Expandable Tubular
An expandable tubular.
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This application is the U.S. National Stage application for PCT application serial no. PCT/US2004/028888, attorney docket no. 25791.305.02, filed on Sep. 7, 2004, which claimed the benefit of: (1) U.S. provisional patent application Ser. No. 60/600,679, attorney docket no 25791.194, filed on Aug. 11, 2004, (2) U.S. provisional patent application Ser. No. 60/585,370, attorney docket no 25791.299, filed on Jul. 2, 2004, and (3) U.S. provisional patent application serial no. 60/500,435, attorney docket no 25791.304, filed on Sep. 5, 2003, the disclosures of which are incorporated herein by reference.
The application is a continuation-in-part of U.S. utility patent application Ser. No. 10/528,498, attorney docket no. 25791.118.08, filed on Mar. 18, 2005, which was the National Stage for PCT application serial no. PCT/US03/025667, attorney docket no. 25791.118.02, filed on Aug. 18, 2003, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/412,653, attorney docket 25791.118, filed on Sep. 20, 2002, the disclosures of which are incorporated herein by reference.
This application is related to the following co-pending applications: (1) U.S. National State patent application Ser. No. ______, attorney docket no. 25791.304.10, filed on Mar. 2, 2006; (2) U.S. National State patent application Ser. No. ______, attorney docket no. 25791.306.04, filed on _; (3) U.S. National State patent application Ser. No. ______, attorney docket no. 25791.307.04, filed on _; and (4) U.S. National State patent application Ser. No. ______, attorney docket no. 25791.308.07, filed on _, the disclosures of which are incorporated herein by reference.
This application is related to the following co-pending applications: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 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. Pat. No. 6,640,903 which was filed as U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (7) U.S. Pat. No. 6,568,471, which was filed as patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,841, filed on Feb. 26, 1999, (8) U.S. Pat. No. 6,575,240, which was filed as patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claims priority from provisional application 60/121,907, filed on Feb. 26, 1999, (9) U.S. Pat. No. 6,557,640, which was filed as patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (12) U.S. patent application Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claims priority from provisional application 60/146,203, filed on Jul. 29, 1999, (13) U.S. provisional patent application Ser. No. 60/143,039, attorney docket No. 25791.26, filed on Jul. 9, 1999, (14) U.S. patent application Ser. No. 10/111,982, attorney docket n0.25791.27.08, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (18) U.S. patent application Ser. No. 10/089,419, filed on Mar. 27, 2002, attorney docket n0.25791.36.03, which claims priority from provisional patent application Ser. No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (19) U.S. patent application Ser. No. 09/679,906, filed on Oct. 5, 2000, attorney docket no. 25791.37.02, which claims priority from provisional patent application Ser. No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (20) U.S. patent application Ser. No. 10/303,992, filed on Nov. 22, 2002, attorney docket no. 25791.38.07, which claims priority from provisional patent application Ser. No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent application Ser. No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S. provisional patent application Ser. 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 serial 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 serial no. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000, (27) U.S. patent application Ser. No. 10/406,648, filed on Mar. 31, 2003, attorney docket no. 25791.48.06, which claims priority from provisional patent application Ser. No. 60/237,334, attorney docket no. 25791.48, filed on Oct. 2, 2000, (28) PCT application US02/04353, filed on Feb. 14, 2002, attorney docket no. 25791.50.02, which claims priority from U.S. provisional patent application Ser. No. 60/270,007, attorney docket no. 25791.50, filed on Feb. 20, 2001, (29) U.S. patent application Ser. No. 10/465,835, filed on Jun. 13, 2003, attorney docket no. 25791.51.06, which claims priority from provisional patent application serial no. 60/262,434, attorney docket no. 25791.51, filed on Jan. 17, 2001, (30) U.S. patent application Ser. No. 10/465,831, filed on Jun. 13, 2003, attorney docket no. 25791.52.06, which claims priority from U.S. provisional patent application Ser. No. 60/259,486, attorney docket no. 25791.52, filed on Jan. 3, 2001, (31) U.S. provisional patent application Ser. No. 60/452,303, filed on Mar. 5, 2003, attorney docket no. 25791.53, (32) U.S. Pat. No. 6,470,966, which was filed as patent application Ser. No. 09/850,093, filed on May 7, 2001, attorney docket no. 25791.55, as a divisional application of 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, (33) U.S. Pat. No. 6,561,227, which was filed as patent application Ser. No. 09/852,026, filed on May 9, 2001, attorney docket no. 25791.56, as a divisional application of 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, (34) U.S. patent application Ser. No. 09/852,027, filed on May 9, 2001, attorney docket no. 25791.57, as a divisional application of 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, (35) PCT Application US02/25608, attorney docket no. 25791.58.02, filed on Aug. 13, 2002, which claims priority from provisional application 60/318,021, filed on Sep. 7, 2001, attorney docket no. 25791.58, (36) PCT Application US02/24399, attorney docket no. 25791.59.02, filed on Aug. 1, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/313,453, attorney docket no. 25791.59, filed on Aug. 20, 2001, (37) PCT Application US02/29856, attorney docket no. 25791.60.02, filed on Sep. 19, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/326,886, attorney docket no. 25791.60, filed on Oct. 3, 2001, (38) PCT Application US02/20256, attorney docket no. 25791.61.02, filed on Jun. 26, 2002, which claims priority from U.S. provisional patent application Ser. No. 60/303,740, attorney docket no. 25791.61, filed on Jul. 6, 2001, (39) U.S. patent application Ser. No. 09/962,469, filed on Sep. 25, 2001, attorney docket no. 25791.62, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (40) U.S. patent application Ser. No. 09/962,470, filed on Sep. 25, 2001, attorney docket no. 25791.63, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (41) U.S. patent application Ser. No. 09/962,471, filed on Sep. 25, 2001, attorney docket no. 25791.64, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (42) U.S. patent application Ser. No. 09/962,467, filed on Sep. 25, 2001, attorney docket no. 25791.65, which is a divisional of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (now U.S. Pat. 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No. 60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, (45) PCT application US02/39425, filed on Dec. 10, 2002, attorney docket no. 25791.68.02, which claims priority from U.S. provisional patent application Ser. No. 60/343,674, attorney docket no. 25791.68, filed on Dec. 27, 2001, (46) U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 which issued Oct. 21, 2003), which is 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, (47) U.S. utility patent application Ser. No. 10/516,467, attorney docket no. 25791.70, filed on Dec. 10, 2001, which is a continuation application of U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, (now U.S. Pat. No. 6,634,431 which issued Oct. 21, 2003), which is 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, (48) PCT application US03/00609, filed on Jan. 9, 2003, attorney docket no. 25791.71.02, which claims priority from U.S. provisional patent application Ser. No. 60/357,372, attorney docket no. 25791.71, filed on Feb. 15, 2002, (49) U.S. patent application Ser. No. 10/074,703, attorney docket no. 25791.74, filed on Feb. 12, 2002, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. 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BACKGROUND OF THE INVENTIONThis invention relates generally to oil and gas exploration, and in particular to forming and repairing wellbore casings to facilitate oil and gas exploration.
BRIEF DESCRIPTION OF THE DRAWINGS
Referring initially to
As illustrated in
As illustrated in
As illustrated in
In an exemplary embodiment, 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.
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, as illustrated in
Referring to
As illustrated in
As illustrated in
As illustrated in
In an exemplary embodiment, 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.
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, as illustrated in
Referring to
As illustrated in
As illustrated in
As illustrated in
In an exemplary embodiment, the anisotropy ratio AR for the first and second expandable tubular members is defined by the following equation:
AR=ln(WTf/WTo)/ln(Df/Do); (1)
where AR=anisotropy ratio;
where WTf=final wall thickness of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member;
where WTi=initial wall thickness of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member;
where Df=final inside diameter of the expandable tubular member following the radial expansion and plastic deformation of the expandable tubular member; and
where Di=initial inside diameter of the expandable tubular member prior to the radial expansion and plastic deformation of the expandable tubular member.
In an exemplary embodiment, the anisotropy ratio AR for the first and/or second expandable tubular members, 204 and 204, is greater than 1.
In an exemplary experimental embodiment, 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.
Referring to
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204, have the following characteristics:
In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 108, 202 and/or 204, are characterized by an expandability coefficient f:
i. f=r×n (2)
-
- ii. where
- f=expandability coefficient;
- 1. r=anisotrophy coefficient; and
- 2. n=strain hardening exponent.
- ii. where
In an exemplary embodiment, the anisotropy coefficient for one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 is greater than 1. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy to radially expand and plastically deform each unit length than a tubular member having a lower expandability coefficient. In an exemplary embodiment, a tubular member having a higher expandability coefficient requires less power and/or energy per unit length to radially expand and plastically deform than a tubular member having a lower expandability coefficient.
In several exemplary experimental embodiments, 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:
In exemplary experimental embodiment, as illustrated in
In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy A exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
In exemplary experimental embodiment, as illustrated in
In an exemplary experimental embodiment, a sample of an expandable tubular member composed of Alloy B exhibited the following tensile characteristics before and after radial expansion and plastic deformation:
In an exemplary experimental embodiment, samples of expandable tubulars composed of Alloys A, B, C, and D exhibited the following tensile characteristics prior to radial expansion and plastic deformation:
In an exemplary embodiment, one or more of the expandable tubular members, 12, 14, 24, 26, 102, 104, 106, 108, 202 and/or 204 have a strain hardening exponent greater than 0.12, and a yield ratio is less than 0.85.
In an exemplary embodiment, the carbon equivalent Ce, for tubular members having a carbon content (by weight percentage) less than or equal to 0.12%, is given by the following expression:
Ce═C+Mn/6+(Cr+Mo+V+Ti+Nb)/5+(Ni+Cu)/15 (3)
where
Ce=carbon equivalent value;
a. C=carbon percentage by weight;
b. Mn=manganese percentage by weight;
c. Cr=chromium percentage by weight;
d. Mo=molybdenum percentage by weight;
e. V=vanadium percentage by weight;
f. Ti=titanium percentage by weight;
g. Nb=niobium percentage by weight;
h. Ni=nickel percentage by weight; and
i. Cu=copper percentage by weight.
In an exemplary embodiment, the carbon equivalent value Ce, 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.
In an exemplary embodiment, the carbon equivalent Ce, for tubular members having more than 0.12% carbon content (by weight), is given by the following expression:
Ce=C+Si/30+(Mn+Cu+Cr)/20+Ni/60+Mo/15+V/10+5*B (4)
-
- where
Ce=carbon equivalent value;
a. C=carbon percentage by weight;
b. Si=silicon percentage by weight;
c. Mn=manganese percentage by weight;
d. Cu=copper percentage by weight;
e. Cr=chromium percentage by weight;
f. Ni=nickel percentage by weight;
g. Mo=molybdenum percentage by weight;
h. V=vanadium percentage by weight; and
i. B=boron percentage by weight.
In an exemplary embodiment, the carbon equivalent value Ce, 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.
Referring to
The internally threaded connection 2212 of the end portion 2214 of the first tubular member 2210 is a box connection, and the externally threaded connection 2224 of the end portion 2226 of the second tubular member 2228 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2216 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, the tubular sleeve 2216 is also radially expanded and plastically deformed. As a result, 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 2228 by a heat shrink fit.
In several alternative embodiments, the 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 Technology L.L.C.
The use of the 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. For example, 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. Furthermore, the 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. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 2216 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the 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. Furthermore, 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. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 2210 and 2228, 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 the 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, 2214 and 2226, of the 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The first tubular member 2310 includes a recess 2331. The internal flange 2321 mates with and is received within the annular recess 2331. Thus, the sleeve 2316 is coupled to and surrounds the external surfaces of the first and second tubular members 2310 and 2328.
The internally threaded connection 2312 of the end portion 2314 of the first tubular member 2310 is a box connection, and the externally threaded connection 2324 of the end portion 2326 of the second tubular member 2328 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2316 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members 2310 and 2328, the tubular sleeve 2316 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The internally threaded connection 2412 of the end portion 2414 of the first tubular member 2410 is a box connection, and the externally threaded connection 2424 of the end portion 2426 of the second tubular member 2428 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2416 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members, 2410 and 2428, the tubular sleeve 2416 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The internally threaded connection 2512 of the end portion 2514 of the first tubular member 2510 is a box connection, and the externally threaded connection 2524 of the end portion 2526 of the second tubular member 2528 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2516 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members 2510 and 2528, the tubular sleeve 2516 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
The addition of the 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The first tubular member 2610 includes a recess 2631. The internal flange 2621 mates with and is received within the annular recess 2631. Thus, the sleeve 2616 is coupled to and surrounds the external surfaces of the first and second tubular members 2610 and 2628.
The internally threaded connection 2612 of the end portion 2614 of the first tubular member 2610 is a box connection, and the externally threaded connection 2624 of the end portion 2626 of the second tubular member 2628 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2616 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members 2610 and 2628, the tubular sleeve 2616 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
The addition of the 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.
In several exemplary embodiments, 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.
Referring to
The first tubular member 2710 includes a recess 2731. The internal flange 2721 mates with and is received within the annular recess 2731. Thus, 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, and the externally threaded connection 2724 of the end portion 2726 of the second tubular member 2728 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 2716 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members 2710 and 2728, the tubular sleeve 2716 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
Referring to
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. In an exemplary embodiment, the internal diameter of the tubular sleeve 2918 is at least approximately 0.020″ greater than the outside diameters of the first tubular member 2910. In this manner, during the threaded coupling of the first and second tubular members 2910 and 2926, fluidic materials within the first and second tubular members may be vented from the tubular members.
The first and second tubular members 2910 and 2926, and the tubular sleeve 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.
During the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, the tubular sleeve 2918 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, the sealing element 2930 seals the interface between the first and second tubular members. In an exemplary embodiment, during and after the radial expansion and plastic deformation of the first and second tubular members 2910 and 2926, and the tubular sleeve 2918, 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. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
In several exemplary embodiments, one or more portions of the first and second tubular members, 2910 and 2926, the tubular sleeve 2918, and the sealing element 2930 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.
Referring to
The internally threaded connections, 3012a and 3012b, of the end portion 3016 of the first tubular member 3010 are box connections, and the externally threaded connections, 3018a and 3018b, of the end portion 3022 of the second tubular member 3024 are pin connections. In an exemplary embodiment, 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.
In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3010 and 3024, the sealing element 3026 seals the interface between the first and second tubular members. In an exemplary embodiment, before, 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 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. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
In an alternative embodiment, 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The internally threaded connections, 3032a and 3032b, of the end portion 3036 of the first tubular member 3030 are box connections, and the externally threaded connections, 3038a and 3038b, of the end portion 3042 of the second tubular member 3044 are pin connections. In an exemplary embodiment, 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.
In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3030 and 3044, the sealing element 3046 seals the interface between the first and second tubular members. In an exemplary embodiment, before, 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 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. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
In an alternative embodiment, 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.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
The internally threaded connections, 3052a and 3052b, of the end portion 3058 of the first tubular member 3050 are box connections, and the externally threaded connections, 3060a and 3060b, of the end portion 3066 of the second tubular member 3068 are pin connections. In an exemplary embodiment, 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.
In an exemplary embodiment, before, during, and after the radial expansion and plastic deformation of the first and second tubular members 3050 and 3068, the sealing element 3070 seals the interface between the first and second tubular members. In an exemplary embodiment, before, during and/or after the radial expansion and plastic deformation of the first and second tubular members, 3050 and 3068, 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. In an exemplary embodiment, the metal to metal seal is both fluid tight and gas tight.
In an alternative embodiment, 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.
In several exemplary embodiments, 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.
Referring to
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.
The internally threaded connections, 3112a and 3112b, of the end portion 3116 of the first tubular member 3110 are box connections, and the externally threaded connections, 3118a and 3118b, of the end portion 3122 of the second tubular member 3124 are pin connections.
The 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.
During the radial expansion and plastic deformation of the first and second tubular members 3110 and 3124, the tubular sleeves 3126, 3128 and/or 3130 are also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In several exemplary embodiments, 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, 104, 106, 108, 202 and/or 204.
Referring to
The internally threaded connection 3212 of the end portion 3214 of the first tubular member 3210 is a box connection, and 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
The first and second tubular members 3210 and 3220, and the tubular sleeve 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.
During the radial expansion and plastic deformation of the first and second tubular members 3210 and 3220, the tubular sleeve 3222 is also radially expanded and plastically deformed. In an exemplary embodiment, as a result, 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.
In several exemplary embodiments, 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, 102, 104, 106, 108, 202 and/or 204.
Referring to
A first end of a tubular sleeve 3318 that includes an internal flange 3320 having a tapered portion 3322 and an annular recess 3324 for receiving the annular projection 3314 of the first tubular member 3310, and a second end that includes a tapered portion 3326, is then mounted upon and receives the end portion 3316 of the first tubular member 3310.
In an exemplary embodiment, 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. An externally threaded connection 3326 of an end portion 3328 of a second tubular member 3330 having an annular recess 3332 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. In an exemplary embodiment, 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. Thus, 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, and the externally threaded connection 3326 of the end portion 3328 of the second tubular member 3330 is a pin connection. In an exemplary embodiment, the internal diameter of the tubular sleeve 3318 is at least approximately 0.020″ 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.
As illustrated in
During the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, the 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.
In several alternative embodiments, the first and second tubular members, 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 Technology L.L.C.
The use of the 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. For example, 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. Furthermore, the 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. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, the tubular sleeve 3318 provides an indication of to what degree the first and second tubular members are threadably coupled. For example, if the 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. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3310 and 3330, 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 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, axial loads and/or torque loads may be transmitted through the tubular sleeve.
In several exemplary embodiments, 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, 108, 202 and/or 204.
Referring to
A first end of a tubular sleeve 3418 that includes an internal flange 3420 and a tapered portion 3422, a second end that includes a tapered portion 3424, and an intermediate portion that includes one or more longitudinally aligned openings 3426, is then mounted upon and receives the end portion 3416 of the first tubular member 3410.
In an exemplary embodiment, 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. An externally threaded connection 3428 of an end portion 3430 of a second tubular member 3432 that includes one or more internal grooves 3434 is then positioned within the tubular sleeve 3418 and threadably coupled to the internally threaded connection 3412 of the end portion 3416 of the first tubular member 3410. In an exemplary embodiment, the internal flange 3420 of the tubular sleeve 3418 mates with and is received within an annular recess 3436 defined in the end portion 3430 of the second tubular member 3432. Thus, the tubular sleeve 3418 is coupled to and surrounds the external surfaces of the first and second tubular members, 3410 and 3432.
The first and second tubular members, 3410 and 3432, and the tubular sleeve 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.
During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the 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.
During the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, 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. As a result, during and after the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, 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. In an exemplary embodiment, the orientations of the grooves 3414 and/or 3434 and the openings 3426 are orthogonal to one another. In an exemplary embodiment, the grooves 3414 and/or 3434 are helical grooves.
In several alternative embodiments, the 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 Technology L.L.C.
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. For example, 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. In this manner, damage to the exterior surfaces of the end portions, 3416 and 3430, of the first and second tubular members, 3410 and 3432, is avoided that could otherwise result in stress concentrations that could cause a catastrophic failure during subsequent radial expansion operations. Furthermore, the 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. In addition, during the relative rotation of the second tubular member with respect to the first tubular member, required during the threaded coupling of the first and second tubular members, 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 3432. In this manner, failure modes such as, for example, longitudinal cracks in the end portions, 3416 and 3430, of the first and second tubular members may be limited in severity or eliminated all together. In addition, after completing the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, the tubular sleeve 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, 3410 and 3432, into the annulus between the first and second tubular members and the structure. Furthermore, because, following the radial expansion and plastic deformation of the first and second tubular members, 3410 and 3432, 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, axial loads and/or torque loads may be transmitted through the tubular sleeve.
In several exemplary embodiments, 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. 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. 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Referring to
Referring to
In several exemplary embodiments, 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. In this manner, the hard phase provides high strength, the soft phase provides ductility, and the transitionary phase transitions to a hard phase, such as martensite, during a radial expansion and plastic deformation. Furthermore, in this manner, the yield point of the tubular member increases as a result of the radial expansion and plastic deformation. Further, in this manner, the tubular member is ductile, prior to the radial expansion and plastic deformation, thereby facilitating the radial expansion and plastic deformation. In an exemplary embodiment, the composition of a dual-phase expandable tubular member includes (weight percentages): about 0.1% C, 1.2% Mn, and 0.3% Si.
In an exemplary experimental embodiment, as illustrated in
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3602a is then heated at a temperature of 790° C. for about 10 minutes in step 3604.
In an exemplary embodiment, the expandable tubular member 3602a is then quenched in water in step 3606.
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3602a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3602a, the yield strength of the expandable tubular member is about 95 ksi.
In an exemplary experimental embodiment, as illustrated in
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3702a is then heated at a temperature of 790° C. for about 10 minutes in step 3704.
In an exemplary embodiment, the expandable tubular member 3702a is then quenched in water in step 3706.
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3702a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3702a, the yield strength of the expandable tubular member is about 130 ksi.
In an exemplary experimental embodiment, as illustrated in
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3802a is then heated at a temperature of 790° C. for about 10 minutes in step 3804.
In an exemplary embodiment, the expandable tubular member 3802a is then quenched in water in step 3806.
In an exemplary experimental embodiment, as illustrated in
In an exemplary embodiment, the expandable tubular member 3802a is then radially expanded and plastically deformed using one or more of the methods and apparatus described above. In an exemplary embodiment, following the radial expansion and plastic deformation of the expandable tubular member 3802a, the yield strength of the expandable tubular member is about 97 ksi.
Referring to
Referring to
During the radial expansion process, the leading edge portion 5025 may be lubricated by the presence of lubricating fluids provided ahead of the expansion cone 5000. However, because the radial clearance between the expansion cone 5000 and the tubular member 5005 in the trailing edge portion 5030 during the radial expansion process is typically extremely small, and the operating contact pressures between the tubular member 5005 and the expansion cone 5000 are extremely high, the quantity of lubricating fluid provided to the trailing edge portion 5030 is typically greatly reduced. In typical radial expansion operations, this reduction in lubrication in the trailing edge portion 5030 increases the forces required to radially expand the tubular member 5005.
Surface Structure of the Expansion Cone Referring to
In an exemplary embodiment, the circumferential grooves 5115 are fluidicly coupled to the internal flow passages 5120. In this manner, during the radial expansion process, 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. Thus, the trailing edge portion of the interface between the expansion cone 5100 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.
In an exemplary embodiment, the expansion cone 5100 includes a plurality of circumferential grooves 5115. In an exemplary embodiment, 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. In an exemplary embodiment, the circumferential grooves 5115 are equally spaced along the trailing edge portion of the expansion cone 5100 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.
In an exemplary embodiment, the expansion cone 5100 includes a plurality of flow passages 5120 coupled to each of the circumferential grooves 5115. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, the circumferential grooves 5215 are fluidicly coupled to the axial groves 5220. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front 5200a of the expansion cone 5200 into the circumferential grooves 5215. Thus, 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 force required to radially expand the tubular member. In an exemplary embodiment, 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. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5200 includes a plurality of circumferential grooves 5215. In an exemplary embodiment, the expansion cone 5200 includes a plurality of axial grooves 5220 coupled to each of the circumferential grooves 5215. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, 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. Thus, 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 force required to radially expand the tubular member. Furthermore, 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. In an exemplary embodiment, the lubricating fluids are injected into the internal flow passages 5320 by pressurizing the area behind the rear 5300b of the expansion cone 5300 during the radial expansion process.
In an exemplary embodiment, the expansion cone 5300 includes a plurality of circumferential grooves 5315. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5300 includes a plurality of flow passages 5320 coupled to each of the circumferential grooves 5315. In an exemplary embodiment, the flow passages 5320 fluidicly coupled the front end 5300a and the rear end 5300b of the expansion cone 5300. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, the circumferential grooves 5415 are fluidicly coupled to the axial grooves 5420. In this manner, during the radial expansion process, 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. Thus, 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. Furthermore, In an exemplary embodiment, pressurized lubricating fluids pass from the fluid passages 5420 to the area in front of the front 5400a of the expansion cone 5400. In this manner, the area adjacent to the front 5400a of the expansion cone 5400 is cleaned of foreign materials. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5400 includes a plurality of circumferential grooves 5415. In an exemplary embodiment, the expansion cone 5400 includes circumferential grooves 5415 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. In an exemplary embodiment, 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 5400 and a tubular member during the radial expansion process.
In an exemplary embodiment, the expansion cone 5400 includes a plurality of axial grooves 5420 coupled to each of the circumferential grooves 5415. In an exemplary embodiment, the axial grooves 5420 fluidicly coupled the front end and the rear end of the expansion cone 5400. In an exemplary embodiment, the cross sectional area of the circumferential grooves 5415 is greater than the cross sectional area of the axial grooves 5420 in order to minimize resistance to fluid flow. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, the circumferential grooves 5515 are fluidicly coupled to the axial grooves 5520. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front 5500a of the expansion cone 5500 into the circumferential grooves 5515. Thus, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5500 includes a plurality of circumferential grooves 5515. In an exemplary embodiment, 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. In an exemplary embodiment, 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 during the radial expansion process.
In an exemplary embodiment, the expansion cone 5500 includes a plurality of axial grooves 5520 coupled to each of the circumferential grooves 5515. In an exemplary embodiment, the axial grooves 5520 intersect each of the circumferential groves 5515 at an acute angle. In an exemplary embodiment, the cross sectional area of the circumferential grooves 5515 is greater than the cross sectional area of the axial grooves 5520. In an exemplary embodiment, the axial grooves 5520 are spaced apart in the circumferential direction by at least about 3 inches in order to provide lubrication during the radial expansion process. In an exemplary embodiment, the axial grooves 5520 intersect the longitudinal axis of the expansion cone 5500 at a larger angle than the angle of attack of the tapered portion 5505 in order to provide lubrication during the radial expansion process.
Referring to
In an exemplary embodiment, the circumferential groove 5615 is fluidicly coupled to the internal flow passage 5620. In this manner, during the radial expansion process, 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. Thus, 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 force required to radially expand the tubular member. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5600 includes a plurality of spiral circumferential grooves 5615. In an exemplary embodiment, 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. In an exemplary embodiment, the circumferential grooves 5615 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.
In an exemplary embodiment, the expansion cone 5600 includes a plurality of flow passages 5620 coupled to each of the circumferential grooves 5615. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, the circumferential groove 5715 is fluidicly coupled to the axial grooves 5720. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front 5700a of the expansion cone 5700 into the circumferential groove 5715. Thus, 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 force required to radially expand the tubular member. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5700 includes a plurality of spiral circumferential grooves 5715. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5700 includes a plurality of axial grooves 5720 coupled to each of the circumferential grooves 5715. In an exemplary embodiment, the axial grooves 5720 intersect the circumferential grooves 5715 in a perpendicular manner. In an exemplary embodiment, the cross sectional area of the circumferential groove 5715 is greater than the cross sectional area of the axial grooves 5720 in order to minimize resistance to fluid flow. In an exemplary embodiment, the circumferential spacing of the axial grooves is greater than about 3 inches in order to provide lubrication during the radial expansion process. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, 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 force required to radially expand the tubular member. In an exemplary embodiment, the lubricating fluids are injected into the first axial groove 5820 by pressurizing the region behind the back 5800b of the expansion cone 5800. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5800 includes a plurality of circumferential grooves 5815. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5800 includes a plurality of first axial grooves 5820 coupled to each of the circumferential grooves 5815. In an exemplary embodiment, the first axial grooves 5820 extend from the back 5800b of the expansion cone 5800 and intersect the circumferential groove 5815. In an exemplary embodiment, the first axial groove 5820 intersects the circumferential groove 5815 in a perpendicular manner. In an exemplary embodiment, the cross sectional area of the circumferential groove 5815 is greater than the cross sectional area of the first axial groove 5820 in order to minimize resistance to fluid flow. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5800 includes a plurality of second axial grooves 5825 coupled to each of the circumferential grooves 5815. In an exemplary embodiment, the second axial grooves 5825 extend from the front 5800a of the expansion cone 5800 and intersect the circumferential groove 5815. In an exemplary embodiment, the second axial grooves 5825 intersect the circumferential groove 5815 in a perpendicular manner. In an exemplary embodiment, 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. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
Referring to
In an exemplary embodiment, the circumferential groove 5915a is fluidicly coupled to the internal flow passages 5920. In this manner, during the radial expansion process, 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. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, the expansion cone 5900 includes a plurality of circumferential grooves 5915a. In an exemplary embodiment, 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 5900 and a tubular member during the radial expansion process. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 5900 includes a plurality of flow passages coupled to each of the circumferential grooves 5915a. In another embodiment, circumferential groove 5915b, which is not fluidicly coupled to the internal flow passages, may also be included.
Referring to
In an exemplary embodiment, the circumferential grooves 6015 are fluidicly coupled to the internal flow passages 6020. In this manner, during the radial expansion process, 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. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, the expansion cone 6000 includes a plurality of circumferential grooves 6015. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 6000 includes a plurality of flow passages coupled to each of the circumferential grooves 6015.
Referring to
In an exemplary embodiment, the circumferential groove 6115a is fluidicly coupled to the internal flow passages 6120. In this manner, during the radial expansion process, 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. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, the expansion cone 6100 includes a plurality of circumferential grooves 6115a. In an exemplary embodiment, 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. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 6100 includes a plurality of flow passages coupled to each of the circumferential grooves 6115a. Alternatively, circumferential groove 6115b, which is not fluidicly coupled to the internal flow passages, may also be included.
Referring to
In an exemplary embodiment, 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 6200a of the expansion cone 6200 into the circumferential grooves 6215, such as, for example, from reservoir 6222 utilizing pump 6224. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, the expansion cone 6200 includes a plurality of circumferential grooves 6215 arranged in a pinecone design. In an exemplary embodiment, 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. In an exemplary embodiment, 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 6200 and a tubular member during the radial expansion process.
Referring to
In an exemplary embodiment, 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. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, a second circumferential groove 6226 is fluidicly coupled to the circumferential grooves 6218.
Referring to
In an exemplary embodiment, 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 6300a of the expansion cone 6300 into the circumferential grooves 6315, such as, for example, from reservoir 6322 utilizing pump 6324. Thus, 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 force required to radially expand the tubular member. In an exemplary embodiment, 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.
In an exemplary embodiment, the expansion cone 6300 includes a plurality of spiral circumferential grooves 6315. In an exemplary embodiment, 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. In an exemplary embodiment, 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. In an exemplary embodiment, the axial grooves 6320 intersect each other in a perpendicular manner.
Referring to
In an exemplary embodiment, 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 6300a of the expansion cone 6300 into the circumferential grooves 6318, such as, for example, from reservoir 6322 utilizing pump 6324. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, a second circumferential groove 6326 is fluidicly coupled to the circumferential grooves 6318.
Referring to
Referring to
In an exemplary embodiment, outer surfaces 6410a and 6410b of tapered portion 6405 are tapered at angle β. In an exemplary embodiment, the angle β 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 6410b in contact with the inner surface of the tubular member for radial expansion. In an exemplary embodiment, 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 α, the sliding angle. In an exemplary embodiment, angle α may be less than or equal to 30 degrees, such as, for example 10 degrees, causing lubricant in the circumferential groove 6415 to be drawn efficiently on to the inner surface of the tubular member during radial expansion.
Referring to
Referring to
In an exemplary embodiment, the circumferential groove 6618 under lip 6615 is fluidicly coupled to the internal flow passages 6660 through port 6662. In this manner, during the radial expansion process, lubricating fluids are transmitted from the area ahead of the front end 6600a of the expansion cone 6600 under lip 6615. Thus, 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 force required to radially expand the tubular member.
In an exemplary embodiment, exemplary relative dimensions of the elements of
1. taper angle N 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—0.020-0.060;
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. diameter 6676 of the cone at rear end 6600b—1.656; and
10. depth 6680 of the vertical portion between the top and first edges—0.015.
Referring to
In an exemplary embodiment, during the radial expansion process, 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. Thus, 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 force required to radially expand the tubular member. In an exemplary embodiment, 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.
In an exemplary embodiment, example relative dimensions of the elements of in
1. taper angle β 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.
Referring to
Referring to
Referring to
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.
In an exemplary embodiment, 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 0.06″:
R=(D1+Dexp)/2=(4.77−5.68)/2=0.42; (5)
Sin(α/2)=1−(H/R)=1−(0.06/0.42); (6)
α/2=12.3°; (7)
α=24.6; (8)
N=360°/α=360°/24.6°=15; (9)
where,
D1=Original tubular member inside diameter;
Dexp=Expanded tubular member inside diameter;
H=Gap between gap surface and tubular member inside diameter;
R=Radius of polygon at midpoint of expansion cone;
α=Angle between circumferential spaced apart contact points of polygon; and
N=Number of polygon flat surfaces.
Accordingly, 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. In an exemplary embodiment, 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.
Referring to
W=[2R sin(α/2)]/K; (10)
R=(D1+D2)/4; (11)
α=360 degrees/N; (12)
where:
W=Width of contact point;
D1=initial tubular member diameter;
D2=expanded diameter;
N=Number of polygon flat surfaces; and
K=System friction coefficient that must be determined.
In an exemplary embodiment, 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. In an exemplary embodiment, K is 4.2.
Referring now to
In several exemplary embodiments, 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, 5900, 6000, 6100, 6200, 6300 and 6600. Furthermore, it may be implemented in any expansion device including one or more expansion surfaces.
The angle of the tapered portion of each expansion cone, the cone angle, in the system for lubricating the interface between an expansion cone and a tubular member during the expansion process, including the tapered portions in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 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. In an exemplary experimental embodiment, 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 4.77″ to an inside diameter of 5.68″. 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.
In several exemplary embodiments, one or more of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 may or may not have internal passages. In another embodiment, 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. In this manner, 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.
Lubricant Delivery System
Regardless of the type of expansion device used in the system for lubricating the interface between an expansion cone and a tubular member during the expansion process, including, for example, expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100, lubricants utilized in the systems may be provided to the system in various manners. In an exemplary embodiment, 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, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 using a supply of lubricating fluids provided adjacent to the front end 5100a, 5200a, 5300a, 5400a, 5500a, 5600a, 5700a, 5800a, 5900a, 6000a, 6100a, 6200a, 6300a, 6600a, 6700a, 6800a, 6900a, 7000a and 7100a, of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100. In another exemplary embodiment, 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, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 using a supply of lubricating fluids provided adjacent to the rear end 5100a, 5200a, 5300a, 5400a, 5500a, 5600a, 5700a, 5800a, 5900a, 6000a, 6100a, 6200a, 6300a, 6600a, 6700a, 6800a, 6900a, 7000a and 7100a, of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100. Alternatively, the lubricating fluids may be injected into any internal flow passages in expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 using a fluid conduit that is fluidicly coupled to the tapered ends of the expansion cones expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100.
Referring to
In an exemplary embodiment, during operation of the system 7200, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7202 is displaced in a direction 7233 relative to the expandable tubular member 7230. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7232 is conveyed through the radial passages, 7228b and 7228c, of the tubular member 7228 into a annular chamber 7234 defined between the internal annular recess 7208 of the expansion cone 7202 and the tubular member 7228. If the operating pressure of the fluidic material 7232 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7226a and 7226b, the fluidic material is then conveyed through the longitudinal passages, 7212a and 7212b, into an annular chamber 7236 defined between the external annular recess 7210 of the expansion cone 7202 and the expandable tubular member 7230. 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, 7218a, 7218b, and 7218c, into the interface between the expansion cone 7202 and the expandable tubular member 7230.
In an exemplary embodiment, 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, 7226a and 7226b. In this manner, during the radial expansion process, the fluidic material 7232 may be controllably injected and metered into the interface between the tapered external expansion surface 7224 of the expansion cone 7202 and the expandable tubular member 7230 continuously during the radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the fluidic material 7232 may be injected into the external grooves, 7224a, 7224b, and 7224c only when required, or as desired. Thus, 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 force required to radially expand and plastically deform the expandable tubular member.
In an alternate embodiment, the spring-biased check valves, 7226a and 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.
Referring to
In an exemplary embodiment, during operation of the system 7300, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7302 is displaced in a direction 7333 relative to the expandable tubular member 7330. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7332 is conveyed through the radial passages, 7328b and 7328c, of the tubular member 7328, into an annular chamber 7336 defined between the external annular recess 7310 of the expansion cone 7302 and the expandable tubular member 7330 above tubular piston 7340. In an exemplary embodiment, a second fluidic material 7344 may be housed in the annular chamber 7336 below tubular piston 7342. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7332 exceeds a predetermined value, which may vary as a function of the operating characteristics the tubular piston 7340, 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. In particular, if the operating pressure of the fluidic material 7332 exceeds a predetermined value, 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 7314b, and the radial passages, 7316a, 7316b, 7316c, 7318a, 7318b, and 7318c, into the interface between the expansion cone 7302 and the expandable tubular member 7330.
In an exemplary embodiment, 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. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7332 may be injected into the external grooves, 7324a, 7324b, and 7324c only when required, or as desired. Thus, 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 force required to radially expand and plastically deform the expandable tubular member.
In an exemplary embodiment, 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. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7300.
Referring to
In an exemplary embodiment, during operation of the system 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. In an exemplary embodiment, 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 7402 is displaced in a direction 7433 relative to the expandable tubular member 7430. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7432 is conveyed through the radial passages, 7428b and 7428c, of the tubular member 7428 into a annular chamber 7434 defined between the internal annular recess 7408 of the expansion cone 7402 and the tubular member 7428. In an exemplary embodiment, 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. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7432 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7426a and 7426b, and tubular piston 7440, the tubular piston is displaced within annular chamber 7434, thereby pumping the second fluidic material through the longitudinal passages, 7412a and 7412b, into the annular chamber 7436. 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.
In an exemplary embodiment, 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, 7426a and 7426b, and tubular piston 7440. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7444 may be injected into the external grooves, 7424a, 7424b, and 7424c only when required, or as desired. Thus, the trailing edge portion of the interface between the tapered external expansion surface 7424 of the expansion cone 7402 and the expandable tubular member 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.
In an embodiment, 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. In an embodiment, 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 7444 exceeds 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.
In an exemplary embodiment, the second fluidic material 7444 in annular chambers, 7434 and 7436 below tubular piston 7440 may be preloaded into expansion cone 7400 prior to being used to expand tubular member 7402. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7400.
In an alternate embodiment, the 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.
Referring to
In an exemplary embodiment, during operation of the system 7500, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7502 is displaced in a direction 7533 relative to the expandable tubular member 7530. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7532 is conveyed through the radial passages, 7528b and 7528c, of the tubular member 7528 into a annular chamber 7534 defined between the internal annular recess 7508 of the expansion cone 7502 and the tubular member 7528. The pressure enhancer 7550 increases the pressure on the fluidic material. If the operating pressure of the fluidic material 7532 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7526a 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 recess 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, 7518a, 7518b, and 7518c, into the interface between the expansion cone 7502 and the expandable tubular member 7530.
In an exemplary embodiment, 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 7502 and the expandable tubular member 7530 continuously during the radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the fluidic material 7532 may be injected into the external grooves, 7524a, 7524b, and 7524c only when required, or as desired. Thus, 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 force required to radially expand and plastically deform the expandable tubular member.
In an alternate embodiment, the spring-biased check valves, 7526a and 7526b, 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. In an alternate embodiment, 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.
Referring to
In an exemplary embodiment, during operation of the system 7600, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7602 is displaced in a direction 7633 relative to the expandable tubular member 7630. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7632 is conveyed through the radial passages, 7628b and 7628c, of the tubular member 7628 into a annular chamber 7634 defined between the internal annular recess 7608 of the expansion cone 7602 and the tubular member 7628. In an exemplary embodiment, 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. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7632 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7626a and 7626b, and tubular piston 7640, the tubular piston is displaced within annular chamber 7634, thereby pumping the second fluidic material through the longitudinal passages, 7612a and 7612b, into the annular chamber 7636. 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, through the longitudinal passages, 7614a and 7614b, and the radial passages, 7616a, 7616b, 7616c, 7618a, 7618b, and 7618c, into the interface between the expansion cone 7602 and the expandable tubular member 7630.
In an exemplary embodiment, 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, 7626a and 7626b, tubular piston 7640 and pressure enhancer 7650. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7644 may be injected into the external grooves, 7624a, 7624b, and 7624c only when required, or as desired. Thus, 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 force required to radially expand and plastically deform the expandable tubular member.
In an embodiment, 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. In an embodiment, 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 7644 exceeds 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.
In an exemplary embodiment, 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. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7600.
In an alternate embodiment, the 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. In an alternate embodiment, 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.
Referring to
In an exemplary embodiment, during operation of the system 7700, 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. In an exemplary embodiment, 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 7702 is displaced in a direction 7733 relative to the expandable tubular member 7730. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, 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. In an exemplary embodiment, 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. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7732 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7726a and 7726b, and tubular piston 7740, the tubular piston is displaced within annular chamber 7734, thereby pumping the second fluidic material through the longitudinal passages, 7712a and 7712b, into the annular chamber 7736. 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. In an embodiment, 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 7744 through electrodes, 7754a and 7754b by the discharging the capacitor bank 7750 to trigger a high-pressure gaseous expansion within the lubricant in external annular recess 7732 by means of an electric discharge.
In an exemplary embodiment, 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, 7726a and 7726b, and tubular piston 7740. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7744 may be injected into the external grooves, 7724a, 7724b, and 7724c only when required, or as desired. Thus, the trailing edge portion of the interface between the tapered external expansion surface 7724 of the expansion cone 7702 and the expandable tubular member 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.
In an embodiment, 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. In an embodiment, 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.
In an exemplary embodiment, 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. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7700.
In an alternate embodiment, 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.
In an exemplary embodiment, 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, which in turn, 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 15 ksi, 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. When the lubricant dielectric between the electrodes 7754a and 7754b breaks down, a high temperature arc is created which vaporizes some of the dielectric. Due to the incompressibility of fluids, the vaporization may create a pulse of pressure, which complements the existing fluid pressure.
The following three properties may be considered when determining the properties of a system for lubricating the interface between an expansion cone and a tubular member implementing a mechanism to trigger a high-pressure gaseous expansion: thermodynamic properties, electric properties, and deformation properties of the tubular member during the expansion process.
Regarding 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
where:
P—Pressure [psi]
Tb—Lubricant's Boiling Point [° K.]
M—Av. Lubricant Molar Mass
ρ—Lubricant Density
R—1.206 [L-psi/K-mol]
a—Experimental Proportionality Constant
b—Experimental Constant Relating to Molecular Volume
Since the volume of the external annular recess 7732 is not well defined, the following constraints may be used. It is assumed that the vaporization takes place at about the boiling point of the dielectric, because the addition of the heat of vaporization does not change the temperature. However, increases beyond this temperature may have no negative effect on vaporization. Furthermore, there is no common direct mathematic relationship between the discharge energy and the pressure created by the vaporization. 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 (Eeffective) of back of capacitor 7750 should be greater than the energy required to vaporize ‘m’ grams of the lubricant as exhibited in the following equation:
Eeffective=½keCVb2>mLv+mLsT (13)
T=Tb−Ti[K] (14)
where:
Eeff.—Effective Lubricant Energy [J]
ke—Energy Efficiency Factor
C—Capacitance
Vb—Breakdown Voltage
m—Mass of Vaporized Lubricant
Lv—Heat of Vaporization [J/gm]
Ls—Specific Heat [J/gm-K]
Tb—Lubricant's Boiling Point [K]
Ti—Dielectric Initial Temperature [K] T−Tb−Ti [K]
The effective discharge energy (Eeffective) 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.
Regarding electric properties, the discharge of electricity takes place when the potential across the electrodes equals the breakdown voltage. Breakdown voltage for two electrodes 7754a and 7754b can be calculated from the lubricant's dielectric strength using the following equations:
Vb=dEds (15)
where:
Vb—Breakdown Voltage
d—Distance Between Electrodes [mm]
Eds—Dielectric Strength [kV/mm]
In general, 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.
An expression for the relation between current and total resistance is as follows:
where:
Vb—Breakdown Voltage
I— Line Current
m—Mass of Vaporized Dielectric
R—System Resistance
Lv—Heat of Vaporization [J/gm]
Ls—Specific Heat [J/gm-K]
T—Tb−Ti[K]
ke—Energy Efficiency Factor
C—Capacitance
R=Rinternal+Rdesign+Zline (17)
where:
R—System Resistance
Rint.—Internal Resistance
Rdesign—Design Resistance
Zline—Line Impedance
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.
The equation for the effective discharge energy Eeffective of bank of capacitors 7752 suggests that minimizing the specific heat and the heat of vaporization may result in lower required discharge energy. 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. However, neither synthetic oils nor mineral based oils may be sufficient for the expected pressures of 10 ksi-15 ksi. It seems that a hard lubricant with a higher tolerance for pressure, such as graphite or molybdenum disulfide, may work better. However, the heat of vaporization of a hard lubricant may be significantly higher than that of a liquid lubricant. Also, 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.
An important aspect of the 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 design is the frequency of the discharges. Assuming, for the purpose of analysis that the breakdown voltage across the electrodes 7754a and 7754b is reached at around t-RC sec, frequency can be easily expressed by thy following equation:
where:
R—System Resistance
λ—Discharge Frequency [Hz]
C—Capacitance
Estimating that the frequency of the discharges will be at least 3 Hz, the lifetime rating of the capacitor bank 7750 should be as high.
Since the expansion cone may be used at considerable depths, it is desirable that capacitor bank 7750 be located as close to the electrodes 7754a and 7754b as possible. In one embodiment, it is anticipated that 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. In addition, the selected capacitor should be able to tolerate significant voltage reversal. In an exemplary embodiment, 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.
In an exemplary embodiment, the following of manufacturers may supply 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)).
In an exemplary embodiment, capacitor bank 7750 may include one capacitor or a plurality of capacitors.
In an exemplary embodiment, 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)).
Regarding the expandable tubular member deformation characteristics, 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 expression for specific work of deformation is as follows:
where:
as—Specific Work of Deformation
E—Deformation Intensity
B, mm—Mechanical characteristics of tubular member 7702
The constant mm, true strain, is defined the following equation:
where:
mm—True Strain
ΔIn/I0—Elongation
In an exemplary embodiment, ΔIn/I0 is the elongation of tubular member 7702, such as for example, in the case of En-80 steel, with ΔIn/I0=0.20, mm=0.182.
The mechanical constant B is defined by the following equation.
For a cylindrical geometry such as that of tubular member 7702, E is defined the following equation:
where:
E—Deformation Intensity
r0—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:
WD<asVw (23)
where:
as—Specific Work of Deformation
Vw—Volume of Deformed Material
WD—Work Due to Discharge
An expression relating the maximum amount of work may be constructed by assuming a discharge volume of axial length β, and an outer radius r0 (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 equation defining the volume of deformed material, Vw, is as follows:
Vw=2β(r2−r02) (24)
where:
β—Axial Length of Discharge Volume
r—Final Radius
r0—Original Radius
Vw—Volume of Deformed Material
In an exemplary embodiment, using the equations specified above for a tubular member 7702 that expands from a 4.77″ inside diameter to a 5.68″ inside diameter, hypothetically the deformation intensity (E) is 0.191, assuming that the axial length of discharge volume (β) is 0.04 m and produces a volume of deformation material (Vw) of 0.005809 m3 and true strain (mm) of 0.182. Note that the yield strength (σb) range for En-80 steel tubes is approximately 48.26×107 N/m2 (70 ksi) to 65.50×107 N/m2 (95 ksi) and mechanical constant (B) is found to range from 48.69×107 N/m2 to 66.08×107 N/m2. Therefore, the specific work (as) of deformation ranges from 5.82×107 N/m2 to 7.90×107 N/m2. For this particular volume and radial expansion, the amount of work required to expand the tubular member 7702 is on the order of 460 kJ to 340 kJ. Hence, the work done on the tubular member 7702 due to the discharge may not exceed 340 kJ. However, 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 70-95 ksi. The pressure produced by the discharge can therefore not exceed 70 ksi. Again, the expected maximum pressure due to the discharge will be approximately 15 ksi. However, should the stated constraints be exceeded, the results would be unpredictable, and control over the process could be lost.
In an exemplary embodiment, 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 7750, system resistances and impedances, and voltage required at power source 7760 for implementation may be found experimentally; and (2) the process values for a given lubricant may be determined by utilizing a discharge volume with piezoelectric sensors. 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.
Referring to
In an exemplary embodiment, during operation of the system 7800, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7802 is displaced in a direction 7833 relative to the expandable tubular member 7830. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7832 is conveyed through the radial passages, 7828b and 7828c, of the tubular member 7828 into a annular chamber 7834 defined between the internal annular recess 7808 of the expansion cone 7802 and the tubular member 7828. In an exemplary embodiment, 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. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7832 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7826a and 7826b, and tubular piston 7840, the tubular piston is displaced within annular chamber 7834, thereby pumping the second fluidic material through the longitudinal passages, 7812a and 7812b, into the annular chamber 7836. 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, 7818a, 7818b, and 7818c, into the interface between the expansion cone 7802 and the expandable tubular member 7830. In an embodiment, 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, 7818a, 7818b, and 7818c, into the interface between the expansion cone 7802 and the expandable tubular member 7830.
In an exemplary embodiment, 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, 7826a and 7826b, and tubular piston 7840. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7844 may be injected into the external grooves, 7824a, 7824b, and 7824c only when required, or as desired. Thus, the trailing edge portion of the interface between the tapered external expansion surface 7824 of the expansion cone 7802 and the expandable tubular member 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.
In an embodiment, 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. In an embodiment, 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 7844 exceeds 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.
In an exemplary embodiment, 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. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7800.
In an alternate embodiment, the 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.
In an exemplary embodiment, 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 7860 is run through magnetic coil 7854 via cables 7856a and 7856b in the fluidic materials 7844 in annular chamber 7836, a magnetic field is generated around the magnetic coils 7854 that may trigger a high-pressure gaseous expansion within an enclosed volume of fluidic materials 7844 by means of force/impulse from a strong magnetic field. The expansion may create a pressure, allowing more lubricant to flow between the expansion cone 7800 and the tubular member 7830 and thereby reducing the friction and working pressure behind the expansion cone 7800. In an exemplary embodiment, cables, 7856a and 7856b may be used to provide power to the magnetic coils 7854 that may generate the magnetic field.
Referring to
In an exemplary embodiment, during operation of the system 7900, 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. In an exemplary embodiment, 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. As a result, the expansion cone 7902 is displaced in a direction 7933 relative to the expandable tubular member 7930. In an exemplary embodiment, 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. In particular, in an exemplary embodiment, the fluidic material 7932 is conveyed through the radial passages, 7928b and 7928c, of the tubular member 7928 into a annular chamber 7934 defined between the internal annular recess 7908 of the expansion cone 7902 and the tubular member 7928. In an exemplary embodiment, 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. In an exemplary embodiment, 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. If the operating pressure of the fluidic material 7932 exceeds a predetermined value, which will vary as a function of the operating characteristics of the check valves, 7926a and 7926b, and tubular piston 7940, the tubular piston is displaced within annular chamber 7937, thereby pumping the second fluidic material through the longitudinal passages, 7912a and 7912b, into the annular chamber 7936. 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. Similarly, in an exemplary embodiment, 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.
In an exemplary embodiment, 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, 7926a and 7926b, and tubular piston 7940. In this manner, during the radial expansion process, 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. In an exemplary embodiment, the fluidic material 7944 may be injected into the external grooves, 7924a, 7924b, and 7924c only when required, or as desired. Thus, the trailing edge portion of the interface between the tapered external expansion surface 7924 of the expansion cone 7902 and the expandable tubular member 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 7926b, and tubular piston 7940, the delivery of the fluidic material 7930 into passageway 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.
In an embodiment, 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. In an embodiment, 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 7944 exceeds 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.
In an exemplary embodiment, 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. Alternatively, the lubricant may be replenished by a lubrication source located in a remote location from expansion cone 7900.
In an alternate embodiment, the 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.
It is understood that variations may be made in the foregoing expansion lubricant delivery systems without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to vary the expansion cone size, shape, and external and internal structure. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
For example, in an exemplary embodiment, valve may not be used in the expansion cone. In another exemplary embodiment only one or a plurality of lubricant reservoirs may be utilized in the expansion cone.
LubricantsWhen selecting a lubricant for a system for lubricating the interface between an expansion cone and a tubular member during the expansion process, 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.
In an exemplary embodiment, 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. In an exemplary embodiment, a lithium based (non-synthetic) multipurpose grease combined with a solid lubricant may be used as the lubricant. In an exemplary embodiment, a grease lubricant for this application may be composed of a solid lubricant in a moderately high temperature resistant thickener. In an exemplary embodiment, the lubricant may have at least 10% Graphite or 10% Molybdenum Disulfide in a thickener with a dropping point above 350-400 F. In an exemplary embodiment, 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 weight percentages interface between an expansion cone and a tubular member may consist of the following component in indicated:
The lubricant may optionally contain various other additives, or mixture thereof, in order to improve the basic properties. In an exemplary embodiment, 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.
Exemplary experiments have shown that the lubricants identified in the table below, 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:
In addition introducing lubricants between an expansion cone and a tubular member to reduce the coefficient of friction, the cone geometry, type of cone material, the cone texture (such as, for example, oil pocket on the surface of the cone) and coatings on the cone all affect the overall coefficient of friction between the expansion cone and the tubular member material, coating and finish.
Expansion Cone MaterialWhen 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. In an exemplary embodiment, example expansion cone materials include, high chrome, high carbon and molybdenum based tool steels, as well as a few powdered materials.
In several exemplary embodiments, 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. Referring to
-
- 1. International Mold Steel, Inc., of Florence, Ky. distributes DC53 material; and
- 2. Crucible Materials Corporation of Syracuse, N.Y. distributes D2, CPM M4, 10V AND 3V materials.
The characteristics of each material are specified below.
In an exemplary embodiment, 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.
In an exemplary embodiment, an example of a DC53 material has the following Coefficient of Thermal Expansion (×10−6/C.°):
In an exemplary embodiment, an example of a DC53 material has the following Coefficient of Thermal Conductivity (cal/cm·sec° C.):
In an exemplary embodiment, an example of a DC53 material has the following physical data:
In an exemplary embodiment, 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.
In an exemplary embodiment, 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.
In an exemplary embodiment, 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 μm/m-° C. 5.83 μin/in-° F. 20-100° C.;
- CTE, linear 250° C. 11.8 μm/m-° C. 6.56 μin/in-° F. from 0-300° C. (68-570° F.); and
- CTE, linear 500° C. 12.5 μm/m-° C. 6.94 μin/in-° F. from 0-500° C. (68-930° F.).
In an exemplary embodiment, the AISI Type D2 Tool Steel has the following material composition:
In an exemplary embodiment, 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 μm/m-° C. 5.94 μin/in-° F. 20-100° C.;
- CTE, linear 250° C. 12.1 μm/m-° C. 6.72 μin/in-° F. from 0-300° C. (68-570° F.); and
- CTE, linear 500° C. 12.8 μm/m-° C. 7.11 μin/in-° F. from 0-500° C. (68-930° F.).
In an exemplary embodiment, the AISI Type D3 Tool Steel has the following material composition:
In an exemplary embodiment, an example of a D5 material has the following characteristics:
In an exemplary embodiment, an example of a D5 material has the following material composition:
In an exemplary embodiment, an example of a D5 material has the following physical data:
In an exemplary embodiment, an example of a D7 material has the following characteristics:
In an exemplary embodiment, an example of a D7 material has the following material composition:
In an exemplary embodiment, an example of a D7 material has the following physical data:
In an exemplary embodiment, 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:
In an exemplary embodiment, an example of a M4 has the following material composition:
In an exemplary embodiment, an example of a M4 material has the following characteristics:
In an exemplary embodiment, an example of a M4 material has the following physical data:
In an exemplary embodiment, the characteristics of exemplary CPM M4, 10V and 3V materials may be found in the resources listed below.
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, Plano, Tex.). When selecting a coating for an expansion cone 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 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.
In several exemplary experimental embodiments, the following coatings with specified characteristics may be utilized as a coating for an expansion cone in a tubular member during the expansion process:
In an exemplary embodiment, 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
Many CVD coatings are processed at temperature above 500 C, 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. In an exemplary embodiment, 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. In an exemplary embodiment, 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, the refinement process, 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.
Referring to
In an exemplary embodiment, one or more of the lubrication systems, expansion devices and elements of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 are incorporated into the method 7880 for expanding tubular members described above with reference to
In several exemplary embodiment, 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
In this manner, the amount of force required to radially expand a tubular member in the formation and/or repair of a wellbore casing, pipeline, or structural support is significantly reduced. Furthermore, the increased lubrication provided to the interface between an expansion cone and tubular member greatly reduces the amount of galling or seizure caused by the interface between the expansion cone and the tubular member during the radial expansion process thereby permitting larger continuous sections of tubulars to be radially expanded in a single continuous operation. Thus, use of the expansion cones 5100, 5200, 5300, 5400, 5500, 5600, 5700, 5800, 5900, 6000, 6100, 6200, 6300, 6600, 6700, 6800, 6900, 7000 and 7100 and/or lubricant delivery systems 7200, 7300, 7400, 7500, 7600, 7700, 7800 and 7900 and/or the lubricants described above reduces the operating pressures required for radial expansion and thereby reduces the sizes of the required hydraulic pumps and related equipment. In addition, failure, bursting, and/or buckling of tubular members during the radial expansion process is significantly reduced, and the success ratio of the radial expansion process is greatly increased.
In several exemplary embodiments, 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.
In several exemplary embodiments, 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.
In several exemplary experimental embodiments, 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. For comparison purposes, tests were also performed on various different tubular members and cones without lubricants. The results of the tests relate to the effect of friction on a system for lubricating the interface between an expansion cone and a tubular member.
The following equation defines the effective force (Feff) of a system for reducing the coefficient of friction in the interface between an expansion cone and a tubular member during the expansion process:
Feff=kgeo(F/(2 sin β+μfric); (25)
where:
F=Force on Tool (Input Pressure)
Feff=Effective Force on the Cone Surface
kgeo=Coefficient of Geometry
μfric=Coefficient of Friction
β=Cone Angle.
The following equation defines the expansion force (F) on an expansion cone of a system radially expanding a tubular member using an expansion cone during the expansion process:
F=πDt(1+f cot β)Yε (26)
where:
F—Expansion force;
D—Inside diameter of tubular member;
t—Wall thickness of tubular member'
f—Coefficient of friction between the tubular member and expansion cone;
Y—Yield strength the tubular material; and
ε—Expansion rate of the tubular material.
Referring to
In an exemplary embodiment, a calculation was completed to determine the effective force Feff on a cone surface and the energy equations necessary to calculate frictional effects for tribological elements, that is the elements that have an impact on coefficient of friction between an expansion cone and a tubular member during the expansion process. 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.
During the expansion process, 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 5½″ LSX-80 tubular member having a 0.3″ wall thickness is approximately 5000 psi. Referring to
Referring to
In several exemplary embodiments, many of the lubricants specified above were tested with different types of expansion cones in tubular members in different conditions to determine the expansion forces necessary to expand the respective tubular members. For comparison purposes, tests were also performed on various different tubular members and cones with out lubricants. The results of the test are shown in
Referring to
The lowest coefficient of friction, approximately 0.02, resulted from Sample 8. 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 Tex., is shown. Phygen film is a chrome nitride coating and is distributed by Phygen, Inc., Minneapolis, Minn.
Referring to
The surface characteristics listed in the table above are well known. Some of the characteristics listed in the table above have the following meanings:
-
- a. 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;
- b. Rz is the average maximum height of the surface;
- c. Rpk—is the reduced peak height, a measure of the peak height above the nominal/core roughness;
- d. Rvk is the reduced valley depth, which is a measure of the valley depth below the nominal/core roughness; and
- e. 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.
Referring to
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In an exemplary embodiment, during operation of the system 10100, the expansion cone 10102 is positioned within, and displaced relative to, an expandable tubular member thereby radially expanding and plastically deforming the expandable tubular member. In an exemplary embodiment, the expansion cone 10102 is displaced relative to the expandable tubular member by injecting a pressurized fluidic material 10132 into and through the passage 10128a of the tubular member 10128. As a result, the expansion cone 10102 is displaced in a direction 10133 relative to the expandable tubular member. In an exemplary embodiment, the fluidic material 10132 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 10102 and the expandable tubular member during the radial expansion process. In an exemplary embodiment, a second pressurized fluidic material 10144 is injected into and through the passage 10129a of the tubular member 10129 though pump 10130. In an exemplary embodiment, the fluidic material 10144 includes one or more lubricant materials suitable for lubricating the interface between the expansion cone 10102 and the expandable tubular member during the radial expansion process. The pressurized fluidic material 10132 may be then conveyed into the external grooves, 10124a, 10124b, and 10124c, into an interface between the expansion cone 10102 and the expandable tubular member. Similarly, in an exemplary embodiment, the fluidic material 10132 is conveyed through the radial passage 10129a, of the tubular member 10129 and through radial passage, 10116, into a passageway between the expansion cone 10102 and the tubular member.
In an exemplary embodiment, the rate of injection of the fluidic material 10144 into the external grooves, 10124a, 10124b, and 10124c, depends on the selected operating pressure of the fluidic material. In this manner, during the radial expansion process, the fluidic material 10144 may be controllably injected and metered into the interface between the tapered external expansion surface 10124 of the expansion cone 10102 and the expandable tubular member 10130 continuously during the radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the fluidic material 10144 may be injected into the external grooves, 10124a, 10124b, and 10124c only when required, or as desired. Thus, the trailing edge portion of the interface between the tapered external expansion surface 10124 of the expansion cone 10102 and the expandable tubular member 10130 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 10132 into passageway 10152 between expansion cone 10100 and tubular member also depends the selected operating pressure of the fluidic material. Since, both the pressures for both fluidic materials, 10132 and 10144, are individually controlled, the pressures may be set at different operating pressures. In this manner, different areas of the interface between the expansion cone 10100 and a tubular member, during the radial expansion and plastic deformation of the tubular member using the expansion cone, can be provided with different formulations of lubricant materials and different operating pressures thereby permitting the control of friction within the interface to be precisely controlled.
One of the problems of the pipe material selection for expandable tubular application is an apparent contradiction or inconsistency between strength and elongation. To increase burst and collapse strength, material with higher yield strength is used. The higher yield strength generally corresponds to a decrease in the fracture toughness and correspondingly limits the extent of achievable expansion.
It is desirable to select the steel material for the tubing by balancing steel strength with amount absorbed energy measure by Charpy testing. Generally these tests are done on samples cut from tubular members. It has been found to be beneficial to cut directional samples both longitudinally oriented (aligned with the axis) and circumferentially oriented (generally perpendicular to the axis). This method of selecting samples is beneficial when both directional orientations are used yet does not completely evaluate possible and characteristic anisotropy throughout a tubular member. Moreover, for small diameter tubing samples representative of the circumferential direction may be difficult and sometimes impossible to obtain because of the significant curvature of the tubing.
To further facilitate evaluation of a tubular member for suitability for expansion it has been found beneficial according to one aspect of the invention to consider the plastic strain ratio. One such ratio is called a Lankford value (or r-value) which is the ratio of the strains occurring in the width and thickness directions measured in a single tension test. The plastic strain ratio (r or Lankford-value) with a value of greater than 1.0 is found to be more resistant to thinning and better suited to tubular expansion. Such a Lankford value is found to be a measure of plastic anisotropy. The Lankford value (r) may be calculated by the Equation 2 below:
where,
r—normal anisotropy coefficient
bo & bk—initial and final width
Lo & Lk—initial and final length
However, it is time consuming and labor intensive for this parameter to be measured using samples cut from real parts such as from the tubular members. The tubular members will have anisotropic characteristics due to crystallographic or “grain” orientation and mechanically induced differences such as impurities, inclusions, and voids, requiring multiple samples for reliably complete information. Moreover, with individual samples, only local characteristics are determined and the complete anisotropy of the tubular member may not be determinable. Further some of the tubular members have small diameters so that cutting samples oriented in a circumferential direction is not always possible. Information regarding the characteristics in the circumferential direction has been found to be important because the plastic deformation during expansion of the tubular members occurs to a very large extent in the circumferential direction,
One aspect of the present exemplary embodiments comprises the development of an improved solution for anisotropy evaluation, including a kind of plastic strain ratio similar to the Lankford parameter that is measured using real tubular members subjected to axial loading.
F(r)—formability anisotropy coefficient
bo & bk—initial and final tube area (inch2)
Lo & Lk—initial and final tube length (inch)
b=(D2−d2)/4—cross section tube area.
In either circumstance, f or F(r), the use of this testing method for an entire tubular member provides useful information including anisotropic characteristics or anisotropy of the tubular member for selecting or producing beneficial tubular members for down hole expansion, similar to the use of the Lankford value for a sheet material.
Just as values for stress and strain may be plotted for solid specimen samples, as schematically depicted in
The foregoing expandability coefficient (or formability coefficient) is found to be useful in predicting good expansion results and may be further useful when used in combination with one or more other properties of a tubular member selected from stress-strain properties in one or more directional orientations of the material, strength & elongation, Charpy V-notch impact value in one or more directional orientations of the material, stress burst rupture, stress collapse rupture, yield strength, ductility, toughness, and strain-hardening exponent (n-value), and hardness.
In an exemplary embodiment, a tribological system is used to reduce friction and thereby minimize the expansion forces required during the radial expansion and plastic deformation of the tubular members that includes one or more of the following: (1) a tubular tribology system; (2) a drilling mud tribology system; (3) a lubrication tribology system; and (4) an expansion device tribology system.
In an exemplary embodiment, the tubular tribology system includes the application of coatings of lubricant to the interior surface of the tubular members.
In an exemplary embodiment, the drilling mud tribology system includes the addition of lubricating additives to the drilling mud.
In an exemplary embodiment, the lubrication tribology system includes the use of lubricating greases, self-lubricating expansion devices, automated injection/delivery of lubricating greases into the interface between an expansion device and the tubular members, surfaces within the interface between the expansion device and the expandable tubular member that are self-lubricating, surfaces within the interface between the expansion device and the expandable tubular member that are textured, self-lubricating surfaces within the interface between the expansion device and the expandable tubular member that include diamond and/or ceramic inserts, thermosprayed coatings, fluoropolymer coatings, PVD films, and/or CVD films.
In an exemplary embodiment, the tubular members include one or more of the following characteristics: high burst and collapse, the ability to be radially expanded more than about 40%, high fracture toughness, defect tolerance, strain recovery @ 150 F, good bending fatigue, optimal residual stresses, and corrosion resistance to H2S in order to provide optimal characteristics during and after radial expansion and plastic deformation.
In an exemplary embodiment, the tubular members are fabricated from a steel alloy having a charpy energy of at least about 90 ft-lbs in order to provided enhanced characteristics during and after radial expansion and plastic deformation of the expandable tubular member.
In an exemplary embodiment, the tubular members are fabricated from a steel alloy having a weight percentage of carbon of less than about 0.08% in order to provide enhanced characteristics during and after radial expansion and plastic deformation of the tubular members. In an exemplary embodiment, the tubular members are fabricated from a steel alloy having reduced sulfur content in order to minimize hydrogen induced cracking.
In an exemplary embodiment, the tubular members are fabricated from a steel alloy having a weight percentage of carbon of less than about 0.20% and a charpy-V-notch impact toughness of at least about 6 joules in order to provide enhanced characteristics during and after radial expansion and plastic deformation of the tubular members.
In an exemplary embodiment, the tubular members are fabricated from a steel alloy having a low weight percentage of carbon in order to enhance toughness, ductility, weldability, shelf energy, and hydrogen induced cracking resistance.
In several exemplary embodiments, the tubular members are fabricated from a steel alloy having the following percentage compositions in order to provide enhanced characteristics during and after radial expansion and plastic deformation of the tubular members:
In an exemplary embodiment, the ratio of the outside diameter D of the tubular members to the wall thickness t of the tubular members range from about 12 to 22 in order to enhance the collapse strength of the radially expanded and plastically deformed tubular members.
In an exemplary embodiment, the outer portion of the wall thickness of the radially expanded and plastically deformed tubular members includes tensile residual stresses in order to enhance the collapse strength following radial expansion and plastic deformation.
In several exemplary experimental embodiments, reducing residual stresses in samples of the tubular members prior to radial expansion and plastic deformation increased the collapse strength of the radially expanded and plastically deformed tubular members.
In several exemplary experimental embodiments, the collapse strength of radially expanded and plastically deformed samples of the tubulars were determined on an as-received basis, after strain aging at 250 F for 5 hours to reduce residual stresses, and after strain aging at 350 F for 14 days to reduce residual stresses as follows:
As indicated by the above table, reducing residual stresses in the tubular members, prior to radial expansion and plastic deformation, significantly increased the resulting collapse strength—post expansion.
In several exemplary experimental embodiments, the collapse strength of radially expanded and plastically deformed samples of the tubulars were determined on an as-received basis, after strain aging at 250 F for 5 hours to reduce residual stresses, and after strain aging at 350 F for 14 days to reduce residual stresses as follows:
As indicated by the above table, reducing residual stresses in the tubular members, prior to radial expansion and plastic deformation, significantly increased the resulting collapse strength—post expansion.
In an exemplary experimental embodiment, residual stresses within a tubular member were decreased from about −12,000 psi to about −6,000 psi, a reduction of about 105%. As a result, the collapse strength of the resulting tubular member was increased from about 1550 psi to about 1750 psi. This was an unexpected result.
In several exemplary experimental embodiments, tubular members were radially expanded and plastically deformed using different lubricants to achieve a range of coefficients of friction between the tubular members and a solid expansion cone during the radial expansion and plastic deformation of the tubular members. As a result, the following experimental results were obtained:
The above tabular experimental results were unexpected. In particular, the resulting collapse strength of the radially expanded and plastically deformed tubular was increased by one or more of the following: 1) reducing the coefficient of friction; and/or 2) reducing the ratio of D/t.
Referring to
The testing results for the Quenched and Tempered Steel Pipe No. 1, illustrated in
Referring to
The testing results for the Quenched and Tempered Steel Pipe No. 2, illustrated in
In an exemplary experimental embodiment, samples of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe Nos. 3 and 4”), were stress and strain tested and exhibited the following characteristics:
The tabular experimental results presented above were unexpected.
In an exemplary experimental embodiment, samples of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe No. 5”), were stress and strain tested and exhibited the following characteristics:
The tabular experimental results presented above were unexpected.
In an exemplary experimental embodiment, a sample of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe Nos. 6 and 7”), a sample of conventional NT80-HE steel pipe from Nippon Steel, and a sample of conventional NT55-HE steel pipe from Nippon Steel were tested to determine absorbed energy and flare expansion characteristics and exhibited the following characteristics:
The testing results for the Quenched and Tempered Steel Pipe Nos. 6 and 7 summarized above in tabular form were unexpected results. Thus, the modification of the normal manufacturing process of the Quenched and Tempered Steel Pipe Nos. 6 and 7, to include a quenching and tempering step, significantly and unexpectedly, enhanced the performance characteristics of the pipe, relative to the conventional NT80-HE and NT55-HE pipes, thereby making the Quenched and Tempered Pipes particularly suited to use as an expandable tubular.
In an exemplary embodiment, the flare expansion of the Quenched and Tempered Steel Pipe Nos. 6 and 7, the sample of conventional NT80-HE steel pipe from Nippon Steel, and the sample of conventional NT55-HE steel pipe from Nippon Steel were performed by pressing a tapered solid expansion cone into an end of the pipe samples to radially expand and plastically deform the ends of the pipe samples.
In an exemplary experimental embodiment, samples of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe No. 8”), were stress and strain tested and exhibited the following characteristics:
The tabular experimental results presented above were unexpected.
In an exemplary experimental embodiment, a sample of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe No. 9”), a sample of conventional NT80-HE steel pipe from Nippon Steel, and a sample of conventional NT55-HE steel pipe from Nippon Steel were tested to determine absorbed energy and flare expansion characteristics and exhibited the following characteristics:
The testing results for the Quenched and Tempered Steel Pipe No. 9 summarized above in tabular form were unexpected results. Thus, the modification of the normal manufacturing process of the Quenched and Tempered Steel Pipe No. 9, to include a quenching and tempering step, significantly and unexpectedly, enhanced the performance characteristics of the pipe, relative to the conventional NT80-HE and NT55-HE pipes, thereby making the Quenched and Tempered Pipes particularly suited to use as an expandable tubular.
In an exemplary experimental embodiment, samples of steel pipe, for which the normal manufacturing process was modified to include quenching and tempering (the “Quenched and Tempered Steel Pipe No. 10”), were stress and strain tested and exhibited the following characteristics:
The tabular experimental results presented above were unexpected.
In an exemplary embodiment, the composition of the Quench and Temper Steel Pipe Nos. 1 to 10 included the following weight percentages:
In an exemplary embodiment, the quenching of the Quench and Temper Steel Pipe Nos. 1 to 10 was provided at 970 C, and the tempering of the Quench and Temper Steel Pipe Nos. 1 to 10 was provided for 10 minutes at 670 C.
In an exemplary embodiment, using a combination of empirical, theoretical, and experimental data, electrical resistance pipe (“ERW”) tubular members most suitable for radial expansion and plastic deformation exhibit the following characteristics:
In an exemplary experimental embodiment, based upon theoretical, empirical, and experimental data, tubular members that exhibit the following characteristics are best suited for radial expansion and plastic deformation:
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, the dual phase steel manufactured pipe 10502a includes a microstructure having about 15% to 30% martensite and ferrite. In an exemplary embodiment, the dual phase steel manufactured pipe 10502a includes a composition of 0.1% C, 1.2% Mn, and 0.3% Si.
In an exemplary embodiment, as illustrated in
In an exemplary embodiment, in step 10504 of the method 10500, as illustrated in
In several exemplary embodiments, the teachings of the present disclosure are combined with one or more of the teachings disclosed in FR 2 841 626, filed on Jun. 28, 2002, and published on Jan. 2, 2004, the disclosure of which is incorporated herein by reference.
A method of forming a tubular liner within a preexisting structure is provided that 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. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the method further includes positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure, wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings include the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings include the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members include the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings include slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly is a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, the hard phase structure comprises martensite. In an exemplary embodiment, the soft phase structure comprises ferrite. In an exemplary embodiment, the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si.
An expandable tubular member has been described that includes a steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 46.9 ksi prior to a radial expansion and plastic deformation; and a yield point of the tubular member is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the tubular member after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described that includes a steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, a yield point of the tubular member is at most about 57.8 ksi prior to a radial expansion and plastic deformation; and the yield point of the tubular member is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, a yield point of the of the tubular member after a radial expansion and plastic deformation is at least about 28% greater than the yield point of the tubular member prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described that includes a steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described that includes a steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the tubular member, prior to a radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the anisotropy of the expandable tubular member, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
A method of radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that includes radially expanding and plastically deforming the tubular assembly within a preexisting structure; and using less power to radially expand each unit length of the first tubular member than to radially expand each unit length of the second tubular member. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
A system for radially expanding and plastically deforming a tubular assembly including a first tubular member coupled to a second tubular member has been described that 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
A method of manufacturing a tubular member has been described that 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation. In an exemplary embodiment, the characteristics are selected from a group consisting of yield point and ductility. In an exemplary embodiment, processing the tubular member within the preexisting structure until the tubular member is characterized one or more final characteristics includes: radially expanding and plastically deforming the tubular member within the preexisting structure.
An apparatus has been described 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. In an exemplary embodiment, the expansion device includes a rotary expansion device, an axially displaceable expansion device, a reciprocating expansion device, a hydroforming expansion device, and/or an impulsive force expansion device. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point than another portion of the expandable tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly includes a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1 In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a first steel alloy including: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a second steel alloy including: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a third steel alloy including: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly includes a fourth steel alloy including: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, a yield point of an inner tubular portion of at least a portion of the tubular assembly is less than a yield point of an outer tubular portion of the portion of the tubular assembly. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, prior to the radial expansion and plastic deformation, at least a portion of the tubular assembly comprises a microstructure comprising a transitional phase structure. In an exemplary embodiment, wherein the hard phase structure comprises martensite. In an exemplary embodiment, wherein the soft phase structure comprises ferrite. In an exemplary embodiment, wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the hard phase structure comprises martensite; wherein the soft phase structure comprises ferrite; and wherein the transitional phase structure comprises retained austentite. In an exemplary embodiment, the portion of the tubular assembly comprising a microstructure comprising a hard phase structure and a soft phase structure comprises, by weight percentage, about 0.1% C, about 1.2% Mn, and about 0.3% Si. In an exemplary embodiment, at least a portion of the tubular assembly comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary embodiment, the portion of the tubular assembly comprises, 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. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: pearlite or pearlite striation. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, the portion of the tubular assembly comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, the portion of the tubular assembly comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
A method of determining the expandability of a selected tubular member has been described that 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. In an exemplary embodiment, an anisotropy value greater than 0.12 indicates that the tubular member is suitable for radial expansion and plastic deformation. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support.
A method of radially expanding and plastically deforming tubular members has been described that 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. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, radially expanding and plastically deforming the selected tubular member includes: inserting the selected tubular member into a preexisting structure; and then radially expanding and plastically deforming the selected tubular member. In an exemplary embodiment, the preexisting structure includes a wellbore that traverses a subterranean formation.
A radially expandable multiple tubular member apparatus has been described that 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. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges.
A method of joining radially expandable multiple tubular members has also been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange; and 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. In an exemplary embodiment, the method further includes providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes providing a recess in each tubular member. In an exemplary embodiment, the method further includes engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges.
A radially expandable multiple tubular member apparatus has been described that 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 the joint; wherein at least a portion of the sleeve is comprised of a frangible material.
A radially expandable multiple tubular member apparatus has been described that 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 the joint; wherein the wall thickness of the sleeve is variable.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a frangible material; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve comprising a variable wall thickness; and mounting the sleeve for overlapping and coupling the first and second tubular members at the joint.
An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
An expandable tubular assembly has been described that includes a first tubular member; a second tubular member coupled to the first tubular member; and means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members.
In several exemplary embodiments of the apparatus described above, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed.
In several exemplary embodiments of the method described above, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression before, during, and/or after the radial expansion and plastic deformation of the first and second tubular members.
An expandable tubular assembly has been described that 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. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
A method of joining radially expandable multiple tubular members has been described that 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, and sealing an interface between the first and second tubular members between the first and second locations using a compressible sealing element. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
An expandable tubular assembly has been described that 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, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, 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, providing a plurality of sleeves, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings.
An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, and a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, providing a plurality of sleeves, coupling the first and second tubular members, and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members.
An expandable tubular assembly has been described that includes a first tubular member, a second tubular member coupled to the first tubular member, a threaded connection for coupling a portion of the first and second tubular members, and a tubular sleeves coupled to and receiving end portions of the first and second tubular members, wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, providing a second tubular member, threadably coupling the first and second tubular members, and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom, and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member.
A radially expandable multiple tubular member apparatus has been described that 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, and one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve.
A method of joining radially expandable multiple tubular members has been described that includes providing a first tubular member, engaging a second tubular member with the first tubular member to form a joint, providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface formed on the flange, and concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint.
A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members, and means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members.
A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
A system for radially expanding and plastically deforming a first tubular member coupled to a second tubular member by a mechanical connection has been described that includes means for radially expanding the first and second tubular members; means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members.
A radially expandable tubular member apparatus has been described that 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 the 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. In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the apparatus is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the apparatus is less than 0.36. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for maintaining portions of the first and second tubular member in circumferential compression following the radial expansion and plastic deformation of the first and second tubular members; and means for concentrating stresses within the mechanical connection during the radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes one or more stress concentrators for concentrating stresses in the joint. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, one or more of the stress concentrators comprises one or more external grooves defined in the first tubular member; wherein one or more of the stress concentrators comprises one or more internal grooves defined in the second tubular member; and wherein one or more of the stress concentrators comprises one or more openings defined in the sleeve. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the apparatus further includes a threaded connection for coupling a portion of the first and second tubular members; wherein at least a portion of the threaded connection is upset. In an exemplary embodiment, at least a portion of tubular sleeve penetrates the first tubular member. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for increasing the axial compression and tension loading capacity of the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for avoiding stress risers in the joint between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the apparatus further includes means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for increasing the axial compression and tension loading capacity of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for avoiding stress risers in the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the means for inducing stresses at selected portions of the coupling between the first and second tubular members before and after a radial expansion and plastic deformation of the first and second tubular members is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the wall thickness of the sleeve is variable. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the sleeve is circumferentially tensioned; and wherein the first and second tubular members are circumferentially compressed. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.
A radially expandable tubular member apparatus has been described that 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. In an exemplary embodiment, the recess includes a tapered wall in mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the sleeve includes a flange at each tapered end and each tapered end is formed on a respective flange. In an exemplary embodiment, each tubular member includes a recess. In an exemplary embodiment, each flange is engaged in a respective one of the recesses. In an exemplary embodiment, each recess includes a tapered wall in mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the apparatus has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the apparatus further includes positioning another apparatus within the preexisting structure in overlapping relation to the apparatus; and radially expanding and plastically deforming the other apparatus within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the apparatus, a predetermined portion of the other apparatus has a lower yield point than another portion of the other apparatus. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the apparatus is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus comprises a plurality of spaced apart predetermined portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises an end portion of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of other portions of the apparatus. In an exemplary embodiment, the other portion of the apparatus comprises a plurality of spaced apart other portions of the apparatus. In an exemplary embodiment, the apparatus comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the apparatus; and wherein the tubular members comprise the other portion of the apparatus. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the apparatus. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the apparatus. In an exemplary embodiment, the predetermined portion of the apparatus defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the apparatus is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the apparatus is greater than 0.12. In an exemplary embodiment, the predetermined portion of the apparatus comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the apparatus comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the apparatus comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the apparatus comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the apparatus is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the apparatus prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the apparatus is greater than the expandability coefficient of the other portion of the apparatus. In an exemplary embodiment, the apparatus comprises a wellbore casing. In an exemplary embodiment, the apparatus comprises a pipeline. In an exemplary embodiment, the apparatus comprises a structural support.
A method of joining radially expandable tubular members has been provided that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing 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. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is less than or equal to 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.21. In an exemplary embodiment, the carbon content of the predetermined portion of the tubular assembly is greater than 0.12 percent; and wherein the carbon equivalent value for the predetermined portion of the tubular assembly is less than 0.36. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: maintaining portions of the first and second tubular member in circumferential compression following a radial expansion and plastic deformation of the first and second tubular members; and concentrating stresses within the joint during a radial expansion and plastic deformation of the first and second tubular members. In an exemplary embodiment, the method further includes: concentrating stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the second tubular member to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the second tubular member and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, concentrating stresses within the joint comprises using the first tubular member, the second tubular member, and the sleeve to concentrate stresses within the joint. In an exemplary embodiment, at least a portion of the sleeve is comprised of a frangible material. In an exemplary embodiment, the sleeve comprises a variable wall thickness. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: maintaining the sleeve in circumferential tension; and maintaining the first and second tubular members in circumferential compression. In an exemplary embodiment, the method further includes: 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; providing a plurality of sleeves; and mounting the sleeves at spaced apart locations for overlapping and coupling the first and second tubular members. In an exemplary embodiment, at least one of the tubular sleeves is positioned in opposing relation to the first threaded coupling; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded coupling. In an exemplary embodiment, at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded couplings. In an exemplary embodiment, the method further includes: threadably coupling the first and second tubular members; and upsetting the threaded coupling. In an exemplary embodiment, the first tubular member further comprises an annular extension extending therefrom; and wherein the flange of the sleeve defines an annular recess for receiving and mating with the annular extension of the first tubular member. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.
A method of joining radially expandable tubular members has been described that includes: providing a first tubular member; engaging a second tubular member with the first tubular member to form a joint; providing a sleeve having opposite tapered ends and a flange, one of the tapered ends being a surface 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. In an exemplary embodiment, the method further includes: providing a tapered wall in the recess for mating engagement with the tapered end formed on the flange. In an exemplary embodiment, the method further includes: providing a flange at each tapered end wherein each tapered end is formed on a respective flange. In an exemplary embodiment, the method further includes: providing a recess in each tubular member. In an exemplary embodiment, the method further includes: engaging each flange in a respective one of the recesses. In an exemplary embodiment, the method further includes: providing a tapered wall in each recess for mating engagement with the tapered end formed on a respective one of the flanges. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support.
An expandable tubular assembly has been described that 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. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the assembly has a larger inside diameter after the radial expansion and plastic deformation than other portions of the tubular assembly. In an exemplary embodiment, the assembly further includes: positioning another assembly within the preexisting structure in overlapping relation to the assembly; and radially expanding and plastically deforming the other assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the assembly, a predetermined portion of the other assembly has a lower yield point than another portion of the other assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly comprises a plurality of spaced apart predetermined portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises an end portion of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of other portions of the assembly. In an exemplary embodiment, the other portion of the assembly comprises a plurality of spaced apart other portions of the assembly. In an exemplary embodiment, the assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the assembly; and wherein the tubular members comprise the other portion of the assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the assembly. In an exemplary embodiment, the predetermined portion of the assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the assembly is greater than the expandability coefficient of the other portion of the assembly. In an exemplary embodiment, the assembly comprises a wellbore casing. In an exemplary embodiment, the assembly comprises a pipeline. In an exemplary embodiment, the assembly comprises a structural support. In an exemplary embodiment, the annulus is at least partially defined by an irregular surface. In an exemplary embodiment, the annulus is at least partially defined by a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material.
A method of joining radially expandable tubular members is provided that 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 using a 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. In an exemplary embodiment, the sealing element includes an irregular surface. In an exemplary embodiment, the sealing element includes a toothed surface. In an exemplary embodiment, the sealing element comprises an elastomeric material. In an exemplary embodiment, the sealing element comprises a metallic material. In an exemplary embodiment, the sealing element comprises an elastomeric and a metallic material. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility and a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a higher ductility prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a lower yield point prior to the radial expansion and plastic deformation than after the radial expansion and plastic deformation. In an exemplary embodiment, the predetermined portion of the tubular assembly has a larger inside diameter after the radial expansion and plastic deformation than the other portion of the tubular assembly. In an exemplary embodiment, the method further includes: positioning another tubular assembly within the preexisting structure in overlapping relation to the tubular assembly; and radially expanding and plastically deforming the other tubular assembly within the preexisting structure; wherein, prior to the radial expansion and plastic deformation of the tubular assembly, a predetermined portion of the other tubular assembly has a lower yield point than another portion of the other tubular assembly. In an exemplary embodiment, the inside diameter of the radially expanded and plastically deformed other portion of the tubular assembly is equal to the inside diameter of the radially expanded and plastically deformed other portion of the other tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a plurality of spaced apart predetermined portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises an end portion of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of other portions of the tubular assembly. In an exemplary embodiment, the other portion of the tubular assembly comprises a plurality of spaced apart other portions of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a plurality of tubular members coupled to one another by corresponding tubular couplings. In an exemplary embodiment, the tubular couplings comprise the predetermined portions of the tubular assembly; and wherein the tubular members comprise the other portion of the tubular assembly. In an exemplary embodiment, one or more of the tubular couplings comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, one or more of the tubular members comprise the predetermined portions of the tubular assembly. In an exemplary embodiment, the predetermined portion of the tubular assembly defines one or more openings. In an exemplary embodiment, one or more of the openings comprise slots. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1. In an exemplary embodiment, the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the anisotropy for the predetermined portion of the tubular assembly is greater than 1; and wherein the strain hardening exponent for the predetermined portion of the tubular assembly is greater than 0.12. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a first steel alloy comprising: 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, and 0.02% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.48. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a second steel alloy comprising: 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, and 0.03% Cr. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.04. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a third steel alloy comprising: 0.08% C, 0.82% Mn, 0.006% P, 0.003% S, 0.30% Si, 0.16% Cu, 0.05% Ni, and 0.05% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.92. In an exemplary embodiment, the predetermined portion of the tubular assembly comprises a fourth steel alloy comprising: 0.02% C, 1.31% Mn, 0.02% P, 0.001% S, 0.45% Si, 9.1% Ni, and 18.7% Cr. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is about 1.34. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 46.9 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 65.9 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 40% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.48. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly is at most about 57.8 ksi prior to the radial expansion and plastic deformation; and wherein the yield point of the predetermined portion of the tubular assembly is at least about 74.4 ksi after the radial expansion and plastic deformation. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly after the radial expansion and plastic deformation is at least about 28% greater than the yield point of the predetermined portion of the tubular assembly prior to the radial expansion and plastic deformation. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.04. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.92. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is at least about 1.34. In an exemplary embodiment, the anisotropy of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 1.04 to about 1.92. In an exemplary embodiment, the yield point of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, ranges from about 47.6 ksi to about 61.7 ksi. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly, prior to the radial expansion and plastic deformation, is greater than 0.12. In an exemplary embodiment, the expandability coefficient of the predetermined portion of the tubular assembly is greater than the expandability coefficient of the other portion of the tubular assembly. In an exemplary embodiment, the tubular assembly comprises a wellbore casing. In an exemplary embodiment, the tubular assembly comprises a pipeline. In an exemplary embodiment, the tubular assembly comprises a structural support. In an exemplary embodiment, the sleeve comprises: a plurality of spaced apart tubular sleeves coupled to and receiving end portions of the first and second tubular members. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; wherein at least one of the tubular sleeves is positioned in opposing relation to the first threaded connection; and wherein at least one of the tubular sleeves is positioned in opposing relation to the second threaded connection. In an exemplary embodiment, the first tubular member comprises a first threaded connection; wherein the second tubular member comprises a second threaded connection; wherein the first and second threaded connections are coupled to one another; and wherein at least one of the tubular sleeves is not positioned in opposing relation to the first and second threaded connections. In an exemplary embodiment, 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. In an exemplary embodiment, the tubular member comprises a wellbore casing.
An expandable tubular member has been described, 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. In an exemplary embodiment, the tubular member comprises a wellbore casing.
A method of selecting tubular members for radial expansion and plastic deformation has been described that 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 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation.
A method of selecting tubular members for radial expansion and plastic deformation has been described that 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 has been described that includes: a tubular body; wherein a yield point of an inner tubular portion of the tubular body is less than a yield point of an outer tubular portion of the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the outer tubular portion of the tubular body varies in an non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the yield point of the inner tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body; and wherein the yield point of the outer tubular portion of the tubular body varies in a non-linear fashion as a function of the radial position within the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body. In an exemplary embodiment, the rate of change of the yield point of the inner tubular portion of the tubular body is different than the rate of change of the yield point of the outer tubular portion of the tubular body.
A method of manufacturing an expandable tubular member has been described that includes: providing a tubular member; heat treating the tubular member; and quenching the tubular member; wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.065% C, 1.44% Mn, 0.01% P, 0.002% S, 0.24% Si, 0.01% Cu, 0.01% Ni, 0.02% Cr, 0.05% V, 0.01% Mo, 0.01% Nb, and 0.01% Ti. In an exemplary embodiment, the provided tubular member comprises, by weight percentage, 0.18% C, 1.28% Mn, 0.017% P, 0.004% S, 0.29% Si, 0.01% Cu, 0.01% Ni, 0.03% Cr, 0.04% V, 0.01% Mo, 0.03% Nb, and 0.01% Ti. In an exemplary embodiment, the provided tubular member comprises, 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. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: martensite, pearlite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: pearlite or pearlite striation. In an exemplary embodiment, the provided tubular member comprises a microstructure comprising one or more of the following: grain pearlite, widmanstatten martensite, vanadium carbide, nickel carbide, or titanium carbide. In an exemplary embodiment, the heat treating comprises heating the provided tubular member for about 10 minutes at 790° C. In an exemplary embodiment, the quenching comprises quenching the heat treated tubular member in water. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, grain pearlite, or martensite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: ferrite, martensite, or bainite. In an exemplary embodiment, following the quenching, the tubular member comprises a microstructure comprising one or more of the following: bainite, pearlite, or ferrite. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 67 ksi and a tensile strength of about 95 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 82 ksi and a tensile strength of about 130 ksi. In an exemplary embodiment, following the quenching, the tubular member comprises a yield strength of about 60 ksi and a tensile strength of about 97 ksi. In an exemplary embodiment, the method further includes: positioning the quenched tubular member within a preexisting structure; and radially expanding and plastically deforming the tubular member within the preexisting structure.
A system for radially expanding and plastically deforming a tubular member has been described 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 0.08. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the system includes a lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the system includes a coating on the expansion device. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the system includes a coating on the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the lubricant is injected through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the system includes a lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A method of radially expanding and plastically deforming a tubular member has been described that 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. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the method includes applying a coating on the expansion device prior to positioning within the tubular member. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the method includes applying a coating on the tubular member prior to positioning the expansion device within the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the method includes injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A system for radially expanding and plastically deforming a tubular member has been described that 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. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the system, includes a means for injecting lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the system includes a means for applying a coating on the expansion device prior to positioning within the tubular member. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the method includes applying a coating on the tubular member prior to positioning the expansion device within the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the system includes a means for injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the system includes a means for injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the system includes a means for injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the system includes a means for injecting lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A lubricant for injecting in an interface between a tubular member and an expansion device has been describe that 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. In an exemplary embodiment, the lubricant by weight includes: 64.25-90.89% base oil; 0.02-0.05% metal deactivator; 0.5-3.0% antioxidants; 4-12% sulfurized natural oils; 4-12% phosphate ester; 0.4-1.5% phosphoric acid; 0.08-1.5% viscosity modifier; 0.1-0.5% pour-point depressant; 0.01-0.2% defoamer; and 0-5% carboxylic acid soaps.
A lubricant for injecting in an interface between a tubular member and an expansion device has been described that 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 has been described that includes: 64.25% canola oil; 0.05% tolyltriazole; 1.0% aminic antioxidant; 2.0% phenolic antioxidant, 12% sulfurized natural oil or sulferized lard oil; 12% phosphate ester; 1.5% phosphoric acid; 1.5% styrene hydrocarbon polymer; 0.5% alkyl ester copolymer; 0.2% silicon based antifoam agent, and 5% carbozylic acid soap.
A lubricant for injecting in an interface between a tubular member and an expansion device has been described that includes: 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 has been described that includes: 68.71% canola oil; 0.04% tolyltriazole; 0.5% aminic antioxidant, 1.0% phenolic antioxidant; 12% sulfurized natural oil or sulferized lard oil; 10% phosphate ester; 1.1% phosphoric acid; 1.5% styrene hydrocarbon polymer; 0.1% alkyl ester copolymer; 0.05% silicon based antifoam agent, and 5% carbozylic acid soap.
A lubricant for injecting in an interface between a tubular member and an expansion device has been described that includes: 82.07% canola oil; 0.03% tolyltriazole; 0.5% aminic antioxidant, 0.5% phenolic antioxidant; 10% sulfurized natural oil or sulferized lard oil; 5% phosphate ester; 0.5% phosphoric acid; 0.1% styrene hydrocarbon polymer; 0.2% alkyl ester copolymer; 0.1% silicon based antifoam agent, and 1% carbozylic acid soap.
A lubricant for injecting in an interface between a tubular member and an expansion device has been described that includes: 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 has been described that includes: 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 has been described that includes: at least 10% Graphite.
A lubricant for injecting in an interface between a tubular member and an expansion device has been described that includes: at least 10% Molybedenum Disulfide in a thickener in with a dropping point above 350-400 F.
An expansion device for radially expanding and plastically deforming the tubular member has been described that 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. In an exemplary embodiment, the lubrication device includes a pump. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant; a means for pressurizing the lubricant; and a means for injecting the lubricant in the reservoir into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant; a means for pressurizing the lubricant, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant, a means for pressurizing the lubricant, a pressure enhancer operably coupled to the reservoir to increase the pressure on the lubricant in the reservoir, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant, a means for pressurizing the lubricant, a piston operably coupled to the reservoir, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08. In an exemplary embodiment, the lubrication device includes the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is in the range of 0.02 to 0.05. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the expansion device includes a coating on the expansion device. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the expansion device includes a coating on the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the expansion device includes a means for injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the expansion device includes a means for injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the expansion device includes a lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A method for radially expanding and plastically deforming the tubular member has been described that 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. In an exemplary embodiment, the lubrication device includes a pump. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant; a means for pressurizing the lubricant; and a means for injecting the lubricant in the reservoir into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant; a means for pressurizing the lubricant, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant, a means for pressurizing the lubricant, a pressure enhancer operably coupled to the reservoir to increase the pressure on the lubricant in the reservoir, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the lubrication device includes a reservoir operably coupled to the expansion surface for house a lubricant, a means for pressurizing the lubricant, a piston operably coupled to the reservoir, and a valve fluidicly coupled to the reservoir and the expansion surface for injecting the lubricant into the interface when the predetermine pressure is reached. In an exemplary embodiment, the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is less than 0.08. In an exemplary embodiment, the lubrication device includes the coefficient of friction between the expansion device and the tubular member during radial expansion and plastic deformation is in the range of 0.02 to 0.05. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the expansion device includes a coating on the expansion device. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the expansion device includes a coating on the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the method includes injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device includes 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 having with a 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 the expansion surfaces are located on the tapered portion. In an exemplary embodiment, the expansion device includes 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 having with a 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 10 degrees and the expansion surfaces are located on the tapered portion. In an exemplary embodiment, the lubricant includes at least nine 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. In an exemplary embodiment, the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the lubricant is stored in a reservoir with electrodes that are electrically coupled a capacitor in the expansion device and the method includes charging the capacitor, discharging the capacitor through the electrodes, and injecting the lubricant through at least a portion of the expansion device between the tubular member and the expansion device when the capacitors discharges. In an exemplary embodiment, the tubular member includes a wellbore casing, a pipeline or a structural support. In an exemplary embodiment, the expansion device includes an expansion cone.
A lubricant delivery assembly for radially expanding and plastically deforming a tubular member has been described 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. In an exemplary embodiment, the lubricant injection mechanism is a valve and the lubricant is drilling fluid received in the reservoir. In an exemplary embodiment, the reservoir is fluidicly connected to drilling fluid used to expand the tubular member and the lubricant injection mechanism includes a pressure accelerator received within the reservoir that separates the drilling fluid and the media.
An expansion device for radially expanding and plastically deforming a tubular member has been described that 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 has been described 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 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 has been described 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 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.
An expansion cone for radially expanding and plastically deforming a tubular member has been described 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 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 has been described 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 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 has been described 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 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 has been described that 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 has been describe that 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 has been describe that 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 element has been described that includes a vaporizer proximate to the interface for vaporizing a lubricant to inject the lubricant in the interface. In an exemplary embodiment, the first element includes an expansion device and the second element includes tubular member during radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the vaporizer includes a reservoir for housing a lubricant, and an electric pulse generator to create an electric pulse in the lubricant. In an exemplary embodiment, the electric impulse generator includes at least two electrodes housed in the reservoir and at least one capacitor electrically coupled to the electrode. In an exemplary embodiment, the vaporizer includes a reservoir for housing a lubricant and an magnetic pulse generator to create a magnetic pulse in the lubricant. In an exemplary embodiment, the electric impulse generator includes magnetic coil housed in the reservoir. In an exemplary embodiment, the system includes an expansion device for positioning in a 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. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the system includes a lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the system includes a coating on the expansion device. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the system includes a coating on the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the lubricant is injected through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the system includes a lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered; portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A method for lubricating an interface between a first element and a second element has been described that includes vaporizing a lubricant proximate to the interface to inject the lubricant in the interface. In an exemplary embodiment, the first element includes an expansion device and the second element includes tubular member during radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the method includes housing a lubricant in a reservoir having an exit passageway and generating an electric pulse in the reservoir, thereby vaporizing the lubricant and causing a pressure pulse to force lubricant out of the exit passageway. In an exemplary embodiment, the electric pulse is generated by discharging a capacitor through electrodes stored in the lubricant. In an exemplary embodiment, the method includes housing a lubricant in a reservoir having an exit passageway; and generating a magnetic pulse in the reservoir, thereby vaporizing the lubricant and causing a pressure pulse to force lubricant out of the exit passageway. In an exemplary embodiment, the magnetic pulse is generated by current running current through magnetic coils stored in the lubricant. In an exemplary embodiment, the method 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. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the method includes applying a coating on the expansion device prior to positioning within the tubular member. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the method includes applying a coating on the tubular member prior to positioning the expansion device within the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the method includes injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A system for lubricating an interface between a first element and a second element has been described that includes means for vaporizing a lubricant proximate to the interface to inject the lubricant in the interface. In an exemplary embodiment, the area includes an interface between an expansion device and a tubular member during radial expansion and plastic deformation of the tubular member. In an exemplary embodiment, the means for vaporizing includes a means for housing a lubricant in a reservoir having an exit passageway and a means for generating an electric pulse in the reservoir, thereby vaporizing the lubricant and causing a pressure pulse to force lubricant out of the exit passageway. In an exemplary embodiment, the electric pulse is generated by discharging a capacitor through electrodes stored in the lubricant. In an exemplary embodiment, the means for vaporizing includes means for housing a lubricant in a reservoir having an exit passageway, and means for generating a magnetic pulse in the reservoir, thereby vaporizing the lubricant and causing a pressure pulse to force lubricant out of the exit passageway. In an exemplary embodiment, the magnetic pulse is generated by current running current through magnetic coils stored in the lubricant. In an exemplary embodiment, the system includes means for positioning an expansion device having a first tapered end and a second end at least partially within a 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. In an exemplary embodiment, the coefficient of friction is in the range of 0.02 to 0.05. In an exemplary embodiment, the system, includes a means for injecting lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the system includes a means for applying a coating on the expansion device prior to positioning within the tubular member. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the method includes applying a coating on the tubular member prior to positioning the expansion device within the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the system includes a means for injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the system includes a means for injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the system includes a means for injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the system includes a means for injecting lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes, a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the tubular member has a non-uniform wall thickness and the expansion device includes a tapered portion having a tapered faceted polygonal outer expansion surface. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A system for radially expanding and plastically deforming a tubular member has been described that 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 has been described that 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 has been described that 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 0.08.
A method of radially expanding and plastically deforming a tubular member has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described that 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 has been described 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 device for radially expanding and plastically deforming a tubular member has been described that 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 has been described 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 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 has been described 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 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 has been described 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 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 has been described 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 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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 has been described 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 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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.
A method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than 0.08 has been described that 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the 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.
A system for radially expanding and plastically deforming a tubular member having a non-uniform wall thickness has been disclosed that 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. In an alternate embodiment, the system includes lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the system includes a coating on the expansion device. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the system includes a coating on the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the lubricant is injected through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the lubricant is injected through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the system includes a lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
A method of radially expanding and plastically deforming a tubular member having a non-uniform wall thickness has been described that includes 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 displacing the expansion device relative to the tubular member to radially expand and plastically deform the tubular member. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device. In an exemplary embodiment, the lubricant includes oil based lubricants, H1 oil, H2 oil, H3 oil, H4 oil, H5 oil, H6 oil, H7 oil, grease, water based lubricants, drilling mud, drilling mud and solid lubricants, grease combined with a solid lubricant, at least 10% Graphite, or at least 10% Molybdenum Disulfide. In an exemplary embodiment, the method includes applying a coating on the expansion device prior to positioning within the tubular member. In an exemplary embodiment, the coating may be Phygen film. In an exemplary embodiment, the method includes applying a coating on the tubular member prior to positioning the expansion device within the tubular member. In an exemplary embodiment, the coating on the tubular member includes PTFE, PTFE based or graphite based. In an exemplary embodiment, the expansion device includes DC53 material, DC2 material, DC3 material, DC5 material, DC7 material, M2 material, CPM M4 material, 10V material, 3V material. In an exemplary embodiment, the expansion device includes an REM finish, a processed finish, or a relatively smooth surface roughness. In an exemplary embodiment, the expansion device includes a relatively smooth surface roughness and includes relatively evenly space oil pockets. In an exemplary embodiment, the expansion device includes a smooth surface roughness in the range of 0.02 to 0.1 micrometers In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device. In an exemplary embodiment, the method includes injecting lubricant through at least a portion of the expansion device between the tubular member and the expansion device when a predetermined pressure is met. In an exemplary embodiment, the method includes injecting lubricant through at least two portions of the expansion device between the tubular member and the expansion device at two different pressures. In an exemplary embodiment, the expansion device 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 having with a 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. In an exemplary embodiment, the expansion device 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 having with a 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 10 degrees. In an exemplary embodiment, the method includes injecting lubricant between the tubular member and the expansion device, comprising at least nine 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. In an exemplary embodiment, the 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. In an exemplary embodiment, the expansion device includes a wellbore casing, a pipeline, or a structural support. In an exemplary embodiment, the expansion device includes expansion cone.
An expansion device for radially expanding and plastically deforming a tubular member has been described that 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 has been described 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 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 has been described 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 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 has been described 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 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 has been described 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 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 has been described 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 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 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.
A system for radially expanding and plastically deforming a tubular member having non-uniform wall thickness has been described that 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.
A system for radially expanding and plastically deforming a tubular member has been described that includes an expansion cone of D53 material having a phygen coating and an REM finish and H1 oil wherein the tubular member is coated with PTFE.
A method for manufacturing an expandable member used to complete a structure by radially expanding and plastically deforming the expandable member has been described that includes forming the expandable member from a steel alloy comprising a charpy energy of at least about 90 ft-lbs.
An expandable member for use in completing a structure by radially expanding and plastically deforming the expandable member has been described that includes a steel alloy comprising a charpy energy of at least about 90 ft-lbs.
A structural completion positioned within a structure has been described that includes one or more radially expanded and plastically deformed expandable members positioned within the structure; wherein one or more of the radially expanded and plastically deformed expandable members are fabricated from a steel alloy comprising a charpy energy of at least about 90 ft-lbs.
A method for manufacturing an expandable member used to complete a structure by radially expanding and plastically deforming the expandable member has been described that includes forming the expandable member from a steel alloy comprising a weight percentage of carbon of less than about 0.08%.
An expandable member for use in completing a wellbore by radially expanding and plastically deforming the expandable member at a downhole location in the wellbore has been described that includes a steel alloy comprising a weight percentage of carbon of less than about 0.08%.
A structural completion has been described that includes one or more radially expanded and plastically deformed expandable members positioned within the wellbore; wherein one or more of the radially expanded and plastically deformed expandable members are fabricated from a steel alloy comprising a weight percentage of carbon of less than about 0.08%.
A method for manufacturing an expandable member used to complete a structure by radially expanding and plastically deforming the expandable member has been described that includes forming the expandable member from a steel alloy comprising a weight percentage of carbon of less than about 0.20% and a charpy V-notch impact toughness of at least about 6 joules.
An expandable member for use in completing a structure by radially expanding and plastically deforming the expandable member has been described that includes a steel alloy comprising a weight percentage of carbon of less than about 0.20% and a charpy V-notch impact toughness of at least about 6 joules.
A structural completion has been described that includes one or more radially expanded and plastically deformed expandable members; wherein one or more of the radially expanded and plastically deformed expandable members are fabricated from a steel alloy comprising a weight percentage of carbon of less than about 0.20% and a charpy V-notch impact toughness of at least about 6 joules.
A method for manufacturing an expandable member used to complete a structure by radially expanding and plastically deforming the expandable member has been described that includes forming the expandable member from a steel alloy comprising the following ranges of weight percentages: C, from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about 5.
An expandable member for use in completing a structure by radially expanding and plastically deforming the expandable member has been described that includes a steel alloy comprising the following ranges of weight percentages: C, from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about 5.
A structural completion has been described that includes one or more radially expanded and plastically deformed expandable members; wherein one or more of the radially expanded and plastically deformed expandable members are fabricated from a steel alloy comprising the following ranges of weight percentages: C, from about 0.002 to about 0.08; Si, from about 0.009 to about 0.30; Mn, from about 0.10 to about 1.92; P, from about 0.004 to about 0.07; S, from about 0.0008 to about 0.006; Al, up to about 0.04; N, up to about 0.01; Cu, up to about 0.3; Cr, up to about 0.5; Ni, up to about 18; Nb, up to about 0.12; Ti, up to about 0.6; Co, up to about 9; and Mo, up to about 5.
A method for manufacturing an expandable tubular member used to complete a structure by radially expanding and plastically deforming the expandable member has been described that includes forming the expandable tubular member with a ratio of the of an outside diameter of the expandable tubular member to a wall thickness of the expandable tubular member ranging from about 12 to 22.
An expandable member for use in completing a structure by radially expanding and plastically deforming the expandable member has been described that includes an expandable tubular member with a ratio of the of an outside diameter of the expandable tubular member to a wall thickness of the expandable tubular member ranging from about 12 to 22.
A structural completion has been described that includes one or more radially expanded and plastically deformed expandable members positioned within the structure; wherein one or more of the radially expanded and plastically deformed expandable members are fabricated from an expandable tubular member with a ratio of the of an outside diameter of the expandable tubular member to a wall thickness of the expandable tubular member ranging from about 12 to 22.
A method of constructing a structure has been described that includes radially expanding and plastically deforming an expandable member; wherein an outer portion of the wall thickness of the radially expanded and plastically deformed expandable member comprises tensile residual stresses.
A structural completion has been described that includes one or more radially expanded and plastically deformed expandable members; wherein an outer portion of the wall thickness of one or more of the radially expanded and plastically deformed expandable members comprises tensile residual stresses.
A method of constructing a structure using an expandable tubular member has been described that includes strain aging the expandable member; and then radially expanding and plastically deforming the expandable member.
A method for manufacturing a tubular member used to complete a wellbore by radially expanding the tubular member at a downhole location in the wellbore has been described that includes forming a steel alloy comprising a concentration of carbon between approximately 0.002% and 0.08% by weight of the steel alloy.
A method of increasing a collapse strength of a tubular member after a radial expansion and plastic deformation of the tubular member using an expansion device has been described that includes reducing a coefficient of friction between the tubular member and the expansion device during the radial expansion and plastic deformation of the tubular member; and reducing a ratio of a diameter of the tubular member to a wall thickness of the tubular member. In an exemplary embodiment, the coefficient of friction is less than 0.075.
In an exemplary embodiment, the ratio of the diameter of the tubular member to a wall thickness of the tubular member is less than 21.6. In an exemplary embodiment, the collapse strength of a tubular member after the radial expansion and plastic deformation of the tubular member using an expansion device is greater than 5000 ksi.
A system for radially expanding and plastically deforming a tubular member has been described that includes a tubular member, and an expansion device positioned within the tubular member, wherein the coefficient of friction between the tubular member and the expansion device is less than 0.075, and wherein the ratio of the diameter of the tubular member to a wall thickness of the tubular member is less than 21.6.
A method of radially expanding and plastically deforming a tubular member using an expansion device has been described that includes quenching and tempering the tubular member; positioning the tubular member within a preexisting structure; and radially expanding and plastically deforming the tubular member. In an exemplary embodiment, the yield strength of the tubular member ranges from about 76.8 ksi to 88.8 ksi. In an exemplary embodiment, the ratio of the yield strength to the tensile strength of the tubular member ranges from about 0.82 to 0.86. In an exemplary embodiment, the longitudinal elongation of the tubular member prior to failure ranges from about 14.8% to 22.0%. In an exemplary embodiment, the width reduction of the tubular member prior to failure ranges from about 32% to 44.0%. In an exemplary embodiment, the width thickness reduction of the tubular member prior to failure ranges from about 41.0% to 45%. In an exemplary embodiment, the anisotropy of the tubular member ranges from about 0.65 to 1.03. In an exemplary embodiment, the absorbed energy in the longitudinal direction of the tubular member ranges from about 125 to 145 ft-lbs. In an exemplary embodiment, the absorbed energy in the transverse direction of the tubular member ranges from about 59 to 59 ft-lbs. In an exemplary embodiment, the absorbed energy in a welded portion of the tubular member ranges from about 174 to 176 ft-lbs. In an exemplary embodiment, a flared expansion of an end of tubular member ranged from about 42 to 52%. In an exemplary embodiment, the tubular member comprises, by weight percentage: 0.27 C, 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr. In an exemplary embodiment, the quenching of the tubular member is provided at about 97° C.; and the tempering the tubular member is provided at about 67° C.
A radially expandable and plastically deformable tubular member has been described that includes a yield strength ranging from about 76.8 ksi to 88.8 ksi, a ratio of the yield strength to a tensile strength of the tubular member ranging from about 0.82 to 0.86, a longitudinal elongation of the tubular member prior to failure ranging from about 14.8% to 22.0%, a width reduction of the tubular member prior to failure ranging from about 32% to 44.0%, a width thickness reduction of the tubular member prior to failure ranges from about 41.0% to 45%, and an anisotropy of the tubular member ranges from about 0.65 to 1.03. In an exemplary embodiment, an absorbed energy in the longitudinal direction of the tubular member ranges from about 125 to 145 ft-lbs. In an exemplary embodiment, the absorbed energy in the transverse direction of the tubular member ranges from about 59 to 59 ft-lbs. In an exemplary embodiment, the absorbed energy in a welded portion of the tubular member ranges from about 174 to 176 ft-lbs. In an exemplary embodiment, a flared expansion of an end of tubular member ranged from about 42 to 52%. In an exemplary embodiment, the tubular member comprises, by weight percentage: 0.27 C, 0.14 Si; 1.28 Mn; 0.009 P; 0.005 S; and 0.14 Cr.
A radially expandable and plastically deformable tubular member has been described that includes: a yield strength ranging from about 40.0 ksi to 100.0 ksi; a ratio of the yield strength to a tensile strength of the tubular member ranging from about 0.40 to 0.85; a longitudinal elongation of the tubular member prior to failure ranging from at least about 22.0 to 35.0%; a width reduction of the tubular member prior to failure ranging from at least about 30.0% to 45.0%; a width thickness reduction of the tubular member prior to failure ranges from at least about 30.0% to 45.0%; and an anisotropy of the tubular member ranges from at least about 0.65 to 1.50. In an exemplary embodiment, an absorbed energy in the longitudinal direction of the tubular member is at least about 80 ft-lbs. In an exemplary embodiment, the absorbed energy in the transverse direction of the tubular member is at least about 60 ft-lbs. In an exemplary embodiment, the absorbed energy in a welded portion of the tubular member is at least about 60 ft-lbs. In an exemplary embodiment, a flared expansion of an end of tubular member ranges from at least about 45 to 75%.
A method of manufacturing a tubular member has been described that includes fabricating a tubular member; positioning the tubular member within a preexisting structure; radially expanding and plastically deforming the tubular member within the preexisting structure; and baking the tubular member within the preexisting structure. In an exemplary embodiment, the preexisting structure comprises a wellbore. In an exemplary embodiment, the fabricated tubular member comprises a dual phase steel pipe. In an exemplary embodiment, the fabricated tubular member comprises a microstructure comprising about 15 to 30% martensite; and ferrite. In an exemplary embodiment, the fabricated tubular member comprises, by weight percentage: 0.1 C, 1.2 Mn; and 0.3 Si. In an exemplary embodiment, the fabricated tubular member comprises a TRIP steel pipe. In an exemplary embodiment, fabricating the tubular member comprises: cold rolling the tubular member; and inter critical annealing the tubular member. In an exemplary embodiment, the fabricated tubular member comprises a dual phase steel pipe. In an exemplary embodiment, prior to the cold rolling, the fabricated tubular member comprises a microstructure comprising ferrite and pearlite. In an exemplary embodiment, the inter critical annealing is performed at about 75° C. In an exemplary embodiment, after the inter critical annealing, the fabricated tubular member comprises a microstructure comprising ferrite and at least one of pearlite and austentite. In an exemplary embodiment, the method further comprising: cooling the tubular member after the inter critical annealing. In an exemplary embodiment, after the cooling, the tubular member comprises a microstructure comprising martensite. In an exemplary embodiment, the baking is provided at about 10° C. to 250 C. In an exemplary embodiment, following at least a portion of the baking, the tubular member comprises a bake-hardened portion. In an exemplary embodiment, following at least a portion of the baking, the tubular member comprises a stress-relieved portion. In an exemplary embodiment, following at least a portion of the baking, the tubular member comprises a bake-hardened portion and a stress-relieved portion. In an exemplary embodiment, the cold rolling comprises: allowing the tubular member to cool over time from a first temperature to a second temperature along a temperature versus time curve; and at a plurality of stages along the curve, deforming the tubular member. In an exemplary embodiment, at a first stage along the curve, insoluble precipitates within the tubular member retard austentite growth. In an exemplary embodiment, at a first stage along the curve, deformation of the tubular member promotes precipitation. In an exemplary embodiment, at a second stage along the curve, insoluble precipitates within the tubular member inhibit recrystallization. In an exemplary embodiment, at a second stage along the curve, austentite grains are conditioned.
It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, the teachings of the present illustrative embodiments may be used to provide a wellbore casing, a pipeline, or a structural support. Furthermore, the elements and teachings of the various illustrative embodiments may be combined in whole or in part in some or all of the illustrative embodiments. In addition, one or more of the elements and teachings of the various illustrative embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.
Claims
1. A method of forming a tubular liner within a preexisting structure, comprising:
- 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.
2. An expandable tubular member comprising a steel alloy comprising, by weight percentage the following:
- 0.065 to 0.18% C,
- 0.006 to 1.44% Mn,
- 0.006 to 0.02% P,
- 0.001 to 0.004% S,
- 0.24 to 0.45% Si,
- up to 0.16% Cu,
- 0.01 to 9.1% Ni, and
- 0.02 to 18.7% Cr.
3. An expandable tubular member, wherein the yield point of the expandable tubular member is at most about 46.9 to 61.7 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 to 74.4 ksi after the radial expansion and plastic deformation.
4. 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 to 40% greater than the yield point of the expandable tubular member prior to the radial expansion and plastic deformation.
5. 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 at least about 1.92.
6. 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.
7. An expandable tubular member, wherein the expandability coefficient of the expandable tubular member is greater than the expandability coefficient of another portion of the expandable tubular member.
8. An expandable tubular member, 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.
9. A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member coupled to a second tubular member, comprising:
- 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.
10. A method of manufacturing a tubular member, comprising:
- 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.
11. An apparatus, comprising:
- 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.
12. 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.
13. A method of determining the expandability of a selected tubular member, comprising:
- 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.
14. A method of radially expanding and plastically deforming tubular members, comprising:
- 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.
15. A radially expandable tubular member apparatus comprising:
- 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 the 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.
16. A method of joining radially expandable tubular members comprising:
- providing a first tubular member;
- engaging a second tubular member with the first tubular member to form a joint;
- providing 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.
17. An expandable tubular member
- wherein, if the carbon content of the tubular member is less than or equal to 0.12 percent, then the carbon equivalent value for the tubular member is less than 0.21; and wherein, if the carbon content of the tubular member is greater than 0.12 percent, then the carbon equivalent value for the tubular member is less than 0.36.
18. A method of selecting tubular members for radial expansion and plastic deformation, comprising:
- 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;
- 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 0.21, then determining that the selected tubular member is suitable for radial expansion and plastic deformation; 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.
19. An expandable tubular member, comprising:
- 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.
20. A method of manufacturing an expandable tubular member, comprising:
- providing a tubular member;
- heat treating the tubular member; and
- quenching the tubular member;
- wherein following the quenching, the tubular member comprises a microstructure comprising a hard phase structure and a soft phase structure.
21. A system for radially expanding and plastically deforming a tubular member, comprising:
- 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.
22. A method of radially expanding and plastically deforming a tubular member, comprising:
- 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.
23. A lubricant for injecting in an interface between a tubular member and an expansion device, comprising, by weight percentage:
- 64.25% to 90.89% canola oil;
- 0.02% to 0.05% tolyltriazole;
- 0.5% to 1.0% aminic antioxidant;
- 0.5% to 2.0% phenolic antioxidant;
- 4% to 12% sulfurized natural oil or sulferized lard oil;
- 4% to 12% phosphate ester;
- 0.4% to 1.5 phosphoric acid;
- 0.08% to 1.5% styrene hydrocarbon polymer;
- 0.1% to 0.5% alkyl ester copolymer;
- 0.01% to 0.2% silicon based antifoam agent; and
- 1% to 5% carbozylic acid soap.
24. An expansion device for radially expanding and plastically deforming the tubular member, comprising:
- 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.
25. An expansion device for radially expanding and plastically deforming a tubular member, comprising:
- 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.
26. A method for radially expanding and plastically deforming the tubular member, comprising:
- 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.
27. A method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than 0.08, comprising:
- 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.
28. A lubrication system for lubricating an interface between a first element and a second element, comprising:
- a vaporizer proximate to the interface for vaporizing a lubricant to inject the lubricant in the interface.
29. A method for lubricating an interface between a first element and a second element, comprising:
- vaporizing a lubricant proximate to the interface to inject the lubricant in the interface.
30. A system for radially expanding and plastically deforming a tubular member, comprising:
- 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.
31. A system for radially expanding and plastically deforming a tubular member, comprising:
- 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.
32. A method of radially expanding and plastically deforming a tubular member, comprising:
- 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 0.08.
33. A method of radially expanding and plastically deforming a tubular member, comprising:
- 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.
34. A lubricant delivery assembly for radially expanding and plastically deforming a tubular member, comprising:
- an expansion device 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.
35. A method of reducing the coefficient of friction between the expansion device and the tubular member during radial expansion to less than 0.08, comprising:
- 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.
Type: Application
Filed: Sep 7, 2004
Publication Date: Sep 20, 2007
Applicant: Enventure Global Technology, LLC (Houston, TX)
Inventors: Mark Shuster (Houston, TX), Malcolm Gray (Houston, TX), Grigoriy Grinberg (Sylvania, OH), Scott Costa (Katy, TX), Matt Shade (Plymouth, MI), Alla Petlyuk (West Chester, PA)
Application Number: 10/571,041
International Classification: E21B 19/16 (20060101);
