Integral Tubular Member and Methods of Manufacturing Same

Abstract

An integral tubular member with at least one integral wear pad is provided. The integral tubular member is formed from a unitary tubular blank having first and second ends and a tube body extending there-between, the tube body being provided with at least one region of a thickened wall to form the at least one wear pad. A method of forming the integral tubular member is provided.

1 - 17 . (canceled) 
     
     
         18 . An integral tubular member formed from a one piece blank, the integral tubular member defining a longitudinal axis along its length, the integral tubular member having a first end, a second end opposite the first end, a first integral connector end adjacent the first end, a second integral connector end adjacent the second end, a tube body located between the first connector end and second connector end,
 the first connector end having a first wall thickness, a first outer diameter, and a first inner diameter, and the second connector end having a second wall thickness, a second outer diameter, and a second inner diameter,   the tube body having a third wall thickness, a third outer diameter, a third inner diameter, and at least one region of locally increased wall thickness forming at least one wear pad,   the at least one wear pad having a fourth wall thickness, a fourth outer diameter, and a fourth inner diameter, the fourth wall thickness being greater than the third wall thickness,   the at least one wear pad having a metallurgical grain structure and grain direction substantially uniform and unaltered from the one piece blank substrate.   
     
     
         19 . The integral tubular member of  claim 18 , wherein the at least one integral wear pad has a fourth wall thickness that is between 50-100% greater than the third wall thickness. 
     
     
         20 . The integral tubular member of  claim 18 , wherein the at least one integral wear pad has a fourth wall thickness that is between 70-80% greater than the third wall thickness. 
     
     
         21 . (canceled) 
     
     
         22 . The integral tubular member of  claim 18 , wherein the ratio of the circumference formed by the third outside diameter to the transverse cross-sectional area formed by the third outside diameter and the third wall thickness is less than or equal to 0.450 in/sq.in. and,
 the ratio of the circumference formed by the fourth outside diameter to the transverse cross-sectional area formed by the fourth outside diameter and the fourth wall thickness is greater than 0.450 in/sq. in.   
     
     
         23 . The integral tubular member of  claim 18 , wherein the third wall thickness is substantially equivalent to a standard drill pipe tube thickness. 
     
     
         24 . The integral tubular member of  claim 18 , wherein the first connector end is provided a first threaded connection and the second connector end is provided a second threaded connection. 
     
     
         25 . The integral tubular member of  claim 24 , wherein the first threaded connection is a box connection. 
     
     
         26 . (canceled) 
     
     
         27 . The integral tubular member of  claim 25 , wherein the second threaded connection is a pin connection. 
     
     
         28 . (canceled) 
     
     
         29 . A method of manufacturing an integral tubular member having at least one wear pad, the method comprising:
 providing a tubular blank having a first end, a second end and a tube body extending between the first and second ends;   forming the at least one wear pad by processing at least one region of the tube body to provide a wall thickness greater than the wall thickness of the tube body.   processing the first and second ends to form, respectively, first and second connectors, the first and second connectors comprising means for connecting the integral tubular member to other tubular members.   
     
     
         30 . The method of  claim 29 , wherein the at least one region is formed with an outer diameter that is equal to or greater than the outer diameter of the tube body. 
     
     
         31 . (canceled) 
     
     
         32 . The method of  claim 29 , wherein the step of forming the at least one wear pad comprises reducing the wall thickness of the tube body in regions adjacent the at least one wear pad. 
     
     
         33 - 39 . (canceled) 
     
     
         40 . The method of  claim 29 , wherein the step of forming the at least one wear pad is performed without redistributing material of the tubular blank. 
     
     
         41 . The method of  claim 29 , wherein step of forming the at least one wear pad is performed without altering the metallurgical grain structure and grain direction of the tubular blank. 
     
     
         42 . A method of manufacturing an integral tubular member having at least one wear pad, comprising the steps of:
 providing a tube having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion;   upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25%-75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25%-75% of the length of the second portion of the tube;   processing the first portion and the second portion of the upset tubular to form integral connector ends; and   processing the central portion of the upset tubular to form a predetermined outer profile, the central portion of the upset tubular being processed to have at least one integral wear pad.   
     
     
         43 - 50 . (canceled) 
     
     
         51 . A method of manufacturing a drilling tubular, comprising the steps of:
 providing a tube having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion being adjacent the first end, the second portion being adjacent the second end and the central portion being positioned between the first portion and the second portion;   upsetting the first portion of the tube and the second portion of the tube to form an upset tubular having an outer wall, a hollow interior, a first end, a second end, a first portion, a central portion and a second portion, the first portion of the upset tubular having a length of between 25%-75% of the length of the first portion of the tube and the second portion of the upset tubular having a length of between 25%-75% of the length of the second portion of the tube;   processing the outer wall of the upset tubular to form a predetermined outer profile;   attaching a tool joint to the first end; and   attaching a tool joint to the second end.   
     
     
         52 . (canceled) 
     
     
         53 . The method of  claim 51 , wherein the predetermined outer profile has at least one integral wear pad. 
     
     
         54 - 58 . (canceled)