Method of radially expanding and plastically deforming tubular members

Abstract

A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member, a second tubular member, and a mechanical coupling for coupling the first tubular member to the second tubular member, the method comprising placing the mechanical coupling in tension; and then radially expanding and plastically deforming the mechanical coupling. It is emphasized that this abstract is provided to comply with the rules requiring an abstract to allow a searcher or other reader to quickly ascertain the subject matter of the technical disclosure; and is submitted with the understanding that it will not be used to interpret or limit the scope or meaning of the claims under 37 CFR 1.72.

1 . A method of creating a casing in a borehole located in a subterranean formation, comprising: 
 installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    radially expanding and plastically deforming at least a portion of the first tubular member;    radially expanding and plastically deforming at least a portion of the second tubular member; and    then radially expanding and plastically deforming the threaded connection;    wherein the radially expanded portion of the first tubular member is not part of the threaded connection; and    wherein the radially expanded portion of the second tubular member is not part of the threaded connection.    
   
   
       2 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       3 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       4 . The method of  claim 1 , wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       5 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with a first expansion device, and wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with a second.  
   
   
       6 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the first tubular member and radially expanding and plastically deforming at least a portion of the second tubular member comprises placing the threaded connection in tension.  
   
   
       7 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       8 . The method of  claim 1 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a preexisting structure and the borehole.  
   
   
       9 . A method of creating a casing in a borehole located in a subterranean formation, comprising: 
 installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    placing a first expansion device and a second expansion device in the casing;    radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member with the first expansion device; and    then radially expanding and plastically deforming the threaded connection with the second expansion device;    wherein the radially expanded portion of the first tubular member is not part of the threaded connection; and    wherein the radially expanded portion of the second tubular member is not part of the threaded connection.    
   
   
       10 . The method of  claim 9 , wherein the radially expanding and plastically deforming the threaded connection is done after radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member.  
   
   
       11 . The method of  claim 9 , wherein the first expansion device is expandable.  
   
   
       12 . The method of  claim 9 , wherein the first expansion device includes rotating elements.  
   
   
       13 . A method of creating a casing in a borehole located in a subterranean formation, comprising: 
 installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a third tubular member, a first threaded connection coupling the first tubular member to the second tubular member, and a second threaded connection coupling the second tubular member to the third tubular member;    radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member;    then radially expanding and plastically deforming the first threaded connection;    radially expanding and plastically deforming at least a portion of the third tubular member; and    then radially expanding and plastically deforming the second threaded connection;    wherein the radially expanded portion of the first tubular member is not part of the first threaded connection;    wherein the radially expanded portion of the second tubular member is not part of the first threaded connection; and    wherein the radially expanded portion of the third tubular member is not part of the second threaded connection.    
   
   
       14 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       15 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       16 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the third tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       17 . The method of  claim 13 , wherein radially expanding and plastically deforming the first threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       18 . The method of  claim 13 , wherein radially expanding and plastically deforming the second threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       19 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with a first expansion device, and wherein radially expanding and plastically deforming the first threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device.  
   
   
       20 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member further comprises placing the first threaded connection in tension.  
   
   
       21 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member further comprises a tensional force on the first threaded connection.  
   
   
       22 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a preexisting structure and the borehole.  
   
   
       23 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       24 . The method of  claim 13 , wherein radially expanding and plastically deforming at least a portion of the third tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a preexisting structure and the borehole.  
   
   
       25 . An expanded casing in a borehole located in a subterranean formation, comprising: 
 a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member, the casing produced by the process of: 
 installing the casing in the borehole;  
 radially expanding and plastically deforming at least a portion of the first tubular member;  
 radially expanding and plastically deforming at least a portion of the second tubular member; and  
 then radially expanding and plastically deforming the threaded connection;  
   wherein the radially expanded portion of the first tubular member is not part of the threaded connection; and    wherein the radially expanded portion of the second tubular member is not part of the threaded connection.    
   
   
       26 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       27 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       28 . The casing of  claim 25 , wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       29 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with a first expansion device, and wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device.  
   
   
       30 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the first tubular member and radially expanding and plastically deforming at least a portion of the second tubular member comprises placing the threaded connection in tension.  
   
   
       31 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       32 . The casing of  claim 25 , wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       33 . A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member, a second tubular member, and a mechanical coupling for coupling the first tubular member to the second tubular member, the method comprising: 
 placing the mechanical coupling in tension; and    then radially expanding and plastically deforming the tubular assembly,    wherein the mechanical coupling is maintained in tension during the radial expansion and plastic deformation of the tubular assembly.    
   
   
       34 . The method of  claim 33 , wherein the mechanical coupling comprises a threaded connection.  
   
   
       35 . The method of  claim 34 , wherein the threaded connection comprises a pin and a box member.  
   
   
       36 . A method of radially expanding and plastically deforming a tubular assembly comprising a first tubular member, a second tubular member, and a mechanical coupling for coupling the first tubular member to the second tubular member, the method comprising: 
 placing the mechanical coupling in tension; and    then radially expanding and plastically deforming the mechanical coupling:    wherein the mechanical coupling is maintained in tension during the radial expansion and plastic deformation of the mechanical coupling.    
   
   
       37 . The method of  claim 36 , wherein the mechanical coupling comprises a threaded connection.  
   
   
       38 . The method of  claim 37 , wherein the threaded connection comprises a pin and a box member.  
   
   
       39 . The method of  claim 36 , wherein the placing comprises engaging at least one out of the first tubular member in the second tubular member with a pre-existing structure.  
   
   
       40 . The method of  claim 39 , wherein the pre-existing structure comprises a borehole.  
   
   
       41 . A system for creating a casing in a borehole located in a subterranean formation, comprising: 
 means for installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    means for radially expanding and plastically deforming at least a portion of the first tubular member;    means for radially expanding and plastically deforming at least a portion of the second tubular member; and    means for then radially expanding and plastically deforming the threaded connection;    wherein the radially expanded portion of the first tubular member is not part of the threaded connection; and    wherein the radially expanded portion of the second tubular member is not part of the threaded connection.    
   
   
       42 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises means for radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       43 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the second tubular member comprises means for radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       44 . The system of  claim 41 , wherein means for radially expanding and plastically deforming the threaded connection comprises means for radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       45 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises means for radially expanding and plastically deforming the portion with a first expansion device, and wherein radially expanding and means for plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device.  
   
   
       46 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member and radially expanding and plastically deforming at least a portion of the second tubular member comprises means for placing the threaded connection in tension.  
   
   
       47 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises means for radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       48 . The system of  claim 41 , wherein means for radially expanding and plastically deforming at least a portion of the second tubular member comprises means for radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       49 . A system for creating a casing in a borehole located in a subterranean formation, comprising: 
 means for installing the casing in the borehole, the casing comprising a first tubular members a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    means for placing a first expansion device and a second expansion device in the casing;    means for radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member with the first expansion device; and    means for then radially expanding and plastically deforming the threaded connection with the second expansion device;    wherein the radially expanded portion of the first tubular member is not part of the threaded connection; and    wherein the radially expanded portion of the second tubular member is not part of the threaded connection.    
   
   
       50 . The system of  claim 49 , wherein the means for radially expanding and plastically deforming the threaded connection is done after means for radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member.  
   
   
       51 . The system of  claim 49 , wherein the first expansion device is expandable.  
   
   
       52 . The system of  claim 49 , wherein the first expansion device includes rotating elements.  
   
   
       53 . A system for creating a casing in a borehole located in a subterranean formation, comprising: 
 means for installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a third tubular member, a first threaded connection coupling the first tubular member to the second tubular member, and a second threaded connection coupling the second tubular member to the third tubular member;    means for radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member, then means for radially expanding and plastically deforming the first threaded connection;    means for radially expanding and plastically deforming at least a portion of the third tubular member; and    then means for radially expanding and plastically deforming the second threaded connection;    wherein the radially expanded portion of the first tubular member is not part of the first threaded connection;    wherein the radially expanded portion of the second tubular member is not part of the first threaded connection; and    wherein the radially expanded portion of the third tubular member is not part of the second threaded connection.    
   
   
       54 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       55 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the second tubular member comprises means for radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       56 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the third tubular member comprises means for radially expanding and plastically deforming the portion with an expandable expansion device.  
   
   
       57 . The system of  claim 53 , wherein means for radially expanding and plastically deforming the first threaded connection comprises means for radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       58 . The system of  claim 53 , wherein means for radially expanding and plastically deforming the second threaded connection comprises means for radially expanding and plastically deforming the connection with an expansion cone.  
   
   
       59 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises means for radially expanding and plastically deforming the portion with a first expansion device, and wherein means for radially expanding and plastically deforming the first threaded connection comprises means for radially expanding and plastically deforming the connection with a second expansion device.  
   
   
       60 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member further comprises means for placing the first threaded connection in tension.  
   
   
       61 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member and at least a portion of the second tubular member further comprises means for applying a tensional force on the first threaded connection.  
   
   
       62 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the first tubular member comprises means for radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       63 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the second tubular member comprises means for radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       64 . The system of  claim 53 , wherein means for radially expanding and plastically deforming at least a portion of the third tubular member comprises means for radially expanding and plastically deforming the portion into engagement with at least one of a pre-existing structure and the borehole.  
   
   
       65 . A system for radially expanding and plastically deforming a tubular assembly comprising a first tubular member, a second tubular member, and a mechanical coupling for coupling the first tubular member to the second tubular member, the method comprising; 
 means for placing the mechanical coupling in tension;    then means for radially expanding and plastically deforming the tubular assembly, and    means for maintaining the mechanical coupling in tension during the radial expansion and plastic deformation of the tubular assembly.    
   
   
       66 . The system of  claim 65 , wherein the mechanical coupling comprises a threaded connection.  
   
   
       67 . The system of  claim 66 , wherein the threaded connection comprises a pin and a box member.  
   
   
       68 . A system for radially expanding and plastically deforming a tubular assembly comprising a first tubular member, a second tubular member, and a mechanical coupling for coupling the first tubular member to the second tubular member, the method comprising: 
 means for placing the mechanical coupling in tension;    then means for radially expanding and plastically deforming the mechanical coupling; and    means for maintaining the mechanical coupling in tension during the radial expansion and plastic deformation of the mechanical coupling.    
   
   
       69 . The system of  claim 68 , wherein the mechanical coupling comprises a threaded connection.  
   
   
       70 . The system of  claim 69 , wherein the threaded connection comprises a pin and a box member.  
   
   
       71 . The system of  claim 68 , wherein the means for placing comprises means for engaging at least one out of the first tubular member in the second tubular member with a pre-existing structure.  
   
   
       72 . The system of  claim 71 , wherein the pre-existing structure comprises a borehole.  
   
   
       73 . An apparatus, comprising: 
 a wellbore that traverses a subterranean formation; and    a wellbore casing positioned within and coupled to the wellbore;    wherein at least a portion of the wellbore casing is in tension; and    wherein the wellbore casing is radially expanded and plastically deformed into connection with a plurality of spaced apart portions of the wellbore.    
   
   
       74 . The apparatus of  claim 73 , wherein an upper portion of the wellbore casing is radially expanded and plastically deformed and coupled to the wellbore; and wherein a lower portion of the wellbore casing, spaced apart from the upper portion, is radially expanded and plastically deformed and coupled to the wellbore.  
   
   
       75 . The apparatus of  claim 74 , wherein an intermediate portion of the wellbore casing, between the upper and lower portions, is not radially expanded and plastically deformed.  
   
   
       76 . The apparatus of  claim 73 , wherein the wellbore casing comprises a plurality of wellbore casings coupled to one another end to end; and wherein one or more of the couplings are in tension.  
   
   
       77 . The apparatus of  claim 76 , wherein one or more of the couplings comprise threaded connections.  
   
   
       78 . A method of creating a casing in a borehole located in a subterranean formation, comprising: 
 installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    radially expanding and plastically deforming at least a portion of the first tubular member;    radially expanding and plastically deforming at least a portion of the second tubular member; and    then radially expanding and plastically deforming the threaded connection;    wherein the radially expanded portion of the first tubular member is spaced apart torn the threaded connection;    wherein the radially expanded portion of the second tubular member is spaced apart from the threaded connection;    wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device;    wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion with an expandable expansion device;    wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone; and    wherein radially expanding and plastically deforming at least a portion of the first tubular member and radially expanding and plastically deforming at least a portion of the second tubular member comprises placing the threaded connection in tension.    
   
   
       79 . The method of  claim 78 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion into engagement with an outer structure; and wherein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion into engagement with the outer structure.  
   
   
       80 . The method of  claim 79 , wherein the outer structure comprises a pre-existing wellbore casing.  
   
   
       81 . A method of creating a casing in a borehole located in a subterranean formation, comprising: 
 installing the casing in the borehole, the casing comprising a first tubular member, a second tubular member, and a threaded connection coupling the first tubular member to the second tubular member;    radially expanding and plastically deforming at least a portion of the first tubular member;    radially expanding and plastically deforming at least a portion of the second tubular member, and then radially expanding and plastically deforming the threaded connection;    wherein the radially expanded portion of the first tubular member is spaced apart from the threaded connection;    wherein the radially expanded portion of the second tubular member is spaced apart from the threaded connection;    wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion with a first expansion device,    wherein radially expanding and plastically deforming the threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device; and    wherein radially expanding and plastically deforming at least a portion of the first tubular member and radially expanding and plastically deforming at least a portion of the second tubular member comprises placing the threaded connection in tension.    
   
   
       82 . The method of  claim 81 , wherein radially expanding and plastically deforming at least a portion of the first tubular member comprises radially expanding and plastically deforming the portion into engagement with an outer structure; and herein radially expanding and plastically deforming at least a portion of the second tubular member comprises radially expanding and plastically deforming the portion into engagement with the outer structure.  
   
   
       83 . The method of  claim 82 , wherein the outer structure comprises a pre-existing wellbore casing.