Method and apparatus for coupling expandable tubular members

Abstract

An expandable tubular coupling apparatus includes a first expandable tubular member, a second expandable tubular member, and means for coupling the first expandable tubular member to the second expandable tubular member.

1 . An expandable tubular member, comprising: 
 a first tubular member comprising a first tubular member diameter which decreases from a first outside diameter along the length of the first tubular member to a second outside diameter adjacent a first tubular member connection end on the first tubular member;    a second tubular member comprising a second tubular member diameter which decreases from a third outside diameter along the length of the second tubular member to a fourth outside diameter adjacent a second tubular member connection end on the second tubular member, whereby the second tubular member connection end is positioned adjacent the first tubular member connection end; and    a connection member coupled to the second outside diameter and the fourth outside diameter, whereby the connection member comprises a connection member diameter which is not substantially greater than the first outside diameter and the third outside diameter.    
   
   
       2 . An expandable tubular member, comprising: 
 a first tubular member comprising an inner surface and an outer surface;    a thread member extending from the inner surface;    an expansion channel defined by the first tubular member and located on the outer surface and adjacent the thread member;    a tubular connection sleeve positioned on the first tubular member;    an expansion slot defined by the tubular connection sleeve in a substantially axial orientation with respect to the tubular connection sleeve and located adjacent the expansion channel; and    a second tubular member coupled the first tubular member and engaging the thread member, whereby upon radial expansion and plastic deformation of the first tubular member and the second tubular member, the first tubular member and the second tubular member can withstand a pressure of up to approximately 4000 pounds per square inch.    
   
   
       3 . An expandable tubular member, comprising: 
 a first tubular member comprising a flange member extending from a surface on the first tubular member, the flange member comprising a resilient beam extending from a distal end of the flange member for forming a seal between the first tubular member and a second tubular member.    
   
   
       4 . An expandable tubular member, comprising: 
 a first tubular member defining a flange channel on a surface of the first tubular member;    a second tubular member comprising a flange member extending from a surface on the second tubular member, the second tubular member coupled to the first tubular member with the flange member positioned in the flange channel, whereby a sealing passageway is defined between the flange member and the flange channel; and    a resilient element for forming a seal between the first tubular member and the second tubular member positioned in the sealing passageway.    
   
   
       5 . An expandable tubular member, comprising: 
 a first tubular member comprising a first connection end;    a second tubular member comprising a second connection end; and    a connection member coupling together the first tubular member and the second tubular member, the connection member comprising:    a tubular connection member comprising an inner surface and an outer surface, the inner surface engaging the first tubular member and the second tubular member;    a primary sealing member having a substantially diamond shaped cross section, extending from a substantially central location on the inner surface, and positioned between the first connection end and the second connection end;    a reinforced section located on the outer surface and adjacent the primary sealing member; and    a plurality of secondary sealing surfaces located on opposite distal ends of the tubular connection member and on opposite sides of the primary sealing member, the secondary sealing surfaces coupled to the first connection end and the second connection end.    
   
   
       6 . An expandable tubular member, comprising: 
 a first tubular member comprising a first connection end;    a second tubular member comprising a second connection end;    a connection member coupled to the first connection end and the second connection end; and    means for providing a primary and secondary metal to metal seal between the connection member and the first tubular member and the second tubular member.    
   
   
       7 . An expandable tubular member, comprising: 
 a first tubular member;    a second tubular member coupled to the first tubular member; and    means for effecting a gas and fluid tight seal between the first tubular member and the second tubular member before, during, and after radial expansion and plastic deformation of the first tubular member and the second tubular member, the means providing a seal which can withstand a pressure of up to 4000 pounds per square inch.    
   
   
       8 . An expandable tubular member, comprising: 
 a first tubular member comprising a first tubular member diameter which decreases from a first outside diameter along the length of the first tubular member to a second outside diameter adjacent a first tubular member connection end on the first tubular member;    a second tubular member comprising a second tubular member diameter which decreases from first outside diameter along the length of the second tubular member to the second outside diameter adjacent a second tubular member connection end on the second tubular member, whereby the second tubular member connection end is coupled to the first tubular member connection end; and    a connection member coupled to the second outside diameter, whereby the connection member comprises a connection member diameter which is less than or equal to the first outside diameter.    
   
   
       9 . An expandable tubular member, comprising: 
 a first tubular member comprising a first connection end;    a second tubular member comprising a second connection end; and    a connection member coupling together the first tubular member and the second tubular member, the connection member comprising:    a tubular connection member comprising an inner surface and an outer surface, the inner surface engaging the first tubular member and the second tubular member;    a primary sealing member having a substantially diamond shaped cross section, extending from a substantially central location on the inner surface, positioned between the first connection end and the second connection end, and deformable to provide a metal to metal seal between the connection member and the first tubular member and the second tubular member;    a reinforced section located on the outer surface and adjacent the primary sealing member; and    a plurality of secondary sealing surfaces located on opposite distal ends of the tubular connection member and on opposite sides of the primary sealing member, the secondary sealing surfaces coupled to the first connection end and the second connection end and deformable to provide a metal to metal seal between the connection member and the first tubular member and the second tubular member.    
   
   
       10 . A connection member for coupling expandable tubular members, comprising: 
 a tubular connection member comprising an inner surface and an outer surface;    a primary sealing member having a substantially diamond shaped cross section and extending from a substantially central location on the inner surface;    a reinforced section located on the outer surface and adjacent the primary sealing member; and    a plurality of secondary sealing surfaces located on opposite distal ends of the tubular connection member and on opposite sides of the primary sealing member.    
   
   
       11 . A connection member for coupling expandable tubular members, comprising: 
 a tubular connection member comprising an inner surface and an outer surface;    a primary sealing member having a substantially diamond shaped cross section, extending from a substantially central location on the inner surface, and deformable to provide a metal to metal seal between the tubular connection member and an expandable tubular member;    a reinforced section located on the outer surface and adjacent the primary sealing member; and    a plurality of secondary sealing surfaces located on opposite distal ends of the tubular connection member on opposite sides of the primary sealing member, and deformable to provide a metal to metal seal between the tubular connection member and an expandable tubular member.    
   
   
       12 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a maximum first tubular member diameter;    providing a second tubular comprising a maximum second tubular member diameter; and    coupling the first tubular member to the second tubular member with a connection member comprising a maximum connection member diameter which is not substantially greater than the maximum first tubular member diameter and the maximum second tubular member diameter.    
   
   
       13 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a flange member extending from an inner surface;    providing a second tubular member defining a flange channel on an outer surface;    positioning a resilient member in the flange channel; and    coupling the first tubular member to the second tubular member by positioning the flange member in the flange channel and adjacent the resilient member.    
   
   
       14 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a first connection end;    providing a second tubular member comprising a second connection end;    positioning a connection member adjacent the first connection end and the second connection end such that a primary sealing member on the connection member is positioned between the first connection end and the second connection end, and a plurality of secondary sealing surfaces are positioned adjacent the first tubular member and the second tubular member; and    coupling the first tubular member to the second tubular member using the connection member.    
   
   
       15 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a maximum first tubular member diameter;    providing a second tubular comprising a maximum second tubular member diameter;    coupling the first tubular member to the second tubular member with a connection member comprising a maximum connection member diameter which is not substantially greater than the maximum first tubular member diameter and the maximum second tubular member diameter;    positioning the first tubular member, the second tubular member, and the connection member in a wellbore; and    radially expanding and plastically deforming the first tubular member and the second tubular member, wherein the radially expanding and plastically deforming comprises one of either radially expanding and plastically deforming a first reduced diameter section on the first tubular member to substantially the maximum first tubular member diameter and radially expanding and plastically deforming a second reduced diameter section on the second tubular member to substantially the maximum second tubular member diameter or radially expanding and plastically deforming the first tubular member and the second tubular member into engagement with the wellbore.    
   
   
       16 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a flange member extending from an inner surface;    providing a second tubular member defining a flange channel on an outer surface;    positioning a resilient member in the flange channel;    coupling the first tubular member to the second tubular member by positioning the flange member in the flange channel and adjacent the resilient member;    positioning the first tubular member and the second tubular member in a wellbore; and    radially expanding and plastically deforming the first tubular member and the second tubular member, whereby the radially expanding and plastically deforming compresses the resilient member and provides a seal between the flange member and the flange channel; whereby the radially expanding and plastically deforming provides a metal to metal seal between the flange member and the flange channel.    
   
   
       17 . A method for coupling expandable tubular members, comprising: 
 providing a first tubular member comprising a first connection end;    providing a second tubular member comprising a second connection end;    positioning a connection member adjacent the first connection end and the second connection end such that a primary sealing member on the connection member is positioned between the first connection end and the second connection end, and a plurality of secondary sealing surfaces are positioned adjacent the first tubular member and the second tubular member;    coupling the first tubular member to the second tubular member using the connection member, whereby the coupling includes providing a metal sealing member between the first tubular member, the second tubular member, and the secondary sealing surfaces;    positioning the first tubular member, the second tubular member, and the connection member in a wellbore; and    radially expanding and plastically deforming the first tubular member and the second tubular member, whereby the radially expanding and plastically deforming provides a primary seal between the primary sealing member and the first tubular member and the second tubular member, and the radially expanding and plastically deforming provides a secondary seal between the secondary sealing surfaces and the first tubular member and the second tubular member.