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.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS  
       [0001]     This application claims the benefit of the filing dates of: 1) U.S. provisional patent application Ser. No. 60/499,576, attorney docket number 25791.215, filed on Sep. 2, 2003, the disclosure of which is incorporated herein by reference.  
         [0002]     The present application is related to the following: (1) U.S. Pat. No. 6,497,289, which was filed as U.S. patent application Ser. No. 09/454,139, attorney docket no. 25791.03.02, filed on Dec. 3, 1999, which claims priority from provisional application 60/111,293, filed on Dec. 7, 1998, (2) U.S. patent application Ser. No. 09/510,913, attorney docket no. 25791.7.02, filed on Feb. 23, 2000, which claims priority from provisional application 60/121,702, filed on Feb. 25, 1999, (3) U.S. patent application Ser. No. 09/502,350, attorney docket no. 25791.8.02, filed on Feb. 10, 2000, which claims priority from provisional application 60/119,611, filed on Feb. /11, 1999, (4) U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (5) U.S. patent application Ser. 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No. 09/588,946, attorney docket no. 25791.17.02, filed on Jun. 7, 2000, which claims priority from provisional application 60/137,998, filed on Jun. 7, 1999, (10) U.S. patent application Ser. No. 09/981,916, attorney docket no. 25791.18, filed on Oct. 18, 2001 as a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (11) U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02 filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on-4/26/99, (12) U.S. patent application Ser. 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No. 10/303,992, filed on Nov. 22, 2002, attorney docket no. 25791.38.07, which claims priority from provisional patent application serial no. 60/212,359, attorney docket no. 25791.38, filed on Jun. 19, 2000, (21) U.S. provisional patent application serial no. 60/165,228, attorney docket no. 25791.39, filed on Nov. 12, 1999, (22) U.S. provisional patent application serial no. 60/455,051, attorney docket no. 25791.40, filed on Mar. 14, 2003, (23) PCT application US02/2477, filed on Jun. 26, 2002, attorney docket no. 25791.44.02, which claims priority from U.S. provisional patent application serial no. 60/303,711, attorney docket no. 25791.44, filed on Jul. 6, 2001, (24) U.S. patent application Ser. No. 10/311,412, filed on Dec. 12, 2002, attorney docket no. 25791.45.07, which claims priority from provisional patent application serial no. 60/221,443, attorney docket no. 25791.45, filed on Jul. 28, 2000, (25) U.S. patent application Ser. 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No. 60/451,152, attorney docket no. 25791.239, filed on Mar. 9, 2003, (108) U.S. provisional patent application Ser. No. 60/455,124, attorney docket no. 25791.241, filed on Mar. 17, 2003, (109) U.S. provisional patent application Ser. No. 60/453,678, attorney docket no. 25791.253, filed on Mar. 11, 2003, (110) U.S. patent application Ser. No. 10/421,682, attorney docket no. 25791.256, filed on Apr. 23, 2003, which is a continuation of U.S. patent application Ser. No. 09/523,468, attorney docket no. 25791.11.02, filed on Mar. 10, 2000, which claims priority from provisional application 60/124,042, filed on Mar. 11, 1999, (111) U.S. provisional patent application Ser. No. 60/457,965, attorney docket no. 25791.260, filed on Mar. 27, 2003, (112) U.S. provisional patent application Ser. No. 60/455,718, attorney docket no. 25791.262, filed on Mar. 18, 2003, (113) U.S. Pat. No. 6,550,821, which was filed as patent application Ser. No. 09/811,734, filed on Mar. 19, 2001, (114) U.S. patent application Ser. No. 10/436,467, attorney docket no. 25791.268, filed on May 12, 2003, which is a continuation of U.S. Pat. No. 6,604,763, which was filed as application Ser. No. 09/559,122, attorney docket no. 25791.23.02, filed on Apr. 26, 2000, which claims priority from provisional application 60/131,106, filed on Apr. 26, 1999, (115) U.S. provisional patent application Ser. No. 60/459,776, attorney docket no. 25791.270, filed on Apr. 2, 2003, (116) U.S. provisional patent application Ser. No. 60/461,094, attorney docket no. 25791.272, filed on Apr. 8, 2003, (117) U.S. provisional patent application Ser. No. 60/461,038, attorney docket no. 25791.273, filed on Apr. 7, 2003, (118) U.S. provisional patent application Ser. No. 60/463,586, attorney docket no. 25791.277, filed on Apr. 17, 2003, (119) U.S. provisional patent application Ser. No. 60/472,240, attorney docket no. 25791.286, filed on May 20, 2003, (120) U.S. patent application Ser. No. 10/619,285, attorney docket no. 25791.292, filed on Jul. 14, 2003, which is a continuation-in-part of U.S. utility patent application Ser. No. 09/969,922, attorney docket no. 25791.69, filed on Oct. 3, 2001, which is a continuation-in-part application of U.S. Pat. No. 6,328,113, which was filed as U.S. patent application Ser. No. 09/440,338, attorney docket number 25791.9.02, filed on Nov. 15, 1999, which claims priority from provisional application 60/108,558, filed on Nov. 16, 1998, (121) U.S. provisional patent application Ser. No. 60/472,240, attorney docket no. 25791.286, filed on May 20, 2003. The disclosures of all of which (01-121) are herein incorporated by reference in their entirety. 
     
    
     FIELD OF THE INVENTION  
       [0003]     This invention relates to expandable tubular members, and in particular to a method of expanding tubular members.  
       BACKGROUND  
       [0004]     Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of a smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in a downward direction. Cement annuli may be provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.  
         [0005]     In order to avoid the nested arrangement of casing as discussed above, wellbore casings may be formed in the wellbore by radially expanding and plastically deforming tubular members in the borehole. These tubular members are often coupled to one another by threaded connections. The threaded engagement between properly secured tubular members in a conventional casing joint is effective in maintaining a secure mechanical connection that holds the string together and effectively seals the internal casing area from the formation wellbore environment. When the casing string and connection are enlarged radially, a conventional connection changes dimensionally in a way that can prevent the engaged components of the connection from properly engaging and sealing. The radial expansion of a conventional connection may weaken or otherwise damage the connection sufficiently to permit mechanical separation or leakage in the connection.  
         [0006]     Furthermore, if a first tubular member is connected to a second tubular member, and then radially expanded and plastically deformed while the connection between the first tubular member and the second tubular member is in compression, the connection may fall during and/or after the radial expansion and plastic deformation.  
         [0007]     What is needed is a new method and apparatus to expand a tubular connection.  
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0008]      FIG. 1  is a sectional view through a borehole illustrating a string of casing run in a borehole prior to being radially expanded and plastically deformed.  
         [0009]      FIG. 2  is a sectional view through a borehole illustrating a string of casing that has been partially radially expanded and plastically deformed.  
         [0010]      FIG. 3  is a sectional view through a borehole illustrating a string of casing that has been radially expanded and plastically deformed.  
         [0011]      FIG. 4  is a sectional view through a borehole illustrating a string of casing being radially expanded and plastically deformed with an expansion device.  
         [0012]      FIG. 5  is a sectional view through a borehole illustrating a partially expanded string of casing and an expandable expansion device.  
         [0013]      FIG. 6  is a sectional view through a borehole illustrating a string of casing being radially expanded and plastically deformed with two expansion devices. 
     
    
     DETAILED DESCRIPTION  
       [0014]     Referring to  FIG. 1 , there is illustrated a subterranean formation  8 , and a borehole  10  positioned in the subterranean formation. As a first step, a string of casing  12  is positioned within the borehole  10 . The string of casing  12  includes a first tubular member  14  and a second tubular member  16 . The first tubular member  14  and the second tubular member  16  are connected by a conventional mechanical connection  18 , for example a conventional threaded connection.  
         [0015]     Referring to  FIG. 2 , a second step is illustrated where a portion of the first tubular member  14  above the connection  18  has been radially expanded and plastically deformed into engagement with the borehole  10 , and a portion of the second tubular member  16  below the connection  18  has been radially expanded and plastically deformed into engagement with the borehole  10 . The connection  18  has not been radially expanded and plastically deformed.  
         [0016]     The connection  18  is shown in tension. The first tubular member  14  is exerting a force on the connection  18  in the direction of an arrow  20 . The second tubular member  16  is exerting a force on the connection  18  in the direction of an arrow  22 .  
         [0017]     It is understood that the connection  18  is in tension because as a portion of the first tubular member  14  is expanded and plastically deformed in a radial direction into engagement with the borehole  10 , that portion contracts in an axial direction due to Poisson&#39;s ratio, and exerts a tensional force on the connection. Alternatively, the connection  18  is in tension because as a portion of the second tubular member  16  is expanded and plastically deformed in a radial direction into engagement with the borehole  10 , that portion contracts in an axial direction due to Poisson&#39;s ratio, and exerts a tensional force on the connection. It is understood that both the first tubular member  14  and the second tubular member  16  are held stationary, for example by being expanded into engagement with the borehole  10 , in order for the connection  18  to be in tension. If either the first tubular member  14  or the second tubular member  16  were not held stationary, there would be no tensional force in the connection  18 , because the tubular members would move in the direction of the tensional force to relieve the force.  
         [0018]     Referring to  FIG. 3 , a third step is illustrated where the string of casing  12  has been radially expanded and plastically deformed within the borehole  10 . The first tubular member  14  and the second tubular member  16  were radially expanded and plastically deformed into engagement with the borehole  10 , as shown in  FIG. 2 , and then the connection  18  was radially expanded and plastically deformed, as shown in  FIG. 3 .  
         [0019]     Referring to  FIG. 4 , there is illustrated a first part of a technique of radially expanding and plastically deforming the string of casing  12  of  FIG. 1 . An expansion device  22  is used to radially expand and plastically deform portions of the string of casing  12 .  
         [0020]     It is understood that suitable expansion devices for the expansion device  22  include conventional expansion devices adjustable between a small diameter configuration and a large diameter configuration. It is also understood that when the expansion device  22  is in the small diameter configuration, the expansion device can fit through the unexpanded connection  18 , as shown in  FIGS. 1 and 2 ; and when the expansion device is in the large diameter configuration, the expansion device can expand a portion of the first tubular member  14 , second tubular member  16 , and/or the connection  18 , as shown in  FIGS. 2 and 3 .  
         [0021]     Referring again to  FIG. 4 , a first part of the technique is illustrated where a portion of the second tubular member  16  below the connection  18  is being radially expanded and plastically deformed by the expansion device  22 . The expansion device  22  is shown in the large diameter configuration. The expansion device  22  is mounted to a support number  23 . It is understood that an area  24  under the expansion device  22  may be pressurized to force the expansion device towards the connection  18  and the first tubular member  14 . Alternatively, the expansion device  22  may be pulled by the support member  23  towards the connection  18  and the first tubular member  14 .  
         [0022]     It is understood that the expansion device  22  may be lowered through the string of casing  12  in the small diameter configuration, then the expansion device may be expanded to the large diameter configuration, and used to expand a portion of the second tubular member  16 . Alternatively, the expansion device  22  may start in the large diameter configuration, and the string of casing  12  may be placed over the support number  23 , so that the expansion device is at the bottom of the string of casing, then the expansion device can be pulled through the second tubular member  16  to radially expand and plastically deform the second tubular member.  
         [0023]     Referring to  FIG. 5 , a second part of the technique is illustrated where the expansion device  22  is in a small diameter configure moving through the connection  18 . It is understood that the expansion device  22  may be used to radially expand and plastically deform a portion of the second tubular member  16  while in a large diameter configuration during the first part of the technique as illustrated in  FIG. 4 , then be collapsed into a small diameter configuration and be pulled through the connection  18  by the support number  23 , during the second part of the technique as illustrated in  FIG. 5 .  
         [0024]     It is also understood that after being pulled through the connection  18  and into the first tubular member  14 , the expansion device  22  may be re-expanded into the large diameter configuration and used to radially expand and plastically deform a portion of the first tubular member  14 , during a third part of the technique.  
         [0025]     After a portion of the second tubular member  16  and a portion of the first tubular member  14  have been radially expanded and plastically deformed with the expansion device  22  in the above described manner, the connection  18  may be radially expanded and plastically deformed with the expansion device  22  or with another expansion device (not shown), during a fourth part of the technique.  
         [0026]     Referring to  FIG. 6 , there is illustrated a second technique of radially expanding and plastically deforming the string of casing  12  of  FIG. 1 . A portion of the string of casing  12  is radially expanded and plastically performed with a first expansion device  26  and a second expansion device  28 . The first expansion device  26  is mounted on a support member  34 . The second expansion device  28  is connected to the first expansion device  26  in a conventional manner by a connecting device  30 .  
         [0027]     It is understood that the first expansion device  26  is expandable between a small diameter configuration and a large diameter configuration, while the second expansion device  28  may or may not be expandable between a small diameter configuration and a large diameter configuration.  
         [0028]     In operation, during a first part of the second technique, the first expansion device  26  is used to radially expand and plastically deform a portion of the second tubular member  16  while in a large diameter configuration. During a second part of the second technique, the first expansion device  26  is then retracted into a small diameter configuration and moved through the connection  18 . During a third part of the second technique, the first expansion device  26  is expanded into a large diameter configuration and used to radially expand and plastically deform a portion of the first tubular member  14 , after moving through the connection  18 .  
         [0029]     The second expansion device  28  is pulled by the connecting device  30  behind the first expansion device  26 . It is understood that the second expansion device  28  has a fixed diameter. Alternatively, the second expansion device  28  is movable between a first small diameter configuration and a second large diameter configuration.  
         [0030]     After the first expansion device  26  has radially expanded and plastically deformed a portion of the second tubular member  16  and a portion of the first tubular member  14  during the third part of the second technique, during a fourth part the second expansion device  28  is pulled through the connection  18  by the connecting device  30 , and the second expansion device radially expands and plastically deforms the connection. After moving the first expansion device  26  and the second expansion device  28  through the string of casing  12  (shown in  FIG. 6 ) using the second technique, the string of casing may look like the string of casing  12  as illustrated in  FIG. 3 .  
         [0031]     It is understood that the first expansion device  26  and the second expansion device  28  may be moved through the string of casing  12  by pulling them with the support member  34 . Alternatively, the first expansion device  26  and the second expansion device  28  are moved through the string of casing  12  by pressurizing an area  32  under the second expansion device, which pushes the second expansion device, the connecting device  30 , and the first expansion device.  
         [0032]     In one embodiment, there is disclosed 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 conventional 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 conventional threaded connection. In another embodiment, the 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. In another embodiment, the 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. In another embodiment, the radially expanding and plastically deforming the conventional threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone. In another embodiment, the 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 conventional threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device. In another embodiment, the 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 conventional threaded connection in tension. In another embodiment, the 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. In another embodiment, the 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.  
         [0033]     In one embodiment, there is disclosed 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 conventional 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 radially expanding and plastically deforming the conventional threaded connection with the second expansion device. In another embodiment, the radially expanding and plastically deforming the conventional 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. In another embodiment, the first expansion device is expandable. In another embodiment, the first expansion device includes rotating elements.  
         [0034]     In one embodiment, there is disclosed 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 conventional threaded connection coupling the first tubular member to the second tubular member, and a second conventional 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 conventional 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 conventional threaded connection. In another embodiment, the 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. In another embodiment, the 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. In another embodiment, the 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. In another embodiment, the radially expanding and plastically deforming the first conventional threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone. In another embodiment, the radially expanding and plastically deforming the second conventional threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone. In another embodiment, the 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 conventional threaded connection comprises radially expanding and plastically deforming the connection with a second expansion device. In another embodiment, the 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 conventional threaded connection in tension. In another embodiment, the 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 conventional threaded connection. In another embodiment, the 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. In another embodiment, the 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. In another embodiment, the 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 pre-existing structure and the borehole.  
         [0035]     In one embodiment, there is disclosed an expanded casing in a borehole located in a subterranean formation, comprising a first tubular member, a second tubular member, and a conventional 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 conventional threaded connection. In another embodiment, the 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. In another embodiment, the 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. In another embodiment, the radially expanding and plastically deforming the conventional threaded connection comprises radially expanding and plastically deforming the connection with an expansion cone. In another embodiment, the 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 conventional threaded connection comprises radially expanding and plastically-deforming the connection with a second expansion device. In another embodiment, the 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 conventional threaded connection in tension. In another embodiment, the 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. In another embodiment, 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.  
         [0036]     In one embodiment, there is disclosed 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. In another embodiment, the mechanical coupling comprises a conventional threaded connection. In another embodiment, the conventional threaded connection comprises a pin and a box member.  
         [0037]     In one embodiment, there is disclosed 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. In another embodiment, the mechanical coupling comprises a conventional threaded connection. In another embodiment, the conventional threaded connection comprises a pin and a box member.  
         [0038]     As illustrated in  FIGS. 1-3 , the first tubular member  14 , the second tubular member  16 , and/or the conventional threaded connection  18  were radially expanded and plastically deformed into engagement with the borehole  10 . Alternatively, it is contemplated that there could be a cement annulus, an existing section of casing, a sleeve member, a pre-existing structure, or space left between the first tubular member  14 , the second tubular member  16 , and/or the conventional threaded connection  18  and the borehole  10 .  
         [0039]     As illustrated in  FIG. 2 , the expanded portion of the first tubular member  14  has been radially expanded and plastically deformed into engagement with the borehole  10 . Alternatively, it is contemplated that there could be a cement annulus, an existing section of casing, a sleeve member, a pre-existing structure, or space left between the first tubular member  14  and the borehole  10 .  
         [0040]     As illustrated in  FIG. 2 , the expanded portion of the second tubular member  16  has been radially expanded and plastically deformed into engagement with the borehole  10 . Alternatively, it is contemplated that there could be a cement annulus, an existing section of casing, a sleeve member, a pre-existing structure, or space left between the second tubular member  16  and the borehole  10 .  
         [0041]     Suitable expansion devices for the expansion device  22 , the first expansion device  26 , and/or the second expansion device  28  include conventional expandable expansion devices commercially available from the Assignee of the present invention; Baker Oil Tools of Houston, Tex.; or Weatherford Completion Systems of Houston, Tex.  
         [0042]     Suitable expansion devices for the expansion device  22 , the first expansion device  26 , and/or the second expansion device  28  include expandable expansion devices as disclosed in U.S. Pat. No. 6,578,630 and/or U.S. Pat. No. 6,012,523, the disclosures of which are herein incorporated by reference in their entirety.  
         [0043]     Suitable expansion devices for the expansion device  22 , the first expansion device  26 , and/or the second expansion device  28  include expandable expansion devices as disclosed in one or more of the Related Applications which were referenced and incorporated by reference above.  
         [0044]     Suitable expansion devices for the second expansion device  28  include conventional expansion devices commercially available from the Assignee of the present invention; Baker Oil Tools of Houston, Tex.; or Weatherford Completion Systems of Houston, Tex.  
         [0045]     Suitable expansion devices for the second expansion device  28  include expansion devices as disclosed in one or more of Related Applications which were referenced and incorporated by reference above.  
         [0046]     The connection  18  includes a conventional pin member on the first tubular member  14 , and a conventional box member on the second tubular member  16 , where the pin member and the box member are threadably engaged.  
         [0047]     Suitable connections for the connection  18  include conventional threaded connections, conventional threaded connections with a pin and a box member, conventional welded connections, conventional butt welds, conventional flanges, conventional bolted flanges, or conventional threaded fittings.  
         [0048]     Suitable tubular members for the string of casing  12 , the first tubular member  14 , and/or the second tubular member  16  include conventional tubular members commercially available from the Assignee of the present invention; Baker Oil Tools of Houston, Tex.; or Weatherford Completion Systems of Houston, Tex.  
         [0049]     Suitable tubular members for the string of casing  12 , the first tubular member  14 , and/or the second tubular member  16  include tubular members as disclosed in one or more of the Related Applications which were referenced and incorporated by reference above.  
         [0050]     Although  FIGS. 4-6  show a bottom-up expansion of the second tubular member  16 , then the first tubular member  14 , it is understood that the expansion device  22 , the first expansion device  26 , and/or the second expansion device  28  may be used in a top-down configuration to expand the first tubular member  14 , then the second tubular member  16 .  
         [0051]     In several alternative embodiments, the method of radially expanding and plastically deforming a tubular member as illustrated in  FIGS. 1-6 , may be implemented in accordance with the teachings of one or more of the Related Applications which were referenced and incorporated by reference above.  
         [0052]     Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.