Apparatus and method for radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool

Abstract

An apparatus and method for radially expanding a wellbore casing using an expansion mandrel and a rotary expansion tool.

1 . An apparatus for radially expanding and plastically deforming a tubular member, comprising: 
 a tubular support member defining a first passage;    a tubular expansion cone defining a second passage coupled to the tubular support member;    a fluid driven motor coupled to the tubular expansion cone comprising an inlet; and    a rotary expansion device coupled to the output shaft of the fluid driven motor;    wherein the first passage is operably coupled to the second passage;    wherein the second passage is operably coupled to the inlet of the fluid driven motor.    
     
     
         2 . An apparatus for radially expanding and plastically deforming a tubular member, comprising: 
 a first expansion device for controllably straining the tubular member; and    a second expansion device coupled to the first expansion device for controllably stressing the tubular member.    
     
     
         3 . The apparatus of  claim 2 , further comprising a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.  
     
     
         4 . A method of radially expanding and plastically deforming a tubular member, comprising: 
 controllably straining the tubular member, and    then controllably stressing the tubular member.    
     
     
         5 . An apparatus for radially expanding and plastically deforming a tubular member, comprising: 
 means for controllably straining the tubular member; and    means for controllably stressing the tubular member after controllably straining the tubular member.    
     
     
         6 . An apparatus for radially expanding and plastically deforming a tubular member, comprising: 
 a first expansion device for radially expanding the tubular member; and    a second expansion device coupled to the first expansion device for further radially expanding the tubular member.    
     
     
         7 . The apparatus of  claim 6 , further comprising a motor coupled to the first expansion device for rotating the second expansion device relative to the first expansion device.  
     
     
         8 . A method of radially expanding and plastically deforming a tubular member, comprising: 
 radially expanding a portion of the tubular member; and    then further radially expanding the portion of the tubular member.    
     
     
         9 . The method of  claim 8 , wherein radially expanding the portion of the tubular member comprises: 
 applying forces to a continuous circumferential portion of the interior surface of the tubular member.    
     
     
         10 . The method of  claim 8 , wherein further radially expanding the portion of the tubular member comprises: 
 applying forces to one or more discrete portions of the interior surface of the tubular member.    
     
     
         11 . A system for radially expanding and plastically deforming a tubular member, comprising: 
 means for radially expanding a portion of the tubular member; and    means for then further radially expanding the portion of the tubular member.    
     
     
         12 . The system of  claim 11 , wherein means for radially expanding the portion of the tubular member comprises: 
 means for applying forces to a continuous circumferential portion of the interior surface of the tubular member.    
     
     
         13 . The system of  claim 11 , wherein means for further radially expanding the portion of the tubular member comprises: 
 means for applying forces to one or more discrete portions of the interior surface of the tubular member.    
     
     
         14 . A method of radially expanding and plastically deforming a tubular member, comprising: 
 controllably stressing the tubular member; and    then controllably straining the tubular member.    
     
     
         15 . An apparatus for radially expanding and plastically deforming a tubular member, comprising: 
 means for controllably stressing the tubular member; and    means for controllably straining the tubular member after controllably stressing the tubular member.