cycle parameters comprising the first spectral content, the maximum magnitude of pressure, and the number of cycles;

c) incrementing one of the pressure cycle signal parameters and holding the other parameters constant and operating the pressure source to generate a pressure cycle signal comprising the incremented pressure cycle parameter;

d) determining the material properties of the tubular member in which the pressure source was operated to generate a pressure signal comprising the incremented pressure cycle parameter;

repeating the procedure a)-d) above until the last increment of the incremented pressure cycle parameter is reached;

comparing the material properties of the tubular member for each increment of the incremented pressure cycle parameter;

determining what is the optimum material property and what is the corresponding increment of the incremented pressure cycle parameter; and

operating the pressure source at the increment of the incremented pressure cycle parameter corresponding to the optimum material property.

14. A method comprising:

providing a pressure source; and

determining one or more pressure cycle signal parameters at which to operate the pressure source to generate a pressure cycle signal within a tubular member to control at least one of the material properties of the tubular member;

wherein at least one of the one or more pressure cycle signal parameters is a function of the following factors: IDpre=internal diameter of the unexpanded tubular member; ODpre=outside diameter of the unexpanded tubular member;

IDpost=internal diameter of the expanded tubular member; and

ODpost=outside diameter of the expanded tubular member.

15. The method of claim 14, wherein the at least one of the one or more pressure cycle signal parameters comprises one or more of the following:

a spectral content of the pressure cycle signal;

a maximum magnitude of pressure of the pressure cycle signal; and

a number of cycles of the pressure cycle signal; and

wherein the at least one of the material properties of the tubular member

comprises one or more of the following:

the collapse strength of the tubular member;

the burst strength of the tubular member;

the yield strength of the tubular member; and

the wall thickness of the tubular member.

16. A method of coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation comprising:

installing a tubular liner and an expansion device in the borehole;

overlapping the tubular liner with an existing tubular member;

injecting fluidic material into the borehole;

pressurizing a portion of an interior region of the tubular liner;

radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device;

positioning a pressure source within the liner; and

operating the pressure source to generate a pressure cycle signal.

17. The method of claim 16, wherein operating the pressure source to generate a pressure cycle signal comprises one or more of the following:

operating the pressure source to generate a pressure cycle signal comprising a predetermined spectral content;

operating the pressure source to generate a pressure cycle signal that varies between a maximum and a minimum pressure; and

operating the pressure source to generate a pressure cycle signal comprising a predetermined number of cycles.

18. The method of claim 16, wherein the pressure source is operated to generate a pressure cycle signal comprising one or more of the following:

a spectral content selected to control the collapse strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the collapse strength of the expanded tubular member;

a number of cycles selected to control the collapse strength of the expanded tubular member;

a spectral content selected to control the burst strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the burst strength of the expanded tubular member;

a number of cycles selected to control the burst strength of the expanded tubular member;

a spectral content selected to control the yield strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the yield strength of the expanded tubular member;

a number of cycles selected to control the yield strength of the expanded tubular member;

a spectral content selected to control the wall thickness of the expanded tubular member;

a maximum magnitude of pressure selected to control the wall thickness of the expanded tubular member;

a number of cycles selected to control the wall thickness of the expanded tubular member;

a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time;

a square wave signal that varies from a maximum value Pmax to a minimum value Pmin over time; and

a triangular signal that varies from a maximum value Pmax to a minimum value Pmin over time.

19. A method of coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation, the method comprising:

installing a tubular liner and an expansion device in the borehole;

overlapping the tubular liner with an existing tubular member;

injecting fluidic material into the borehole;

pressurizing a portion of an interior region of the tubular liner;

radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device;

positioning a pressure source within the liner; and

operating the pressure source to generate a pressure cycle signal, the pressure cycle signal comprising: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time.

20. A system for coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation, the system comprising:

means for installing a tubular liner and an expansion device in the borehole;

means for overlapping the tubular liner with an existing tubular member;

means for injecting fluidic material into the borehole;

means for pressurizing a portion of an interior region of the tubular liner;

means for radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device;

means for positioning a pressure source within the liner; and

means for operating the pressure source to generate a pressure cycle signal.

21. The system of claim 20, wherein means for operating the pressure source to generate a pressure cycle signal comprises one or more of the following:

means for operating the pressure source to generate a pressure cycle signal comprising a predetermined spectral content;

means for operating the pressure source to generate a pressure cycle signal that varies between a maximum and a minimum pressure; and

means for operating the pressure source to generate a pressure cycle signal comprising a predetermined number of cycles.

22. The system of claim 20, wherein the pressure cycle signal comprises one or more of the following:

a spectral content selected to control the collapse strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the collapse strength of the expanded tubular member;

a number of cycles selected to control the collapse strength of the expanded tubular member;

a spectral content selected to control the burst strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the burst strength of the expanded tubular member;

a number of cycles selected to control the burst strength of the expanded tubular member;

a spectral content selected to control the yield strength of the expanded tubular member;

a maximum magnitude of pressure selected to control the yield strength of the expanded tubular member;

a number of cycles selected to control the yield strength of the expanded tubular member;

a spectral content selected to control the wall thickness of the expanded tubular member;

a maximum magnitude of pressure selected to control the wall thickness of the expanded tubular member;

a number of cycles selected to control the wall thickness of the expanded tubular member;

a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time;

a square wave signal that varies from a maximum value Pmax to a minimum value Pmin over time; and

a triangular signal that varies from a maximum value Pmax to a minimum value Pmin over time.

23. A system for coupling a tubular member to an existing tubular member in a borehole located in a subterranean formation, the system comprising:

means for installing a tubular liner and an expansion device in the borehole;

means for overlapping the tubular liner with an existing tubular member;

means for injecting fluidic material into the borehole;

means for pressurizing a portion of an interior region of the tubular liner;

means for radially expanding at least a portion of the liner in the borehole by extruding at least a portion of the liner off of the expansion device;

means for positioning a pressure source within the liner; and

means for operating the pressure source to generate a pressure cycle signal, the pressure cycle signal comprising: a spectral content selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a maximum magnitude of pressure selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; a number of cycles selected to control the collapse strength, burst strength, yield strength or wall thickness of the plastically deformed tubular member; and a sinusoidal signal that varies from a maximum value Pmax to a minimum value Pmin over time.