GB2391575A

GB2391575A - Lubricant coating for expandable tubular members

Info

Publication number: GB2391575A
Application number: GB0325072A
Authority: GB
Inventors: Lev Ring; Andrei Gregory Filippov; Mike Cowan; William J Dean
Original assignee: Enventure Global Technology Inc
Current assignee: Enventure Global Technology Inc
Priority date: 1999-10-12
Filing date: 2000-10-05
Publication date: 2004-02-11
Anticipated expiration: 2020-10-05
Also published as: GB0325071D0; GB0325072D0; GB2391033B; GB2391033A; GB2391575B

Abstract

A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure which comprises ```coating the interior surfaces of the tubular members with a first part of a lubricant; ```positioning the tubular members within a preexisting structure; ```circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant; and ```radially expanding the tubular members into contact with the preexisting structure. An apparatus formed using the above method.

Description

- LUBRICANT COATING FOR EXPANDABLE

TUBULAR MEMBERS

Cross Reference To Related Applications

5 This application claims the benefit of the filing date of: (1) U.S. Provisional Patent Application serial no. 601159,039, attorney docket no. 25791.36, filed on October i2, 19uu; and (A u.3. Firosionai Patent Application serial no. 60ii65,228, affomey docket no. 25791.39, filed on November 12, 1999, the disclosures of which

are incorporated herein by reference.

10 This application is related to the following co-pending applications: l Provisional Patent I Affomey Filing Date Application Number Docket No. I 60/108,558 25791.9 11-16-1998

60/111,293 --1 25791.3 12-7-1998

^ ^. in, ___ 60/119,611 25791.8 2-11 -1999

_ 60/121,702 25791.7 2-25- 1999

_ _ 60/121,841 25791.12 2-26-1999

_.. _ 60/121,907 25791.16 2-26- 1999

_, __.

60/124,042 25791.11 3-11-1999

._ 60/131,106 25791.23 426-1999

_ _ 60/137,998 25791.17 6-7-1 g99 _ 60/143,039 25791.26 7-9-1999

_. _, 60/146,203 25791.25 7-29-1999

_ _ 60/154,047 25791.29 9-16-1999

_ _ 60/159,082 25791.34 10-12-1999

__ 1 60/159,039 25791.36 10-12-1999

. i

f Provisional Patent Attorney Filing Date Application Number Docket No. 60/159,033 25791.37 1121999

60/162,671 25791.27 11-01 -1999

p,,ca.,t3 In=, Jo, ate by r6.'ercn the disclosures of these applicsff^ns.

Background of the Invention

This invention relates generally to wellbore casings, and in particular to wellbore 5 casings that are formed using expandable tubing.

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 forcnation 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 10 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 smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annul) are provided between the outer surfaces of the casings and the borehole wall to 15 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, 20 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. The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbores.

25 Summary of the Invention

According to one aspect of the present invention, an expandable tubular assembly is provided that includes one or more tubular members and a layer of a lubricant coupled to the interior surfaces of the tubular members.

- According to another aspect of the presen invention, a method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure is provided that includes coating the interior surfaces of the tubular members ninth a lubricant, positioning the tubular members within a preexisting structure and 5 radially expanding the tubular members into contact with the preexisting structure.

According to another aspect of the present invention, an apparatus is provided that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a lubricant, 10 positioning the tubular members within a preexisting structure, and radially expanding the tubular members into contact with the preexisting structure.

According to another aspect of the present invention, an expandable tubular assembly is provided that includes one or more tubular members, and a layer of a first part of a lubricant coupled to the interior surfaces of the tubular members.

15 According to another aspect of the present invention, a method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure is provided that includes positioning the expandable tubular assembly into the preexisting structure, injecting a quantity of a lubricant material into contact with the expandable tubular assembly, and radially expanding the expandable tubular assembly 20 into contact with the preexisting structure.

According to another aspect of the present invention, an apparatus is provided that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure, injecting 25 a quantity of a lubricant material into contact with the tubular members, and radially expanding the tubular members into contact with the preexisting structure.

According to another aspect of the present invention, a method of coupling an expandable tubular assembly induding one or more tubular members to a preexisting structure is provided that includes coating the interior surfaces of the tubular members 30 with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant, and radially expanding the tubular members into contact with the preexisting structure.

According to another aspect of the present invention, an apparatus is provided 35 that includes a preexisting structure and one or more tubular members coupled to the

(. - preexisting structure. The tubular members are coupled to the preexisting structure by the process of coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a Acidic.m. ate".a!s having a ceond pad Of th"!ubn.cnt Into Bantam Unth the mating of 5 the first part of the lubricant, and radially expanding the tubular members into contact with the preexisting structure.

Brief Description of the Drawings

Fig. 1 is a flow chart illustrating a preferred embodiment of a method for coupling a plurality of tubular members to a preexisting structure.

10 Fig. 2 is cross sectional illustration of a plurality of tubular members including in internal coating of a lubricant.

Fig. 3 is a fragmentary cross sectional illustration of the radial expansion of the tubular members of Fig. 2 into contact with a preexisting structure.

Fig. 4 is a flow chart illustrating an alternative preferred embodiment of a 15 method for coupling a plurality of tubular members to a preexisting structure.

Detailed Description

A method and apparatus for coupling tubular members to a preexisting stricture is provided. The internal surfaces of the tubular members are coated with a lubricant. The tubular members are then radially expanded into contact with a 20 preexisting structure. In several alternative embodiments, the method and apparatus are used to form and/or repair a wellbore casing, a pipeline, or a structural support.

In Fig. 1, a preferred embodiment of a method 100 for forming and/or repairing a wellbore casing, pipeline, or structural support includes the steps of: (1) providing one or more tubular members in step 105; (2) applying a lubricant coating to the interior 25 walls of the tubular members in step 110; (3) coupling the first and second tubular members in step 115; and (4) radially expanding the tubular members into contact with the preexisting structure in step 120.

As illustrated in Fig. 2, in a preferred embodiment, in step 105, a first tubular member 205 having a first threaded portion 210 and a second tubular member 215 30 having a second threaded portion 220 are provided. The first and second tubular members, 205 and 215, may be any number of conventional commercially available tubular members. In a preferred embodiment, the first tubular member 205 includes a recess 225 containing a sealing member 230 and a retaining ring 235. In a preferred embodiment, the first and second tubular members, 205 and 210, are further provided 35 substantially as disclosed in one or more of the following co-pending applications:

! if_ Provisional Patent Afforney Filing Date I Application Number Docket No. i 60/108558 25791.9 11-16-1998

60/111,293 25791.3 12-7-1998

60/119,611 25791.8 2-11-1999

60/121,702 25791.7 2-25-1999

60/121,841 25791.12 2-26-1999

60/121,907 25791.16 2-26-1999

60/124,042 25791.11 1 3-11-1999

60/131,106 25791.23 4-26- 1999

l 60/137,998 1 25791.17 6-7-1999 60/143,039 25791.26 7-1999

60/146,203 25791.25 7-29-1999

. . _ _

60/154,047 1 25791.29 9-16-1999

60/159,082 25791.34 10-12-1999

_ 60/159,039 25791.36 10-12-1999

60/159,033 25791.37 10-12-1999

60/162,671 25791.27 1 111-1999

Applicants incorporate by reference the disclosures of these applications.

In a preferred embodiment, in step 110, a coating 240 of a lubricant is applied to the interior surfaces of the first and second tubular members, 205 and 215. The 5 coating 240 of lubricant may be applied prior to, or after, the first and second tubular members, 205 and 215, are coupled. The coating 240 of lubricant may be applied using any number of conventional methods such as, for example, dipping, spraying, spuKer coating or electrostatic deposition. In a preferred embodiment, the coating 240

( - of lubricant is chemically, mechanically, and/or adhesively bonded to the interior surfaces of the first and second tubular members, 205 and 215, in order to optimally provide a durable and consistent lubricating effect. In a preferred embodiment, the f! that bonds the!ubncnt tQ the interior surfaces of the first and second tubular 5 members, 205 and 215, is greater than the shear force applied during the radial expansion process.

In a preferred embodiment, the coating 240 of lubricant is applied to the interior surfaces of the first and second tubular members, 205 and 215, by first applying a phenolic primer to the interior surfaces of the first and second tubular members, 205 10 and 215, and then bonding the coating 240 of lubricant to the phenolic primer using an antifriction paste having the coating 240 of lubricant carried in an epoxy resin. In a preferred embodiment, the antitriction paste includes, by weight, 40-80% epoxy resin, 15-30% molybdenum disulfide, 1 0-15% graphite, 5-10% aluminum, 5-10% copper, 8 15% alumisilicate, and 5-10% polyethylenepolyamine. In a preferred embodiment, the 15 anfffriction paste is provided substantially as disclosed in U.S. Patent No. 4,329,238, the disclosure of which is incorporate herein by reference.

The coating 240 of lubricant may be any number of conventional commercially available lubricants such as, for example, metallic soaps or zinc phosphates. In a preferred embodiment, the coating 240 of lubricant is compatible with conventional 20 water, oil and synthetic base mud formulations. In a preferred embodiment, the coating 240 of lubricant reduces metal-to-metal frictional forces, operating pressures, reduces frictional forces by about 50%, and provides a coefficient of dynamic friction of between about 0.08 to 0.1 during the radial expansion process. In a preferred embodiment, the coating 240 of lubricant does not increase the toxicity of conventional base mud 25 fonnulabons and will not sheer in synthetic mud. In a preferred embodiment, the coating 240 of lubricant is stable for temperatures ranging from about -100 to 500 OF.

In a preferred embodiment, the coating 240 of lubricant is stable when exposed to shear stresses. In a preferred embodiment, the coating 240 of lubricant is stable for storage periods of up to about 5 years. In a preferred embodiment, the coating 240 of 30 lubricant provides corrosion protection for expandable tubular members during storage and transport.

In a preferred embodiment, the coating 240 of lubricant indudes sodium, calcium, and/or zinc stearates; and/or zinc and/or manganese phosphates; and/or C Lube-10; and/or C-Phos-58-M; and/or C-Phos-58-R; and/or polytetrafluoroethylene 35 (PTFE); and/or molybdenum disulfide; and/or metallic soaps (stearates, oleates, etc)

in order to optimally provide a coating of lubricant. In a preferred embodiment, the coating 240 of lubricant provides a sliding coefficient of friction less than about 0.20 in order to optimally reduce the force required to radially expand the tubular members, And and 16, Busing In "ypa,ninn cone.

5 In a preferred embodiment, in step 115, the first and second tubular members, 205 and 215, are coupled. The first and second tubular members, 205 and 215, may be coupled using a threaded connection, or altematively, the first and second tubular members, 205 and 215, may be coupled by welding or brazing. In a preferred embodiment, the first and second tubular members, 205 and 215, are coupled 10 substantially as disclosed in provisional patent application serial number 60/159O33, attorney docket number 25791.37, filed on October 12, 1999, the disclosure of which is

incorporated herein by reference.

As illustrated in Fig. 3, in steps 120, the first and second tubular members 205 and 215 are then positioned within a preexisting structure 505, and radially expanded 15 into contact with the interior walls of the preexisting structure 505 using an expansion cone 510. The tubular members 205 and 215 may be radially expanded into intimate contact with the interior walls of the preexisting structure 505, for example, by: (1) pushing or pulling the expansion cone 510 through the interior of the tubular members 205 and 215; and/or (2) pressurizing the region within the tubular members 205 and 20 215 behind the expansion cone 510 with a fluid. In a preferred embodiment, one or more sealing members 515 are further provided on the outer surface of the tubular members 205 and 215, in order to optimally seal the interface between the radially expanded tubular members 205 and 215 and the interior walls of the preexisting structure 505.

25 In a preferred embodiment, the radial expansion of the tubular members 205 and 215 into contact with the interior walls of the preexisting structure 505 is performed substantially as disclosed in one or more of the following co-pending patent applications: U.S. Provisional Patent Attomey Filing l:)ate Application Number Docket No. _ _ 60/108,558 25791. 9 11-16-1998

__ _ 60/111,293 25791.3 12-7-1998

_ _

f' U.S. Provisional Patent Attomey Filing Date Application Number Docket No. 60/11 9,611 25791.8 2-11 -1999

60/121,702 25791.7 2-25-19g9 60/121,841 25791.12 2-26-1999

60/121,907 25791.16 2-26-1999

60/124,042 25791.11 3-11-1999

60/131,106 25791.23 4-26-1999

60/137,998 25791.17 6-7-1999

60/143,039 25791.26 7-9-1999

60/146,203 25791.25 7-29-1999

60/154,047 25791.29 9-1 6-1999

60/159,082 25791.34 1 0-12-1999

60/159,039 25791.36 1 0-12-1999

60/159,033 25791.37 1 0-12-1999

60/162,671 25791.27 11-01-1999

The disclosures of each of the above co pending patent applications are incorporated

by reference.

As illustrated in Fig. 4, an alternate embodiment of a method 400 for forming 5 and/or repairing a wellbore casing, pipeline, or structural support includes the steps of: (1) providing one or more tubular members in step 405; (2) applying a Coating including a first part of a lubricant to the interior walls of the tubular members in step 410; (3) coupling the first and second tubular members in step 415; and (4) radially expanding the tubular members into contact with the preexisting structure while also circulating 10 fluidic materials into contact with the interior walls of the tubular members having a second part of the lubricant in step 420.

In a preferred embodiment, in step 410, a coating including a first part of a lubricant is applied to the interior walls of the tubular members, 205 and 215. In a preferred embodiment, the first part of the lubricant forms a first part of a metallic soap.

In an pre.f=.r."d embodiment, the fleet pa. of the!'hnrnt mating indudes zinc 5 phosphate.

In a preferred embodiment, in step 420, a second part of the lubricant is circulated within a fluidic carrier into contact with the coating of the first part of the lubricant applied to the interior walls of the tubular members, 205 and 215. In a preferred embodiment, the first and second parts react to form a lubricating layer 10 between the interior walls of the tubular members, 205 and 215, and the exterior surface of the expansion cone. In this manner, a lubricating layer is provided in exact concentration, exactly when and where it is needed. Furthermore, because the second part of the lubricant is Circulated in a carrier fluid, the dynamic interface between the interior surfaces of the tubular members, 205 and 215, and the exterior surface of the 15 expansion cone 510 is also preferably provided with hydrodynamic lubrication. In a preferred embodiment, the first and second parts of the lubricant react to form a metallic soap. In a preferred embodiment, the second part of the lubricant is sodium, calcium and/or zinc stearate.

In several experimental exemplary embodiments of the methods 100 and 400, 20 the following observations were made regarding lubricant coatings for expandable tubular members: (1) boundary lubrication with a lubricant coating having high adhesion (high fllm/shear strength) to the expandable tubular is the single-most important lubricanVlubricabon process in the radial expansion process; 25 (2) hydrodynamic lubrication plays a secondary role in the lubrication process; (3) expandable tubular lubricant coating offers Me more reliable and more effective fomm of boundary lubrication; (4) a liquid lubricant viscosity and/or film strength that provides effective, 30 consistent boundary lubrication typically limits the effectiveness of additives for the mud alone to provide the necessary lubrication while maintaining drilling fluid properties (rheology, toxicity); (5) consistent reductions of 20 to 25 percent in propagation force during the radial expansion process (compared to uncoated expandable tubular 35 control results) were obtained with the following dry film coatings: (1)

polytetrafluoroethylene (PTFE), (2) molybdenum disuRide, and (3) metallic soap (stearates), these results are for laboratory tests on one inch dry pipe, in the absence of any drilling fluid; tat a 20 to 25 ne!Ant red'uion in propagation force during the radial 5 expansion process was observed; (7) synthetic oil muds do not typically provide sufficient, reliable lubrication for uncoated pipe; (8) the coefficient of friction for expandable tubular lubricant coatings remains essentially constant across a wide temperature range; 10 (9) the expected application range for expandable tubular casing expansion is between 40 OF and 400 OF, this range is well within the essentially constant range for coefficient of friction for good coatings; and (10) good extreme pressure boundary lubricants have a characteristic of performing better (lower coefficients of friction) as the load increases, 15 coefficients of friction between 0. 02 and 0.08 are reported for some coatings. In a preferred embodiment, the optimum lubrication for in-situ expandable tubular radial expansion operations using the methods 100 and/or 400 includes a combination of lubrication techniques and lubricants. These can be summarized as 20 follows: (1) extreme pressure lubricants/lubrication techniques; and (2) hydrodynamic lubrication from the fluid in the pipe during expansion.

Extreme pressure lubrication is preferably provided by: (1) liquid extreme pressure lubricants added to the fluid (e.g., drilling fluid, etc) in contact with the internal surface of the expandable tubular during the radial expansion process, and/or (2) solid 25 lubricants added to the fluid added to, or Contained within, the fluid in contact with the internal surface of the expandable tubular member during the radial expansion process, andlor (3) solid lubricants applied to the internal surface of the expandable tubular member to be radially expanded, and/or (4) combinations of (1), (2) and (3) above. 30 Liquid extreme pressure lubricant additives preferably work by chemically adhering to or being strongly attracted to the surface of the expandable tubular to be expanded. These types of liquid extreme pressure lubricant additives preferably form a film' on the surface of the expandable tubular member. The adhesive strength of this filn, is preferably greater than the shearing force along the internal surface of the 35 expandable tubular member during the radial expansion process. This adhesive force

is referred to as film strength. The film strength can be increased by increasing the viscosity of the fluid. Common viscosifiers, such as polymeric additives, are preferably i added to the fluid in wntact with the internal surface of the expandable tubular member d urin 6 the Fad i. ! e,xpans ion process to Incise! u h."catlo".! n a pr=.fe.. ed 5 embodiment, these liquid extreme pressure lubricant additives include one or more of the following: polyacrylamide polymers, AMPS-acrylamide wpolyrners, modified cellulose derivatives such asi for example, hvdroxvethylcellulose] carbox,vmethy hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vnyl acetate copolymers, polyvinyl pyrrolidone and copolymers including 10 polyolefins, latexes such as, for example, styrene butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils such as polyacrylate esters, block copolymers including styrene, isoprene butadiene and ethylene, ethylene acrylic acid copolymers.

In a preferred embodiment, extreme pressure lubrication is provided using solid 15 lubricants that are applied to the internal surface of the expandable tubular member.

These solid lubricants can be applied using various conventional methods of applying a film to a surface. In a preferred embodiment, these solid lubricants are applied in a manner that ensures that the solid lubricants remain on the surface of the expandable tubular member during installation and radial expansion of the expandable tubular 20 member. The solid lubricants preferably include one or more of the following: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), or silicone polymers. Furthermore, blends of these solid lubricants are preferred.

In a preferred embodiment, the solid lubricants are applied directly to the - expandable tubulars as coatings. The Coating of the solid lubricant preferably includes! 25 a binder to help hold or fix the solid lubricant to the expandable tubular. The binders preferably include curable resins such as, for example, epoxies, acrylic, urea- -

forrnaldehyde, melamine formaldehyde, furan based resins, acetone formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, etc. The binder is preferably selected to withstand the expected temperature range, pH, salinity and fluid types 30 during the installation and radial expansion operations. Polymeric materials are preferably used to bind the solid lubricants to the expandable tubular such as, for example, Selfadhesive" polymers such as those copolymers or terpolymers based upon vinyl acetate, vinyl chloride, maleic annhydride/maleic acid, and ethylene-acrylic acid copolymers, ethylene-methacrylic acid copolymers and ethylene-vinyl acetate 35 copolymers. In an alternative embodiment, the solid lubricants are applied as

suspensions of fine particles in a carrier solvent without the presenceluse of a chemical binder. In a preferred embodiment, the solid lubricant coating and the liquid lubricant additive (added to the fluid in contact with the internal surface of the expandable 5 tubular member during the radial expansion process) interact during the radial expansion process to improve the overall lubrication. In an exemplary embodiment, for phosphate solid lubricant coatings, manganese phosphate is preferred over zinc or iron phosphate because it more effectively attracts and retains liquid lubricant additives such as oils, esters, amides, etc. 10 In a preferred embodiment, solid lubricant coatings use binders that provide low friction that is enhanced under extreme pressure conditions by the presence of the solid lubricant. Preferred solid lubricant coatings includes one or more of the following: graphite, molybdenum disulfide, silicone polymers and polytetrafluoroethylene (PTFE).

In a preferred embodiment, blends of these materials are used since each material has 15 lubrication characteristics that optimally work at different stages in the radial expansion process. In a preferred embodiment, a solid, dry film lubricant coating for the internal surface of the expandable tubular includes: (1) 1 to 90 percent solids by volume; (2) more preferably, 5 to 70 percent solids by volume; and (3) most preferably, 15 to 50 percent solids by volume. In a preferred embodiment, the solid lubricants include: (1 j 5 20 to 80 percent graphite; (2) 5 to 80 percent molybdenum disulfide; (3) 1 to 40 percent PTFE; and (4) 1 to 40 percent silicone polymers.

In several exemplary embodiment, the liquid lubricant additives include one or more of the following: (1) esters including: ta) organic acid esters (preferably fatty acid esters) such as, for example, trimethylol propane, isopropyl, penterithritol, n-butyl, etc.; 25 (b) glycerol tri(acetoxy stearate) and N,N' ethylene his 12 hydroxystearate and octyl hydroxystearate; (c) phosphate and phosphite such as, for example, butylated triphenyl phosphate and isodiphenyl phosphate; (2) sulfurized natural and synthetic oils; (3) alkanolamides such as, for example, coco diethanolamide; (4) amines and amine salts; (5) olefins and polyolefins; (6) C-8 to C-18 linear alcohols and derivatives containing or 30 consisting of esters, amines, carboxylates, etc.; (7) overbased sulfonates such as, for example, calcium sulfonate, sodium sulfonate, magnesium sulfonate; (8) polyethylene glycols; (9) silicones and siloxanes such as, for example, dimethylpolysiloxanes and fluorosilicone derivatives; (10) dinonyl phenols; and (11) ethylene oxide/propylene oxide block copolymers.

f- An expandable tubular assembly has been described that indudes one or more tubular members and a layer of a lubricant coupled to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant includes a metallic soap.

In a p.r=.ferrd embowelment, the!uh.n.cnt Is severed from the group consisting of! 5 sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C Lube-10, C-PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE!, and silicone polymers. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. 3 In a preferred embodiment, the lubricant is chemically bonded to the interior surfaces of 10 the tubular members. In a preferred embodiment, the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant includes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In apreferred 3 15 embodiment, the layer of lubricant includes: a binder and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, 3 acrylic, ureaformaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, 20 molybdenum disulfide, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 25 percent silicone polymers. In a preferred embodiment, the layer of lubricant includes about 1% to 90% of the solid lubricant materially volume. In a preferred embodiment, ' the layer of lubricant includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the layer of lubricant includes about 15% to 50% of the solid lubricant material by volume.

30 A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure has also been described that includes coating the interior surfaces of the tubular members with a lubricant, positioning the tubular members within a preexisting structure and radially expanding the tubular members into contact with the preexisting structure. In a preferred embodiment, the 35 lubricant coating includes a metallic soap. In a preferred embodiment, the lubricant

f coating is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-Lube-10, GPHOS-58-M, PHOS-58-R, graphite' molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and si!ine polymers. in a profaned embodiment; the lubricant coating 5 provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the lubricant coating is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant coating is adhesively bonded to the interior surface of the tubular members.

10 In a preferred embodiment, the lubricant coating indudes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the lubricant coating includes: a binder, and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd 15 resins, vinyl acetate, vinyl chloride, and maleic annhydridelmaelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, 20 the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the lubricant coating includes about 1% to 90% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 5% to 70% of the solid 25 lubricant material by volume. In a preferred embodiment, the lubricant coating indudes about 15% to 50% of the solid lubricant material by volume. In a preferred embodiment, the method further indudes: infecting a quantity of a lubricating material into contact with the expandable tubular assembly. In a preferred embodiment, the lubricant coating includes a Brat part of a lubricating substance; and the lubricating 30 material includes a second part of the lubricating substance.

An apparatus has also been described that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a lubricant, positioning the tubular members 35 within a preexisting structure, and radially expanding the tubular members into contact

with the preexisting structure. In a preferred embodiment, the lubricant coating includes a metallic soap. In a preferred embodiment, the lubricant coating is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C:- Luh-10, n-PHO-M C:-PHOS-58-R aranhite 5 molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene (PTFE), and silicone polymers. In a preferred embodiment, the lubricant coating provides a sliding friction coemdent of less than about 0.20. In a preferred embodiment, the lubricant coating is chemically bonded to the interior surfaces of the tubular members.

In a preferred embodiment, the lubricant coating is mechanically bonded to the interior 10 surfaces of the tubular members. In a preferred embodiment, the lubricant coating is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the lubricant coating indudes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the lubricant coating includes: a binder and a solid lubricant material. In a 15 preferred embodiment, the binder is selected from the group consisting of: epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, viny chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disuifide, silicone polymers, and polytetrafluoroethylene. In a preferred 20 embodiment, the solid lubricant material includes: graphite, molybdenum disulflde, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the lubricant coating includes 25 about 1% to 90% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the lubricant coating includes about 15% to 50% of the solid lubricant material by volume. In a preferred embodiment, the method further includes: injecting a quantity of a lubricating material into contact with the 30 expandable tubular assembly. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the injected lubricating material includes a second part of the lubricating substance.

An expandable tubular assembly has also been described that includes one or more tubular members and a layer of a first part of a lubricant coupled to the interior 35 surfaces of the tubular members. In a preferred embodiment, the lubricant includes a

( - metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, C-Lube-10, PHOS-58-M, C-PHOS-58-R, graphite, molybdenum disulfide, lead pn..'der, antimony bode, My tetfl. unrnethy!nnn PTFE!i and silicone polymers.

5 In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the lubricant is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the lubricant is adhesively bonded to the interior surface of the tubular 10 members. In a preferred embodiment, the lubricant indudes epoxy, molybdenum disulfide, graphite, aluminum, copper, alumisilicate and polyethylenepolyamine. In a preferred embodiment, the layer of lubricant includes: a binder and a solid lubricant material. In a preferred embodiment, the binder is selected from the group consisting of: 15 epoxy, acrylic, urea-formaldehyde, phenolic, alkyd resins, silicone modified alkyd resins, vinyl acetate, vinyl chloride, and maleic annhydride/maelic acid. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfede, silicone polymers, and polytetrafluoroethylene. In a preferred embodiment, the solid lubricant material includes: graphite, molybdenum 20 disulfide, polytetrafluoroethylene, and silicone polymers. In a preferred embodiment, the solid lubricant material includes: about 5 to 80 percent of graphite, about 5 to 80 percent of molybdenum disulfide, about 1 to 40 percent polytetrafluoroethylene, and about 1 to 40 percent silicone polymers. In a preferred embodiment, the layer of lubricant includes about 1% to 90% of the solid lubricant material by volume. In a 25 preferred embodiment, the layer of lubricant includes about 5% to 70% of the solid lubricant material by volume. In a preferred embodiment, the layer of lubricant includes about 15% to 50% of the solid lubricant material by volume.

A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure has also been described that indudes 30 positioning the expandable tubular assembly into the preexisting structure, injecting a quantity of a lubricant material into contact with the expandable tubular assembly, and radially expanding the expandable tubular assembly into contact with the preexisting structure. In a preferred embodiment, the injected lubricant material includes a liquid lubricant material. In a preferred embodiment, the liquid lubricant material is selected 35 from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers,

f-- modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vinyl acetate copolymers, polyvinyl pyrrolidone, copolymers including polyolefins, latexes, s.y.rene but='lie. ne!=tex, urethane!atexec. sh/rene-maleic annhydnde copolymers 5 viscosity index improvers for motor oils, polyacrylate esters, block copolymers induding styrene, isoprene butadiene and ethylene, ethylene acrylic acid copolymers, esters, organic acid esters, trimethylol propane, isopropyl, penterithritol, n-butyl, glycerol triacetoxy stearate, N,N' ethylene his 12 hydroxystearate, octyl hydroxystearate, phosphate, phosphite, butylated triphenyl phospate, isodiphenyl phosphate, sulfurized 10 natural oils, synthetic oils, alkanolamides, coca diethanolamide, amines, amine salts, olefins, polyolefins, C-8 to C-18 linear alcohols and derivatives including esters, amines, carboxylates, overbased sulfonates, calcium sulfonate, sodium sulfonate, magnesium sulfonate, polyethylene glycols, silicones, siloxanes, dimethylpolysiloxanes, fluorosilicone derivatives, dinonyl phenols, and ethylene 15 oxide/propylene oxide block copolymers. In a preferred embodiment, the injected lubricant material includes a solid lubricant material. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers.

In a preferred embodiment, the method further includes: coating the interior surfaces of 20 the tubular members with a lubricant prior to positioning the tubular members within the preexisting structure. In a preferred embodiment, the lubricant coating includes a first part of a lubricating substance; and the injected lubricating material includes a second part of the lubricating substance.

An apparatus has also been described that includes a preexisting structure and 25 one or more tubular members coupled to the preexisting structure. The tubular members are coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure, injecting a quantity of a lubricant material into contact with the tubular members, and radially expanding the tubular members into contact with the preexisting structure. In a preferred embodiment, the 30 injected lubficant material includes a liquid lubricant material. In a preferred embodiment, the liquid lubricant material is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol/vinyl acetate 35 copolymers, polyvinyl pyrrolidone, copolymers including polyolefins, latexes, styrene r

butadiene latex, urethane latexes, styrene-maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, I isoprene butadiene and ethylene, ethylene acrylic add copolymers, esters, organic acid estem. tmethylo! propane; isopropyl penterithritol, n-butvl! glycerol triacetoxy 5 stearate, N,N' ethylene his 12 hydroxystearate, octyl hydroxystearate, phosphate, phosphite, butylated triphenyl phospate, isodiphenyl phosphate, sulfurized natural oils, synthetic oils, alkanolamides, coco diethanolamide, amines, amine salts, olefins, I polyolefins, C-8 to C-18 linear alcohols and derivatives induding esters, amines,: carboxylates, overbased sulfonates, calcium sulfonate, sodium sulfonate, magnesium 10 sulfonate, polyethylene glycols, silicones, siloxanes, dimethylpolysiloxanes, fluorosilicone derivatives, dinonyl phenols, and ethylene oxide/propylene oxide block copolymers. In a preferred embodiment, the injected lubricant material includes a solid! lubricant material. In a preferred embodiment, the solid lubricant material is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony 15 oxide, poly tetrafluoroethylene, and silicone polymers. In a preferred embodiment, the apparatus further includes: coating the interior surfaces of the tubular members with a lubricant prior to positioning the tubular members within the preexisting structure. In a 1 preferred embodiment, the lubricant Coating includes a first part of a lubricating; substance; and the injected lubricating material includes a second part of the 20 Lubricating substance.

A method of coupling an expandable tubular assembly including one or more I tubular members to a preexisting structure has also been described that indudes: coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic: 25 material induding a second part of the lubricant into contact with the coating of the first part of the lubricant, and radially expanding the tubular members into Contact with the preexisting structure. In a preferred embodiment, the lubricant includes a metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, 30 Lube-10, C-PHOS-58-M, and C-F,HOS-58-R. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the first part of the lubricant is chemically bonded to the interior surfaces: of the tubular members. In a preferred embodiment, the first part of the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred 35 embodiment, the first part of the lubricant is adhesively bonded to the interior surface of

( the tubular members. In a preferred embodiment, the method further includes: combining the first and second parts of the lubricant to generate the lubricant.

An apparatus has also been described that includes a preexisting structure and one or more tubular members coupled to the preexisting structure. The tubular 5 members are coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a first part of a lubricant, positioning the tubular members within a preexisting structure, circulating a fluidic materials having a second I part of the lubricant into contact with the coating of the first part of the lubricant, and radially expanding the tubular members into contact with the preexisting structure. In a 10 preferred embodiment, the lubricant includes a metallic soap. In a preferred embodiment, the lubricant is selected from the group consisting of sodium, calcium, and/or zinc stearates, zinc phosphates, manganese phosphate, GLube-10, C- PHOS-

58-M, and C-PHO58-R. In a preferred embodiment, the lubricant provides a sliding friction coefficient of less than about 0.20. In a preferred embodiment, the first part of 15 the lubricant is chemically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is mechanically bonded to the interior surfaces of the tubular members. In a preferred embodiment, the first part of the lubricant is adhesively bonded to the interior surface of the tubular members. In a preferred embodiment, the apparatus further includes combining the first and second 20 parts of the lubricant to generate the lubricant.

Although this detailed description has shown and described illustrative I

embodiments of the invention, this description contemplates a wide range of

modifications, changes, and substitutions. In some instances, one may employ some features of the present invention without a corresponding use of the other features.

25 Accordingly, it is appropriate that readers should construe the appended claims broadly, and in a manner consistent with the scope of the invention.

Claims

Claims

1. A method of coupling an expandable tubular assembly induding one or more tubular members ho a pmex.stin9 structure; comprising 5 coating the interior surfaces of the tubular members with a first part of a lubricant; positioning the tubular members within a preexisting structure; I circulating a fluidic material including a second part of the lubricant into contact with the coating of the first part of the lubricant; and 10 radially expanding the tubular members into contact with the preexisting structure. 2. An apparatus, comprising: a preexisting structure; and 15 one or more tubular members coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a first part of a lubricant; positioning the tubular members within a preexisting structure; i 20 circulating a fluidic materials having a second part of the lubricant into contact with the coating of the first part of the lubricant; and radially expanding the tubular members into contact with the preexisting structure. 25 3. The method of claim 1, wherein the tubular members comprise wellbore casings. 4. The method of claim 1, wherein the tubular members comprise underground pipes. 5. The method of claim 1, wherein the tubular members comprise structural supports. 6. The method of claim 1, wherein the lubricant comprises a metallic soap.

l 7. The method of claim 1, wherein the lubricant comprises zinc phosphate.

8. The method of claim 1, wherein the lubricant provides a coefficient of dynamic flatiron of hat'A"n n no to n 1 _._... __... __.. _. __ _...

9. The method of claim 1, wherein the lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, polytetrafluoroethylene, molybdenum disulfide, and metallic 1 0 soaps.

10. The method of claim 1, wherein the lubricant provides a sliding coefficient of friction less than 0.20.

15 11. The method of claim 1, wherein the lubricant is selected from the group consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, 20 polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers.nduding polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene- maleic annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers induding isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers.

12. The method of claim 1, wherein the lubricant is selected from the group consisting of: graphite, molybdenum disulfide, lead powder, antimony oxide, poly tetrafluoroethylene, and silicone polymers.

13. The method of claim 1, wherein the lubricant comprises a suspension of particles in a carrier solvent.

14. The method of claim 1, wherein the lubricant is selected from the group 35 consisting of:

- manganese phosphate, zinc phosphate, and iron phosphate.

15. The method of claim 1, wherein the lubricant comprises: 1 to SO percent soRds by v. olume 16. The method of claim 13, wherein the lubricant comprises: 5 to 70 percent solids by volume.

17. The method of claim 14, wherein the lubricant comprises: 10 15 to 50 percent solids by volume.

18. The method of claim 1, wherein the lubricant comprises: 5 to 80 percent graphite; 5 to 80 percent molybdenum disumde; 15 1 to 40 percent PTFE; and 1 to 40 percent silicone polymers.

19. The method of claim 1, wherein the lubricant comprises one or more of the following: 20 ester; sulfurized oil; alkanolamides; amine; amine salt; 25 olefin; polyolefins; G8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester, derivative of C-8 to C-18 linear alcohol including amine; 30 derivative of C-8 to C-18 linear alcohol including carboxylate; sulfonate; polyethylene glycol; silicone; siloxane; 35 dinonyl phenol;

ethylene oxide block copolymer; and propylene oxide block copolymer.

C. T6 "jp=,-"s OF Cl-,,,, a,::..n. t'b..! mmherQ Impose..!!hnre 5 casings.

21.,T.he pparat's of cialm 9, wherein the tubular membem compose underground pipes. 10 22. The apparatus of claim 2, wherein the tubular members comprise structural supports. 23. The apparatus of claim 2, wherein the lubricant comprises a metallic soap.

15 24. The apparatus of claim 2, wherein the lubricant comprises zinc phosphate.

25. The apparatus of claim 2, wherein the lubricant provides a coefficient of dynamic friction of between 0.08 to 0.1.

20 26. The apparatus of claim 2, wherein the lubricant is selected from the group consisting of: sodium stearates, calcium stearates, zinc stearates, zinc phosphate, manganese phosphate, polytetrafluoroethylene, molybdenum disulfide, and metallic soaps. 27. The apparatus of claim 2, wherein the lubricant provides a sliding coemcient of friction less than 0.20.

28. The apparatus of claim 2, wherein the lubricant is selected from the group 30 consisting of: polyacrylamide polymers, AMPS-acrylamide copolymers, modified cellulose derivatives, hydroxyethylcellulose, carboxymethyl hydroxyethyl cellulose, polyvinyl alcohol polymers, polyvinyl acetate polymers, polyvinyl alcohol acetate copolymers, polyvinyl vinyl acetate copolymers, polyvinyl pyrrolidone and copolymers including 35 polyolefins, latexes, styrene butadiene latex, urethane latexes, styrene-maleic

f annhydride copolymers, viscosity index improvers for motor oils, polyacrylate esters, block copolymers including styrene, block copolymers including isoprene butadiene, block copolymers including ethylene, and ethylene acrylic acid copolymers.

5 29. The apparatus of claim 2, wherein the lubricant is selected from the group consisting of: graphite' molybdenum disulfide lead powder, antimony oxide,- poly tetrafluoroethylene, and silicone polymers.

10 30. The apparatus of claim 2, wherein the lubricant comprises a suspension of particles in a carrier solvent.

31. The apparatus of claim 2, wherein the lubricant is selected from the group consisting of: 15 manganese phosphate, zinc phosphate, and iron phosphate.

32. The apparatus of claim 2, wherein the lubricant comprises: 1 to 90 percent solids by volume.

20 33. The apparatus of claim 30, wherein the lubricant comprises: 5 to 70 percent solids by volume.

34. The apparatus of claim 31, wherein the lubricant comprises: 15 to 50 percent solids by volume.

35. The apparatus of claim 2, wherein the lubricant comprises: 5 to 80 percent graphite; 5 to 80 percent molybdenum disulfide; 1 to 40 percent PTFE; and 30 1 to 40 percent silicone polymers.

36. The apparatus of claim 2, wherein the lubricant comprises one or more of the following: ester; 35 sulfurized oil;

alkanolamides; amine; amine salt; olefin,. 5 polyolefins; C-8 to C-18 linear alcohol; derivative of C-8 to C-18 linear alcohol including ester; derivative of C-8 to C-18 linear alcohol including amine; derivative of C8 to C-18 linear alcohol including carboxylate; 1 0 sulfonate; polyethylene glycol; silicone; siloxane; dinonyl phenol; 15 ethylene oxide block copolymer; and propylene oxide block copolymer.

1. An expandable tubular assembly, comprising: one or more tubular members; and a layer of a lubricant coupled to the interior surfaces of the tubular members.

5 2. A method of coupling an expandable tubular assembly including one or more tubular members to a preexisting structure, comprising: coating the interior surfaces of the tubular members with a lubricant; positioning the tubular members within a preexisting structure; and radially expanding the tubular members into contact with the preexisting 1 0 structure.

3. An apparatus, comprising: a preexisting structure; and one or more tubular members coupled to the preexisting structure by the 15 process of: coating the interior surfaces of the tubular members with a lubricant; À positioning the tubular members within a preexisting structure; and radially expanding the tubular members into contact with the preexisting structure. 4 An expandable tubular assembly, comprising: one or more tubular members; and a layer of a first part of a lubricant coupled to the interior surfaces of the tubular members. 5. A method of coupling an expandable tubular assembly induding one or more tubular members to a preexisting structure, comprising: positioning the expandable tubular assembly into the preexisting structure; injecting a quantity of a lubricant material into contact with the expandable 30 tubular assembly; and radially expanding the expandable tubular assembly into contact with the preexisting structure.

6. An apparatus, comprising: 35 a preexisting structure; and

one or more tubular members coupled to the preexisting structure by the process of: positioning the tubular members into the preexisting structure; injecting a quantity' v'$ I"h"..nt mate.n.a! into contact wrth the tubular 5 members; and radially expanding the tubular members into contact with the preexisting I stir" - ure.

7. A method of coupling an expandable tubular assembly induding one or more 10 tubular members to a preexisting structure, comprising: coating the interior surfaces of the tubular members with a first part of a lubricant; positioning the tubular members within a preexisting structure; circulating a fluidic material including a second part of the lubricant into contact 15 with the coating of the first part of the lubricant; and I radially expanding the tubular members into contact with the preexisting structure. 8. An apparatus, comprising: 20 a preexisting structure; and one or more tubular members coupled to the preexisting structure by the process of: coating the interior surfaces of the tubular members with a first part of a lubricant; 25 positioning the tubular members within a preexisting structure; Circulating a fluidic materials having a second part of the lubricant into contact with the coating of the first part of the lubricant; and radially expanding the tubular members into contact with the preexisting! structure.