Expansion system

Abstract

An apparatus for the radial expansion and plastic deformation of a tubular member that includes a coating to reduce the frictional forces of expansion.

1 . An expansion device for radially expanding a tubular member comprising: 
 a first outer surface comprising a first angle of attack;    wherein the first outer surface comprises a tungsten disulfide coating.    
   
   
       2 . The expansion device of  claim 1 , further comprising: 
 a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the first angle of attack is greater than the second angle of attack; and    wherein the second outer surface comprises a tungsten disulfide coating.    
   
   
       3 . The expansion device of  claim 1 , further comprising: 
 a rear end coupled to the second outer surface.    
   
   
       4 . The expansion device of  claim 2 , wherein the first angle of attack ranges from about 8 to 20 degrees; and wherein the second angle of attack ranges from about 4 to 15 degrees.  
   
   
       5 . The expansion device of  claim 2 , further comprising one or more intermediate outer surfaces coupled between the first and second outer surfaces; 
 wherein the one or more intermediate outer surfaces comprise a tungsten disulfide coating.    
   
   
       6 . The expansion device of  claim 5 , wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface.  
   
   
       7 . The expansion device of  claim 5 , wherein the angle of attack of the intermediate outer surfaces decreases in steps from the first outer surface to the second outer surface.  
   
   
       8 . The expansion device of  claim 5 , wherein the angle of attack of the outer surfaces is defined by a parabolic equation.  
   
   
       9 . An expansion device for radially expanding a tubular member comprising: 
 a first outer surface comprising a first angle of attack;    wherein the first outer surface comprises a tungsten disulfide coating;    wherein the first angle of attack ranges from about 8 to 20 degrees;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the second outer surface comprises a tungsten disulfide coating;    wherein the second angle of attack ranges from about 4 to 15 degrees;    wherein the first angle of attack is greater than the second angle of attack; and    a rear end coupled to the second outer surface.    
   
   
       10 . An expansion device for radially expanding a tubular member comprising: 
 a first outer surface comprising a first angle of attack;    wherein the first outer surface comprises a tungsten disulfide coating;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the second outer surface comprises a tungsten disulfide coating;    wherein the first angle of attack is greater than the second angle of attack; and    further comprising one or more intermediate outer surfaces coupled between the first and second outer surfaces;    wherein the one or more intermediate outer surfaces comprise a tungsten disulfide coating;    wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface; and    wherein the angle of attack of the outer surfaces is defined by a parabolic equation.    
   
   
       11 . An expandable tubular member for traversing a borehole in a subterranean formation comprising: 
 a tungsten disulfide coating applied to the interior surface of the expandable tubular member.    
   
   
       12 . An expansion system for radially expanding a tubular member comprising: 
 an expansion device comprising a first outer surface comprising a first angle of attack;    wherein at least one of the following surfaces comprises a tungsten disulfide coating: the first outer surface of the expansion device and the interior surface of the expandable tubular member; and    means for displacing the expansion device relative to the expandable tubular member.    
   
   
       13 . The expansion system of  claim 12 , wherein the expansion device further comprises a second outer surface comprising a second angle of attack coupled to the first outer surface; 
 wherein the first angle of attack is greater than the second angle of attack; and    wherein the second outer surface comprises a tungsten disulfide coating.    
   
   
       14 . The expansion device of  claim 12 , wherein the expansion device further comprises a rear end coupled to the second outer surface.  
   
   
       15 . The expansion system of  claim 13 , wherein the first angle of attack ranges from about 8 to 20 degrees; and 
 wherein the second angle of attack ranges from about 4 to 15 degrees.    
   
   
       16 . The expansion system of  claim 13 , wherein the expansion device further comprises one or more intermediate outer surfaces coupled between the first and second outer surfaces; 
 wherein the one or more intermediate outer surfaces comprise a tungsten disulfide coating.    
   
   
       17 . The expansion system of  claim 16 , wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface.  
   
   
       18 . The expansion system of  claim 16 , wherein the angle of attack of the intermediate outer surfaces decreases in steps from the first outer surface to the second outer surface.  
   
   
       19 . The expansion system of  claim 16 , wherein the angle of attack of the outer surfaces is defined by a parabolic equation.  
   
   
       20 . An expansion system for radially expanding a tubular member comprising: 
 an expansion device comprising a first outer surface comprising a first angle of attack;    wherein the first angle of attack ranges from about 8 to 20 degrees;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the second angle of attack ranges from about 4 to 15 degrees;    wherein the first angle of attack is greater than the second angle of attack; and    a rear end coupled to the second outer surface; and    means for displacing the expansion device relative to the expandable tubular member;    wherein at least one of the following surfaces comprises a tungsten disulfide coating: the first and second outer surfaces of the expansion device and the interior surface of the expandable tubular member.    
   
   
       21 . An expansion system for radially expanding a tubular member comprising: 
 an expansion device comprising a first outer surface comprising a first angle of attack;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the first angle of attack is greater than the second angle of attack; and    further comprising one or more intermediate outer surfaces coupled between the first and second outer surfaces;    wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface;    wherein the angle of attack of the outer surfaces is defined by a parabolic equation; and    means for displacing the expansion device in an expandable tubular member;    wherein at least one of the following surfaces comprises a tungsten disulfide coating: the first, second, and intermediate outer surfaces of the expansion device and the interior surface of the expandable tubular member.    
   
   
       22 . A method of expanding an expandable tubular member comprising: 
 radially expanding at least a portion of the tubular member by extruding at least a portion of the tubular member off of an expansion device;    wherein the expansion device comprises a first outer surface comprising a first angle of attack;    wherein a tungsten disulfide coating is applied to at least one of the following surfaces: the interior surface of the expandable tubular member and the first outer surface of the expansion device.    
   
   
       23 . The method of expanding a tubular member according to  claim 22 , wherein the expansion device further comprises: 
 a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the first angle of attack is greater than the second angle of attack; and    wherein a tungsten disulfide coating is applied to at least one of the following surfaces: the interior surface of the expandable tubular member and the first and second outer surfaces of the expansion device.    
   
   
       24 . The method of expanding a tubular member according to  claim 22 , wherein the expansion device further comprises: 
 a rear end coupled to the second outer surface.    
   
   
       25 . The method of expanding a tubular member according to  claim 22 , wherein the first angle of attack ranges from about 8 to 20 degrees; and wherein the second angle of attack ranges from about 4 to 15 degrees.  
   
   
       26 . The method of expanding a tubular member according to  claim 22 , wherein the expansion device further comprises one or more intermediate outer surfaces coupled between the first and second outer surfaces; 
 wherein a tungsten disulfide coating is applied to at least one of the following surfaces: the interior surface of the expandable tubular member and the first, second, and intermediate outer surfaces of the expansion device.    
   
   
       27 . The method of expanding a tubular member according to  claim 22 , wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface.  
   
   
       28 . The method of expanding a tubular member according to  claim 22 , wherein the angle of attack of the intermediate outer surfaces decreases in steps from the first outer surface to the second outer surface.  
   
   
       29 . The method of expanding a tubular member according to  claim 22 , wherein the angle of attack of the outer surfaces is defined by a parabolic equation.  
   
   
       30 . A method of expanding an expandable tubular member comprising: 
 radially expanding at least a portion of the tubular member by extruding at least a portion of the tubular member off of an expansion device;    wherein the expansion device comprises a first outer surface comprising a first angle of attack;    wherein the first angle of attack ranges from about 8 to 20 degrees;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein a tungsten disulfide coating is applied to at least one of the following surfaces: the interior surface of the expandable tubular member and the first and second outer surfaces of the expansion device;    wherein the second angle of attack ranges from about 4 to 15 degrees;    wherein the first angle of attack is greater than the second angle of attack; and    a rear end coupled to the second outer surface.    
   
   
       31 . A method of expanding an expandable tubular member comprising: 
 radially expanding at least a portion of the tubular member by extruding at least a portion of the tubular member off of an expansion device;    wherein the expansion device comprises a first outer surface comprising a first angle of attack;    a second outer surface comprising a second angle of attack coupled to the first outer surface;    wherein the first angle of attack is greater than the second angle of attack; and    further comprising one or more intermediate outer surfaces coupled between the first and second outer surfaces;    wherein a tungsten disulfide coating is applied to at least one of the following surfaces: the interior surface of the expandable tubular member and the first, second, and intermediate outer surfaces of the expansion device;    wherein the angle of attack of the intermediate outer surfaces continually decreases from the first outer surface to the second outer surface; and    wherein the angle of attack of the outer surfaces is defined by a parabolic equation.