US20080115939A1 - Radial Expansion of Tubular Members - Google Patents
Radial Expansion of Tubular Members Download PDFInfo
- Publication number
- US20080115939A1 US20080115939A1 US11/859,193 US85919307A US2008115939A1 US 20080115939 A1 US20080115939 A1 US 20080115939A1 US 85919307 A US85919307 A US 85919307A US 2008115939 A1 US2008115939 A1 US 2008115939A1
- Authority
- US
- United States
- Prior art keywords
- filed
- attorney docket
- tubular member
- patent application
- application ser
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Abandoned
Links
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Images
Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
- B21D39/04—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders of tubes with tubes; of tubes with rods
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B21—MECHANICAL METAL-WORKING WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D—WORKING OR PROCESSING OF SHEET METAL OR METAL TUBES, RODS OR PROFILES WITHOUT ESSENTIALLY REMOVING MATERIAL; PUNCHING METAL
- B21D39/00—Application of procedures in order to connect objects or parts, e.g. coating with sheet metal otherwise than by plating; Tube expanders
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- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
- E21B17/02—Couplings; joints
- E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
- E21B17/042—Threaded
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- E21B17/02—Couplings; joints
- E21B17/04—Couplings; joints between rod or the like and bit or between rod and rod or the like
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- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
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- E21B23/00—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells
- E21B23/01—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells for anchoring the tools or the like
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- E21B23/04—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells operated by fluid means, e.g. actuated by explosion
- E21B23/0411—Apparatus for displacing, setting, locking, releasing, or removing tools, packers or the like in the boreholes or wells operated by fluid means, e.g. actuated by explosion specially adapted for anchoring tools or the like to the borehole wall or to well tube
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- E21B29/00—Cutting or destroying pipes, packers, plugs, or wire lines, located in boreholes or wells, e.g. cutting of damaged pipes, of windows; Deforming of pipes in boreholes or wells; Reconditioning of well casings while in the ground
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- E—FIXED CONSTRUCTIONS
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- E21B33/02—Surface sealing or packing
- E21B33/03—Well heads; Setting-up thereof
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- E—FIXED CONSTRUCTIONS
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- E21B33/03—Well heads; Setting-up thereof
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- E21B33/047—Casing heads; Suspending casings or tubings in well heads for plural tubing strings
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- E—FIXED CONSTRUCTIONS
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- E—FIXED CONSTRUCTIONS
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- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
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- E—FIXED CONSTRUCTIONS
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- E21B36/00—Heating, cooling, insulating arrangements for boreholes or wells, e.g. for use in permafrost zones
- E21B36/04—Heating, cooling, insulating arrangements for boreholes or wells, e.g. for use in permafrost zones using electrical heaters
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- E—FIXED CONSTRUCTIONS
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- E—FIXED CONSTRUCTIONS
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- E21B43/084—Screens comprising woven materials, e.g. mesh or cloth
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- E—FIXED CONSTRUCTIONS
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- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/08—Screens or liners
- E21B43/086—Screens with preformed openings, e.g. slotted liners
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- E—FIXED CONSTRUCTIONS
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- E—FIXED CONSTRUCTIONS
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- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
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- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
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- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/105—Expanding tools specially adapted therefor
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- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/106—Couplings or joints therefor
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
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- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/108—Expandable screens or perforated liners
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/14—Obtaining from a multiple-zone well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/30—Specific pattern of wells, e.g. optimizing the spacing of wells
- E21B43/305—Specific pattern of wells, e.g. optimizing the spacing of wells comprising at least one inclined or horizontal well
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B7/00—Special methods or apparatus for drilling
- E21B7/20—Driving or forcing casings or pipes into boreholes, e.g. sinking; Simultaneously drilling and casing boreholes
- E21B7/208—Driving or forcing casings or pipes into boreholes, e.g. sinking; Simultaneously drilling and casing boreholes using down-hole drives
-
- F—MECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
- F16—ENGINEERING ELEMENTS AND UNITS; GENERAL MEASURES FOR PRODUCING AND MAINTAINING EFFECTIVE FUNCTIONING OF MACHINES OR INSTALLATIONS; THERMAL INSULATION IN GENERAL
- F16B—DEVICES FOR FASTENING OR SECURING CONSTRUCTIONAL ELEMENTS OR MACHINE PARTS TOGETHER, e.g. NAILS, BOLTS, CIRCLIPS, CLAMPS, CLIPS OR WEDGES; JOINTS OR JOINTING
- F16B17/00—Connecting constructional elements or machine parts by a part of or on one member entering a hole in the other and involving plastic deformation
- F16B17/004—Connecting constructional elements or machine parts by a part of or on one member entering a hole in the other and involving plastic deformation of rods or tubes mutually
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH DRILLING; MINING
- E21B—EARTH DRILLING, e.g. DEEP DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B33/00—Sealing or packing boreholes or wells
- E21B33/10—Sealing or packing boreholes or wells in the borehole
- E21B33/13—Methods or devices for cementing, for plugging holes, crevices, or the like
- E21B33/14—Methods or devices for cementing, for plugging holes, crevices, or the like for cementing casings into boreholes
- E21B33/16—Methods or devices for cementing, for plugging holes, crevices, or the like for cementing casings into boreholes using plugs for isolating cement charge; Plugs therefor
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/49—Method of mechanical manufacture
- Y10T29/49826—Assembling or joining
- Y10T29/49908—Joining by deforming
- Y10T29/49909—Securing cup or tube between axially extending concentric annuli
- Y10T29/49911—Securing cup or tube between axially extending concentric annuli by expanding inner annulus
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
- Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
- Y10T29/00—Metal working
- Y10T29/53—Means to assemble or disassemble
- Y10T29/53039—Means to assemble or disassemble with control means energized in response to activator stimulated by condition sensor
- Y10T29/53061—Responsive to work or work-related machine element
- Y10T29/53065—Responsive to work or work-related machine element with means to fasten by deformation
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Physics & Mathematics (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Mechanical Engineering (AREA)
- General Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Dispersion Chemistry (AREA)
- Lining Or Joining Of Plastics Or The Like (AREA)
- Exhaust-Gas Circulating Devices (AREA)
- Facsimile Heads (AREA)
- Apparatus Associated With Microorganisms And Enzymes (AREA)
- Joints Allowing Movement (AREA)
- Mutual Connection Of Rods And Tubes (AREA)
- Protection Of Pipes Against Damage, Friction, And Corrosion (AREA)
- Nitrogen And Oxygen Or Sulfur-Condensed Heterocyclic Ring Systems (AREA)
- Joining Of Building Structures In Genera (AREA)
- Radiation-Therapy Devices (AREA)
- Medicines That Contain Protein Lipid Enzymes And Other Medicines (AREA)
- Earth Drilling (AREA)
Abstract
An apparatus and method for coupling a tubular member to a preexisting structure.
Description
- This application is a continuation of U.S. application Ser. No. 10/950,749, filed Sep. 27, 2004, attorney docket no. 25791.334, which is a divisional of U.S. Pat. No. 7,270,188, filed as application Ser. No. 10/303,992, filed Nov. 22, 2002, attorney docket no. 25791.38.07, which is 1) the National Stage filing of the International Application No. PCT/US01/19014, filed Jun. 12, 2001, attorney docket number 25791.38.02, which is based on U.S. provisional application Ser. No. 60/212,359, filed on Jun. 19, 2000, attorney docket number 25791.38; and 2) a continuation-in-part of the following co-pending patent applications: (1) U.S. Pat. No. 6,561,227, which was filed as U.S. utility patent application Ser. No. 09/852,026, attorney docket no. 25791.56, filed on May 9, 2001, which was a division of U.S. Pat. No. 6,497,289, which was filed as U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, now U.S. Pat. No. 6,823,937, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) 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 was a continuation of U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, now U.S. Pat. No. 6,328,113, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no, 25791.9, filed on Nov. 16, 1998; (5) U.S. utility patent application Ser. No. 10/169,434, attorney docket no. 25791.10.04, filed on Jul. 1, 2002, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, now U.S. Pat. No. 6,640,903, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, now U.S. Pat. No. 6,568,471, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, now U.S. Pat. No. 6,575,240, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, now U.S. Pat. No. 6,557,640, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; and (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, now U.S. Pat. No. 6,604,763, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999. Applicants incorporate by reference the disclosures of these applications.
- This application is related to the following co-pending patent applications: (11) U.S. utility patent application Ser. No. 10/030,593, attorney docket no. 25791.25.08, filed on Jan. 8, 2002, which claimed the benefit of the filing date of U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999 and U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (12) U.S. utility patent application Ser. No. 10/111,982, attorney docket no. 25791.27.08, filed on Apr. 30, 2002, now U.S. Pat. No. 7,048,067, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (13) U.S. utility patent application Ser. No. 10/089,419, attorney docket no. 25791.36.03, filed on Mar. 27, 2002, now U.S. Pat. No. 6,695,012, which claimed the benefit of the filing date of U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999 and U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999; (14) U.S. utility patent application Ser. No. 09/679,906, attorney docket no. 25791.37.02, filed on Oct. 5, 2000, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999. Applicants incorporate by reference the disclosures of these applications.
- 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, now U.S. Pat. No. 6,823,937 which issued Nov. 30, 2004, 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 no. 25791.27.08, filed on Apr. 30, 2002, which claims priority from provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999, (15) U.S. provisional patent application Ser. No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999, (16) U.S. provisional patent application Ser. No. 60/438,828, attorney docket no. 25791.31, filed on Jan. 9, 2003, (17) U.S. Pat. No. 6,564,875, which was filed as application Ser. No. 09/679,907, attorney docket no. 25791.34.02, on Oct. 5, 2000, which claims priority from provisional patent application Ser. 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, now U.S. Pat. No. 6,695,012 which issued Feb. 24, 2004, attorney docket no. 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. 10/322,947, filed on Dec. 18, 2002, attorney docket no. 25791.46.07, which claims priority from provisional patent application Ser. No. 60/221,645, attorney docket no. 25791.46, filed on Jul. 28, 2000, (26) U.S. patent application Ser. No. 10/322,947, filed on Jan. 22, 2003, now U.S. Pat. No. 6,976,541 which issued Dec. 20, 2005, attorney docket no. 25791.47.07, which claims priority from provisional patent application Ser. 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 Ser. 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, now U.S. Pat. No. 6,892,819 which issued May 17, 2005, 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, now U.S. Pat. No. 6,739,392 which issued May 25, 2004, 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, now U.S. Pat. No. 6,725,919 which issued Apr. 27, 2004, 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. No. 6,640,903 which issued Nov. 4, 2003), which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (43) U.S. patent application Ser. No. 09/962,468, filed on Sep. 25, 2001, now U.S. Pat. No. 6,758,278 which issued Jul. 6, 2004, attorney docket no. 25791.66, 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, (44) PCT application US02/25727, filed on Aug. 14, 2002, attorney docket no. 25791.67.03, which claims priority from U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, and U.S. provisional patent application Ser. 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, now U.S. Pat. No. 6,745,845 which issued Jun. 8, 2004, 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, now U.S. Pat. No. 6,705,395 which issued Mar. 16, 2004, 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. 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, (50) U.S. patent application Ser. No. 10/074,244, attorney docket no. 25791.75, filed on Feb. 12, 2002, now U.S. Pat. No. 6,631,759 which issued Oct. 14, 2003, which is a divisional of 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, (51) U.S. patent application Ser. No. 10/076,660, attorney docket no. 25791.76, filed on Feb. 15, 2002, which is a divisional of 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, (52) U.S. patent application Ser. No. 10/076,661, attorney docket no. 25791.77, filed on Feb. 15, 2002, now U.S. Pat. No. 6,631,769 which issued Oct. 14, 2003, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. 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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, (55) U.S. patent application Ser. No. 10/078,922, attorney docket no. 25791.80, filed on Feb. 20, 2002, now U.S. Pat. No. 6,966,370 which issued Nov. 22, 2005, which is a divisional of 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, (56) U.S. patent application Ser. No. 10/078,921, attorney docket no. 25791.81, filed on Feb. 20, 2002, now U.S. Pat. No. 7,044,221 which issued May 16, 2006, which is a divisional of U.S. Pat. No. 6,568,471, which was filed as patent application Ser. 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- This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubular members.
- Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.
- The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores.
- According to one aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member, and lubricating the interface between the expansion cone and the tubular member.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member. The tubular member includes: an annular member, including: a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes injecting a lubricating fluid into the preexisting structure, positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. The expandable tubular member includes: a first tubular member, a second tubular member, and a threaded connection for coupling the first tubular member to the second tubular member. The threaded connection includes: one or more sealing members for sealing the interface between the first and second tubular members.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. The expandable tubular member includes a plurality of tubular members having threaded portions that are coupled to one another by the process of: coating the threaded portions of the tubular members with a sealant, coupling the threaded portions of the tubular members and curing the sealant.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the expandable tubular member. The tubular member includes: a pair of rings for engaging the preexisting structure, and a sealing element positioned between the rings for sealing the interface between the tubular member and the preexisting structure.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. The tubular member includes one or more slots.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. The tubular member includes: a first preexpanded portion, an intermediate portion coupled to the first preexpanded portion including a sealing element, and a second preexpanded portion coupled to the intermediate portion.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member by applying an axial force to the expansion cone. The axial force includes: a substantially constant axial force, and an increased axial force.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pushing and pulling the expansion cone through the expandable tubular member.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the expandable tubular member, and injecting a curable fluidic sealing material between the tubular member and the preexisting structure prior to axially displacing the expansion cone.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure by increasing the size of the expansion cone, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure by heating a portion of the tubular member, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the expandable tubular member, an expansion cone, and an anchoring device within the preexisting structure, positioning the anchoring device above the expansion cone, anchoring the expandable tubular member to the preexisting structure using the anchoring device, and axially displacing the expansion cone.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, explosively anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member.
- According to another aspect of the present invention, a method of coupling an expandable tubular to a preexisting structure is provided that includes fixing the position of an expansion cone within the preexisting structure, driving the expandable tubular member onto the expansion cone in a first direction, and axially displacing the expansion cone in a second direction relative to the expandable tubular member. The first and second directions are different.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular, an expansion cone, and a resilient anchor within the preexisting structure, releasing the resilient anchor, and axially displacing the expansion cone within the expandable tubular member.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member, an expansion cone, and an anchor into the preexisting structure, and anchoring the expandable tubular member to the preexisting structure by: pivoting one or more engagement elements, and axially displacing the expansion cone.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member and an expansion cone into the preexisting structure, placing a quantity of a fluidic material onto the expandable tubular member to anchor the expandable tubular member to the preexisting structure, and axially displacing the expansion cone.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes positioning the expandable tubular member and an expansion cone into the preexisting structure, anchoring the expandable tubular member to the preexisting structure by injecting a quantity of a hardenable fluidic material into the preexisting structure, at least partially curing the hardenable fluidic sealing material, and axially displacing the expansion cone.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member and an expansion cone within the preexisting structure and applying an axial force to the expandable tubular member in a downward direction.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member and an expansion cone within the preexisting structure, injecting a quantity of a first fluidic material having a first density into the region of the preexisting structure outside of the expandable tubular member, and injecting a quantity of a second fluidic material having a second density into a portion of the expandable tubular member below the expansion cone. The second density is greater than the first density.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member and an expansion cone into the preexisting structure, anchoring the expandable tubular member to the preexisting structure, applying an axial force to the expansion cone, and pressurizing an interior portion of the expandable tubular member below the expansion cone.
- According to another aspect of the present invention, a method of coupling an expandable tubular member to a preexisting structure is provided that includes placing the expandable tubular member and an expansion cone into the preexisting structure and applying an axial force to the expandable tubular member.
- According to another aspect of the present invention, an apparatus for coupling a tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member, including: a housing including a tapered first end and a second end, one or more grooves formed in the outer surface of the tapered first end, and one or more axial flow passages fluidicly coupled to the grooves.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: an annular member, having: a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: a first tubular member, a second tubular member, and a threaded connection for coupling the first tubular member to the second tubular member, the threaded connection including: one or more sealing members for sealing the interface between the first and second tubular members.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: a layer of a lubricant coupled to the interior surface of the tubular member.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: a pair of tubular members having threaded portions coupled to one another, and a quantity of a sealant within the threaded portions of the tubular members.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: a pair of rings for engaging the preexisting structure, and a sealing element positioned between the rings for sealing the interface between the tubular member and the preexisting structure.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes one or more slots.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. The expandable tubular member includes: a first preexpanded portion, an intermediate portion coupled to the first preexpanded portion including a sealing element, and a second preexpanded portion coupled to the intermediate portion.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member, and a valveable fluid passage coupled to the anchoring device.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a first support member, a second support member coupled to the first support member, an expansion cone coupled to the first support member, an expandable tubular member coupled to the expansion cone, and an anchoring device coupled to the second support member adapted to couple the expandable tubular member to the preexisting structure. The anchoring device is positioned above the expansion cone.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a first support member, a second support member coupled to the first support member, an expansion cone coupled to the first support member, an expandable tubular member coupled to the expansion cone, and an explosive anchoring device coupled to the second support member adapted to couple the expandable tubular member to the preexisting structure.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expandable expansion cone coupled to the support member, and an expandable tubular member coupled to the expansion cone.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expandable expansion cone coupled to the support member, and an expandable tubular member coupled to the expandable expansion cone.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular to a preexisting structure is provided that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone including one or more shape memory metal inserts, and a heater coupled to the support member in opposing relation to the shape memory metal inserts.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and a resilient anchor coupled to the expandable tubular member.
- According to another aspect of the present invention, an expandable tubular member is provided that includes: an expandable tubular body, one or more resilient panels coupled to the expandable tubular body, and a release member releasably coupled to the resilient panels adapted to controllably release the resilient panels.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and an anchor coupled to the expandable tubular member, including: one or more spikes pivotally coupled to the expandable tubular member for engaging the preexisting structure.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and an anchor coupled to the expandable tubular member, including: one or more petal baskets pivotally coupled to the expandable tubular member.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone, including: a slotted portion provided at one end of the expandable tubular member.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member, an expansion cone, an expandable tubular member coupled to the expansion cone, a coupling device coupled to the support member and an end portion of the expandable tubular member, and
- A mass coupled to the end portion of the expandable tubular member. The weight of the mass is greater than the yield strength of the expandable tubular member.
- According to another aspect of the present invention, an apparatus for coupling an expandable tubular member to a preexisting structure is provided that includes a support member including a fluid passage, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone, a slip joint coupled to the expansion cone, an end plate coupled to the slip joint, a fluid chamber coupled to the fluid passage, the fluid chamber defined by the interior portion of the expandable tubular member between the expansion cone and the end plate.
- According to another aspect of the present invention, a method of coupling a tubular member to a preexisting structure is provided that includes positioning the tubular member and an expansion cone within the preexisting structure, axially displacing the expansion cone, removing the expansion cone, and applying direct radial pressure to the tubular member.
- According to another aspect of the present invention, an apparatus is provided that includes a tubular member coupled to a preexisting structure. The tubular member is coupled to the preexisting structure by the process of:
- Positioning the tubular member and an expansion cone within the preexisting structure, axially displacing the expansion cone, removing the expansion cone, and applying direct radial pressure to the tubular member.
-
FIG. 1 a is a fragmentary cross-sectional illustration of the placement of an embodiment of an apparatus for expanding a tubular member within a wellbore casing. -
FIG. 1 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 a after anchoring the expandable tubular member of the apparatus to the wellbore casing. -
FIG. 1 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 b after initiating the axial displacement of the expansion cone. -
FIG. 1 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 b after initiating the axial displacement of the expansion cone by pulling on the expansion cone and injecting a pressurized fluid below the expansion cone. -
FIG. 1 e is a fragmentary cross-sectional illustration of the apparatus ofFIGS. 1 c and 1 d after the completion of the radial expansion of the expandable tubular member. -
FIG. 1 f is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 e after the decoupling of the anchoring device of the apparatus from the wellbore casing. -
FIG. 1 g is a fragmentary cross-sectional illustration of the apparatus ofFIG. 1 f after the removal of the anchoring device of the apparatus from the wellbore casing. -
FIG. 2 a is a fragmentary cross-sectional illustration of the placement of an embodiment of an apparatus for expanding a tubular member within a wellbore casing and an open hole in a subterranean formation. -
FIG. 2 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 2 a after anchoring the expandable tubular member of the apparatus to the open hole. -
FIG. 2 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 2 b after initiating the axial displacement of the expansion cone. -
FIG. 2 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 2 b after initiating the axial displacement of the expansion cone by pulling on the expansion cone and also by injecting a pressurized fluid below the expansion cone. -
FIG. 2 e is a fragmentary cross-sectional illustration of the apparatus ofFIGS. 2 c and 2 d after the completion of the radial expansion of the expandable tubular member. -
FIG. 2 f is a fragmentary cross-sectional illustration of the apparatus ofFIG. 2 e after the decoupling of the anchoring device of the apparatus from the open hole. -
FIG. 3 a is a fragmentary cross-sectional illustration of the placement of an embodiment of an apparatus for expanding a tubular member within a wellbore casing. -
FIG. 3 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 3 a after anchoring the expandable tubular member of the apparatus to the wellbore casing. -
FIG. 3 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 3 b after initiating the axial displacement of the expansion cone. -
FIG. 3 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 3 c after completing the radial expansion of the expandable tubular member. -
FIG. 4 is a fragmentary cross-sectional illustration of an embodiment of a shock absorbing system for use in the apparatus ofFIGS. 1 a to 3 d. -
FIG. 5 is a cross-sectional illustration of an embodiment of a coupling arrangement for use in the expandable tubular members of the apparatus ofFIGS. 1 a to 3 d. -
FIG. 6 is a cross-sectional illustration of an embodiment of an expandable tubular member having a slotted lower section for use in the apparatus ofFIGS. 1 a to 3 d. -
FIG. 7 is a cross-sectional illustration of an embodiment of an expandable tubular member having a pre-expanded upper portion for use in the apparatus ofFIGS. 1 a to 3 d. -
FIG. 8 is a cross-sectional illustration of an embodiment of an expandable tubular member having a slotted upper section for use in the apparatus ofFIGS. 1 a to 3 d. -
FIG. 9 is a graphical illustration of an embodiment of a method of applying an axial force to the expansion cones of the apparatus ofFIGS. 1 a to 3 d. -
FIG. 10 a is a fragmentary cross-sectional illustration of the placement of an embodiment of an apparatus for expanding a tubular member within a wellbore casing. -
FIG. 10 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 a during the injection of a non-hardenable fluidic material into and out of the apparatus. -
FIG. 10 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 b during the injection of a hardenable fluidic sealing material into and out of the apparatus. -
FIG. 10 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 c after the placement of a valve closure element into the valve passage of the anchoring device of the apparatus. -
FIG. 10 e is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 d after anchoring the expandable tubular member of the apparatus to the wellbore casing. -
FIG. 10 f is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 e after initiating the axial displacement of the expansion cone. -
FIG. 10 g is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 e after initiating the axial displacement of the expansion cone by pulling on the expansion cone and injecting a pressurized fluid below the expansion cone. -
FIG. 10 h is a fragmentary cross-sectional illustration of the apparatus ofFIGS. 10 f and 10 g after the completion of the radial expansion of the expandable tubular member. -
FIG. 10 i is a fragmentary cross-sectional illustration of the apparatus ofFIG. 10 h after the decoupling and removal of the anchoring device of the apparatus from the wellbore casing. -
FIG. 11 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure. -
FIG. 11 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 a after anchoring the expandable tubular member of the apparatus to the wellbore casing. -
FIG. 11 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 b after initiating the axial displacement of the expansion cone. -
FIG. 11 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 c after stopping the axial displacement of the expansion cone prior to deactivating the anchoring device. -
FIG. 11 e is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 d after deactivating the anchoring device. -
FIG. 11 f is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 e after initiating the axial displacement of the expansion cone and the deactivated anchoring device. -
FIG. 11 g is a fragmentary cross-sectional illustration of the apparatus ofFIG. 11 f after the completion of the radial expansion of the expandable tubular member. -
FIG. 12 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore. -
FIG. 12 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 12 a after expanding the expandable expansion cone in order to anchor the expandable tubular member to the wellbore casing. -
FIG. 12 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 12 b after initiating the axial displacement of the expandable expansion cone. -
FIG. 12 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 12 c after completing the radial expansion of the expandable tubular member. -
FIG. 13 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore. -
FIG. 13 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 13 a after activating the shape memory metal inserts in order to anchor the expandable tubular member to the wellbore casing. -
FIG. 13 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 13 b after initiating the axial displacement of the expansion cone. -
FIG. 13 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 13 c after completing the radial expansion of the expandable tubular member. -
FIG. 14 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore casing. -
FIG. 14 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 14 a after coupling the packer to the wellbore casing. -
FIG. 14 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 14 b after initiating the axial displacement of the expandable tubular member towards the expansion cone. -
FIG. 14 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 14 c after radially expanding the end of the expandable tubular member onto the expansion cone. -
FIG. 14 e is a fragmentary cross-sectional illustration of the apparatus ofFIG. 14 d after decoupling the packer from the wellbore casing. -
FIG. 14 f is a fragmentary cross-sectional illustration of the apparatus ofFIG. 14 e after initiating the axial displacement of the expansion cone relative to the expandable tubular member. -
FIG. 14 g is a fragmentary cross-sectional illustration of the completion of the radial expansion of the expandable tubular member. -
FIG. 15 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore. -
FIG. 15 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 15 a after coupling the resilient anchor to the wellbore casing. -
FIG. 15 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 15 b after initiating the axial displacement of the expansion cone. -
FIG. 15 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 15 c after completion of the radial expansion of the expandable tubular member. -
FIG. 16 a is a top view of an embodiment of a resilient anchor for use in the apparatus ofFIG. 15 a. -
FIG. 16 b is a top view of the resilient anchor ofFIG. 16 a after releasing the coiled resilient member. -
FIG. 17 a is a top view of an alternate embodiment of a resilient anchor for use in the apparatus ofFIG. 15 a. -
FIG. 17 b is a top view of the resilient anchor ofFIG. 17 a after releasing the resilient elements. -
FIG. 18 a is a fragmentary cross-sectional top view of an alternate embodiment of a resilient anchor for use in the apparatus ofFIG. 15 a. -
FIG. 18 b is a fragmentary cross-sectional top view of the resilient anchor ofFIG. 18 a after releasing the resilient elements. -
FIG. 19 a is an front view of an embodiment of an expandable tubular member including one or more resilient panels. -
FIG. 19 b is a cross-sectional view of the expandable tubular member ofFIG. 19 a. -
FIG. 19 c is a bottom view of the expandable tubular member ofFIG. 19 a. -
FIG. 20 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore. -
FIG. 20 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 20 a after coupling the anchor to the wellbore casing. -
FIG. 20 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 20 b after initiating the axial displacement of the expansion cone. -
FIG. 20 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 20 c after completion of the radial expansion of the expandable tubular member. -
FIG. 21 a is an illustration of an embodiment of the anchor of the apparatus ofFIG. 20 a. -
FIG. 21 b is an illustration of the anchor ofFIG. 21 a after outwardly extending the spikes. -
FIG. 22 a is an illustration of an alternative embodiment of the anchor of the apparatus ofFIG. 20 a. -
FIG. 22 b is an illustration of the anchor ofFIG. 22 a after outwardly extending the spikes. -
FIG. 22 c is a cross-sectional illustration of the petals of the anchor ofFIG. 22 a. -
FIG. 23 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure positioned within a wellbore. -
FIG. 23 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 20 a after injecting a quantity of a hardenable fluidic sealing material into the open hole wellbore section proximate the lower section of the expandable tubular member. -
FIG. 23 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 23 b after permitting the hardenable fluidic sealing material to at least partially cure. -
FIG. 23 d is a fragmentary cross-sectional illustration of the apparatus ofFIG. 23 c after initiating the axial displacement of the expansion cone. -
FIG. 23 e is a fragmentary cross-sectional illustration of the apparatus ofFIG. 23 d after completion of the radial expansion of the expandable tubular member. -
FIG. 24 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure positioned within a wellbore casing and an open hole wellbore section. -
FIG. 24 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 24 a after releasing the packer. -
FIG. 24 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 24 b after extruding the expandable tubular member off of the expansion cone. -
FIG. 25 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure positioned within a wellbore casing and an open hole wellbore section. -
FIG. 25 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 25 a after injecting a quantity of a fluidic material into the expandable tubular member having a higher density than the fluid within the preexisting structure outside of the expandable tubular member. -
FIG. 25 c is a fragmentary cross-sectional illustration of the apparatus ofFIG. 25 b after extruding the expandable tubular member off of the expansion cone. -
FIG. 26 a is a fragmentary cross-sectional illustration of an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure. -
FIG. 26 b is a fragmentary cross-sectional illustration of the apparatus ofFIG. 26 a after the initiation of the radial expansion process. -
FIG. 26 c is a fragmentary cross-sectional illustration of the completion of the radial expansion process using the apparatus ofFIG. 26 b. -
FIG. 27 is a flow chart illustration of an exemplary embodiment of a method of coupling an expandable tubular to a preexisting structure. -
FIG. 28 is a cross-sectional illustration of an expandable tubular coupled to a preexisting structure using an expansion cone. -
FIG. 29 is a cross-sectional illustration of the subsequent application of radial pressure to the expandable tubular member ofFIG. 28 . - A method and apparatus for coupling tubular members to a preexisting structure is provided. In an exemplary embodiment, the tubular members are coupled to the preexisting structure by radially expanding the tubular members into contact with the preexisting structure. In an exemplary embodiment, the tubular members are radially expanded by anchoring one end of the tubular members to the preexisting structure and then pulling an expansion cone through the tubular members. In this manner, the tubular members are radially expanded and coupled to the preexisting structure.
- Referring initially to
FIGS. 1 a, 1 b, 1 c, 1 d, 1 e, 1 f and 1 g, an exemplary embodiment of a method and apparatus for coupling an expandable tubular member to a preexisting structure will be described. Referring toFIG. 1 a, awellbore casing 100 is positioned within asubterranean formation 105. Thewellbore casing 100 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 100 further includes one ormore openings 110 that may have been the result of unintentional damage to thewellbore casing 100, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 105. As will be recognized by persons having ordinary skill in the art, theopenings 110 can adversely affect the subsequent operation and use of thewellbore casing 100 unless they are sealed off. - In an exemplary embodiment, an
apparatus 115 is utilized to seal off theopenings 110 in thewellbore casing 100. More generally, theapparatus 115 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 115 preferably includes afirst support member 120, asecond support member 125, anexpansion cone 130, ananchoring device 135, and expandabletubular member 140, and one ormore sealing members 145. - The
first support member 120 is preferably adapted to be coupled to a surface location. Thefirst support member 120 is further coupled to theanchoring device 135. Thefirst support member 120 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchoring device 135. Thefirst support member 120 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
second support member 125 is preferably adapted to be coupled to a surface location. Thesecond support member 125 is further coupled to theexpansion cone 130. Thesecond support member 125 is preferably adapted to permit theexpansion cone 130 to be axially displaced relative to thefirst support member 120. Thesecond support member 125 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expansion cone 130 is coupled to thesecond support member 125. Theexpansion cone 130 is preferably adapted to radially expand theexpandable tubular member 140 when theexpansion cone 130 is axially displaced relative to theexpandable tubular member 140. In an exemplary embodiment, theexpansion cone 130 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
anchoring device 135 is coupled to thefirst support member 120. Theanchoring device 135 is preferably adapted to be controllably coupled to theexpandable tubular member 140 and thewellbore casing 100. In this manner, theanchoring device 135 preferably controllably anchors theexpandable tubular member 140 to thewellbore casing 100 to facilitate the radial expansion of theexpandable tubular member 140 by the axial displacement of theexpansion cone 130. In an exemplary embodiment, theanchoring device 135 includes one or moreexpandable elements 150 that are adapted to controllably extend from the body of theanchoring device 135 to engage both theexpandable tubular member 140 and thewellbore casing 100. In an exemplary embodiment, theexpandable elements 150 are actuated using fluidic pressure. In an exemplary embodiment, theanchoring device 135 is any one of the hydraulically actuated packers commercially available from Halliburton Energy Services or Baker-Hughes. - The
expandable tubular member 140 is removably coupled to theexpansion cone 130. Theexpandable tubular member 140 is further preferably adapted to be removably coupled to theexpandable element 150 of theanchoring device 135. In an exemplary embodiment, theexpandable tubular member 140 includes one ormore anchoring windows 155 for permitting theexpandable elements 150 of theanchoring device 135 to engage thewellbore casing 100 and theexpandable tubular member 140. - In an exemplary embodiment, the
expandable tubular member 140 further includes alower section 160, anintermediate section 165, and anupper section 170. In an exemplary embodiment, thelower section 160 includes the anchoringwindows 155 in order to provide anchoring at an end portion of theexpandable tubular member 140. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 160 and 165, are less than the wall thickness of theupper section 170 in order to optimally couple the radially expanded portion of theexpandable tubular member 140 to thewellbore casing 100. - In an exemplary embodiment, the
expandable tubular member 140 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The sealing
members 145 are coupled to the outer surface of theupper portion 170 of theexpandable tubular member 140. The sealingmembers 145 are preferably adapted to engage and fluidicly seal the interface between the radially expanded expandabletubular member 140 and thewellbore casing 100. In an exemplary embodiment, theapparatus 115 includes a plurality of sealingmembers 145. In an exemplary embodiment, the sealingmembers 145 surround and isolate theopening 110. - As illustrated in
FIG. 1 a, theapparatus 115 is preferably positioned within thewellbore casing 100 with theexpandable tubular member 140 positioned in opposing relation to theopening 110. In an exemplary embodiment, theapparatus 115 includes a plurality of sealingmembers 145 that are positioned above and below theopening 110. In this manner, the radial expansion of theexpandable tubular member 140 optimally fluidicly isolates theopening 110. - As illustrated in
FIG. 1 b, theapparatus 115 is then anchored to thewellbore casing 100 using theanchoring device 135. In an exemplary embodiment, theanchoring device 135 is pressurized and theexpandable element 150 is extended from theanchoring device 135 through thecorresponding anchoring window 155 in theexpandable tubular member 140 into intimate contact with thewellbore casing 100. In this manner, thelower section 160 of theexpandable tubular member 140 is removably coupled to thewellbore casing 100. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 140 and thewellbore casing 100. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 140. - As illustrated in
FIG. 1 c, theexpansion cone 130 is then axially displaced by applying an axial force to thesecond support member 125. In an exemplary embodiment, the axial displacement of theexpansion cone 130 radially expands theexpandable tubular member 140 into intimate contact with the walls of thewellbore casing 100. - In an alternative embodiment, as illustrated in
FIG. 1 d, the axial displacement of theexpansion cone 130 is enhanced by injecting a pressurized fluidic material into the annular space between thefirst support member 120 and thesecond support member 125. In this manner, an upward axial force is applied to the lower annular face of theexpansion cone 130 using the pressurized fluidic material. In this manner, a temporary need for increased axial force during the radial expansion process can be easily satisfied. - As illustrated in
FIGS. 1 e, 1 f, and 1 g, after theexpandable tubular member 140 has been radially expanded by the axial displacement of theexpansion cone 130, thefirst support member 120 and theanchoring device 135 are preferably removed from expandabletubular member 140 by de-pressurizing theanchoring device 135 and then lifting thefirst support member 120 and anchoringdevice 135 from thewellbore casing 100. - As illustrated in
FIG. 1 g, in an exemplary embodiment, theopening 110 in thewellbore casing 100 is sealed off by the radially expandedtubular member 140. In this manner, repairs to thewellbore casing 100 are optimally provided. More generally, theapparatus 115 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 2 a, 2 b, 2 c, 2 d, 2 e and 2 f, an alternative embodiment of a method and apparatus for coupling an expandable tubular member to a preexisting structure will be described. Referring toFIG. 2 a, awellbore casing 200 and an openhole wellbore section 205 are positioned within asubterranean formation 210. Thewellbore casing 200 and the openhole wellbore section 205 may be positioned in any orientation from the vertical direction to the horizontal direction. - In an exemplary embodiment, an
apparatus 215 is utilized to couple an expandable tubular member to an end portion of thewellbore casing 200. In this manner, the openhole wellbore section 205 is provided with a cased portion. More generally, theapparatus 215 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 215 preferably includes afirst support member 220, asecond support member 225, anexpansion cone 230, ananchoring device 235, anexpandable tubular member 240, one or moreupper sealing members 245, one or morelower sealing members 250, and aflexible coupling element 255. - The
first support member 220 is preferably adapted to be coupled to a surface location. Thefirst support member 220 is further coupled to theanchoring device 235. Thefirst support member 220 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchoring device 235. Thefirst support member 220 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
second support member 225 is preferably adapted to be coupled to a surface location. Thesecond support member 225 is further coupled to theexpansion cone 230. Thesecond support member 225 is preferably adapted to permit theexpansion cone 230 to be axially displaced relative to thefirst support member 220. Thesecond support member 225 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - In an alternative embodiment, the
support member 220 is telescopically coupled to thesupport member 225, and thesupport member 225 is coupled to a surface support structure. - The
expansion cone 230 is coupled to thesecond support member 225. Theexpansion cone 230 is preferably adapted to radially expand theexpandable tubular member 240 when theexpansion cone 230 is axially displaced relative to theexpandable tubular member 240. In an exemplary embodiment, theexpansion cone 230 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
anchoring device 235 is coupled to thefirst support member 220. Theanchoring device 235 is preferably adapted to be controllably coupled to theexpandable tubular member 240 and the openhole wellbore section 205. In this manner, theanchoring device 235 preferably controllably anchors theexpandable tubular member 240 to the openhole wellbore section 205 to facilitate the radial expansion of theexpandable tubular member 240 by the axial displacement of theexpansion cone 230. In an exemplary embodiment, theanchoring device 235 includes one or moreexpandable elements 260 that are adapted to controllably extend from the body of theanchoring device 235 to engage both theflexible coupling element 255 and the openhole wellbore section 205. In an exemplary embodiment, theexpandable elements 260 are actuated using fluidic pressure. In an exemplary embodiment, theanchoring device 235 is any one of the hydraulically actuated packers commercially available from Halliburton Energy Services or Baker-Hughes. - The
expandable tubular member 240 is removably coupled to theexpansion cone 230. Theexpandable tubular member 240 is further preferably coupled to theflexible coupling element 255. - In an exemplary embodiment, the
expandable tubular member 240 further includes alower section 265, anintermediate section 270, and anupper section 275. In an exemplary embodiment, thelower section 265 is coupled to theflexible coupling element 255 in order to provide anchoring at an end portion of theexpandable tubular member 240. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 265 and 270, are less than the wall thickness of theupper section 275 in order to optimally couple the radially expanded portion of theexpandable tubular member 240 to thewellbore casing 200 and the openhole wellbore section 205. - In an exemplary embodiment, the
expandable tubular member 240 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
upper sealing members 245 are coupled to the outer surface of theupper portion 275 of theexpandable tubular member 240. Theupper sealing members 245 are preferably adapted to engage and fluidicly seal the interface between the radially expanded expandabletubular member 240 and thewellbore casing 200. In an exemplary embodiment, theapparatus 215 includes a plurality ofupper sealing members 245. - The
lower sealing members 250 are coupled to the outer surface of theupper portion 275 of theexpandable tubular member 240. Thelower sealing members 250 are preferably adapted to engage and fluidicly seal the interface between the radially expanded expandabletubular member 240 and theopen wellbore section 205. In an exemplary embodiment, theapparatus 215 includes a plurality oflower sealing members 250. - The
flexible coupling element 255 is coupled to thelower portion 265 of theexpandable tubular member 240. Theflexible coupling element 255 is preferably adapted to radially expanded by theanchoring device 235 into engagement within the walls of the openhole wellbore section 205. In this manner, thelower portion 265 of theexpandable tubular member 240 is coupled to the walls of the openhole wellbore section 205. In an exemplary embodiment, theflexible coupling element 255 is a slotted tubular member. In an exemplary embodiment, theflexible coupling element 255 includes one or more hook elements for engaging the walls of the openhole wellbore section 205. - As illustrated in
FIG. 2 a, theapparatus 215 is preferably positioned with theexpandable tubular member 240 positioned in overlapping relation with a portion of thewellbore casing 200. In this manner, the radially expandedtubular member 240 is coupled to the lower portion of thewellbore casing 200. In an exemplary embodiment, theupper sealing members 245 are positioned in opposing relation to the lower portion of thewellbore casing 200 and thelower sealing members 250 are positioned in opposing relation to the walls of the openhole wellbore section 205. In this manner, the interface between the radially expandedtubular member 240 and thewellbore casing 200 and openhole wellbore section 205 is optimally fluidicly sealed. - As illustrated in
FIG. 2 b, theapparatus 215 is then anchored to the openhole wellbore section 205 using theanchoring device 235. In an exemplary embodiment, theanchoring device 235 is pressurized and theexpandable element 260 is radially extended from theanchoring device 235 causing theflexible coupling element 255 to radially expand into intimate contact with the walls of the openhole wellbore section 205. In this manner, thelower section 265 of theexpandable tubular member 240 is removably coupled to the walls of the openhole wellbore section 205. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 240 and thewellbore casing 100 and/or the openhole wellbore section 205. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 240. - As illustrated in
FIG. 2 c, theexpansion cone 230 is then axially displaced by applying an axial force to thesecond support member 225. In an exemplary embodiment, the axial displacement of theexpansion cone 230 radially expands theexpandable tubular member 240 into intimate contact with the walls of the openhole wellbore section 205. - In an alternative embodiment, as illustrated in
FIG. 2 d, the axial displacement of theexpansion cone 230 is enhanced by injecting a pressurized fluidic material into the annular space between thefirst support member 220 and thesecond support member 225. In this manner, an upward axial force is applied to the lower annular face of theexpansion cone 230 using the pressurized fluidic material. In this manner, a temporary need for increased axial force during the radial expansion process can be easily satisfied. - As illustrated in
FIGS. 2 e and 2 f, after theexpandable tubular member 240 has been radially expanded by the axial displacement of theexpansion cone 230, thefirst support member 220 and theanchoring device 235 are preferably removed from expandabletubular member 240 by de-pressurizing theanchoring device 235 and then lifting thefirst support member 220 and anchoringdevice 235 from thewellbore casing 200 and the openhole wellbore section 205. - Referring to
FIGS. 3 a, 3 b, 3 c, and 3 d, an alternative embodiment of a method and apparatus for coupling an expandable tubular member to a preexisting structure will be described. Referring toFIG. 3 a, awellbore casing 300 is positioned within asubterranean formation 305. Thewellbore casing 300 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 300 further includes one ormore openings 310 that may have been the result of unintentional damage to thewellbore casing 300, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 305. As will be recognized by persons having ordinary skill in the art, theopenings 310 can adversely affect the subsequent operation and use of thewellbore casing 300 unless they are sealed off. - In an exemplary embodiment, an
apparatus 315 is utilized to seal off theopenings 310 in thewellbore casing 300. More generally, theapparatus 315 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 315 preferably includes asupport member 320, anexpansion cone 325, ananchoring device 330, anexpandable tubular member 335, and one ormore sealing members 340. - The
support member 320 is preferably adapted to be coupled to a surface location. Thesupport member 320 is further coupled to theexpansion cone 325 and theanchoring device 330. Thesupport member 320 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchoring device 330. Thesupport member 320 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expansion cone 325 is coupled to thesupport member 320. Theexpansion cone 325 is preferably adapted to radially expand theexpandable tubular member 335 when theexpansion cone 325 is axially displaced relative to theexpandable tubular member 335. In an exemplary embodiment, theexpansion cone 325 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
anchoring device 330 is coupled to thesupport member 320 and theexpansion cone 325. Theanchoring device 335 is preferably adapted to controllably coupled to theexpandable tubular member 335 to thewellbore casing 300. In this manner, theanchoring device 330 preferably controllably anchors theexpandable tubular member 335 to thewellbore casing 300 to facilitate the radial expansion of theexpandable tubular member 335 by the axial displacement of theexpansion cone 325. In an exemplary embodiment, theanchoring device 330 includes one or moreexpandable elements 345 that are adapted to controllably extend from the body of theanchoring device 330 to radially displace correspondingengagement elements 350 provided in theexpandable tubular member 335. In an exemplary embodiment, the radial displacement of theengagement elements 350 couples theexpandable tubular member 335 to thewellbore casing 300. In an exemplary embodiment, theexpandable elements 345 are pistons that are actuated using fluidic pressure. In an exemplary embodiment, theanchoring device 330 is any one of the hydraulically actuated anchoring devices commercially available from Halliburton Energy Services or Baker-Hughes. - In an alternative embodiment, the
expandable elements 345 are explosive devices that controllably generate a radially directed explosive force for radially displacing theengagement elements 350. In an exemplary embodiment, the explosiveexpandable elements 345 are shaped explosive charges commercially available from Halliburton Energy Services. - The
expandable tubular member 335 is removably coupled to theexpansion cone 325. In an exemplary embodiment, theexpandable tubular member 335 includes one ormore engagement devices 350 that are adapted to be radially displaced by theanchoring device 330 into engagement with the walls of thewellbore casing 300. In this manner, theexpandable tubular member 335 is coupled to thewellbore casing 300. In an exemplary embodiment, theengagement devices 350 include teeth for biting into the surface of thewellbore casing 100. - In an exemplary embodiment, the
expandable tubular member 335 further includes alower section 355, anintermediate section 360, and anupper section 365. In an exemplary embodiment, thelower section 355 includes theengagement device 350 in order to provide anchoring at an end portion of theexpandable tubular member 335. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 355 and 360, are less than the wall thickness of theupper section 365 in order to optimally couple the radially expanded portion of theexpandable tubular member 335 to thewellbore casing 300. - In an exemplary embodiment, the
expandable tubular member 335 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 5, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The sealing
members 340 are coupled to the outer surface of theupper portion 365 of theexpandable tubular member 335. The sealingmembers 340 are preferably adapted to engage and fluidicly seal the interface between the radially expanded expandabletubular member 335 and thewellbore casing 300. In an exemplary embodiment, theapparatus 315 includes a plurality of sealingmembers 340. In an exemplary embodiment, the sealingmembers 340 surround and isolate theopening 310. - As illustrated in
FIG. 3 a, theapparatus 315 is preferably positioned within thewellbore casing 300 with theexpandable tubular member 335 positioned in opposing relation to theopening 310. In an exemplary embodiment, theapparatus 315 includes a plurality of sealingmembers 340 that are positioned above and below theopening 310. In this manner, the radial expansion of theexpandable tubular member 335 optimally fluidicly isolates theopening 310. - As illustrated in
FIG. 3 b, theexpandable tubular member 335 of theapparatus 315 is then anchored to thewellbore casing 300 using theanchoring device 330. In an exemplary embodiment, theanchoring device 330 is pressurized and theexpandable element 345 is extended from theanchoring device 330 and radially displaces thecorresponding engagement elements 350 of theexpandable tubular member 335 into intimate contact with thewellbore casing 300. In this manner, thelower section 355 of theexpandable tubular member 335 is coupled to thewellbore casing 300. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 335 and thewellbore casing 300. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 335. - As illustrated in
FIG. 3 c, theanchoring device 330 is then deactivated and theexpansion cone 325 is axially displaced by applying an axial force to thesupport member 320. In an exemplary embodiment, the deactivation of theanchoring device 330 causes theexpandable elements 345 to radially retract into theanchoring device 330. Alternatively, theexpandable elements 345 are resiliently coupled to theanchoring device 330. In this manner, theexpandable elements 345 retract automatically upon the deactivation of theanchoring device 330. In an exemplary embodiment, the axial displacement of theexpansion cone 325 radially expands theexpandable tubular member 335 into intimate contact with the walls of thewellbore casing 300. - As illustrated in
FIG. 3 d, after theexpandable tubular member 335 has been radially expanded by the axial displacement of theexpansion cone 335, thesupport member 320,expansion cone 325, and theanchoring device 330 are preferably removed from the expanded expandabletubular member 335. - In an exemplary embodiment, the
opening 310 in thewellbore casing 300 is sealed off by the radially expandedtubular member 335. In this manner, repairs to thewellbore casing 300 are optimally provided. More generally, theapparatus 315 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIG. 4 , an embodiment of asystem 400 for applying an axial force to theexpansion cones lifting device 405, afirst support member 410, ashock absorber 415, and asecond support member 420. In an exemplary embodiment, thesystem 400 is adapted to minimize the transfer of shock loads, created during the completion of the radial expansion of tubular members by theexpansion cones lifting device 405. In this manner, the radial expansion of tubular members by theexpansion cones - The
lifting device 405 is supported at a surface location and is coupled to thefirst support member 410. Thelifting device 405 may comprise any number of conventional commercially available lifting devices suitable for manipulating tubular members within a wellbore. - The
first support member 410 is coupled to thelifting device 405 and theshock absorber 415. Thefirst support member 410 may comprise any number of conventional commercially available support members such as, for example, coiled tubing, a drill string, a wireline, braided wire, or a slick line. - The
shock absorber 415 is coupled to thefirst support member 410 and thesecond support member 420. Theshock absorber 415 is preferably adapted to absorb shock loads transmitted from thesecond support member 420. Theshock absorber 415 may be any number of conventional commercially available shock absorbers. - The
second support member 420 is coupled to theshock absorber 415. Thesecond support member 420 is further preferably adapted to be coupled to one or more of theexpansion cones - In an exemplary embodiment, during operation of the
system 400, the lifting device applies an axial force to one of theexpansion cones expansion cones shock absorber 415. In this manner, the radial expansion of tubular members by pulling theexpansion cones lifting device 405 is provided in an optimally safe manner. - Referring to
FIG. 5 , an embodiment of acoupling system 500 for use in the expandabletubular members system 500 includes anupper ring 505, a sealingelement 510, and alower ring 515. In an exemplary embodiment, theupper ring 505, the sealingelement 510, and thelower ring 515 are provided on the outer surfaces of the expandabletubular members tubular members upper ring 505, the sealingelement 510, and thelower ring 515 engage the interior surface of the preexisting structure that the expandabletubular members tubular members tubular members element 510 is compressed into contact with the interior surface of the preexisting structure that the expandabletubular members tubular members - In an exemplary embodiment, the upper and lower rings, 505 and 515, extend from the outer surfaces of the
tubular members tubular members - In an exemplary embodiment, the sealing
element 510 extends from the outer surfaces of thetubular members tubular members element 510 is fabricated from rubber in order to optimally fluidicly seal and engage the preexisting structure. - In an exemplary embodiment, the
tubular members coupling systems 500. In an exemplary embodiment, thecoupling systems 500 are provided on the lower, intermediate, and upper portions of thetubular members - Referring now to
FIG. 6 , an exemplary embodiment of anexpandable tubular member 600 for use in theapparatus tubular member 600 preferably includes alower portion 605, anintermediate portion 610, and anupper portion 615. - The
lower portion 605 is coupled to theintermediate portion 610. In an exemplary embodiment, thelower portion 605 is further adapted to mate with the anchoringdevices lower portion 605 further preferably includes one or more slottedportions 620 for facilitating the radial expansion of thelower portion 605 by the anchoringdevices lower portion 605 of thetubular member 600 is preferably radially expanded by the anchoringdevices lower portion 605 of thetubular member 600 is anchored to the preexisting structure prior to the initiation of the radial expansion process. - The
intermediate portion 610 is coupled to thelower portion 605 and theupper portion 615. In an exemplary embodiment, the wall thicknesses of the lower and intermediate portions, 605 and 610, are less than the wall thickness of theupper portion 615 in order to facilitate the radial expansion of thetubular member 600. In an exemplary embodiment, the lower and intermediate portions, 605 and 610, are preexpanded to mate with the expansion cone. - Referring to
FIG. 7 , an exemplary embodiment of anexpandable tubular member 700 for use in theapparatus tubular member 700 minimizes the shock loads created upon the completion of the radial expansion process. In an exemplary embodiment, thetubular member 700 includes alower portion 705, a lowertransitionary portion 710, anintermediate portion 715, an uppertransitionary portion 720, anupper portion 725, and asealing element 730. - The
lower portion 705 is coupled to the lowertransitionary portion 710. Thelower portion 705 is preferably adapted to mate with the expansion cone and the anchoring device. - The lower
transitionary portion 710 is coupled to thelower portion 705 and theintermediate portion 715. In an exemplary embodiment, the lowertransitionary portion 710 is adapted to mate with the expansion cone. In an exemplary embodiment, the wall thicknesses of thelower portion 705 and the lowertransitionary portion 710 are less than the wall thicknesses of theintermediate portion 715, the uppertransitionary portion 720 and theupper portion 725 in order to optimally facilitate the radial expansion process. - The
intermediate portion 715 is coupled to the lowertransitionary portion 710 and the uppertransitionary portion 720. In an exemplary embodiment, the outside diameter of theintermediate portion 715 is less than the wall thicknesses of thelower portion 705 and theupper portion 725. - The upper
transitionary portion 720 is coupled to theintermediate portion 715 and theupper portion 725. - The
upper portion 725 is coupled to the uppertransitionary portion 720. - The sealing
element 730 is coupled to the outside surface of theintermediate portion 715. In an exemplary embodiment, the outside diameter of the sealingelement 730 is less than or equal to the outside diameter of thelower portion 705 and theupper portion 725 in order to optimally protect the sealing element 703 during placement of thetubular member 700 within the preexisting structure. - In an exemplary embodiment, during the radial expansion of the
tubular member 700 using theapparatus transitionary portion 720 and theupper portion 725 reduces the shock loads typically created during the end portion of the radial expansion process. In this manner, the radial expansion process is optimally provided in a safe manner. Furthermore, because the sealingelement 730 is preferably recessed below the surfaces of thelower portion 705 and theupper portion 725, the sealingelement 730 is optimally protected from damage during the placement of thetubular member 700 within the preexisting structure. - Referring to
FIG. 8 , an exemplary embodiment of anexpandable tubular member 800 for use in theapparatus tubular member 800 preferably includes alower portion 805, anintermediate portion 810, and anupper portion 815. - The
lower portion 805 is coupled to theintermediate portion 810. In an exemplary embodiment, thelower portion 805 is further adapted to mate with theexpansion cones anchoring devices - The
intermediate portion 810 is coupled to thelower portion 805 and theupper portion 815. In an exemplary embodiment, the wall thicknesses of the lower and intermediate portions, 805 and 810, are less than the wall thickness of theupper portion 815 in order to facilitate the radial expansion of thetubular member 800. In an exemplary embodiment, the lower and intermediate portions, 805 and 810, are preexpanded to mate with the expansion cone. - The
upper portion 815 is coupled to theintermediate portion 810. In an exemplary embodiment, theupper portion 815 further preferably includes one or more slottedportions 820 for facilitating the radial expansion of theupper portion 815 by theexpansion cones upper portion 815 of thetubular member 800 is preferably radially expanded by theexpansion cones expansion cones expandable tubular member 800. - Referring to
FIG. 9 , an exemplary embodiment of a method of applying an axial force to theexpansion cones expansion cones expansion cones - Referring to
FIGS. 10 a to 10 i, an embodiment of an apparatus and method for forming a wellbore casing will now be described. As illustrated inFIG. 10 a, awellbore casing 1000 and an openhole wellbore section 1005 are provided in asubterranean formation 1010. Thewellbore casing 1000 and openhole wellbore section 1005 may be orientated at any orientation ranging from the vertical to the horizontal. In an exemplary embodiment, a new section of wellbore casing is formed in the openhole wellbore section 1005 using anapparatus 1015. More generally, theapparatus 1015 is utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1015 preferably includes afirst support member 1020, asecond support member 1025, anexpansion cone 1030, ananchoring device 1035, anexpandable tubular member 1040, one or moreupper sealing members 1045, one or morelower sealing members 1050, and aflexible coupling element 1055. - The
first support member 1020 is preferably adapted to be coupled to a surface location. Thefirst support member 1020 is further coupled to theanchoring device 1035. Thefirst support member 1020 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchoring device 1035. Thefirst support member 1020 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
second support member 1025 is preferably adapted to be coupled to a surface location. Thesecond support member 1025 is further coupled to theexpansion cone 1030. Thesecond support member 1025 is preferably adapted to permit theexpansion cone 1030 to be axially displaced relative to thefirst support member 1020. Thesecond support member 1025 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - In an alternative embodiment, the
support member 1020 is telescopically coupled to thesupport member 1025, and thesupport member 1025 is coupled to a surface support member. - The
expansion cone 1030 is coupled to thesecond support member 1025. Theexpansion cone 1030 is preferably adapted to radially expand theexpandable tubular member 1040 when theexpansion cone 1030 is axially displaced relative to theexpandable tubular member 1040. In an exemplary embodiment, theexpansion cone 1030 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
anchoring device 1035 is coupled to thefirst support member 1020. Theanchoring device 1035 is preferably adapted to be controllably coupled to theexpandable tubular member 1040 and the openhole wellbore section 1005. In this manner, theanchoring device 1035 preferably controllably anchors theexpandable tubular member 1040 to the openhole wellbore section 1005 to facilitate the radial expansion of theexpandable tubular member 1040 by the axial displacement of theexpansion cone 1030. - In an exemplary embodiment, the
anchoring device 1035 includes one or moreexpandable elements 1060 that are adapted to controllably extend from the body of theanchoring device 1035 to engage both theflexible coupling element 1055 and the openhole wellbore section 1005. In an exemplary embodiment, theexpandable elements 1060 are actuated using fluidic pressure. - In an exemplary embodiment, the
anchoring device 1035 further includes afluid passage 1036 adapted to receive a ball plug or other similar valving element. In this manner, fluidic materials can be exhausted from theanchoring device 1035 and thefluid passage 1036 can be controllably plugged. In an exemplary embodiment, theanchoring device 1035 is any one of the hydraulically actuated packers commercially available from Halliburton Energy Services or Baker-Hughes, modified in accordance with the teachings of the present disclosure. - In an exemplary embodiment, the anchoring
devices devices - The
expandable tubular member 1040 is removably coupled to theexpansion cone 1030. Theexpandable tubular member 1040 is further preferably coupled to theflexible coupling element 1055. - In an exemplary embodiment, the
expandable tubular member 1040 further includes alower section 1065, anintermediate section 1070, and anupper section 1075. In an exemplary embodiment, thelower section 1065 is coupled to theflexible coupling element 1055 in order to provide anchoring at an end portion of theexpandable tubular member 1040. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 1065 and 1070, are less than the wall thickness of theupper section 1075 in order to optimally couple the radially expanded portion of theexpandable tubular member 1040 to thewellbore casing 1000 and the openhole wellbore section 1005. - In an exemplary embodiment, the
expandable tubular member 1040 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - In an exemplary embodiment, the
expandable tubular member 1040 is further provided in accordance with the teachings of embodiments of expandable tubular members described above and illustrated inFIGS. 5-8 . - The
upper sealing members 1045 are coupled to the outer surface of theupper portion 1075 of theexpandable tubular member 1040. Theupper sealing members 1045 are preferably adapted to engage and fluidicly seal the interface between the radially expandedexpandable tubular member 1040 and thewellbore casing 1000. In an exemplary embodiment, theapparatus 1015 includes a plurality ofupper sealing members 1045. - The
lower sealing members 1050 are coupled to the outer surface of theupper portion 1075 of theexpandable tubular member 1040. Thelower sealing members 1050 are preferably adapted to engage and fluidicly seal the interface between the radially expandedexpandable tubular member 1040 and theopen wellbore section 1005. In an exemplary embodiment, theapparatus 1015 includes a plurality oflower sealing members 1050. - The
flexible coupling element 1055 is coupled to thelower portion 1065 of theexpandable tubular member 1040. Theflexible coupling element 1055 is preferably adapted to radially expanded by theanchoring device 1035 into engagement within the walls of the openhole wellbore section 1005. In this manner, thelower portion 1065 of theexpandable tubular member 1040 is coupled to the walls of the openhole wellbore section 1005. In an exemplary embodiment, theflexible coupling element 1055 is a slotted tubular member. In an exemplary embodiment, theflexible coupling element 1055 includes one or more hook elements for engaging the walls of the openhole wellbore section 1005. - As illustrated in
FIG. 10 a, theapparatus 1015 is preferably positioned with theexpandable tubular member 1040 positioned in overlapping relation with a portion of thewellbore casing 1000. In this manner, the radially expandedtubular member 1040 is coupled to the lower portion of thewellbore casing 1000. In an exemplary embodiment, theupper sealing members 1045 are positioned in opposing relation to the lower portion of thewellbore casing 1000 and thelower sealing members 1050 are positioned in opposing relation to the walls of the openhole wellbore section 1005. In this manner, the interface between the radially expandedtubular member 1040 and thewellbore casing 1000 and openhole wellbore section 1005 is optimally fluidicly sealed. - As illustrated in
FIG. 10 b, in an exemplary embodiment, a quantity of a non-hardenable fluidic material is then injected into and then out of theapparatus 1015. In an exemplary embodiment, the non-hardenable material is discharged from theapparatus 1015 using thevalveable flow passage 1065. The non-hardenable fluidic material may be any number of conventional commercially available fluidic materials such as, for example, drilling mud. - As illustrated in
FIG. 10 c, in an exemplary embodiment, a quantity of a hardenable fluidic sealing material is then injected into and out of theapparatus 1015. In an exemplary embodiment, the hardenable fluidic sealing material is exhausted from theapparatus 1015 using thevalveable flow passage 1065. In an exemplary embodiment, the hardenable fluidic sealing material is permitted to completely fill the annular space between thetubular member 1040 and the openhole wellbore section 1005. The hardenable fluidic sealing material may be any number of conventional commercially available materials such as, for example, cement, slag mix and/or epoxy resin. In this manner, a fluidic sealing annular element is provided around the radially expandedtubular member 1040. - As illustrated in
FIG. 10 d, in an exemplary embodiment, another quantity of a non-hardenable fluidic material is then injected into and out of theapparatus 1015. In an exemplary embodiment, a ball plug ordart 1080, or other similar fluid passage blocking device, is placed into the non-hardenable fluid material. In an exemplary embodiment, theball plug 1080 then seats in and seals off thevalveable fluid passage 1065. In this manner, theanchoring device 1035 is then pressurized to anchor thetubular member 1040 to the openhole wellbore section 1005. - In an alternative embodiment, the
valveable fluid passage 1065 includes a remote or pressure activated valve for sealing off thevalveable fluid passage 1065. - As illustrated in
FIG. 10 e, in an exemplary embodiment, theapparatus 1015 is then anchored to the openhole wellbore section 1005 using theanchoring device 1035. In an exemplary embodiment, theanchoring device 1035 is pressurized and theexpandable element 1060 is radially extended from theanchoring device 1035 causing theflexible coupling element 1055 to radially expand into intimate contact with the walls of the openhole wellbore section 1005. In this manner, thelower section 1065 of theexpandable tubular member 1040 is removably coupled to the walls of the openhole wellbore section 1005. - As illustrated in
FIG. 10 f, theexpansion cone 1030 is then axially displaced by applying an axial force to thesecond support member 1025. In an exemplary embodiment, the axial displacement of theexpansion cone 1030 radially expands theexpandable tubular member 1040 into intimate contact with the walls of the openhole wellbore section 1005. - In an alternative embodiment, as illustrated in
FIG. 10 g, the axial displacement of theexpansion cone 1030 is enhanced by injecting a pressurized fluidic material into the annular space between thefirst support member 1020 and thesecond support member 1025. In this manner, an upward axial force is applied to the lower annular face of theexpansion cone 1030 using the pressurized fluidic material. In this manner, a temporary need for increased axial force during the radial expansion process can be easily satisfied. - In an exemplary embodiment, the hardenable fluidic sealing material is then permitted to at least partial cure.
- As illustrated in
FIGS. 10 h and 10 i, after theexpandable tubular member 1040 has been radially expanded by the axial displacement of theexpansion cone 1030, thefirst support member 1020 and theanchoring device 1035 are preferably removed fromexpandable tubular member 1040 by de-pressurizing theanchoring device 1035 and then lifting thefirst support member 1020 andanchoring device 1035 from thewellbore casing 1000 and the openhole wellbore section 1005. - In an exemplary embodiment, the resulting new section of wellbore casing includes the radially expanded
tubular member 1040 and the outer annular layer of the cured fluidic sealing material. In this manner, a new section of wellbore casing is optimally provided. More generally, theapparatus 1015 is used to form and/or repair wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 11 a to 11 g, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 11 a, awellbore casing 1100 is positioned within asubterranean formation 1105. Thewellbore casing 1100 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 1100 further includes one ormore openings 1110 that may have been the result of unintentional damage to thewellbore casing 1100, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 1105. As will be recognized by persons having ordinary skill in the art, theopenings 1110 can adversely affect the subsequent operation and use of thewellbore casing 1100 unless they are sealed off. - In an exemplary embodiment, an
apparatus 1115 is utilized to seal off theopenings 1110 in thewellbore casing 1100. More generally, theapparatus 1115 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1115 preferably includes afirst support member 1120, asecond support member 1125, anexpansion cone 1130, ananchoring device 1135, andexpandable tubular member 1140, and one ormore sealing members 1145. - The
first support member 1120 is preferably adapted to be coupled to a surface location. Thefirst support member 1120 is further coupled to theanchoring device 1135. Thefirst support member 1120 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchoring device 1135. Thefirst support member 1120 preferably has a substantially hollow annular cross sectional shape. Thefirst support member 1120 may, for example, be fabricated from conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
second support member 1125 is preferably adapted to be coupled to a surface location. Thesecond support member 1125 is further coupled to theexpansion cone 1130. Thesecond support member 1125 is preferably adapted to permit theexpansion cone 1130 to be axially displaced relative to thefirst support member 1120. Thesecond support member 1125 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - In an exemplary embodiment, the
first support member 1120 is coupled to a surface location by a slip joint and/or sliding sleeve apparatus that is concentrically coupled to thesecond support member 1125. - The
expansion cone 1130 is coupled to thesecond support member 1125. Theexpansion cone 1130 is preferably adapted to radially expand theexpandable tubular member 1140 when theexpansion cone 1130 is axially displaced relative to theexpandable tubular member 1140. In an exemplary embodiment, theexpansion cone 1130 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
anchoring device 1135 is coupled to thefirst support member 1120. Theanchoring device 1135 is preferably adapted to be controllably coupled to theexpandable tubular member 1140 and thewellbore casing 1100. In this manner, theanchoring device 1135 preferably controllably anchors theexpandable tubular member 1140 to thewellbore casing 1100 to facilitate the radial expansion of theexpandable tubular member 1140 by the axial displacement of theexpansion cone 1130. In an exemplary embodiment, theanchoring device 1135 includes one or moreexpandable elements 1150 that are adapted to controllably extend from the body of theanchoring device 1135 to engage both theexpandable tubular member 1140 and thewellbore casing 1100. In an exemplary embodiment, theexpandable elements 1150 are actuated using fluidic pressure. In an exemplary embodiment, theanchoring device 1135 is any one of the hydraulically actuated packers commercially available from Halliburton Energy Services or Baker-Hughes modified in accordance with the teachings of the present disclosure. - The
expandable tubular member 1140 is removably coupled to theexpansion cone 1130. Theexpandable tubular member 1140 is further preferably adapted to be removably coupled to theexpandable elements 1150 of theanchoring device 1135. In an exemplary embodiment, theexpandable tubular member 1140 includes one ormore anchoring windows 1155 for permitting theexpandable elements 1150 of theanchoring device 1135 to engage thewellbore casing 1100 and theexpandable tubular member 1140. - In an exemplary embodiment, the
expandable tubular member 1140 further includes alower section 1160, anintermediate section 1165, and anupper section 1170. In an exemplary embodiment, thelower section 1160 rests upon and is supported by theexpansion cone 1130. In an exemplary embodiment, theintermediate section 1165 includes the anchoringwindows 1155 in order to provide anchoring at an intermediate portion of theexpandable tubular member 1140. - In an exemplary embodiment, the
expandable tubular member 1140 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application no. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The sealing
members 1145 are coupled to the outer surface of theexpandable tubular member 1140. The sealingmembers 1145 are preferably adapted to engage and fluidicly seal the interface between the radially expandedexpandable tubular member 1140 and thewellbore casing 1100. In an exemplary embodiment, theapparatus 1115 includes a plurality of sealingmembers 1145. In an exemplary embodiment, the sealingmembers 1145 surround and isolate theopening 1110. - As illustrated in
FIG. 11 a, theapparatus 1115 is preferably positioned within thewellbore casing 1100 with theexpandable tubular member 1140 positioned in opposing relation to theopening 1110. In an exemplary embodiment, theapparatus 1115 includes a plurality of sealingmembers 1145 that are positioned above and below theopening 1110. In this manner, the radial expansion of theexpandable tubular member 1140 optimally fluidicly isolates theopening 1110. - As illustrated in
FIG. 11 b, theapparatus 1115 is then anchored to thewellbore casing 1100 using theanchoring device 1135. In an exemplary embodiment, theanchoring device 1135 is pressurized and theexpandable element 1150 is extended from theanchoring device 1135 through thecorresponding anchoring window 1155 in theexpandable tubular member 1140 into intimate contact with thewellbore casing 1100. In this manner, theintermediate section 1165 of theexpandable tubular member 1140 is removably coupled to thewellbore casing 1100. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into at least a portion of the annular space between the unexpanded portion of the
tubular member 1140 and thewellbore casing 1100. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 1140. - As illustrated in
FIG. 11 c, in an exemplary embodiment, theexpansion cone 1130 is then axially displaced by applying an axial force to thesecond support member 1125. In an exemplary embodiment, the axial displacement of theexpansion cone 1130 radially expands thelower section 1160 of theexpandable tubular member 1140 into intimate contact with the walls of the wellbore or thewellbore casing 1100. - As illustrated in
FIG. 11 d, in an exemplary embodiment, the axial displacement of theexpansion cone 1130 is stopped once theexpansion cone 1130 contacts the lower portion of theanchoring device 1135. - As illustrated in
FIG. 11 e, in an exemplary embodiment, theanchoring device 1135 is then decoupled from thewellbore casing 1100 and theexpandable tubular member 1140. - As illustrated in
FIG. 11 f, in an exemplary embodiment, the axial displacement of theexpansion cone 1130 is then resumed. In an exemplary embodiment, theanchoring device 1135 is also axial displaced. In this manner, thelower section 1160 of theexpandable tubular member 1140 is self-anchored to thewellbore casing 1100. In an exemplary embodiment, thelower section 1160 of theexpandable tubular member 1140 includes one or more outer rings or other coupling members to facilitate the self-anchoring of thelower section 1160 of theexpandable tubular member 1140 to the wellbore or thewellbore casing 1100. - As illustrated in
FIG. 11 g, after theexpandable tubular member 1140 has been completely radially expanded by the axial displacement of theexpansion cone 1130, the 1110 in thewellbore casing 1100 is sealed off by the radially expandedtubular member 1140. In this manner, repairs to thewellbore casing 1100 are optimally provided. More generally, theapparatus 1115 is used to repair or form wellbore casings, pipelines, and structural supports. In an exemplary embodiment, the inside diameter of the radially expandedtubular member 1140 is substantially constant. - Referring to
FIGS. 12 a to 12 d, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 12 a, awellbore casing 1200 is positioned within asubterranean formation 1205. Thewellbore casing 1200 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 1200 further includes one ormore openings 1210 that may have been the result of unintentional damage to thewellbore casing 1200, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 1205. As will be recognized by persons having ordinary skill in the art, theopenings 1210 can adversely affect the subsequent operation and use of thewellbore casing 1200 unless they are sealed off. - In an exemplary embodiment, an
apparatus 1215 is utilized to seal off theopenings 1210 in thewellbore casing 1200. More generally, theapparatus 1215 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1215 preferably includes asupport member 1220, anexpandable expansion cone 1225, anexpandable tubular member 1235, and one ormore sealing members 1240. - The
support member 1220 is preferably adapted to be coupled to a surface location. Thesupport member 1220 is further coupled to theexpandable expansion cone 1225. Thesupport member 320 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to the expandable expansion cone. Thesupport member 1220 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable expansion cone 1225 is coupled to thesupport member 1220. Theexpandable expansion cone 1225 is preferably adapted to radially expand theexpandable tubular member 1235 when theexpandable expansion cone 1225 is axially displaced relative to theexpandable tubular member 1235. Theexpandable expansion cone 1225 is further preferably adapted to radially expand at least a portion of theexpandable tubular member 1235 when theexpandable expansion cone 1225 is controllably radially expanded. Theexpandable expansion cone 1225 may be any number of conventional commercially available radially expandable expansion cones. In an exemplary embodiment, theexpandable expansion cone 1225 is provided substantially as disclosed in U.S. Pat. No. 5,348,095, the disclosure of which is incorporated herein by reference. - In an exemplary embodiment, the
expansion cone 1225 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expandable tubular member 1235 is removably coupled to theexpansion cone 1225. In an exemplary embodiment, theexpandable tubular member 1235 includes one ormore engagement devices 1250 that are adapted to couple with and penetrate thewellbore casing 1200. In this manner, theexpandable tubular member 1235 is optimally coupled to thewellbore casing 1200. In an exemplary embodiment, theengagement devices 1250 include teeth for biting into the surface of thewellbore casing 1200. - In an exemplary embodiment, the
expandable tubular member 1235 further includes alower section 1255, anintermediate section 1260, and anupper section 1265. In an exemplary embodiment, thelower section 1255 includes theengagement devices 1250 in order to provide anchoring at an end portion of theexpandable tubular member 1235. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 1255 and 1260, are less than the wall thickness of theupper section 1265 in order to optimally facilitate the radial expansion of the lower and intermediate sections, 1255 and 1260, of theexpandable tubular member 1235. In an alternative embodiment, thelower section 1255 of theexpandable tubular member 1235 is slotted in order to optimally facilitate the radial expansion of thelower section 1255 of theexpandable tubular member 1235 using theexpandable expansion cone 1225. - In an exemplary embodiment, the
expandable tubular member 1235 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application no. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application serial no. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application no. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The sealing
members 1240 are preferably coupled to the outer surface of theupper portion 1265 of theexpandable tubular member 1235. The sealingmembers 1240 are preferably adapted to engage and fluidicly seal the interface between the radially expandedexpandable tubular member 1235 and thewellbore casing 1200. In an exemplary embodiment, theapparatus 1215 includes a plurality of sealingmembers 1240. In an exemplary embodiment, the sealingmembers 1240 surround and isolate theopening 1210. - As illustrated in
FIG. 12 a, theapparatus 1215 is preferably positioned within thewellbore casing 1200 with theexpandable tubular member 1235 positioned in opposing relation to theopening 1210. In an exemplary embodiment, theapparatus 1215 includes a plurality of sealingmembers 1240 that are positioned above and below theopening 1210. In this manner, the radial expansion of theexpandable tubular member 1235 optimally fluidicly isolates theopening 1210. - As illustrated in
FIG. 12 b, theexpandable tubular member 1235 of theapparatus 1215 is then anchored to thewellbore casing 1200 by expanding theexpandable expansion cone 1225 into contact with thelower section 1255 of theexpandable tubular member 1235. In an exemplary embodiment, thelower section 1255 of theexpandable tubular member 1235 is radially expanded into intimate contact with thewellbore casing 1200. In an exemplary embodiment, theengagement devices 1250 are thereby coupled to, and at least partially penetrate into, thewellbore casing 1200. In this manner, thelower section 1255 of theexpandable tubular member 1235 is optimally coupled to thewellbore casing 1200. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 1235 and thewellbore casing 1200. The compressible cement and/or epoxy may then be permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 1235. - As illustrated in
FIG. 12 c, theexpandable expansion cone 1225 is then axially displaced by applying an axial force to thesupport member 1220. In an exemplary embodiment, the axial displacement of theexpansion cone 1225 radially expands theexpandable tubular member 1235 into intimate contact with the walls of thewellbore casing 1200. - As illustrated in
FIG. 12 d, in an exemplary embodiment, after theexpandable tubular member 1235 has been radially expanded by the axial displacement of theexpandable expansion cone 1235, theopening 1210 in thewellbore casing 1200 is sealed off by the radially expandedtubular member 1235. In this manner, repairs to thewellbore casing 1200 are optimally provided. More generally, theapparatus 1215 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 13 a to 13 d, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 13 a, awellbore casing 1300 is positioned within asubterranean formation 1305. Thewellbore casing 1300 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 1300 further includes one ormore openings 1310 that may have been the result of unintentional damage to thewellbore casing 1300, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 1305. As will be recognized by persons having ordinary skill in the art, theopenings 1310 can adversely affect the subsequent operation and use of thewellbore casing 1300 unless they are sealed off. - In an exemplary embodiment, an
apparatus 1315 is utilized to seal off theopenings 1310 in thewellbore casing 1300. More generally, theapparatus 1315 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1315 preferably includes asupport member 1320, anexpansion cone 1325, anexpandable tubular member 1335, aheater 1340, and one ormore sealing members 1345. - The
support member 1320 is preferably adapted to be coupled to a surface location. Thesupport member 1320 is further coupled to theexpansion cone 1325. Thesupport member 1320 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theexpansion cone 1325 andheater 1340. Thesupport member 1320 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expansion cone 1325 is coupled to thesupport member 1320. Theexpansion cone 1325 is preferably adapted to radially expand theexpandable tubular member 1335 when theexpansion cone 1325 is axially displaced relative to theexpandable tubular member 1335. Theexpansion cone 1325 may be any number of conventional commercially available expansion cones. - In an exemplary embodiment, the
expansion cone 1325 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application no. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expandable tubular member 1335 is removably coupled to theexpansion cone 1325. In an exemplary embodiment, theexpandable tubular member 1335 includes one ormore engagement devices 1350 that are adapted to couple with and penetrate thewellbore casing 1300. In this manner, theexpandable tubular member 1335 is optimally coupled to thewellbore casing 1300. In an exemplary embodiment, theengagement devices 1350 include teeth for biting into the surface of thewellbore casing 1300. - In an exemplary embodiment, the
expandable tubular member 1335 further includes alower section 1355, anintermediate section 1360, and anupper section 1365. In an exemplary embodiment, thelower section 1355 includes theengagement devices 1350 in order to provide anchoring at an end portion of theexpandable tubular member 1335. In an exemplary embodiment, the wall thickness of the lower and intermediate sections, 1355 and 1360, are less than the wall thickness of theupper section 1365 in order to optimally facilitate the radial expansion of the lower and intermediate sections, 1355 and 1360, of theexpandable tubular member 1335. - In an exemplary embodiment, the
lower section 1355 of theexpandable tubular member 1335 includes one or more shape memory metal inserts 1370. In an exemplary embodiment, theinserts 1370 are adapted to radially expand thelower section 1355 of theexpandable tubular member 1335 into intimate contact with thewellbore casing 1300 when heated by theheater 1340. The shapememory metal inserts 1370 may be fabricated from any number of conventional commercially available shape memory alloys such as, for example, NiTi or NiTiNOL using conventional forming processes such as, for example, those described in U.S. Pat. Nos. 5,312,152, 5,344,506, and 5,718,531, the disclosures of which are incorporated herein by reference. In this manner, the shapememory metal inserts 1370 preferably radially expand thelower section 1355 of theexpandable tubular member 1335 when theinserts 1370 are heated to a temperature above their transformation temperature using theheater 1340. In an exemplary embodiment, the transformation temperature of theinserts 1370 ranges from about 250E F to 450E F. In an exemplary embodiment, the material composition of thelower section 1355 of theexpandable tubular member 1335 is further selected to maximize the radial expansion of thelower section 1355 during the transformation process. - In an exemplary embodiment, the
inserts 1370 are positioned within one or morecorresponding recesses 1375 provided in thelower section 1355 of theexpandable tubular member 1335. Alternatively, theinserts 1370 are completely contained within thelower section 1355 of theexpandable tubular member 1335. - In an exemplary embodiment, the
expandable tubular member 1335 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
heater 1340 is coupled to thesupport member 1320. Theheater 1340 is preferably adapted to controllably generate a localized heat source for elevating the temperature of theinserts 1370. In an exemplary embodiment, theheater 1340 includes a conventional thermostat control in order to control the operating temperature. Theheater 1340 is preferably controlled by a surface control device in a conventional manner. - The sealing
members 1345 are preferably coupled to the outer surface of theupper portion 1365 of theexpandable tubular member 1335. The sealingmembers 1345 are preferably adapted to engage and fluidicly seal the interface between the radially expandedexpandable tubular member 1335 and thewellbore casing 1300. In an exemplary embodiment, theapparatus 1315 includes a plurality of sealingmembers 1345. In an exemplary embodiment, the sealingmembers 1345 surround and isolate theopening 1310. - As illustrated in
FIG. 13 a, theapparatus 1315 is preferably positioned within thewellbore casing 1300 with theexpandable tubular member 1335 positioned in opposing relation to theopening 1310. In an exemplary embodiment, theapparatus 1315 includes a plurality of sealingmembers 1345 that are positioned above and below theopening 1310. In this manner, the radial expansion of theexpandable tubular member 1335 optimally fluidicly isolates theopening 1310. - As illustrated in
FIG. 13 b, in an exemplary embodiment, theexpandable tubular member 1335 of theapparatus 1315 is then anchored to thewellbore casing 1300 by radially expanding theinserts 1370 using theheater 1340. In an exemplary embodiment, the expansion of theinserts 1370 causes thelower section 1355 of theexpandable tubular member 1335 to contact thewellbore casing 1300. In an exemplary embodiment, theengagement devices 1350 are thereby coupled to, and at least partially penetrate into, thewellbore casing 1300. In this manner, thelower section 1355 of theexpandable tubular member 1335 is optimally coupled to thewellbore casing 1300. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 1335 and thewellbore casing 1300. The compressible cement and/or epoxy may then be permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 1335. - As illustrated in
FIG. 13 c, theexpansion cone 1325 is then axially displaced by applying an axial force to thesupport member 1320. In an exemplary embodiment, the axial displacement of theexpansion cone 1325 radially expands theexpandable tubular member 1335 into intimate contact with the walls of thewellbore casing 1300. - As illustrated in
FIG. 13 d, in an exemplary embodiment, after theexpandable tubular member 1335 has been completely radially expanded by the axial displacement of theexpansion cone 1335, theopening 1310 in thewellbore casing 1300 is sealed off by the radially expandedtubular member 1335. In this manner, repairs to thewellbore casing 1300 are optimally provided. More generally, theapparatus 1315 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 14 a to 14 g, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 14 a, awellbore casing 1400 is positioned within asubterranean formation 1405. Thewellbore casing 1400 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 1400 further includes one ormore openings 1410 that may have been the result of unintentional damage to thewellbore casing 1400, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 1405. As will be recognized by persons having ordinary skill in the art, theopenings 1410 can adversely affect the subsequent operation and use of thewellbore casing 1400 unless they are sealed off. - In an exemplary embodiment, an
apparatus 1415 is utilized to seal off theopenings 1410 in thewellbore casing 1400. More generally, theapparatus 1415 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1415 preferably includes afirst support member 1420, asecond support member 1425, acoupling 1430, anexpandable tubular member 1435, anexpansion cone 1440, athird support member 1445, and apacker 1450. - The
first support member 1420 is preferably adapted to be coupled to a surface location. Thesupport member 1420 is further coupled to theexpansion cone 1440. Thefirst support member 1420 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theexpansion cone 1440 and thepacker 1450. Thefirst support member 1420 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
second support member 1425 is preferably adapted to be coupled to a surface location. Thesupport member 1425 is further coupled to thecoupling 1430. Thefirst support member 1425 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to thecoupling 1430. Thesecond support member 1425 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
coupling 1430 is coupled to thesecond support member 1425. Thecoupling 1430 is further preferably removably coupled to theexpandable tubular member 1435. Thecoupling 1430 may be any number of conventional commercially available passive or actively controlled coupling devices such as, for example, packers or slips. In an exemplary embodiment, thecoupling 1430 is a mechanical slip. - The
expandable tubular member 1435 is removably coupled to thecoupling 1430. In an exemplary embodiment, theexpandable tubular member 1435 includes one or more engagement devices that are adapted to couple with and penetrate thewellbore casing 1400. In this manner, theexpandable tubular member 1435 is optimally coupled to thewellbore casing 1400. In an exemplary embodiment, the engagement devices include teeth for biting into the surface of thewellbore casing 1400. In an exemplary embodiment, theexpandable tubular member 1435 further includes one or more sealing members on the outside surface of theexpandable tubular member 1435 in order to optimally seal the interface between theexpandable tubular member 1435 and thewellbore casing 1400. - In an exemplary embodiment, the
expandable tubular member 1435 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 1440 is coupled to thefirst support member 1420 and thethird support member 1445. Theexpansion cone 1440 is preferably adapted to radially expand theexpandable tubular member 1435 when theexpansion cone 1440 is axially displaced relative to theexpandable tubular member 1435. - In an exemplary embodiment, the
expansion cone 1440 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application no. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
third support member 1445 is preferably coupled to theexpansion cone 1440 and thepacker 1450. Thethird support member 1445 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to thepacker 1450. Thethird support member 1445 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
packer 1450 is coupled to thethird support member 1445. Thepacker 1450 is further preferably adapted to controllably coupled to thewellbore casing 1400. Thepacker 1450 may be any number of conventional commercially available packer devices. In an alternative embodiment, a bladder, slipped cage assembly or hydraulic slips may be substituted for thepacker 1450. - As illustrated in
FIG. 14 a, theapparatus 1415 is preferably positioned within thewellbore casing 1400 with the bottom of theexpandable tubular member 1435 and the top of theexpansion cone 1440 positioned proximate theopening 1410. - As illustrated in
FIG. 14 b, in an exemplary embodiment, thepacker 1450 is then anchored to thewellbore casing 1400. In this manner, theexpansion cone 1440 is maintained in a substantially stationary position. - As illustrated in
FIG. 14 c, in an exemplary embodiment, theexpandable tubular member 1435 is then lowered towards thestationary expansion cone 1440. In an exemplary embodiment, as illustrated inFIG. 14 d, the lower end of theexpandable tubular member 1435 impacts theexpansion cone 1440 and is radially expanded into contact with thewellbore casing 1400. In an exemplary embodiment, the lower end of theexpandable tubular member 1435 includes one or more engagement devices for engaging thewellbore casing 1400 in order to optimally couple the end of theexpandable tubular member 1435 to thewellbore casing 1400. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 1435 and thewellbore casing 1400. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 1435. - As illustrated in
FIG. 14 e, in an exemplary embodiment, thepacker 1450 is decoupled from thewellbore casing 1400. - As illustrated in
FIG. 14 f, in an exemplary embodiment, theexpansion cone 1440 is then axially displaced by applying an axial force to thefirst support member 1420. In an exemplary embodiment, the axial displacement of theexpansion cone 1440 radially expands theexpandable tubular member 1435 into intimate contact with the walls of thewellbore casing 1400. In an exemplary embodiment, prior to the initiation of the axial displacement of theexpansion cone 1440, thecoupling 1430 is decoupled from theexpandable tubular member 1430. - As illustrated in
FIG. 14 g, in an exemplary embodiment, after theexpandable tubular member 1435 has been completely radially expanded by the axial displacement of theexpansion cone 1440, theopening 1410 in thewellbore casing 1400 is sealed off by the radially expandedtubular member 1435. In this manner, repairs to thewellbore casing 1400 are optimally provided. More generally, theapparatus 1415 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 15 a to 15 d, an alternative embodiment of an apparatus for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 15 a, awellbore casing 1500 is positioned within asubterranean formation 1505. Thewellbore casing 1500 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 1500 further includes one ormore openings 1510 that may have been the result of unintentional damage to thewellbore casing 1500, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 1505. As will be recognized by persons having ordinary skill in the art, theopenings 1510 can adversely affect the subsequent operation and use of thewellbore casing 1500 unless they are sealed off. - In an exemplary embodiment, an
apparatus 1515 is utilized to seal off theopenings 1510 in thewellbore casing 1500. More generally, theapparatus 1515 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 1515 preferably includes asupport member 1520, anexpandable tubular member 1525, anexpansion cone 1530, acoupling 1535, aresilient anchor 1540, and one ormore seals 1545. - The
support member 1520 is preferably adapted to be coupled to a surface location. Thesupport member 1520 is further coupled to theexpansion cone 1530. Thesupport member 1520 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theresilient anchor 1540. Thesupport member 1520 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 1525 is removably coupled to theexpansion cone 1530. In an exemplary embodiment, theexpandable tubular member 1525 includes one or more engagement devices that are adapted to couple with and penetrate thewellbore casing 1500. In this manner, theexpandable tubular member 1525 is optimally coupled to thewellbore casing 1500. In an exemplary embodiment, the engagement devices include teeth for biting into the surface of thewellbore casing 1500. In an exemplary embodiment, theexpandable tubular member 1525 further includes one ormore sealing members 1545 on the outside surface of theexpandable tubular member 1525 in order to optimally seal the interface between theexpandable tubular member 1525 and thewellbore casing 1500. - In an exemplary embodiment, the
expandable tubular member 1525 includes alower section 1550, anintermediate section 1555, and anupper section 1560. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 1550 and 1555, are less than the wall thickness of theupper section 1560 in order to optimally facilitate the radial expansion of theexpandable tubular member 1525. In an exemplary embodiment, the sealingmembers 1545 are provided on the outside surface of theupper section 1560 of theexpandable tubular member 1525. In an exemplary embodiment, theresilient anchor 1540 is coupled to thelower section 1550 of theexpandable tubular member 1525 in order to optimally anchor theexpandable tubular member 1525 to thewellbore casing 1500. - In an exemplary embodiment, the
expandable tubular member 1525 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application no. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application no. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 1530 is coupled to thesupport member 1520 and thecoupling 1535. Theexpansion cone 1530 is preferably adapted to radially expand theexpandable tubular member 1525 when theexpansion cone 1530 is axially displaced relative to theexpandable tubular member 1525. Theexpansion cone 1530 may be any number of conventional commercially available expansion cones. - In an exemplary embodiment, the
expansion cone 1530 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application no. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
coupling 1535 is preferably coupled to thesupport member 1520, theexpansion cone 1530 and theresilient anchor 1540. Thecoupling 1535 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theresilient anchor 1535. Thecoupling 1535 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. In an exemplary embodiment, thecoupling 1535 is decoupled from theresilient anchor 1540 upon initiating the axial displacement of theexpansion cone 1530. - The
resilient anchor 1540 is preferably coupled to thelower section 1550 of theexpandable tubular member 1525 and thecoupling 1535. Theresilient anchor 1540 is further preferably adapted to be controllably coupled to thewellbore casing 1500. - Referring to
FIGS. 16 a and 16 b, in an exemplary embodiment, theresilient anchor 1540 includes one or more coiledresilient members 1600 and correspondingreleasable coupling devices 1605. In an exemplary embodiment, theresilient anchor 1540 is maintained in a compressed elastic position that is controllably released thereby causing theresilient anchor 1540 to expand in size thereby releasing the elastic energy stored within theresilient anchor 1540. As illustrated inFIG. 16 b, in an exemplary embodiment, when thecoupling device 1605 is released, the coiledresilient member 1600 at least partially uncoils in the outward radial direction. In an exemplary embodiment, at least a portion of the coiledmember 1600 is coupled to thelower section 1550 of theexpandable tubular member 1525. In an exemplary embodiment, the uncoiledmember 1600 thereby couples thelower section 1550 of theexpandable tubular member 1525 to thewellbore casing 1500. - The coiled
member 1600 may be fabricated from any number of conventional commercially available resilient materials. In an exemplary embodiment, the coiledmember 1600 is fabricated from a resilient material such as, for example, spring steel. In an exemplary embodiment, the coiledmember 1600 is fabricated from memory metals in order to optimally provide control of shapes and stresses. - In an exemplary embodiment, the
releasable coupling device 1605 maintains the coiledmember 1600 is a coiled position until thedevice 1605 is released. Thereleasable coupling device 1605 may be any number of conventional commercially available releasable coupling devices such as, for example, an explosive bolt. - The
resilient anchor 1540 may be positioned in any desired orientation. In an exemplary embodiment, theresilient anchor 1540 is positioned to apply the maximum normal force to the walls of thewellbore casing 1500 after releasing theresilient anchor 1540. - In an alternate embodiment, as illustrated in
FIGS. 17 a and 17 b, theresilient anchor 1540 includes atubular member 1700, one or more resilient anchoring members 1705, one or more corresponding rigid attachments 1710, and one more corresponding releasable attachments 1715. In an exemplary embodiment, the resilient anchoring members 1705 are maintained in compressed elastic condition by the corresponding rigid and releasable attachments, 1710 and 1715. In an exemplary embodiment, when the corresponding releasable attachment 1715 is released, the corresponding resilient anchoring member 1705 expands, releasing the stored elastic energy, away from thetubular member 1700. - As illustrated in
FIG. 17 a, one end of each resilient anchoring member 1705 is rigidly attached to the outside surface of thetubular member 1700 by a corresponding rigid attachment 1710. The other end of each resilient anchoring member 1705 is removably attached to the outside surface of thetubular member 1700 by a corresponding releasable attachment 1715. As illustrated inFIG. 17 b, in an exemplary embodiment, releasing the releasable attachment 1715 permits the resilient energy stored in the resilient anchoring member 1705 to be released thereby causing the resilient anchoring member 1705 to swing radially outward from thetubular member 1700. - The
tubular member 1700 may be fabricated from any number of conventional materials. - The resilient anchoring members 1705 may be fabricated from any number of resilient materials. In an exemplary embodiment, the resilient anchoring members 1705 are fabricated from memory metal in order to optimally provide control of shapes and stresses.
- The rigid attachments 1710 may be fabricated from any number of conventional commercially available materials. In an exemplary embodiment, the rigid attachments 1710 are fabricated from 4140 steel in order to optimally provide high strength.
- The releasable attachments 1715 may be fabricated from any number of conventional commercially available devices such as, for example, explosive bolts.
- In another alternative embodiment, as illustrated in
FIGS. 18 a and 18 b, theresilient anchor 1540 includes atubular member 1800, one or more anchoring devices 1805, one or more resilient members 1810, and one or more release devices 1815. In an exemplary embodiment, the anchoring devices 1805 and resilient members 1810 are maintained in a compressed elastic position by the release devices 1815. As illustrated inFIG. 18 b, in an exemplary embodiment, when the release devices 1815 are removed, the anchoring devices 1805 and resilient members 1810 are permitted to expand outwardly in the radial direction. - The
tubular member 1800 preferably includes one or more openings 1820 for containing the release devices 1815 and for permitting the anchoring devices 1805 to pass through. Thetubular member 1800 may be fabricated from any number of conventional commercially available materials. In an exemplary embodiment, thetubular member 1800 is fabricated from 4140 steel in order to optimally provide high strength. - The anchoring devices 1805 are housed within the
tubular member 1800. The anchoring devices 1805 are preferably adapted to at least partially extend through the corresponding openings 1820 in thetubular member 1800. The anchoring devices 1805 are preferably adapted to couple to, and at least partially penetrate, the surface of thewellbore 1500. The anchoring devices 1805 may be fabricated from any number of durable hard materials such as, for example, tungsten carbide, machine tool steel, or hard faced steel. In an exemplary embodiment, the anchoring devices 1805 are fabricated from machine tool steel in order to optimally provide high strength, hardness, and fracture toughness. - The resilient members 1810 are coupled to the inside surface of the
tubular member 1800. The resilient members 1810 are preferably adapted to apply a radial force upon the corresponding anchoring devices 1805. In an exemplary embodiment, when the release devices 1815 release the anchoring devices 1805, the resilient members 1810 are preferably adapted to force the anchoring devices at least partially through the corresponding openings 1820 into contact with, to at least partially penetrate, thewellbore casing 1500. - The release devices 1815 are positioned within and coupled to the openings 1820 in the
tubular member 1800. The release devices 1815 are preferably adapted to hold the corresponding anchoring devices 1805 within thetubular member 1800 until released by a control signal provided from a surface, or other, location. The release devices 1815 may be any number of conventional commercially available release devices. In an exemplary embodiment, the release devices 1815 are pressure activated in order to optimally provide ease of operation. - As illustrated in
FIG. 15 a, theapparatus 1515 is preferably positioned within thewellbore casing 1500 with theexpandable tubular member 1525 positioned in opposing relation to theopening 1510. - As illustrated in
FIG. 15 b, in an exemplary embodiment, theresilient anchor 1540 is then anchored to thewellbore casing 1500. In this manner, thelower section 1550 of theexpandable tubular member 1525 is anchored to thewellbore casing 1500. In an exemplary embodiment, theresilient anchor 1540 is anchored by a control and/or electrical power signal transmitted from a surface location. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 1525 and thewellbore casing 1500. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 1525. - As illustrated in
FIG. 15 c, in an exemplary embodiment, theexpansion cone 1530 is then axially displaced by applying an axial force to thesupport member 1520. In an exemplary embodiment, the axial displacement of theexpansion cone 1530 radially expands theexpandable tubular member 1525 into intimate contact with the walls of thewellbore casing 1500. - As illustrated in
FIG. 15 d, in an exemplary embodiment, after theexpandable tubular member 1525 has been completely radially expanded by the axial displacement of theexpansion cone 1530, theopening 1510 in thewellbore casing 1500 is sealed off by the radially expandedtubular member 1525. In this manner, repairs to thewellbore casing 1500 are optimally provided. More generally, theapparatus 1515 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 19 a, 19 b and 19 c, an alternative embodiment of anexpandable tubular member 1900 for use in theapparatus 1515 will now be described. In an exemplary embodiment, theexpandable tubular member 1900 includes atubular body 1905, one or moreresilient panels 1910, one or morecorresponding engagement members 1915, and arelease member 1920. In an exemplary embodiment, theresilient panels 1910 are adapted to expand in the radial direction after being released by therelease member 1920. In this manner, theexpandable tubular member 1900 is anchored to a preexisting structure such as, for example, a wellbore casing, an open hole wellbore section, a pipeline, or a structural support. - The
tubular member 1905 is coupled to theresilient panels 1910. Thetubular member 1905 may be any number of conventional commercially available expandable tubular members. In an exemplary embodiment, thetubular member 1905 is an expandable casing in order to optimally provide high strength. - The
resilient panels 1910 are coupled to thetubular member 1905. Theresilient panels 1910 are further releasably coupled to therelease member 1920. Theresilient panels 1910 are preferably adapted to house theexpansion cone 1530. Theresilient panels 1910 are preferably adapted to extend to theposition 1925 upon being released by therelease member 1920. In an exemplary embodiment, theresilient panels 1910 are coupled to thetubular member 1905 by welding in order to optimally provide high strength. Theresilient panels 1910 may be fabricated from any number of conventional commercially available resilient materials. In an exemplary embodiment, theresilient panels 1910 are fabricated from spring steel in order to optimally store elastic radially directed energy. - The
engagement members 1915 are coupled to corresponding resilient panels. Theengagement members 1915 are preferably adapted to engage, and at least partially penetrate, thewellbore casing 1500, or other preexisting structure. - The
release member 1920 is releasably coupled to theresilient panels 1910. Therelease member 1920 is preferably adapted to controllably release theresilient panels 1910 from their initial strained positions in order to permit theresilient panels 1910 to expand to their expandedpositions 1925. In an exemplary embodiment, therelease member 1920 is releasably coupled to thecoupling 1535. In this manner, electrical and/or control and/or hydraulic signals are communicated to and/or from therelease member 1920. Therelease member 1920 may be any number of conventional commercially available release devices. - Referring to
FIGS. 20 a to 20 d, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 20 a, awellbore casing 2000 is positioned within asubterranean formation 2005. Thewellbore casing 2000 may be positioned in any orientation from the vertical direction to the horizontal direction. Thewellbore casing 2000 further includes one ormore openings 2010 that may have been the result of unintentional damage to thewellbore casing 2000, or due to a prior perforation or fracturing operation performed upon the surroundingsubterranean formation 2005. As will be recognized by persons having ordinary skill in the art, theopenings 2010 can adversely affect the subsequent operation and use of thewellbore casing 2000 unless they are sealed off. - In an exemplary embodiment, an
apparatus 2015 is utilized to seal off theopenings 2010 in thewellbore casing 2000. More generally, theapparatus 2015 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 2015 preferably includes asupport member 2020, anexpandable tubular member 2025, anexpansion cone 2030, acoupling 2035, aresilient anchor 2040, and one ormore seals 2045. - The
support member 2020 is preferably adapted to be coupled to a surface location. Thesupport member 2020 is further coupled to theexpansion cone 2030. Thesupport member 2020 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchor 2040. Thesupport member 2020 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 2025 is removably coupled to theexpansion cone 2030. In an exemplary embodiment, theexpandable tubular member 2025 includes one or more engagement devices that are adapted to couple with and penetrate thewellbore casing 2000. In this manner, theexpandable tubular member 2025 is optimally coupled to thewellbore casing 2000. In an exemplary embodiment, the engagement devices include teeth for biting into the surface of thewellbore casing 2000. In an exemplary embodiment, theexpandable tubular member 2025 further includes one ormore sealing members 2045 on the outside surface of theexpandable tubular member 2025 in order to optimally seal the interface between theexpandable tubular member 2025 and thewellbore casing 2000. - In an exemplary embodiment, the
expandable tubular member 2025 includes alower section 2050, anintermediate section 2055, and anupper section 2060. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 2050 and 2055, are less than the wall thickness of theupper section 2060 in order to optimally facilitate the radial expansion of theexpandable tubular member 2025. In an exemplary embodiment, the sealingmembers 2045 are provided on the outside surface of theupper section 2060 of theexpandable tubular member 2025. In an exemplary embodiment, theresilient anchor 2040 is coupled to thelower section 2050 of theexpandable tubular member 2025 in order to optimally anchor theexpandable tubular member 2025 to thewellbore casing 2000. - In an exemplary embodiment, the
expandable tubular member 2025 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 2030 is preferably coupled to thesupport member 2020 and thecoupling 2035. Theexpansion cone 2030 is preferably adapted to radially expand theexpandable tubular member 2025 when theexpansion cone 2030 is axially displaced relative to theexpandable tubular member 2025. - In an exemplary embodiment, the
expansion cone 2030 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
coupling 2035 is preferably coupled to thesupport member 2020, theexpansion cone 2030, and theanchor 2040. Thecoupling 2035 is preferably adapted to convey pressurized fluidic materials and/or electrical current and/or communication signals from a surface location to theanchor 2035. Thecoupling 2035 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. In an exemplary embodiment, thecoupling 2035 is decoupled from theanchor 2040 upon initiating the axial displacement of theexpansion cone 2030. - The
anchor 2040 is preferably coupled to thelower section 2050 of theexpandable tubular member 2025 and thecoupling 2035. Theanchor 2040 is further preferably adapted to be controllably coupled to thewellbore casing 2000. - Referring to
FIGS. 21 a and 21 b, in an exemplary embodiment, theanchor 2040 includes ahousing 2100, one ormore spikes 2105, and one or morecorresponding actuators 2110. In an exemplary embodiment, thespikes 2105 are outwardly extended by the correspondingactuators 2110. In an alternative embodiment, thespikes 2105 are outwardly actuated by displacing theapparatus 2015 upwardly. In another alternative embodiment, thespikes 2105 are outwardly extended by placing a quantity of fluidic material onto thespikes 2105. - The
housing 2100 is coupled to thelower section 2050 of theexpandable tubular member 2025, thespikes 2105, and theactuators 2110. Thehousing 2100 is further preferably coupled to thecoupling 2035. In an exemplary embodiment, thehousing 2100 is adapted to convey electrical, communication, and/or hydraulic signals from thecoupling 2035 to theactuators 2110. - The
spikes 2105 are preferably movably coupled to thehousing 2100 and the correspondingactuators 2110. Thespikes 2105 are preferably adapted to pivot relative to thehousing 2100. Thespikes 2105 are further preferably adapted to extend outwardly in a radial direction to engage, and at least partially penetrate, thewellbore casing 2000, or other preexisting structure such as, for example, the wellbore. Each of thespikes 2105 further preferably include a concave upwardly facingsurface 2115. In an exemplary embodiment, the placement of a quantity of fluidic material such as, for example, a barite plug or a flex plug, onto thesurfaces 2115 causes thespikes 2105 to pivot outwardly away from thehousing 2100 to engage thewellbore casing 2000, or other preexisting structure such as, for example, the wellbore. Alternatively, the upward displacement of theapparatus 2015 causes thespikes 2105 to pivot outwardly away from thehousing 2100 to engage thewellbore casing 2000, or other preexisting structure such as, for example, the wellbore. - The
actuators 2110 are preferably coupled to thehousing 2100 and the corresponding spikes 2105. Theactuators 2110 are preferably adapted to apply a force to the correspondingspikes 2105 sufficient to pivot the correspondingspikes 2105 outwardly and away from thehousing 2100. Theactuators 2110 may be any number of conventional commercially available actuators such as, for example, a spring, an electric or hydraulic motor, a hydraulic piston/cylinder. In an exemplary embodiment, theactuators 2100 are hydraulic pistons in order to optimally provide ease of operation. In an alternative embodiment, theactuators 2110 are omitted and the spikes are pivotally coupled to thehousing 2100. - Referring to
FIGS. 22 a, 22 b, and 22 c, in an alternative embodiment, theanchor 2040 includes thehousing 2100, one ormore petal baskets 2205, and one or morecorresponding actuators 2110. In an exemplary embodiment, thepetal baskets 2205 are outwardly extended by the correspondingactuators 2110. In an alternative embodiment, thepetal baskets 2205 are outwardly actuated by displacing theapparatus 2015 upwardly. In another alternative embodiment, thepetal baskets 2205 are outwardly extended by placing a quantity of fluidic material onto thepetal baskets 2205. - The
housing 2100 is coupled to thelower section 2050 of theexpandable tubular member 2025, thepetal baskets 2205, and theactuators 2110. - The
petal baskets 2205 are preferably movably coupled to thehousing 2100 and the correspondingactuators 2110. Thepetal baskets 2205 are preferably adapted to pivot relative to thehousing 2100. Thepetal baskets 2205 are further preferably adapted to extend outwardly in a radial direction to engage, and at least partially penetrate, thewellbore casing 2000, or other preexisting structure. As illustrated inFIG. 22 c, each of thepetal baskets 2205 further preferably include a concave upwardly facingsurface 2215. In an exemplary embodiment, the placement of a quantity of fluidic material such as, for example, a barite plug or a flex plug, onto thesurfaces 2215 causes thepetal baskets 2205 to pivot outwardly away from thehousing 2100 to engage thewellbore casing 2000, or other preexisting structure. Alternatively, the weight of the fluidic materials placed onto thepetal baskets 2205 is sufficient to anchor theexpandable tubular member 2025. Alternatively, the upward displacement of theapparatus 2015 causes thepetal baskets 2205 to pivot outwardly away from thehousing 2100 to engage thewellbore casing 2000, or other preexisting structure. - The
actuators 2110 are preferably coupled to thehousing 2100 and thecorresponding petal baskets 2205. Theactuators 2110 are preferably adapted to apply a force to thecorresponding petal baskets 2205 sufficient to pivot the correspondingpetal baskets 2205 outwardly and away from thehousing 2100. In an alternative embodiment, theactuators 2110 are omitted and the petal baskets are pivotally coupled to thehousing 2100. - In an alternative embodiment, the
anchor 2040 includes one ormore spikes 2105 and one ormore petal baskets 2205. - As illustrated in
FIG. 20 a, theapparatus 2015 is preferably positioned within thewellbore casing 2000 with theexpandable tubular member 2025 positioned in opposing relation to theopening 2010. - As illustrated in
FIG. 20 b, in an exemplary embodiment, theanchor 2040 is then anchored to thewellbore casing 2000. In this manner, thelower section 2050 of theexpandable tubular member 2025 is anchored to thewellbore casing 2000 or the wellbore casing. In an exemplary embodiment, theanchor 2040 is anchored by a control and/or electrical power signal transmitted from a surface location to theactuators 2110 of theanchor 2040. In an alternative embodiment, theanchor 2040 is anchored to thewellbore casing 2000 by upwardly displacing theapparatus 2015. In an alternative embodiment, theanchor 2040 is anchored to thewellbore casing 2000 by placing a quantity of a fluidic material such, for example, a barite plug or a flex plug, onto thespikes 2105 orpetal baskets 2205 of theanchor 2040. In an alternative embodiment, theanchor 2040 is omitted, and theapparatus 2015 is anchored by placing a quantity of a fluidic material such, for example, a barite plug or a flex plug, onto at least the lower and/or the intermediate sections, 2050 and 2055, of theexpandable tubular member 2025. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 2025 and thewellbore casing 2000. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 2025. - As illustrated in
FIG. 20 c, in an exemplary embodiment, theexpansion cone 2030 is then axially displaced by applying an axial force to thesupport member 2020. In an exemplary embodiment, the axial displacement of theexpansion cone 2030 radially expands theexpandable tubular member 2025 into intimate contact with the walls of thewellbore casing 2000. - As illustrated in
FIG. 20 d, in an exemplary embodiment, after theexpandable tubular member 2025 has been completely radially expanded by the axial displacement of theexpansion cone 2030, theopening 2010 in thewellbore casing 2000 is sealed off by the radially expandedtubular member 1435. In this manner, repairs to thewellbore casing 2000 are optimally provided. More generally, theapparatus 2015 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 23 a to 23 e, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 23 a, awellbore casing 2300 and an openhole wellbore section 2305 are positioned within asubterranean formation 2310. Thewellbore casing 2300 and the openhole wellbore section 2305 may be positioned in any orientation from the vertical direction to the horizontal direction. - In an exemplary embodiment, an
apparatus 2320 is utilized to form a new section of wellbore casing within the openhole wellbore section 2305. More generally, theapparatus 2320 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 2320 preferably includes asupport member 2325, anexpandable tubular member 2330, anexpansion cone 2335, one or moreupper sealing members 2340, and one ormore sealing members 2345. - The
support member 2325 is preferably adapted to be coupled to a surface location. Thesupport member 2325 is further coupled to theexpansion cone 2335. Thesupport member 2325 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 2330 is removably coupled to theexpansion cone 2335. In an exemplary embodiment, theexpandable tubular member 2025 further includes one or more upper and lower sealing members, 2340 and 2345, on the outside surface of theexpandable tubular member 2330 in order to optimally seal the interface between theexpandable tubular member 2330 and thewellbore casing 2300 and the openhole wellbore section 2305. - In an exemplary embodiment, the
expandable tubular member 2025 further includes alower section 2350, anintermediate section 2355, and anupper section 2360. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 2350 and 2355, are less than the wall thickness of theupper section 2360 in order to optimally facilitate the radial expansion of theexpandable tubular member 2330. In an exemplary embodiment, thelower section 2350 of theexpandable tubular member 2330 includes one ormore slots 2365 adapted to permit a fluidic sealing material to penetrate thelower section 2350. - In an exemplary embodiment, the
expandable tubular member 2330 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application no. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 2335 is preferably coupled to thesupport member 2325. Theexpansion cone 2335 is further preferably removably coupled to theexpandable tubular member 2330. Theexpansion cone 2335 is preferably adapted to radially expand theexpandable tubular member 2330 when theexpansion cone 2335 is axially displaced relative to theexpandable tubular member 2330. - In an exemplary embodiment, the
expansion cone 2335 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application no. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
upper sealing member 2340 is coupled to the outside surface of theupper section 2360 of theexpandable tubular member 2330. Theupper sealing member 2340 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2360 of theexpandable tubular member 2330 and thewellbore casing 2300. Theupper sealing member 2340 may be any number of conventional commercially available sealing members. In an exemplary embodiment, theupper sealing member 2340 is a viton rubber in order to optimally provide load carrying and pressure sealing capacity. - The
lower sealing member 2345 is preferably coupled to the outside surface of theupper section 2360 of theexpandable tubular member 2330. Thelower sealing member 2340 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2360 of theexpandable tubular member 2330 and the openhole wellbore section 2305. Thelower sealing member 2345 may be any number of conventional commercially available sealing members. In an exemplary embodiment, thelower sealing member 2345 is viton rubber in order to optimally provide load carrying and sealing capacity. - As illustrated in
FIG. 23 a, theapparatus 2320 is preferably positioned within thewellbore casing 2300 and the openhole wellbore section 2305 with theexpandable tubular member 2330 positioned in overlapping relation to thewellbore casing 2300. - As illustrated in
FIG. 23 b, in an exemplary embodiment, a quantity of a hardenablefluidic sealing material 2365 is then injected into the openhole wellbore section 2305 proximate to thelower section 2350 of theexpandable tubular member 2330. The sealingmaterial 2365 may be any number of conventional commercially available sealing materials such as, for example, cement and/or epoxy resin. In an exemplary embodiment, the hardenablefluidic sealing material 2365 at least partially enters the slots provided in thelower section 2350 of theexpandable tubular member 2330. - As illustrated in
FIG. 23 c, the hardenablefluidic sealing material 2365 is preferably then permitted to at least partially cure. In this manner, thelower section 2350 of theexpandable tubular member 2330 is anchored to the openhole wellbore section 2305. - In an alternative embodiment, a compressible cement and/or epoxy is then injected into the annular space between the unexpanded portion of the
tubular member 2330 and thewellbore casing 2300. The compressible cement and/or epoxy is then permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 2330. - As illustrated in
FIG. 23 d, in an exemplary embodiment, theexpansion cone 2335 is then axially displaced by applying an axial force to thesupport member 2325. In an exemplary embodiment, the axial displacement of theexpansion cone 2335 radially expands theexpandable tubular member 2330 into intimate contact with the walls of thewellbore casing 2300. - As illustrated in
FIG. 23 e, in an exemplary embodiment, after theexpandable tubular member 2330 has been completely radially expanded by the axial displacement of theexpansion cone 2335, a new section of wellbore casing is formed that preferably includes the radially expandedtubular member 2330 and an outer annular layer of a fluidic sealing material. More generally, theapparatus 2320 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 24 a to 24 c, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 24 a, awellbore casing 2400 and an openhole wellbore section 2405 are positioned within asubterranean formation 2410. Thewellbore casing 2400 and the openhole wellbore section 2405 may be positioned in any orientation from the vertical direction to approximately the horizontal direction. - In an exemplary embodiment, an
apparatus 2420 is utilized to form a new section of wellbore casing within the openhole wellbore section 2405. More generally, theapparatus 2420 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 2420 preferably includes asupport member 2425, anexpandable tubular member 2430, anexpansion cone 2435, acoupling 2440, apacker 2445, amass 2450, one or moreupper sealing members 2455, and one ormore sealing members 2460. - The
support member 2425 is preferably adapted to be coupled to a surface location. Thesupport member 2425 is further coupled to theexpansion cone 2435. Thesupport member 2425 is preferably adapted to convey electrical, communication, and/or hydraulic signals to and/or from thepacker 2445. Thesupport member 2425 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 2430 is removably coupled to theexpansion cone 2435 and thepacker 2445. Theexpandable tubular member 2430 is further preferably coupled to themass 2450. In an exemplary embodiment, theexpandable tubular member 2430 further includes one or more upper and lower sealing members, 2455 and 2460, on the outside surface of theexpandable tubular member 2430 in order to optimally seal the interface between theexpandable tubular member 2430 and thewellbore casing 2400 and the openhole wellbore section 2405. - In an exemplary embodiment, the
expandable tubular member 2430 further includes alower section 2465, anintermediate section 2470, and anupper section 2430. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 2465 and 2470, are less than the wall thickness of theupper section 2475 in order to optimally facilitate the radial expansion of theexpandable tubular member 2430. In an exemplary embodiment, thelower section 2465 of theexpandable tubular member 2430 is coupled to themass 2450. - In an exemplary embodiment, the
expandable tubular member 2430 is further provided substantially as disclosed in one or more of the following: - The
expansion cone 2435 is preferably coupled to thesupport member 2425 and thecoupling 2440. Theexpansion cone 2435 is further preferably removably coupled to theexpandable tubular member 2430. Theexpansion cone 2435 is preferably adapted to radially expand theexpandable tubular member 2430 when theexpansion cone 2435 is axially displaced relative to theexpandable tubular member 2430. - In an exemplary embodiment, the
expansion cone 2435 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application no. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
coupling 2440 is preferably coupled to thesupport member 2425 and theexpansion cone 2435. Thecoupling 2440 is preferably adapted to convey electrical, communication, and/or hydraulic signals to and/or from thepacker 2445. Thecoupling 2440 may be any number of conventional support members such as, for example, commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
packer 2445 is coupled to thecoupling 2440. Thepacker 2445 is further removably coupled to thelower section 2465 of theexpandable wellbore casing 2430. Thepacker 2445 is preferably adapted to provide sufficient frictional force to support thelower section 2465 of theexpandable wellbore casing 2430 and themass 2450. Thepacker 2445 may be any number of conventional commercially available packers. In an exemplary embodiment, thepacker 2445 is an RTTS packer available from Halliburton Energy Services in order to optimally provide multiple sets and releases. In an alternative embodiment, hydraulic slips may be substituted for, or used to supplement, thepacker 2445. - The
mass 2450 is preferably coupled to thelower section 2465 of theexpandable tubular member 2430. Themass 2450 is preferably selected to provide a tensile load on thelower section 2465 of theexpandable tubular member 2430 that ranges from about 50 to 100% of the yield point of theupper section 2475 of theexpandable tubular member 2430. In this manner, when thepacker 2445 is released, the axial force provided by themass 2450 optimally radially expands and extrudes theexpandable tubular member 2430 off of theexpansion cone 2435. - The
upper sealing member 2455 is preferably coupled to the outside surface of theupper section 2475 of theexpandable tubular member 2430. Theupper sealing member 2455 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2475 of theexpandable tubular member 2430 and thewellbore casing 2400. Theupper sealing member 2455 may be any number of conventional commercially available sealing members. In an exemplary embodiment, theupper sealing member 2455 is viton rubber in order to optimally provide load carrying and pressure sealing capacity. - The
lower sealing member 2460 is preferably coupled to the outside surface of theupper section 2475 of theexpandable tubular member 2430. Thelower sealing member 2460 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2475 of theexpandable tubular member 2430 and the openhole wellbore section 2405. Thelower sealing member 2460 may be any number of conventional commercially available sealing members. In an exemplary embodiment, thelower sealing member 2460 is viton rubber in order to optimally provide lead bearing and sealing capacity. - As illustrated in
FIG. 24 a, theapparatus 2420 is preferably positioned within thewellbore casing 2400 and the openhole wellbore section 2405 with theexpandable tubular member 2430 positioned in overlapping relation to thewellbore casing 2400. In an exemplary embodiment, the weight of themass 2450 is supported by thesupport member 2425, theexpansion cone 2435, thecoupling 2440, thepacker 2445, and thelower section 2465 of theexpandable tubular member 2430. In this manner, theintermediate section 2470 of theexpandable tubular member 2430 preferably does not support any of the weight of themass 2450. - As illustrated in
FIG. 24 b, in an exemplary embodiment, thepacker 2445 is then released from connection with thelower section 2465 of theexpandable tubular member 2430. In this manner, themass 2450 is preferably now supported by thesupport member 2425,expansion cone 2435, and the lower and intermediate sections, 2465 and 2470, of theexpandable tubular member 2430. In an exemplary embodiment, the weight of themass 2450 then causes theexpandable tubular member 2430 to be radially expanded by, and extruded off of, theexpansion cone 2435. In an exemplary embodiment, during the extrusion process, the position of thesupport member 2425 is adjusted to ensure an overlapping relation between theexpandable tubular member 2430 and thewellbore casing 2400. - In an alternative embodiment, a compressible cement and/or epoxy is injected into the annular space between the unexpanded portion of the
tubular member 2430 and thewellbore casing 2400 before and/or during the extrusion process. The compressible cement and/or epoxy is then preferably permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 2430. - As illustrated in
FIG. 24 c, in an exemplary embodiment, after theexpandable tubular member 2430 has been completely extruded off of theexpansion cone 2435, a new section of wellbore casing is formed that preferably includes the radially expandedtubular member 2430 and an outer annular layer of a fluidic sealing material. More generally, theapparatus 2420 is used to repair or form wellbore casings, pipelines, and structural supports. - In an alternative embodiment, the
mass 2450 is positioned on top of theupper section 2475 of thetubular member 2430. In an exemplary embodiment, themass 2450 is fabricated from a thick walled tubular member that is concentric with respect to thesupport member 2425, and also rests on top of theupper section 2475 of thetubular member 2430. In this manner, when theexpansion cone 2435 exits thetubular member 2430, the expansion cone will carry the mass 2450 out of thewellbore 2405. - Referring to
FIGS. 25 a to 25 c, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 25 a, awellbore casing 2500 and an openhole wellbore section 2505 are positioned within asubterranean formation 2510. Thewellbore casing 2500 and the openhole wellbore section 2505 may be positioned in any orientation from the vertical direction to approximately the horizontal direction. - In an exemplary embodiment, an
apparatus 2520 is utilized to form a new section of wellbore casing within the openhole wellbore section 2505. More generally, theapparatus 2520 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 2520 preferably includes asupport member 2525, anexpandable tubular member 2530, anexpansion cone 2535, achamber 2440, anend plate 2545, one or moreupper sealing members 2555, and one ormore sealing members 2560. - The
support member 2525 is preferably adapted to be coupled to a surface location. Thesupport member 2525 is further coupled to theexpansion cone 2535. Thesupport member 2525 is preferably adapted to convey fluidic materials to and/or from thechamber 2540. Thesupport member 2525 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 2530 is removably coupled to theexpansion cone 2535. In an exemplary embodiment, theexpandable tubular member 2530 further includes one or more upper and lower sealing members, 2555 and 2560, on the outside surface of theexpandable tubular member 2530 in order to optimally seal the interface between theexpandable tubular member 2530 and thewellbore casing 2500 and the openhole wellbore section 2505. - In an exemplary embodiment, the
expandable tubular member 2530 further includes alower section 2565, anintermediate section 2570, and anupper section 2530. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 2565 and 2570, are less than the wall thickness of theupper section 2575 in order to optimally facilitate the radial expansion of theexpandable tubular member 2530. - In an exemplary embodiment, the
lower section 2565 of theexpandable tubular member 2530 further includes thechamber 2540 and theend plate 2545. - In an exemplary embodiment, the
expandable tubular member 2530 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 2535 is preferably coupled to thesupport member 2525. Theexpansion cone 2535 is further preferably removably coupled to theexpandable tubular member 2530. Theexpansion cone 2535 is preferably adapted to radially expand theexpandable tubular member 2530 when theexpansion cone 2535 is axially displaced relative to theexpandable tubular member 2530. Theexpansion cone 2535 is further preferably adapted to convey fluidic materials to and/or from thechamber 2540. - In an exemplary embodiment, the
expansion cone 2535 is provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
chamber 2540 is defined by the interior portion of thelower section 2565 of theexpandable tubular member 2530 below theexpansion cone 2535 and above theend plate 2545. Thechamber 2540 is preferably adapted to contain a quantity of a fluidic materials having a higher density than the fluidic materials outside of theexpandable tubular member 2530. - The
upper sealing member 2555 is preferably coupled to the outside surface of theupper section 2575 of theexpandable tubular member 2530. Theupper sealing member 2555 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2575 of theexpandable tubular member 2530 and thewellbore casing 2500. Theupper sealing member 2555 may be any number of conventional commercially available sealing members. In an exemplary embodiment, theupper sealing member 2555 is viton rubber in order to optimally provide load carrying and pressure sealing capacity. - The
lower sealing member 2560 is preferably coupled to the outside surface of theupper section 2575 of theexpandable tubular member 2530. Thelower sealing member 2560 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2575 of theexpandable tubular member 2530 and the openhole wellbore section 2505. Thelower sealing member 2560 may be any number of conventional commercially available sealing members. In an exemplary embodiment, thelower sealing member 2560 is viton rubber in order to optimally provide load carrying and pressure sealing capacity. - As illustrated in
FIG. 25 a, theapparatus 2520 is preferably positioned within thewellbore casing 2500 and the openhole wellbore section 2505 with theexpandable tubular member 2530 positioned in overlapping relation to thewellbore casing 2500. - As illustrated in
FIG. 25 b, a quantity of afluidic material 2580 having a density greater than the density of the fluidic material within theregion 2585 outside of theexpandable tubular member 2530 is injected into thechamber 2540. In an exemplary embodiment, the difference in hydrostatic pressure between thechamber 2540 and theregion 2585, due to the differences in fluid densities of these regions, causes theexpandable tubular member 2530 to be radially expanded by, and extruded off of, theexpansion cone 2535. In an exemplary embodiment, during the extrusion process, the position of thesupport member 2525 is adjusted to ensure an overlapping relation between theexpandable tubular member 2530 and thewellbore casing 2500. In an exemplary embodiment, the quantity of thefluidic material 2580 initially injected into thechamber 2540 is subsequently increased as the size of thechamber 2540 increases during the extrusion process. In this manner, high pressure pumping equipment is typically not required, or the need for it is at least minimized. Rather, in an exemplary embodiment, a column of thefluidic material 2580 is maintained within thesupport member 2525. - In an alternative embodiment, a compressible cement and/or epoxy is injected into the annular space between the unexpanded portion of the
tubular member 2530 and thewellbore casing 2500 before and/or during the extrusion process. The compressible cement and/or epoxy is then preferably permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 2530. - As illustrated in
FIG. 25 c, in an exemplary embodiment, after theexpandable tubular member 2530 has been completely extruded off of theexpansion cone 2535, a new section of wellbore casing is formed that preferably includes the radially expandedtubular member 2530 and an outer annular layer of a fluidic sealing material. More generally, theapparatus 2520 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring to
FIGS. 26 a to 26 c, an alternative embodiment of an apparatus and method for coupling an expandable tubular member to a preexisting structure will now be described. Referring toFIG. 26 a, awellbore casing 2600 and an openhole wellbore section 2605 are positioned within asubterranean formation 2610. Thewellbore casing 2600 and the openhole wellbore section 2605 may be positioned in any orientation from the vertical direction to approximately the horizontal direction. - In an exemplary embodiment, an
apparatus 2620 is utilized to form a new section of wellbore casing within the openhole wellbore section 2605. More generally, theapparatus 2620 is preferably utilized to form or repair wellbore casings, pipelines, or structural supports. - The
apparatus 2620 preferably includes a support member 2625, anexpandable tubular member 2630, anexpansion cone 2635, a slip joint 2640, anend plate 2545, achamber 2650, one ormore slip members 2655, one ormore sealing members 2670, one or moreupper sealing members 2675, and one or morelower sealing members 2680. - The support member 2625 is preferably adapted to be coupled to a surface location. The support member 2625 is further coupled to the
expansion cone 2635. The support member 2625 is preferably adapted to convey fluidic materials to and/or from thechamber 2640. The support member 2625 may, for example, be conventional commercially available slick wire, braided wire, coiled tubing, or drilling stock material. - The
expandable tubular member 2630 is removably coupled to theexpansion cone 2635. In an exemplary embodiment, theexpandable tubular member 2630 further includes one or more upper and lower sealing members, 2675 and 2680, on the outside surface of theexpandable tubular member 2630 in order to optimally seal the interface between theexpandable tubular member 2630 and thewellbore casing 2600 and the openhole wellbore section 2605. - In an exemplary embodiment, the
expandable tubular member 2630 further includes alower section 2685, anintermediate section 2690, and anupper section 2695. In an exemplary embodiment, the wall thicknesses of the lower and intermediate sections, 2685 and 2690, are less than the wall thickness of theupper section 2695 in order to optimally facilitate the radial expansion of theexpandable tubular member 2630. - In an exemplary embodiment, the
lower section 2685 of theexpandable tubular member 2630 houses the slip joint 2640, theend plate 2645, theslips 2655, and the sealingmembers 2670. In an exemplary embodiment, the interior portion of thelower section 2685 of theexpandable tubular member 2630 below theexpansion cone 2635 and above the end plate defines thechamber 2650. In an exemplary embodiment, thelower section 2685 of theexpandable tubular member 2630 further includes one or more of the anchoring devices described above with reference toFIGS. 1 a to 25 c. - In an exemplary embodiment, the
expandable tubular member 2630 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The
expansion cone 2635 is preferably coupled to the support member 2625 and the slip joint 2640. Theexpansion cone 2635 is further preferably removably coupled to theexpandable tubular member 2630. Theexpansion cone 2635 is preferably adapted to radially expand theexpandable tubular member 2630 when theexpansion cone 2635 is axially displaced relative to theexpandable tubular member 2630. Theexpansion cone 2635 is further preferably adapted to convey fluidic materials to and/or from thechamber 2650. - In an exemplary embodiment, the
expansion cone 2635 is further provided substantially as disclosed in one or more of the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application No. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. - The slip joint 2640 is coupled to the
expansion cone 2635 and theend plate 2645. The slip joint 2640 is preferably adapted to permit theend plate 2645 to be axially displaced relative to theexpansion cone 2635. In this manner, the size of thechamber 2650 is variable. The slip joint 2640 may be any number of conventional commercially available slip joints modified in accordance with the teachings of the present disclosure. - The slip joint 2640 preferably includes an
upper member 2640 a, aresilient member 2640 b, and alower member 2640 c. Theupper member 2640 a is coupled to theexpansion cone 2635 and theresilient member 2640 b. Theupper member 2640 a is movably coupled to thelower member 2640 b. Theupper member 2640 a preferably includes one or morefluid passages 2640 aa that permit the passage of fluidic materials. Thelower member 2640 b is coupled to theend plate 2645 and theresilient member 2640 b. Thelower member 2640 b is movably coupled to theupper member 2640 a. Thelower member 2640 b preferably includes one or morefluid passages 2640 ba that permit the passage of fluidic materials. Theresilient member 2640 c is coupled between the upper and lower members, 2640 a and 2640 b. Theresilient member 2640 c is preferably adapted to apply an upward axial force to theend plate 2645. - The
end plate 2645 is coupled to the slip joint 2640, theslips 2655, and the sealingmembers 2670. Theend plate 2645 is preferably adapted to seal off a portion of the interior of thelower section 2685 of theexpandable tubular member 2630. Theend plate 2645 is further adapted to define, in combination with theexpandable tubular member 2630, and theexpansion cone 2635, thechamber 2650. - The
chamber 2650 is defined by the interior portion of thelower section 2685 of theexpandable tubular member 2630 below theexpansion cone 2635 and above theend plate 2645. In an exemplary embodiment, the pressurization of thechamber 2650 causes theexpansion cone 2635 to be axially displaced and thereby radially expand theexpandable tubular member 2630. Thechamber 2650 is preferably adapted to move upwardly within theexpandable tubular member 2630 as theexpansion cone 2635 andend plate 2645 are axially displaced within theexpandable tubular member 2630. - The
slips 2655 are coupled to theend plate 2645. Theslips 2655 are preferably adapted to permit theend plate 2645 to be displaced in the upward axial direction; but prevent axial displacement of theend plate 2645 in the downward direction. In this manner, thechamber 2650 is pressurized by injecting fluidic materials into thechamber 2650. Because theend plate 2645 is maintained in a substantially stationary position, relative to theexpandable tubular member 2630, during the injection of pressurized fluidic materials into thechamber 2650, the pressurization of thechamber 2650 preferably axially displaces theexpansion cone 2635. In an exemplary embodiment, when the slip joint 2640 is fully extended, the slip joint 2640 then displaces theend plate 2645 in the upward axial direction. In an exemplary embodiment, when the spring force of theelastic member 2640 c of the slip joint 2640 is greater than the fluidic pressurization force within thechamber 2650, theend plate 2645 is displaced in the upward axial direction. - The sealing
members 2670 are coupled to theend plate 2645. The sealingmembers 2670 are further preferably sealingly coupled to the interior walls of theexpandable tubular member 2630. In this manner, thechamber 2650 is optimally pressurized during operation of theapparatus 2620. - The
upper sealing member 2675 is preferably coupled to the outside surface of theupper section 2695 of theexpandable tubular member 2630. Theupper sealing member 2675 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2695 of theexpandable tubular member 2630 and thewellbore casing 2600. Theupper sealing member 2675 may be any number of conventional commercially available sealing members. In an exemplary embodiment, theupper sealing member 2675 is viton rubber in order to optimally provide load carrying and pressure sealing capacity. - The
lower sealing member 2680 is preferably coupled to the outside surface of theupper section 2695 of theexpandable tubular member 2630. Thelower sealing member 2680 is preferably adapted to fluidicly seal the interface between the radially expandedupper section 2695 of theexpandable tubular member 2630 and the openhole wellbore section 2605. Thelower sealing member 2680 may be any number of conventional commercially available sealing members. In an exemplary embodiment, thelower sealing member 2680 is viton rubber in order to optimally provide load carrying and pressure sealing capacity. - As illustrated in
FIG. 26 a, theapparatus 2620 is preferably positioned within thewellbore casing 2600 and the openhole wellbore section 2605 with theexpandable tubular member 2630 positioned in overlapping relation to thewellbore casing 2600. In an exemplary embodiment, thelower section 2685 of theexpandable tubular member 2630 is then anchored to the openhole wellbore section 2605 using one or more of the apparatus and methods described above with reference toFIGS. 1 a to 25 c. - As illustrated in
FIG. 26 b, the radial expansion of theexpandable tubular member 2630 is then initiated by: (1) applying an upward axial force to theexpansion cone 2635; and/or (2) pressurizing thechamber 2650 by injecting a pressurized fluidic material into thechamber 2650. - In an exemplary embodiment, the
expandable tubular member 2630 is radially expanded by applying an upward axial force to theexpansion cone 2635. In an exemplary embodiment, once the slip joint 2640 is fully extended, theend plate 2645 is then axially displaced in the upward direction. In this manner, theend plate 2645 follows theexpansion cone 2635. In an exemplary embodiment, thechamber 2650 is pressurized when the frictional forces exceed a predetermined value. In this manner, the axial displacement of theexpansion cone 2635 is provided by applying an axial force that is selectively supplemented by pressurizing thechamber 2650. - In an alternative embodiment, a compressible cement and/or epoxy is injected into the annular space between the unexpanded portion of the
tubular member 2630 and thewellbore casing 2600 before and/or during the extrusion process. The compressible cement and/or epoxy is then preferably permitted to at least partially cure prior to the initiation of the radial expansion process. In this manner, an annular structural support and fluidic seal is provided around thetubular member 2630. - As illustrated in
FIG. 26 c, in an exemplary embodiment, after theexpandable tubular member 2630 has been completely extruded off of theexpansion cone 2635, a new section of wellbore casing is formed that preferably includes the radially expandedtubular member 2630 and an outer annular layer of a fluidic sealing material. More generally, theapparatus 2620 is used to repair or form wellbore casings, pipelines, and structural supports. - Referring initially to
FIG. 27 , anexemplary method 2700 of coupling an expandable tubular member to a preexisting structure includes the steps of: (1) coupling the expandable tubular member to the preexisting structure by axially displacing an expansion cone; and (2) radially expanding the expandable tubular by applying direct radial pressure. - In an exemplary embodiment, as illustrated in
FIG. 28 , instep 2705, anexpandable tubular member 2805 is coupled to apreexisting wellbore casing 2810 positioned within asubterranean formation 2815. In an exemplary embodiment, thewellbore casing 2810 further includes an outerannular layer 2820 of a fluidic sealing material such as, for example, cement. Theexpandable tubular member 2805 may be coupled to the preexistingwellbore casing 2810 using any number of conventional commercially available methods for coupling an expandable tubular member to a preexisting structure such as, for example, pulling an expansion cone through a tubular member, or pushing an expansion cone through a tubular member using a pressurized fluidic material. In an exemplary embodiment, theexpandable tubular member 2805 is coupled to thepreexisting structure 2810 using one or more of the apparatus and methods disclosed in the following: (1) U.S. utility patent application Ser. No. 09/454,139, attorney docket no. 25791.3.02, filed on Dec. 3, 1999, which claimed the benefit of the filing date of U.S. provisional patent application No. 60/111,293, attorney docket no. 25791.3, filed on Dec. 7, 1998; (2) U.S. utility patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/121,702, filed on Feb. 25, 1999; (3) U.S. utility patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/119,611, attorney docket no. 25791.8; (4) U.S. utility patent application Ser. No. 09/440,338, attorney docket no. 25791.9.02, filed on Nov. 15, 1999, which claimed the benefit of the filing date of U.S. provisional application No. 60/108,558, attorney docket no. 25791.9, filed on Nov. 16, 1998; (5) U.S. provisional patent application No. 60/183,546, filed on Feb. 18, 2000; (6) U.S. utility patent application Ser. No. 09/523,460, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/124,042, filed on Mar. 11, 1999; (7) U.S. utility patent application Ser. No. 09/512,895, attorney docket no. 25791.12.02, filed on Feb. 24, 2000, which claimed the benefit of the filing dates of U.S. provisional application No. 60/121,841, attorney docket no. 25791.12, filed on Feb. 26, 1999 and U.S. provisional application No. 60/154,047, attorney docket no. 25791.29, filed on Sep. 16, 1999; (8) U.S. utility application Ser. No. 09/511,941, attorney docket no. 25791.16.02, filed on Feb. 24, 2000, which claimed the benefit of the filing date of U.S. provisional Ser. No. 60/121,907, attorney docket no. 25791.16, filed on Feb. 26, 1999; (9) U.S. utility patent application Ser. No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claimed the benefit of the filing date of U.S. provisional patent application Ser. No. 60/137,998, attorney docket no. 25791.17, filed on Jun. 7, 1999; (10) U.S. utility patent application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claimed the benefit of the filing date of U.S. provisional application No. 60/131,106, attorney docket no. 25791.23, filed on Apr. 26, 1999; (11) U.S. provisional application No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999; (12) U.S. provisional application No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999; (13) U.S. provisional patent application Ser. No. 60/162,671, attorney docket no. 25791.27, filed on Nov. 1, 1999; (14) U.S. provisional application no. 60/159,039, attorney docket no. 25791.36, filed on Oct. 12, 1999; (15) U.S. provisional patent application No. 60/159,033, attorney docket no. 25791.37, filed on Oct. 12, 1999; and (16) U.S. provisional patent application No. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, the disclosures of which are incorporated herein by reference. In an exemplary embodiment, the amount of radial expansion provided instep 105 ranges from about 5% to 20%. - In an exemplary embodiment, as illustrated in
FIG. 29 , instep 2710, at least a portion of theexpandable tubular member 2805 is further radially expanded by using aradial expansion tool 2905 to apply direct radial pressure to theexpandable tubular member 2805. Theradial expansion tool 2905 may be any number of conventional radial expansion tools suitable for applying direct radial pressure to a tubular member. In an exemplary embodiment, theradial expansion tool 2905 is provided substantially as disclosed on one or more of the following U.S. Pat. Nos. 5,014,779 and 5,083,608, the disclosures of which are incorporated herein by reference. In an exemplary embodiment, the amount of radial expansion of theexpandable tubular member 2805 provided instep 2710 ranges up to about 5%. In an exemplary embodiment, the radial contact pressures generated by theradial expansion tool 2905 instep 2710 range from about 5,000 to 140,000 psi. in order to optimally plastically deform theexpandable tubular member 205 to the final desired geometry. - In an exemplary embodiment, the radial expansion provided in
step 2705 is limited to the portion of theexpandable tubular member 2805 that overlaps with the preexistingwellbore casing 2810. In this manner, the high compressive forces typically required to radially expand the portion of theexpandable tubular member 2805 that overlaps with the preexistingwellbore casing 2810 are optimally provided. - In an alternative embodiment, the radial expansion in
step 2705 radially expands theexpandable tubular member 2805 to provide an inside diameter substantially equal to the inside diameter of thepre-existing wellbore casing 2810. In this manner, a mono-diameter wellbore casing is optimally provided. - Thus, the
method 2700 provides a 2-step radial expansion process that utilizes: (1) a relatively quick method of radial expansion for the majority of the radial expansion; and (2) a high contact pressure method for the remaining radial expansion. In several alternative embodiments, themethod 2700 is used to form or repair wellbore casings, pipelines, or structural supports. - The
method 2700 further provides an apparatus and method for coupling an expandable tubular member to a preexisting structure. The expandable tubular is initially coupled to the preexisting structure by axially displacing an expansion cone within the expandable tubular member. The expandable tubular member is then further radially expanded by applying a radial force to the expandable tubular. The apparatus and method have wide application to the formation and repair of wellbore casings, pipelines, and structural supports. The apparatus and method provide an efficient and reliable method for forming and repairing wellbore casings, pipelines, and structural supports. In an exemplary implementation, the initial radial expansion of the expandable tubular member by axially displacing the expansion cone provide from about 5% to 25% of radial expansion, and the subsequent application of direct radial pressure to the expandable tubular member provides an additional radial expansion of up to about 10%. In this manner, the desired final geometry of the radially expanded tubular member is optimally achieved in a time efficient and reliable manner. This method and apparatus is particularly useful in optimally creating profiles and seal geometries for liner tops and for connections between jointed tubulars. - In several alternative embodiments, the tubular members of the various exemplary embodiments may be radially expanded and plastically deformed using, for example, other types of conventional expansion tools such as, for example, conventional roller expansion devices such as, for example, the roller expansion devices commercially available from Weatherford International.
- A method of coupling an expandable tubular member to a preexisting structure has been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member, and lubricating the interface between the expansion cone and the tubular member. In an exemplary embodiment, lubricating the interface between the expansion cone and the tubular member includes: injecting a lubricating fluid into the trailing edge of the interface between the expansion cone and the tubular member. In an exemplary embodiment, the lubricating fluid has a viscosity ranging from about 1 to 10,000 centipoise. In an exemplary embodiment, the injecting includes: injecting lubricating fluid into a tapered end of the expansion cone. In an exemplary embodiment, the injecting includes: injecting lubricating fluid into the area around the axial midpoint of a first tapered end of the expansion cone. In an exemplary embodiment, the injecting includes: injecting lubricating fluid into a second end of the expansion cone. In an exemplary embodiment, the injecting includes: injecting lubricating fluid into a tapered first end and a second end of the expansion cone. In an exemplary embodiment, the injecting includes: injecting lubricating fluid into an interior of the expansion cone. In an exemplary embodiment, the injecting includes: injecting lubricating fluid through an outer surface of the expansion cone. In an exemplary embodiment, the injecting includes: injecting the lubricating fluid into a plurality of discrete locations along the trailing edge portion. In an exemplary embodiment, the lubricating fluid includes drilling mud. In an exemplary embodiment, the lubricating fluid further includes: TorqTrim III, EP Mudlib, and DrillN-Slid. In an exemplary embodiment, the lubricating fluid includes TorqTrim III, EP Mudlib, and Drill-N-Slid. In an exemplary embodiment, the interface between the expansion cone and the tubular member includes: coating the interior surface of the tubular member with a lubricant. In an exemplary embodiment, lubricating the interface between the expansion cone and the tubular member includes: coating the interior surface of the tubular member with a first part of a lubricant, and applying a second part of the lubricant to the interior surface of the tubular member. In an exemplary embodiment, the lubricant includes a metallic soap. In an exemplary embodiment, the lubricant is selected from the group consisting of C-Lube-10, C-PHOS-58-M, and C-PHOS-58-R. In an exemplary embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In an exemplary embodiment, the lubricant is chemically bonded to the interior surfaces of the tubular members. In an exemplary embodiment, the lubricant is mechanically bonded to the interior surfaces of the tubular members. In an exemplary embodiment, the lubricant is adhesively bonded to the interior surface of the tubular members. In an exemplary embodiment, the lubricant includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member. The tubular member preferably includes: an annular member, including: a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%, imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
- A method of coupling a tubular member to a preexisting structure has also been described that includes injecting a lubricating fluid into the preexisting structure, positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member. In an exemplary embodiment, the lubricating fluid includes: BARO-LUB GOLD-SEALJ brand drilling mud lubricant.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and
- Axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a first tubular member, a second tubular member, and a threaded connection for coupling the first tubular member to the second tubular member. In an exemplary embodiment, the threaded connection includes: one or more sealing members for sealing the interface between the first and second tubular members. In an exemplary embodiment, the threaded connection includes a pin and box threaded connection. In an exemplary embodiment, the sealing members are positioned adjacent to an end portion of the threaded connection. In an exemplary embodiment, one of the sealing members is positioned adjacent to an end portion of the threaded connection; and wherein another one of the sealing members is not positioned adjacent to an end portion of the threaded connection. In an exemplary embodiment, a plurality of the sealing members are positioned adjacent to an end portion of the threaded connection.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes a plurality of tubular members having threaded portions that are coupled to one another by the process of: coating the threaded portions of the tubular members with a sealant, coupling the threaded portions of the tubular members, and curing the sealant. In an exemplary embodiment, the sealant is selected from the group consisting of epoxies, thermosetting sealing compounds, curable sealing compounds, and sealing compounds having polymerizable materials. In an exemplary embodiment, the method further includes: initially curing the sealant prior to radially expanding the tubular members, and finally curing the sealant after radially expanding the tubular members. In an exemplary embodiment, the sealant can be stretched up to about 30 to 40 percent after curing without failure. In an exemplary embodiment, the sealant is resistant to conventional wellbore fluidic materials. In an exemplary embodiment, the material properties of the sealant are substantially stable for temperatures ranging from about 0 to 450 EF. In an exemplary embodiment, the method further includes: applying a primer to the threaded portions of the tubular members prior to coating the threaded portions of the tubular members with the sealant. In an exemplary embodiment, the primer includes a curing catalyst. In an exemplary embodiment, the primer is applied to the threaded portion of one of the tubular members and the sealant is applied to the threaded portion of the other one of the tubular members. In an exemplary embodiment, the primer includes a curing catalyst.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, the tubular member includes: a pair of rings for engaging the preexisting structure, and a sealing element positioned between the rings for sealing the interface between the tubular member and the preexisting structure.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, the tubular member includes one or more slots. In an exemplary embodiment, the slots are provided at a preexpanded portion of the tubular member. In an exemplary embodiment, the slots are provided at a non-preexpanded portion of the tubular member.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, the tubular member includes: a first preexpanded portion, an intermediate portion coupled to the first preexpanded portion including a sealing element, and a second preexpanded portion coupled to the intermediate portion.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone within the preexisting structure, anchoring the expandable tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pulling the expansion cone through the expandable tubular member by applying an axial force to the expansion cone. The axial force preferably includes a substantially constant axial force, and an increased axial force. In an exemplary embodiment, the increased axial force is provided on a periodic basis. In an exemplary embodiment, the increased axial force is provided on a random basis. In an exemplary embodiment, the ratio of the increased axial force to the substantially constant axial force ranges from about 5 to 40%.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the expandable tubular member by pushing and pulling the expansion cone through the expandable tubular member. In an exemplary embodiment, pushing the expansion cone includes: injecting a pressurized fluidic material into contact with the expansion cone.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure, axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the expandable tubular member, and injecting a curable fluidic sealing material between the tubular member and the preexisting structure prior to axially displacing the expansion cone.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure by increasing the size of the expansion cone, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member.
- A method of coupling a tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, anchoring the tubular member to the preexisting structure by heating a portion of the tubular member, and axially displacing the expansion cone relative to the tubular member by pulling the expansion cone through the tubular member.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member, an expansion cone, and an anchoring device within the preexisting structure, positioning the anchoring device above the expansion cone, anchoring the expandable tubular member to the preexisting structure using the anchoring device, and axially displacing the expansion cone.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes positioning the tubular member and an expansion cone within the preexisting structure, explosively anchoring the tubular member to the preexisting structure, and axially displacing the expansion cone relative to the tubular member.
- A method of coupling an expandable tubular to a preexisting structure has also been described that includes fixing the position of an expansion cone within the preexisting structure, driving the expandable tubular member onto the expansion cone in a first direction, and axially displacing the expansion cone in a second direction relative to the expandable tubular member. In an exemplary embodiment, the first and second directions are different.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular, an expansion cone, and a resilient anchor within the preexisting structure, releasing the resilient anchor, and axially displacing the expansion cone within the expandable tubular member.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member, an expansion cone, and an anchor into the preexisting structure, anchoring the expandable tubular member to the preexisting structure by: pivoting one or more engagement elements, and axially displacing the expansion cone. In an exemplary embodiment, pivoting the engagement elements includes: actuating the engagement elements. In an exemplary embodiment, pivoting the engagement elements includes: placing a quantity of a fluidic material onto the engagement elements. In an exemplary embodiment, pivoting the engagement elements includes: displacing the expandable tubular member.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member and an expansion cone into the preexisting structure, placing a quantity of a fluidic material onto the expandable tubular member to anchor the expandable tubular member to the preexisting structure, and axially displacing the expansion cone. In an exemplary embodiment, the fluidic material includes a barite plug. In an exemplary embodiment, the fluidic material includes a flex plug.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes positioning the expandable tubular member and an expansion cone into the preexisting structure, anchoring the expandable tubular member to the preexisting structure by injecting a quantity of a hardenable fluidic material into the preexisting structure, at least partially curing the hardenable fluidic sealing material, and
- Axially displacing the expansion cone.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member and an expansion cone within the preexisting structure, and applying an axial force to the expandable tubular member in a downward direction.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member and an expansion cone within the preexisting structure, injecting a quantity of a first fluidic material having a first density into the region of the preexisting structure outside of the expandable tubular member, and injecting a quantity of a second fluidic material having a second density into a portion of the expandable tubular member below the expansion cone. In an exemplary embodiment, the second density is greater than the first density.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member and an expansion cone into the preexisting structure, anchoring the expandable tubular member to the preexisting structure, applying an axial force to the expansion cone, and pressurizing an interior portion of the expandable tubular member below the expansion cone.
- A method of coupling an expandable tubular member to a preexisting structure has also been described that includes placing the expandable tubular member and an expansion cone into the preexisting structure, and applying an axial force to the expandable tubular member.
- An apparatus for coupling a tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member, including: a housing including a tapered first end and a second end, one or more grooves formed in the outer surface of the tapered first end, and one or more axial flow passages fluidicly coupled to the grooves. In an exemplary embodiment, the grooves include circumferential grooves. In an exemplary embodiment, the grooves include spiral grooves. In an exemplary embodiment, the grooves are concentrated around the axial midpoint of the tapered portion of the housing. In an exemplary embodiment, the axial flow passages include axial grooves. In an exemplary embodiment, the axial grooves are spaced apart by at least about 3 inches in the circumferential direction. In an exemplary embodiment, the axial grooves extend from the tapered first end of the body to the grooves. In an exemplary embodiment, the axial grooves extend from the second end of the body to the grooves. In an exemplary embodiment, the axial grooves extend from the tapered first end of the body to the second end of the body. In an exemplary embodiment, the axial flow passages are positioned within the housing of the expansion cone. In an exemplary embodiment, the axial flow passages extend from the tapered first end of the body to the grooves. In an exemplary embodiment, the axial flow passages extend from the tapered first end of the body to the second end of the body. In an exemplary embodiment, the axial flow passages extend from the second end of the body to the grooves. In an exemplary embodiment, one or more of the flow passages include inserts having restricted flow passages. In an exemplary embodiment, one or more of the axial flow passages include filters. In an exemplary embodiment, the cross sectional area of the grooves is greater than the cross sectional area of the axial flow passages. In an exemplary embodiment, the cross-sectional area of the grooves ranges from about 2×10−4 in2 to 5×10−2 in2. In an exemplary embodiment, the cross-sectional area of the axial flow passages ranges from about 2×10−4 in2 to 5×10−2 in2. In an exemplary embodiment, the angle of attack of the first tapered end of the body ranges from about 10 to 30 degrees. In an exemplary embodiment, the grooves are concentrated in a trailing edge portion of the tapered first end. In an exemplary embodiment, the angle of inclination of the axial flow passages relative to the longitudinal axis of the expansion cone is greater than the angle of attack of the first tapered end. In an exemplary embodiment, the grooves include: a flow channel having a first radius of curvature, a first shoulder positioned on one side of the flow channel having a second radius of curvature, and a second shoulder positioned on the other side of the flow channel having a third radius of curvature. In an exemplary embodiment, the first, second and third radii of curvature are substantially equal. In an exemplary embodiment, the axial flow passages include: a flow channel having a first radius of curvature, a first shoulder positioned on one side of the flow channel having a second radius of curvature, and a second shoulder positioned on the other side of the flow channel having a third radius of curvature. In an exemplary embodiment, the first, second and third radii of curvature are substantially equal. In an exemplary embodiment, the second radius of curvature is greater than the third radius of curvature.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: an annular member, having: a wall thickness that varies less than about 8%, a hoop yield strength that varies less than about 10%; imperfections of less than about 8% of the wall thickness, no failure for radial expansions of up to about 30%, and no necking of the walls of the annular member for radial expansions of up to about 25%.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a first tubular member, a second tubular member, and a threaded connection for coupling the first tubular member to the second tubular member. In an exemplary embodiment, the threaded connection includes: one or more sealing members for sealing the interface between the first and second tubular members. In an exemplary embodiment, the threaded connection includes a pin and box threaded connection. In an exemplary embodiment, the sealing members are positioned adjacent to an end portion of the threaded connection. In an exemplary embodiment, one of the sealing members is positioned adjacent to an end portion of the threaded connection, and another one of the sealing members is not positioned adjacent to an end portion of the threaded connection. In an exemplary embodiment, the plurality of the sealing members are positioned adjacent to an end portion of the threaded connection.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a layer of a lubricant coupled to the interior surface of the tubular member. In an exemplary embodiment, the lubricant includes a metallic soap. In an exemplary embodiment, the lubricant is selected from the group consisting of C-Lube-10, C-PHOS-58-M, and C-PHOS-58-R. In an exemplary embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In an exemplary embodiment, the lubricant is chemically bonded to the interior surface of the expandable tubular member. In an exemplary embodiment, the lubricant is mechanically bonded to the interior surface of the expandable tubular member. In an exemplary embodiment, the lubricant is adhesively bonded to the interior surface of the expandable tubular member. In an exemplary embodiment, the lubricant includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a pair of tubular members having threaded portions coupled to one another, and a quantity of a sealant within the threaded portions of the tubular members. In an exemplary embodiment, the sealant is selected from the group consisting of epoxies, thermosetting sealing compounds, curable sealing compounds, and sealing compounds having polymerizable materials. In an exemplary embodiment, the sealant includes an initial cure cycle and a final cure cycle. In an exemplary embodiment, the sealant can be stretched up to about 30 to 40 percent without failure. In an exemplary embodiment, the sealant is resistant to conventional wellbore fluidic materials. In an exemplary embodiment, the material properties of the sealant are substantially stable for temperatures ranging from about 0 to 450 EF. In an exemplary embodiment, the threaded portions of the tubular members include a primer for improving the adhesion of the sealant to the threaded portions.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a pair of rings for engaging the preexisting structure, and a sealing element positioned between the rings for sealing the interface between the tubular member and the preexisting structure.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes one or more slots. In an exemplary embodiment, the slots are provided at a preexpanded portion of the expandable tubular member. In an exemplary embodiment, the slots are provided at a non-preexpanded portion of the tubular member.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, and an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member. In an exemplary embodiment, the expandable tubular member includes: a first preexpanded portion, an intermediate portion coupled to the first preexpanded portion including a sealing element, and a second preexpanded portion coupled to the intermediate portion.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes an expandable tubular member, an anchoring device adapted to couple the expandable tubular member to the preexisting structure, an expansion cone movably coupled to the expandable tubular member and adapted to radially expand the expandable tubular member, and a valveable fluid passage coupled to the anchoring device.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a first support member, a second support member coupled to the first support member, an expansion cone coupled to the first support member, an expandable tubular member coupled to the expansion cone, and an anchoring device coupled to the second support member adapted to couple the expandable tubular member to the preexisting structure. In an exemplary embodiment, the anchoring device is positioned above the expansion cone. In an exemplary embodiment, the outside diameter of the expansion cone is greater than the inside diameter of the expandable tubular member. In an exemplary embodiment, the outside diameter of the expansion cone is approximately equal to the outside diameter of the expandable tubular member.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a first support member, a second support member coupled to the first support member, an expansion cone coupled to the first support member, an expandable tubular member coupled to the expansion cone, and an explosive anchoring device coupled to the second support member adapted to couple the expandable tubular member to the preexisting structure.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member, an expandable expansion cone coupled to the support member, and an expandable tubular member coupled to the expansion cone.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member, an expandable expansion cone coupled to the support member, and an expandable tubular member coupled to the expandable expansion cone. In an exemplary embodiment, the expandable tubular member includes one or more anchoring devices. In an exemplary embodiment, the expandable tubular member includes a slotted end portion.
- An apparatus for coupling an expandable tubular to a preexisting structure has also been described that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone including one or more shape memory metal inserts, and a heater coupled to the support member in opposing relation to the shape memory metal inserts.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member,
- An expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and a resilient anchor coupled to the expandable tubular member. In an exemplary embodiment, the resilient anchor includes a resilient scroll. In an exemplary embodiment, the resilient anchor includes one or more resilient arms. In an exemplary embodiment, the resilient anchor includes: one or more resilient radially oriented elements. In an exemplary embodiment, the resilient anchor is adapted to mate with the expansion cone.
- An expandable tubular member has also been described that includes an expandable tubular body, one or more resilient panels coupled to the expandable tubular body, and a release member releasably coupled to the resilient panels adapted to controllably release the resilient panels.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member,
- An expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and an anchor coupled to the expandable tubular member, including: one or more spikes pivotally coupled to the expandable tubular member for engaging the preexisting structure. In an exemplary embodiment, the apparatus further includes one or more corresponding actuators for pivoting the spikes.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member,
- An expansion cone coupled to the support member, an expandable tubular member coupled to the expandable expansion cone, and an anchor coupled to the expandable tubular member, including: one or more petal baskets pivotally coupled to the expandable tubular member. In an exemplary embodiment, the apparatus further includes one or more corresponding actuators for pivoting the petal baskets.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone, including: a slotted portion provided at one end of the expandable tubular member.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member, an expansion cone, an expandable tubular member coupled to the expansion cone, a coupling device coupled to the support member and an end portion of the expandable tubular member, and a mass coupled to the end portion of the expandable tubular member. In an exemplary embodiment, the weight of the mass is greater than about 50 to 100% of the yield strength of the expandable tubular member.
- An apparatus for coupling an expandable tubular member to a preexisting structure has also been described that includes a support member including a fluid passage, an expansion cone coupled to the support member, an expandable tubular member coupled to the expansion cone, a slip joint coupled to the expansion cone, an end plate coupled to the slip joint, a fluid chamber coupled to the fluid passage, the fluid chamber defined by the interior portion of the expandable tubular member between the expansion cone and the end plate.
- A method of coupling a tubular member to a preexisting structure has been described that includes positioning the tubular member and an expansion cone within the preexisting structure, axially displacing the expansion cone, removing the expansion cone, and applying direct radial pressure to the first tubular member. In an exemplary embodiment, axially displacing the expansion cone includes pressurizing at least a portion of the interior of the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: injecting a fluidic material into the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: applying a tensile force to the expansion cone. In an exemplary embodiment, axially displacing the expansion cone includes: displacing the expansion cone into the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: displacing the expansion cone out of the tubular member. In an exemplary embodiment, axially displacing the expansion cone radially expands the tubular member by about 10% to 20%. In an exemplary embodiment, applying direct radial pressure to the first tubular member radially expands the tubular member by up to about 5%. In an exemplary embodiment, applying direct radial pressure to the tubular member includes applying a radial force at discrete locations. In an exemplary embodiment, the preexisting structure includes a wellbore casing. In an exemplary embodiment, the preexisting structure includes a pipeline. In an exemplary embodiment, the preexisting structure includes a structural support.
- An apparatus also has been described that includes a tubular member coupled to a preexisting structure. The tubular member is coupled to the preexisting structure by the process of: positioning the tubular member and an expansion cone within the preexisting structure, axially displacing the expansion cone, removing the expansion cone, and applying direct radial pressure to the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: pressurizing at least a portion of the interior of the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: injecting a fluidic material into the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: applying a tensile force to the expansion cone. In an exemplary embodiment, axially displacing the expansion cone includes: displacing the expansion cone into the tubular member. In an exemplary embodiment, axially displacing the expansion cone includes: displacing the expansion cone out of the tubular member. In an exemplary embodiment, axially displacing the expansion cone radially expands the tubular member by about 10% to 20%. In an exemplary embodiment, applying direct radial pressure to the tubular member radially expands the tubular member by up to about 5%. In an exemplary embodiment, applying direct radial pressure to the tubular member includes applying a radial force at discrete locations. In an exemplary embodiment, the preexisting structure includes a wellbore casing. In an exemplary embodiment, the preexisting structure includes a pipeline. In an exemplary embodiment, the preexisting structure includes a structural support.
- Although this detailed description has shown and described illustrative embodiments of the invention, this description contemplates a wide range of modifications, changes, and substitutions. In some instances, one may employ some features of the present invention without a corresponding use of the other features. Accordingly, it is appropriate that readers should construe the appended claims broadly, and in a manner consistent with the scope of the invention.
Claims (15)
1. An apparatus, comprising:
a tubular member coupled to a preexisting structure;
wherein the tubular member is coupled to the preexisting structure by the process of:
positioning the tubular member and an expansion device within the preexisting structure;
axially displacing the expansion device relative to the tubular member to radially expand and plastically deform a portion of the tubular member;
removing the expansion device; and
applying direct radial pressure to the interior surface of the radially expanded portion of the tubular member to further radially expand and plastically deform the portion of the tubular member.
2. The apparatus of claim 1 , wherein axially displacing the expansion device includes:
pressurizing at least a portion of the interior of the tubular member.
3. The apparatus of claim 1 , wherein axially displacing the expansion device includes:
injecting a fluidic material into the tubular member.
4. The apparatus of claim 1 , wherein axially displacing the expansion device includes:
applying a tensile force to the expansion cone.
5. The apparatus of claim 1 , wherein axially displacing the expansion device includes:
displacing the expansion device into the tubular member.
6. The apparatus of claim 1 , wherein axially displacing the expansion device includes:
displacing the expansion device out of the tubular member.
7. The apparatus of claim 1 , wherein axially displacing the expansion device radially expands the tubular member by about 10% to 20%.
8. The apparatus of claim 1 , wherein applying direct radial pressure to the tubular member radially expands the tubular member by up to about 5%.
9. The apparatus of claim 1 , wherein applying direct radial pressure to the tubular member includes applying a radial force at discrete spaced apart locations about the inner circumference of the tubular member.
10. The apparatus of claim 1 , wherein the preexisting structure includes a wellbore casing.
11. The apparatus of claim 1 , wherein the preexisting structure includes a pipeline.
12. The apparatus of claim 1 , wherein the preexisting structure includes a structural support.
13. A method of radially expanding and plastically deforming a tubular member, comprising:
positioning an expansion cone within the tubular member;
axially displacing the expansion cone relative to the tubular member to radially expand and plastically deform a portion of the tubular member; and
then applying direct radial pressure at a plurality of circumferentially spaced apart locations on the interior surface of the radially expanded portion of the tubular member to further radially expand and plastically deform the portion of the tubular member.
14. The method of claim 13 , wherein axially displacing the expansion cone radially expands the tubular member by about 10% to 20%.
15. The method of claim 13 , wherein applying direct radial pressure at the plurality of circumferentially spaced apart locations on the interior surface of the radially expanded portion of the tubular member further radially expands the tubular member by up to about 5%.
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US09/510,913 US7357188B1 (en) | 1998-12-07 | 2000-02-23 | Mono-diameter wellbore casing |
US09/511,941 US6575240B1 (en) | 1998-12-07 | 2000-02-24 | System and method for driving pipe |
US09/512,895 US6568471B1 (en) | 1999-02-26 | 2000-02-24 | Liner hanger |
US09/523,468 US6640903B1 (en) | 1998-12-07 | 2000-03-10 | Forming a wellbore casing while simultaneously drilling a wellbore |
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US09/588,946 US6557640B1 (en) | 1998-12-07 | 2000-06-07 | Lubrication and self-cleaning system for expansion mandrel |
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US7357188B1 (en) * | 1998-12-07 | 2008-04-15 | Shell Oil Company | Mono-diameter wellbore casing |
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2001
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- 2001-06-12 WO PCT/US2001/019014 patent/WO2001098623A1/en active IP Right Grant
- 2001-06-12 GB GB0229708A patent/GB2384502B/en not_active Expired - Lifetime
- 2001-06-12 AU AU6981001A patent/AU6981001A/en active Pending
- 2001-06-12 CA CA002407983A patent/CA2407983C/en not_active Expired - Fee Related
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2002
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-
2004
- 2004-09-10 US US10/938,788 patent/US7168499B2/en not_active Expired - Fee Related
- 2004-09-27 US US10/950,749 patent/US7299881B2/en not_active Expired - Fee Related
- 2004-09-27 US US10/950,869 patent/US7246667B2/en not_active Expired - Lifetime
- 2004-09-28 US US10/952,416 patent/US7357190B2/en not_active Expired - Lifetime
- 2004-09-28 US US10/952,288 patent/US7275601B2/en not_active Expired - Lifetime
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2007
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US20130255935A1 (en) * | 2012-03-30 | 2013-10-03 | Halliburton Energy Services, Inc. | Expansion Tool for Non-Cemented Casing-Casing Annulus (CCA) Wellbores |
US20130255967A1 (en) * | 2012-03-30 | 2013-10-03 | Halliburton Energy Services, Inc. | Expansion Tool for Non-Cemented Casing-Casing Annulus (CCA) Wellbores |
US9109437B2 (en) * | 2012-03-30 | 2015-08-18 | Halliburton Energy Services, Inc. | Method of using an expansion tool for non-cemented casing annulus (CCA) wellbores |
US9169721B2 (en) * | 2012-03-30 | 2015-10-27 | Halliburton Energy Services, Inc. | Expansion tool for non-cemented casing-casing annulus (CCA) wellbores |
JP7072922B1 (en) | 2020-12-14 | 2022-05-23 | 大容基功工業株式会社 | Forced re-stretching method of fixed plate in underground hole excavator |
JP2022093803A (en) * | 2020-12-14 | 2022-06-24 | 大容基功工業株式会社 | Forced re-stretching method of fixed plate in underground hole drilling apparatus |
Also Published As
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US20050077051A1 (en) | 2005-04-14 |
US7299881B2 (en) | 2007-11-27 |
NO20026074D0 (en) | 2002-12-18 |
WO2001098623A1 (en) | 2001-12-27 |
US20030121558A1 (en) | 2003-07-03 |
AU6981001A (en) | 2002-01-02 |
US7270188B2 (en) | 2007-09-18 |
US7168499B2 (en) | 2007-01-30 |
US7246667B2 (en) | 2007-07-24 |
US20050045341A1 (en) | 2005-03-03 |
CA2407983A1 (en) | 2001-12-27 |
CA2407983C (en) | 2010-01-12 |
AU2001269810B2 (en) | 2005-04-07 |
US20050081358A1 (en) | 2005-04-21 |
US7357190B2 (en) | 2008-04-15 |
US20050028988A1 (en) | 2005-02-10 |
WO2001098623B1 (en) | 2002-04-04 |
GB2384502A (en) | 2003-07-30 |
US7275601B2 (en) | 2007-10-02 |
NO20026074L (en) | 2002-12-18 |
GB0229708D0 (en) | 2003-01-29 |
US20050039928A1 (en) | 2005-02-24 |
GB2384502B (en) | 2004-10-13 |
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