Claims
- 1. An apparatus for plastically deforming and radially expanding a tubular member, comprising:
a tubular support member including a first fluid passage; an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface; a removable annular conical sleeve coupled to the outer conical surface of the expansion cone; an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member; and a shoe having a valveable passage coupled to an end of the expansion cone launcher.
- 2. The apparatus of claim 1, wherein the conical sleeve is frangible.
- 3. The apparatus of claim 1, wherein the conical sleeve is elastic.
- 4. The apparatus of claim 1, wherein the conical sleeve comprises a plurality of arcuate elements.
- 5. A method of plastically deforming and radially expanding a tubular member, comprising:
plastically deforming and radially expanding a portion of the tubular member to a first outside diameter; and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter; wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using a conical sleeve.
- 6. The method of claim 5, wherein the conical sleeve is frangible.
- 7. The method of claim 5, wherein the conical sleeve is elastic.
- 8. The method of claim 5, wherein the conical sleeve comprises a plurality of arcuate elements.
- 9. A method of plastically deforming and radially expanding a tubular member, comprising:
plastically deforming and radially expanding a portion of the tubular member to a first outside diameter; and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.
- 10. The method of claim 9, wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using an inflatable bladder.
- 11. The method of claim 9, wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using a roller expansion device.
- 12. A method of coupling a first tubular member to a second tubular member, comprising:
plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter; plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter; positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member; plastically deforming and radially expanding the second tubular member to a third outside diameter; and plastically deforming and radially expanding the second tubular member to a fourth outside diameter; wherein the first and second tubular members after the plastic deformations and radial expansions define a passage having a constant cross sectional area.
- 13. The method of claim 12, wherein the first outside diameter is greater than the second outside diameter.
- 14. The method of claim 12, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the portion of the tubular member using a conical sleeve.
- 15. The method of claim 14, wherein the conical sleeve is frangible.
- 16. The method of claim 14, wherein the conical sleeve is elastic.
- 17. The method of claim 14, wherein the conical sleeve comprises a plurality of arcuate elements.
- 18. The method of claim 12, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the first portion of the first tubular member using an inflatable bladder.
- 19. The method of claim 12, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the first portion of the first tubular member using a roller expansion device.
- 20. An apparatus for forming a wellbore casing within a wellbore, comprising:
a tubular support member including a first fluid passage; an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface; a removable annular conical sleeve coupled to the outer conical surface of the expansion cone; an annular expansion cone launcher coupled to the conical sleeve and a lower portion of the tubular member; and a shoe having a valveable passage coupled to an end of the expansion cone launcher.
- 21. The apparatus of claim 20, wherein the conical sleeve is frangible.
- 22. The apparatus of claim 20, wherein the conical sleeve is elastic.
- 23. The apparatus of claim 20, wherein the conical sleeve comprises a plurality of arcuate elements.
- 24. A method of forming a wellbore casing within a wellbore, comprising:
supporting a tubular member within a wellbore; plastically deforming and radially expanding a portion of the tubular member to a first outside diameter; and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter; wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using a conical sleeve.
- 25. The method of claim 24, wherein the conical sleeve is frangible.
- 26. The method of claim 24, wherein the conical sleeve is elastic.
- 27. The method of claim 24, wherein the conical sleeve comprises a plurality of arcuate elements.
- 28. A method of forming a wellbore casing within a wellbore, comprising:
supporting a tubular member within a wellbore; plastically deforming and radially expanding a portion of the tubular member to a first outside diameter; and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter.
- 29. The method of claim 28, wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using an inflatable bladder.
- 30. The method of claim 28, wherein plastically deforming and radially expanding the portion of the tubular member comprises:
applying a radial force to the portion of the tubular member using a roller expansion device.
- 31. A method of forming a mono-diameter wellbore casing within a wellbore, comprising:
supporting a first tubular member within the wellbore; plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter; plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter; positioning the second tubular member inside the first tubular member in overlapping relation to the radially expanded first portion of the first tubular member; plastically deforming and radially expanding the second tubular member to a third outside diameter; and plastically deforming and radially expanding the second tubular member to a fourth outside diameter; wherein the first and second tubular members after the plastic deformations and radial expansions define a passage having a constant cross sectional area.
- 32. The method of claim 31, wherein the first outside diameter is greater than the second outside diameter.
- 33. The method of claim 31, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the portion of the tubular member using a conical sleeve.
- 34. The method of claim 33, wherein the conical sleeve is frangible.
- 35. The method of claim 33, wherein the conical sleeve is elastic.
- 36. The method of claim 33, wherein the conical sleeve comprises a plurality of arcuate elements.
- 37. The method of claim 31, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the first portion of the first tubular member using an inflatable bladder.
- 38. The method of claim 31, wherein plastically deforming and radially expanding the first portion of the first tubular member comprises:
applying a radial force to the first portion of the first tubular member using a roller expansion device.
- 39. The method of claim 32, further comprising:
injecting an annular body of a hardenable fluidic sealing material into an annulus between the first tubular member and the wellbore.
- 40. The method of claim 33, further comprising:
curing the annular body of hardenable fluidic sealing material.
- 41. The method of claim 34, further comprising:
injecting an annular body of a hardenable fluidic sealing material into an annulus between the second tubular member and the wellbore.
- 42. The method of claim 35, further comprising:
curing the annular body of hardenable fluidic sealing material.
- 43. An apparatus for forming a wellbore casing within a wellbore, comprising:
a tubular support member including a first fluid passage; an expansion cone coupled to the tubular support member having a second fluid passage fluidicly coupled to the first fluid passage and an outer conical surface; an annular expansion cone launcher comprising:
a first annular portion coupled to a lower portion of the tubular member; a second annular portion coupled to the first annular portion that mates with the outer conical surface of the expansion cone; a third annular portion coupled to the second annular portion having a first outside diameter; and a fourth annular portion coupled to the third annular portion having a second outside diameter; wherein the second outside diameter is less than the first outside diameter; and a shoe having a valveable passage coupled to fourth annular portion of the expansion cone launcher.
- 44. A method of forming a wellbore casing in a wellbore, comprising:
supporting a tubular member within the wellbore; providing a lipped portion in a portion of the tubular member; and plastically deforming and radially expanding another portion of the tubular member.
- 45. The method of claim 44, further comprising:
injecting a hardenable fluidic sealing material in an annulus between the tubular member and the wellbore.
- 46. The method of claim 45, further comprising:
curing the fluidic sealing material.
- 47. A method of forming a mono-diameter wellbore casing within a wellbore, comprising:
supporting a first tubular member within the wellbore; providing a lipped portion in a portion of the first tubular member; plastically deforming and radially expanding another portion of the first tubular member; positioning the second tubular member inside the first tubular member in overlapping relation to the lipped portion of the first tubular member; and plastically deforming and radially expanding the second tubular member; wherein the inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.
- 48. The method of claim 47, further comprising:
injecting a hardenable fluidic sealing material in an annulus between the first tubular member and the wellbore.
- 49. The method of claim 48, further comprising:
curing the fluidic sealing material.
- 50. The method of claim 47, further comprising:
injecting a hardenable fluidic sealing material in an annulus between the second tubular member and the wellbore.
- 51. The method of claim 50, further comprising:
curing the fluidic sealing material.
- 52. An apparatus for plastically deforming and radially expanding a tubular member, comprising:
a tubular support member including a first passage; an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface; an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone; an expandable tubular member coupled to an end of the annular expansion cone launcher; a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage; and another annular expansion cone movably coupled to the tubular support member; wherein the annular expansion cones are positioned in opposite orientations.
- 53. The apparatus of claim 52, wherein the annular expansion cone is adapted to plastically deform and radially expand a first end of the expandable tubular member and the other annular expansion cone is adapted to plastically deform and radially expand a second end of the expandable tubular member.
- 54. The apparatus of claim 52, further comprising:
an anchoring member coupled to the tubular support member adapted to hold the expandable tubular.
- 55. An apparatus for forming a wellbore casing within a wellbore, comprising:
a tubular support member including a first passage; an expansion cone coupled to the tubular support having a second passage fluidicly coupled to the first passage and an outer conical surface; an annular expansion cone launcher movably coupled to outer conical surface of the expansion cone; an expandable tubular member coupled to an end of the annular expansion cone launcher; a shoe coupled to another end of the annular expansion cone launcher having a valveable fluid passage; and another annular expansion cone movably coupled to the tubular support member; wherein the annular expansion cones are positioned in opposite orientations.
- 56. The apparatus of claim 55, wherein the annular expansion cone is adapted to plastically deform and radially expand a first end of the expandable tubular member and the other annular expansion cone is adapted to plastically deform and radially expand a second end of the expandable tubular member.
- 57. The apparatus of claim 55, further comprising:
an anchoring member coupled to the tubular support member adapted to hold the expandable tubular.
- 58. A method of bridging an axial gap between opposing pairs of wellbore casing within a wellbore, comprising:
supporting a tubular member in overlapping relation to the opposing ends of the wellbore casings; plastically deforming and radially expanding the tubular member; and plastically deforming and radially expanding the tubular member and the opposing ends of the wellbore casings.
- 59. A method of forming a mono-diameter wellbore casing, comprising:
positioning a first tubular member within a wellbore, the first tubular member having an original outside diameter OD0 and an original wall thickness t0; plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter; plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter; positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member; plastically deforming and radially expanding the second tubular member to a third outside diameter; and plastically deforming and radially expanding the second tubular member to a fourth outside diameter; wherein the inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal; and wherein the ratio of the original outside diameter OD0 of the first tubular member to the original wall thickness t0 of the first tubular member is greater than or equal to 16.
- 60. An apparatus, comprising:
a plastically deformed and radially expanded tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter; wherein the ratio of the original outside diameter OD0 of the first tubular member to the original wall thickness t0 of the first tubular member is greater than or equal to 16.
- 61. An apparatus, comprising:
a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter; and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member; wherein the ratio of the original outside diameter OD0 of the first tubular member to the original wall thickness t0 of the first tubular member is greater than or equal to 16.
- 62. The apparatus of claim 61, wherein the inside diameters of the first and second tubular members are substantially equal.
- 63. A wellbore casing formed in a wellbore, comprising:
a plastically deformed and radially expanded first tubular member having a first portion having a first outside diameter and a remaining portion having a second outside diameter; and a plastically deformed and radially expanded second tubular member coupled to the first portion of the first tubular member; wherein the ratio of the original outside diameter OD0 of the first tubular member to the original wall thickness t0 of the first tubular member is greater than or equal to 16.
- 64. The casing of claim 63, wherein the inside diameters of the first and second tubular members are substantially equal.
- 65. An apparatus, comprising:
a plastically deformed and radially expanded tubular member; wherein the ratio of the original outside diameter OD0 of the tubular member to the original wall thickness t0 of the tubular member is greater than or equal to 16.
- 66. A method of forming a wellbore casing within a wellbore, comprising:
supporting a tubular member within a wellbore; plastically deforming and radially expanding a portion of the tubular member to a first outside diameter using a first expansion cone coupled to a second expansion cone; decoupling the first and second expansion cones; and plastically deforming and radially expanding another portion of the tubular member to a second outside diameter using the second expansion cone; wherein the first outside diameter is greater than the second outside diameter.
- 67. A method of forming a mono-diameter wellbore casing within a wellbore, comprising:
supporting a first tubular member within the wellbore; plastically deforming and radially expanding a first portion of the first tubular member to a first outside diameter using a first expansion cone coupled to a second expansion cone; decoupling the first and second expansion cones; plastically deforming and radially expanding another portion of the first tubular member to a second outside diameter using the second expansion cone; positioning the second tubular member inside the first tubular member in overlapping relation to the first portion of the first tubular member; plastically deforming and radially expanding the second tubular member to a third outside diameter; and plastically deforming and radially expanding the second tubular member to a fourth outside diameter; wherein the first outside diameter is greater than the second outside diameter; and wherein the inside diameters of the first and second tubular members after the plastic deformations and radial expansions are substantially equal.
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a National Phase of the International Application No. PCT/US01/30256, attorney docket number 25791.48.02 which is based on U.S. Application Serial No. 60/237,334, filed on Oct. 2, 2000, attorney docket number 25791.48, the disclosure of which is incorporated herein by reference.
[0002] This application is related to the following co-pending applications: (1) U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, (4) U.S. patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, (5) U.S. patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, (6) U.S. patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, (7) U.S. patent application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, (8) U.S. patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, (9) U.S. patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, (10) PCT patent application serial no. PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jun. 9, 2000, (11) U.S. provisional patent application serial No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (12) U.S. provisional patent application serial No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (13) U.S. provisional patent application serial No. 60/159,082, attorney docket no. 25791.34, filed on Oct. 12, 1999, (14) U.S. provisional patent application serial No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999, (15) U.S. provisional patent application serial No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999, (16) U.S. provisional patent application serial No. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (17) U.S. provisional patent application serial No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (18) U.S. provisional patent application serial No. 60/165,228, attorney docket no. 25791.45, filed on Jul. 28, 2000, (19) U.S. provisional patent application serial No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, and (20) U.S. provisional patent application serial No. 60/233,638, attorney docket no. 25791.47, filed on Sep. 18, 2000. Applicants incorporate by reference the disclosures of these applications.
Provisional Applications (1)
|
Number |
Date |
Country |
|
60237334 |
Oct 2000 |
US |
Continuations (1)
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Number |
Date |
Country |
Parent |
PCT/US01/30256 |
Sep 2001 |
US |
Child |
10406648 |
Mar 2003 |
US |