Expandable tubular

Abstract

An expandable tubular member.

1 - 990 . (canceled) 
   
   
       991 . An expandable tubular assembly, comprising:
 a structure defining a passage therein;   an expandable tubular member positioned in the passage; and   one or more of the following:
 means for providing a substantially uniform distance between the expandable tubular member and the structure after radial expansion and plastic deformation of the expandable tubular member in the passage; 
 means for creating a circumferential tensile force in the structure upon radial expansion and plastic deformation of the expandable tubular member in the passage, whereby the circumferential tensile force increases the collapse strength of the combined structure and expandable tubular member; and 
 means positioned between the expandable tubular member and the structure for increasing the collapse strength of the expandable tubular member upon radial expansion and plastic deformation of the expandable tubular member in the passage. 
   
   
   
       992 . The assembly of claim  1 , comprising the means for providing a substantially uniform distance between the expandable tubular member and the structure after radial expansion and plastic deformation of the expandable tubular member in the passage. 
   
   
       993 . The assembly of claim  2  wherein the structure comprises at least one of a wellbore casing and a tubular member. 
   
   
       994 . The assembly of claim  2  wherein the means for providing a substantially uniform distance between the expandable tubular member and the structure after radial expansion and plastic deformation of the expandable tubular member in the passage comprises one or more of the following:
 an interstitial layer comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising aluminum;   an interstitial layer comprising aluminum and zinc;   an interstitial layer comprising a plastic;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising aluminum;   an interstitial layer comprising a material lining an inner surface of the structure;   an interstitial layer comprising a material lining an inner surface of the structure and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material lining an inner surface of the structure and comprising aluminum;   an interstitial layer having multiple layers; and   an interstitial layer having multiple layers comprising respective materials selected from the group consisting of a soft metal having a yield strength which is less than the yield strength of the expandable tubular member, a plastic, a composite material, and combinations thereof.   
   
   
       995 . The assembly of claim  1 , comprising the means for creating a circumferential tensile force in the structure upon radial expansion and plastic deformation of the expandable tubular member in the passage, whereby the circumferential tensile force increases the collapse strength of the combined structure and expandable tubular member. 
   
   
       996 . The assembly of claim  5  wherein the structure comprises at least one of a wellbore casing and a tubular member. 
   
   
       997 . The assembly of claim  5  wherein the means for creating a circumferential tensile force in the structure upon radial expansion and plastic deformation of the expandable tubular member in the passage comprises one or more of the following:
 an interstitial layer comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising aluminum;   an interstitial layer comprising aluminum and zinc;   an interstitial layer comprising a plastic;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising aluminum;   an interstitial layer comprising a material lining an inner surface of the structure;   an interstitial layer comprising a material lining an inner surface of the structure and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material lining an inner surface of the structure and comprising aluminum;   an interstitial layer of varying thickness;   a non uniform interstitial layer;   an interstitial layer having multiple layers; and   an interstitial layer having multiple layers comprising respective materials selected from the group consisting of a soft metal having a yield strength which is less than the yield strength of the expandable tubular member, a plastic, a composite material, and combinations thereof.   
   
   
       998 . The assembly of claim  1 , comprising the means positioned between the expandable tubular member and the structure for increasing the collapse strength of the expandable tubular member upon radial expansion and plastic deformation of the expandable tubular member in the passage. 
   
   
       999 . The assembly of claim  8  wherein the structure comprises at least one of a wellbore casing and a tubular member. 
   
   
       1000 . The assembly of claim  8  wherein the structure is in circumferential tension. 
   
   
       1001 . The assembly of claim  8  wherein the means positioned between the expandable tubular member and the structure for increasing the collapse strength of the expandable tubular member upon radial expansion and plastic deformation of the expandable tubular member in the passage comprises one or more of the following:
 an interstitial layer comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising aluminum;   an interstitial layer comprising aluminum and zinc;   an interstitial layer comprising a plastic;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising aluminum;   an interstitial layer comprising a material lining an inner surface of the structure;   an interstitial layer comprising a material lining an inner surface of the structure and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material lining an inner surface of the structure and comprising aluminum;   an interstitial layer of varying thickness;   a non uniform interstitial layer;   an interstitial layer having multiple layers; and   an interstitial layer having multiple layers comprising respective materials selected from the group consisting of a soft metal having a yield strength which is less than the yield strength of the expandable tubular member, a plastic, a composite material, and combinations thereof.   
   
   
       1002 . A method comprising:
 providing the expandable tubular member;   applying a soft metal having a yield strength which is less than the yield strength of the expandable tubular member to the outer surface of the expandable tubular member;   positioning the expandable tubular member in the preexisting structure; and   radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure.   
   
   
       1003 . The method of claim  12  wherein radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure comprises:
 radially expanding and plastically deforming the expandable tubular member such that the soft metal forms an interstitial layer between the preexisting structure and the expandable tubular member.   
   
   
       1004 . The method of claim  13  wherein selecting a soft metal having a yield strength which is less than the yield strength of the expandable tubular member comprises:
 selecting a soft metal having a yield strength which is less than the yield strength of the expandable tubular member such that, upon radial expansion and plastic deformation, the interstitial layer results in an increased collapse strength of the combined expandable tubular member and the preexisting structure.   
   
   
       1005 . The method of claim  13  further comprising:
 providing a substantially uniform distance between the expandable tubular member and the preexisting structure with the interstitial layer after radial expansion and plastic deformation.   
   
   
       1006 . The method of claim  12  further comprising:
 creating a circumferential tensile force in the preexisting structure resulting in an increased collapse strength of the combined expandable tubular member and the preexisting structure.   
   
   
       1007 . The method of claim  12  further comprising:
 creating a circumferential tensile force in the preexisting structure by radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure.   
   
   
       1008 . The method of claim  12  wherein a tubular assembly comprising the expandable tubular member and the preexisting structure is formed in response to radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure; and
 wherein the tubular assembly has a collapse strength which exceeds a theoretical collapse strength of a tubular member having a thickness equal to the sum of a thickness of the expandable tubular member and a thickness of the preexisting structure.   
   
   
       1009 . A method comprising:
 providing an expandable tubular member;   applying a layer of material to the outer surface of the expandable tubular member;   positioning the expandable tubular member in a preexisting structure;   radially expanding and plastically deforming the expandable tubular member to form a tubular assembly comprising the expandable tubular member and the preexisting structure; and   providing a substantially uniform distance between the expandable tubular member and the preexisting structure with the interstitial layer after radial expansion and plastic deformation;   wherein the collapse strength of the tubular assembly is increased in response to providing a substantially uniform distance between the expandable tubular member and the preexisting structure with the interstitial layer after radial expansion and plastic deformation.   
   
   
       1010 . An expandable tubular assembly, comprising:
 a first tubular member comprising a first tubular member wall thickness and defining a passage;   a second tubular member comprising a second tubular member wall thickness and positioned in the passage; and   means for increasing the collapse strength of the combined first tubular member and the second tubular member upon radial expansion and plastic deformation of the first tubular member in the passage, whereby the increased collapse strength exceeds the theoretically calculated collapse strength of a tubular member having a thickness approximately equal to the sum of the first tubular wall thickness and the second tubular wall thickness.   
   
   
       1011 . The assembly of claim  20  wherein the first tubular member comprises a wellbore casing. 
   
   
       1012 . The assembly of claim  20  wherein the theoretically calculated collapse strength of a tubular member having a thickness approximately equal to the sum of the first tubular wall thickness and the second tubular wall thickness is calculated using API collapse modeling. 
   
   
       1013 . The assembly of claim  20  wherein the means for increasing the collapse strength of the combined first tubular member and the second tubular member upon radial expansion and plastic deformation of the first tubular member in the passage comprises one or more of the following:
 an interstitial layer comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising aluminum;   an interstitial layer comprising aluminum and zinc;   an interstitial layer comprising a plastic;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising aluminum;   an interstitial layer comprising a material lining an inner surface of the structure;   an interstitial layer comprising a material lining an inner surface of the structure and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member;   an interstitial layer comprising a material lining an inner surface of the structure and comprising aluminum;   an interstitial layer of varying thickness;   a non uniform interstitial layer;   an interstitial layer having multiple layers; and   an interstitial layer having multiple layers comprising respective materials selected from the group consisting of a soft metal having a yield strength which is less than the yield strength of the expandable tubular member, a plastic, a composite material, and combinations thereof.   
   
   
       1014 . An expandable tubular assembly, comprising:
 a first tubular member comprising a first tubular member wall thickness and defining a passage;   a second tubular member comprising a second tubular member wall thickness and positioned in the passage; and   means for increasing the collapse strength of the combined first tubular member and the second tubular member upon radial expansion and plastic deformation of the first tubular member in the passage, whereby the increased collapse strength exceeds the theoretically calculated collapse strength of a tubular member having a thickness approximately equal to the sum of the first tubular wall thickness and the second tubular wall thickness;   wherein the first tubular member comprises a wellbore casing;   wherein the theoretically calculated collapse strength of a tubular member having a thickness approximately equal to the sum of the first tubular wall thickness and the second tubular wall thickness is calculated using API collapse modeling; and   wherein the means for increasing the collapse strength of the combined first tubular member and the second tubular member upon radial expansion and plastic deformation of the first tubular member in the passage comprises one or more of the following:
 an interstitial layer comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member; 
 an interstitial layer comprising aluminum; 
 an interstitial layer comprising aluminum and zinc; 
 an interstitial layer comprising a plastic; 
 an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member; 
 an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member; 
 an interstitial layer comprising a material wrapped around an outer surface of the expandable tubular member and comprising aluminum; 
 an interstitial layer comprising a material lining an inner surface of the structure; 
 an interstitial layer comprising a material lining an inner surface of the structure and comprising a soft metal having a yield strength which is less than the yield strength of the expandable tubular member; 
 an interstitial layer comprising a material lining an inner surface of the structure and comprising aluminum; 
 an interstitial layer of varying thickness; 
 a non uniform interstitial layer; 
 an interstitial layer having multiple layers; and 
 an interstitial layer having multiple layers comprising respective materials selected from the group consisting of a soft metal having a yield strength which is less than the yield strength of the expandable tubular member, a plastic, a composite material, and combinations thereof. 
   
   
   
       1015 . A method comprising:
 providing the expandable tubular member;   applying a soft metal having a yield strength which is less than the yield strength of the expandable tubular member to the outer surface of the expandable tubular member;   positioning the expandable tubular member in the preexisting structure; and   radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure;   wherein radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure comprises radially expanding and plastically deforming the expandable tubular member such that the soft metal forms an interstitial layer between the preexisting structure and the expandable tubular member;   wherein the method further comprises:
 providing a substantially uniform distance between the expandable tubular member and the preexisting structure with the interstitial layer after radial expansion and plastic deformation; and 
 creating a circumferential tensile force in the preexisting structure by radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure; 
   wherein a tubular assembly comprising the expandable tubular member and the preexisting structure is formed in response to radially expanding and plastically deforming the expandable tubular member such that the soft metal engages the preexisting structure; and   wherein the tubular assembly has a collapse strength which exceeds a theoretical collapse strength of a tubular member having a thickness equal to the sum of a thickness of the expandable tubular member and a thickness of the preexisting structure.