# US 7,610,667 B2 · Method of connecting expandable tubulars > Agents: this data is available as JSON from the patentgrep API and MCP server — see https://patentgrep.com/llms.txt - Number: US 7,610,667 B2 - Document ID: US7610667B2 - Status: Granted - Kind: B2 - Application number: 11/339,202 - Filed: 2006-01-25 - Published: 2006-06-22 - Granted: 2009-11-03 - Earliest claimed: 2002-06-10 - Assignees: Weatherford/Lamb, Inc. - Inventors: Ghazi J. Hashem - Web page: https://patentgrep.com/patent/US7610667B2 ## CPC - E21B 43/106: {Couplings or joints therefor} - C23C 16/0218: {in a reactive atmosphere (C23C16/0227 takes precedence)} - C23C 16/40: Oxides - C23C 16/401: {containing silicon} - C23C 16/405: {of refractory metals or yttrium} - C23C 16/4405: {Cleaning of reactor or parts inside the reactor by using reactive gases} - C23C 16/56: After-treatment - E21B 43/103: {of expandable casings, screens, liners, or the like} - E21B 43/105: {Expanding tools specially adapted therefor} - F16L 15/006: {with straight threads} - F16L 2201/00: Special arrangements for pipe couplings - Y10T 29/49911: by expanding inner annulus - E21B: EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS - C23C: COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL (making metal-coated products by extrusion B21C23/22; covering with metal by connecting pre-existing layers to articles, see the relevant places, e.g. B21D39/00, B23K; metallising of glass C03C; metallising mortars, concrete, artificial stone, ceramics or natural stone C04B41/00; enamelling of, or applying a vitreous layer to, metals C23D; treating metal surfaces or coating of metals by electrolysis or electrophoresis C25D; single-crystal film growth C30B; by metallising textiles D06M11/83; decorating textiles by locally metallising D06Q1/04) - F16L: PIPES; JOINTS OR FITTINGS FOR PIPES; SUPPORTS FOR PIPES, CABLES OR PROTECTIVE TUBING; MEANS FOR THERMAL INSULATION IN GENERAL - Y10T: TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION ## Abstract A method and apparatus for providing an expandable threaded connection between segments of expandable tubulars. Threaded connections are machined into pre-expanded ends of tubulars. Once the threaded connections are machined into the pre-expanded ends, two joints of tubulars are connected using the threads, thus creating a pre-expanded threaded connection. After a tubular string is made up and lowered into a wellbore, the entire length of the string is expanded using known methods for expanding tubulars. During the downhole expansion operation, the pre-expanded threaded connections experience minimal expansion. The minimal downhole expansion of the pre-expanded threaded connections allows the threaded connections to maintain their sealing ability and coupling strength. ## Claims ### Claim 1 A method of connecting expandable tubulars comprising: expanding an end of a first tubular segment; expanding an end of a second tubular segment; creating a pin member with interengageable thread means on said expanded end of said first tubular segment; creating a box member with interengageable thread means in said expanded end of said second tubular segment, whereby said interengageable thread means of said box member are suitable for threadedly engaging said pin member of said first tubular segment; inserting said pin member of said first tubular segment into said box member of said second tubular segment; and connecting said first tubular segment and said second tubular segment together, wherein a diameter of the ends of the first and second tubular segments is selected such that the ends of the first and second tubular segments, including the thread means of the first and second tubular segments, are expanded less than the first and second tubular segments after the expandable tubulars are inserted downhole. ### Claim 2 (depends on 1) The method of claim 1, further comprising: expanding the end of the first tubular segment by inserting an expansion tool into the end of the first tubular segment to a predetermined length; expanding the end of the second tubular segment by inserting an expansion tool into the end of the second tubular segment to a predetermined length. ### Claim 3 (depends on 1) The method of claim 1, further comprising: expanding the end of the first tubular segment by axially forcing an expansion mandrel with a pilot section into the end of the first tubular segment to a predetermined length; expanding the end of the second tubular segment by axially forcing an expansion mandrel with a pilot section into the end of the second tubular segment to a predetermined length. ### Claim 4 (depends on 1) The method of claim 1, further comprising: expanding the end of the first tubular segment through the use of a rotary expansion tool; expanding the end of the second tubular segment through the use of a rotary expansion tool. ### Claim 5 (depends on 1) The method of claim 1 further comprising stress relieving the expanded ends of the first tubular segment and the second tubular segment. ### Claim 6 (depends on 1) The method of claim 1 further comprising heat treating the ends of the first tubular segment and the second tubular segment. ### Claim 7 (depends on 1) The method of claim 1 further comprising heat treating the entire length of the first tubular segment and the second tubular segment. ### Claim 8 (depends on 1) The method of claim 1 further comprising surrounding the point of connection of the expandable tubulars with a sealing material. ### Claim 9 A method of connecting expandable tubulars comprising: expanding an end of a first tubular segment; expanding an end of a second tubular segment; creating a pin member with interengageable threads on the expanded end of the first tubular segment; creating a box member with interengageable threads on the expanded end of the second tubular segment; connecting the first tubular segment to the second tubular segment; and expanding downhole the entire first tubular segment and the entire second tubular segment. ### Claim 10 (depends on 9) The method of claim 9 wherein the amount the ends of the first and second tubular segments are expanded downhole is less than the amount the remainders of the first and second tubular segments are expanded downhole. ### Claim 11 (depends on 9) The method of claim 9 wherein the outer diameter of the expanded ends of the first and second tubular segments are expanded downhole approximately 2%. ### Claim 12 (depends on 11) The method of claim 11 wherein the outer diameter of the remainder of the first tubular segment and the remainder of the second tubular segment is expanded downhole approximately 15% to 25%. ### Claim 13 (depends on 9) The method of claim 9 further comprising expanding the end of the first tubular segment by inserting an expansion tool into the end of the first tubular segment to a predetermined length and expanding the end of the second tubular segment by inserting an expansion tool into the end of the second tubular segment to a predetermined length. ### Claim 14 (depends on 9) The method of claim 9 further comprising expanding the end of the first tubular segment by axially forcing an expansion mandrel with a pilot section into the end of the first tubular segment to a predetermined length and expanding the end of the second tubular segment by axially forcing an expansion mandrel with a pilot section into the end of the second tubular segment to a predetermined length. ### Claim 15 (depends on 9) The method of claim 9 further comprising expanding the end of the first tubular segment through the use of a rotary expansion tool and expanding the end of the second tubular segment through the use of a rotary expansion tool. ### Claim 16 (depends on 9) The method of claim 9 further comprising stress relieving the expanded ends of the first tubular segment and the second tubular segment. ### Claim 17 (depends on 9) The method of claim 9 further comprising heat treating the ends of the first tubular segment and the second tubular segment. ### Claim 18 (depends on 9) The method of claim 9 further comprising heat treating the entire length of the first tubular segment and the second tubular segment. ### Claim 19 (depends on 9) The method of claim 9 further, wherein the step of expanding the end of the first tubular segment further comprises the step of forging the first tubular segment with the end of the first tubular segment having an outside diameter larger than an outside diameter of the remainder of the first tubular segment and, wherein the step of expanding an end of the second tubular segment further comprises the step of forging the second tubular segment with the end of the second tubular segment having an outside diameters larger than an outside diameter of the remainder of the second tubular segment. ### Claim 20 (depends on 9) The method of claim 9 further comprising surrounding a point of connection of the expandable tubular segments with a sealing material. ### Claim 21 (depends on 9) The method of claim 9 wherein the entire first and second tubular segments are expanded downhole until the first and second tubular segments contact an inside wall of a host string. ### Claim 22 (depends on 21) The method of claim 21 wherein the outer diameter of the expanded end of the first tubular segment and the expanded end of the second tubular segment is expanded downhole approximately 2%. ### Claim 23 (depends on 22) The method of claim 22 wherein the outer diameter of the remainder of the first tubular segment and the remainder of the second tubular segment is expanded downhole approximately 15% to 25%.