Abstract: The present invention generally relates to an apparatus for sealing a wellbore. The sealing apparatus includes an expandable tubular body having one or more sealing elements disposed thereon. In one aspect, the sealing elements include swelling and non-swelling sealing elements. Preferably, the swelling sealing elements are made of a swelling elastomer capable of swelling upon activation by an activating agent. The swelling elements may be covered with a protective layer during the run-in. When the tubular body is expanded, the protective layer breaks, thereby exposing the swelling elements to the activating agent. In turn, the swelling elements swell and contact the wellbore to form a fluid tight seal.

Abstract: An improved expansion assembly for an expander tool is provided. The expander tool is used to expand a surrounding tubular body within a wellbore. Accordingly, a method for expanding a surrounding tubular is also provided. The expansion assembly first comprises a piston disposed within a recess of the expander tool. The top surface of the piston closely receives a pad. The pad is held in close proximity to the top surface of the piston such that it does not rotate about a shaft. This arrangement reduces the geometric size of the expansion assembly, affording a larger inner diameter for the hollow bore of the expander tool itself. At least one reinforcement member is disposed on or within the pad to strengthen the pad during an expansion operation. The reinforcement member is fabricated from a durable material, and is arranged along the pad in the area of contact with the surrounding tubular during an expansion operation.

Abstract: A method and apparatus for completing a wellbore junction is provided. In one embodiment, a first leg of a screen is fastened within a first tubular with a preformed window. The first tubular houses a whipstock with a cut-out portion containing a folded second leg of the screen. The first tubular is lowered into a junction of a central and a lateral wellbore. A second tubular is lowered within the first tubular and catches an end of the folded second leg of the screen thereby unfolding and expanding the screen as the second tubular is guided into the lateral wellbore. In another embodiment, an expandable sand screen junction component with expandable sand screen production tubing is lowered through a junction of a central and lateral wellbore into the lateral wellbore and expanded into place. A central wellbore access port is milled into the junction component.

Abstract: The present invention generally relates to an apparatus for sealing a wellbore. The sealing apparatus includes an expandable tubular body having one or more sealing elements disposed thereon. In one aspect, the sealing elements include swelling and non-swelling sealing elements. Preferably, the swelling sealing elements are made of a swelling elastomer capable of swelling upon activation by an activating agent. The swelling elements may be covered with a protective layer during the run-in. When the tubular body is expanded, the protective layer breaks, thereby exposing the swelling elements to the activating agent. In turn, the swelling elements swell and contact the wellbore to form a fluid tight seal.

Abstract: An improved expansion assembly for an expander tool is provided. The expander tool is used to expand a surrounding tubular body within a wellbore. Accordingly, a method for expanding a surrounding tubular is also provided. The expansion assembly first comprises a piston disposed within a recess of the expander tool. The top surface of the piston closely receives a pad. The pad is held in close proximity to the top surface of the piston such that it does not rotate about a shaft. This arrangement reduces the geometric size of the expansion assembly, affording a larger inner diameter for the hollow bore of the expander tool itself. At least one reinforcement member is disposed on or within the pad to strengthen the pad during an expansion operation. The reinforcement member is fabricated from a durable material, and is arranged along the pad in the area of contact with the surrounding tubular during an expansion operation.

Abstract: The present invention provides a connector arrangement for connecting a first tubular to a second tubular. The first tubular member has at least one circumferential ring profile, and the second tubular member has a corresponding number of matching circumferential ring profiles. When the ring profiles of the two tubulars are mated and interlocked, they form separate and independent fluid seals as well as a mechanical lock able to hold the tubulars together during future expansion of the entire tubular and joint. Further, selecting properties of the tubulars such as yield strength and modulus of elasticity or constraining a diameter of one of the tubulars during expansion or compression forms a tight connection due to elastic recovery of the tubulars.

Abstract: An expander tool for expanding a first tubular into a second surrounding tubular within a wellbore. The expander tool first comprises a body. Within the body is an expansion member capable of being actuated outwardly from the body when expansion of the first tubular is desired. In one aspect, the expander tool is a rotary expander tool, and the expansion members define a plurality of rollers. The expander tool further comprises at least one sensor for sensing a downhole condition during expansion of the tubular. The sensors in one aspect include at least one tool for sensing wall dimensions of the first tubular such as inner diameter or wall thickness. Examples include sonic logs, caliper logs, and electromagnetic wall thickness tools. A depth gauge may also be included. In one aspect, a data transmission device is provided between a surface server and the sensors downhole. In this way, the operator at the surface can monitor progress of the expansion operation downhole.

Abstract: An apparatus and method for expanding a lower string of casing into frictional contact with an upper string of casing, and thereby hanging the lower string of casing onto the upper string of casing is provided. The apparatus essentially defines a lower string of casing having a separation region formed in the top end thereof. The lower string of casing is run into the wellbore, and positioned so that the top end overlaps with the bottom end of an upper string of casing already cemented into the wellbore. The top end of the lower casing string is expanded below the depth of the separation region into frictional contact with the upper string of casing. At the same time, or shortly thereafter, the top end of the upper string of casing is expanded. As the portion of the lower casing string having the separation region is expanded, the casing severs into upper and lower portions.

Abstract: An apparatus and method for expanding a lower string of casing into frictional contact with an upper string of casing, and thereby hanging the lower string of casing onto the upper string of casing is provided. The apparatus essentially defines a lower string of casing having a separation region formed in the top end thereof. The lower string of casing is run into the wellbore, and positioned so that the top end overlaps with the bottom end of an upper string of casing already cemented into the wellbore. The top end of the lower casing string is expanded below the depth of the separation region into frictional contact with the upper string of casing. At the same time, or shortly thereafter, the top end of the upper string of casing is expanded. As the portion of the lower casing string having the separation region is expanded, the casing severs into upper and lower portions.

Abstract: The present invention provides apparatus and methods for controlling and/or powering downhole components without the need for control and/or power lines extending from the components to the surface of the well and without the need for power or control lines to be inserted into the wellbore along with the components. In one aspect of the invention, a borehole is lined with a casing, the casing having at least one aperture disposed. Adjacent the aperture, on the outer surface of the casing, is a docking station, which is permanently attached to the casing and includes a socket. After the casing is installed in the borehole, a downhole component can be lowered into the wellbore. The downhole component is equipped with a connector extending from an outer surface thereof. The connector assembly is disposable through the aperture in the casing and, the connector assembly can be connected to the socket of docking station.

Abstract: An inflatable packer with a packer body, an inflatable bladder mounted around the packer body, a bladder support mounted around the inflatable bladder, the packer body, the inflatable bladder and the bladder support made of drillable material. A method for reclaiming a borehole extending from an earth surface into the earth, part of which is in a lost circulation zone, the method including closing off the borehole to fluid flow above the lost circulation zone by installing a packer system with an inflatable packer element and a valve apparatus in the borehole above the lost circulation zone, inflating the inflatable packer element with cement, and allowing the cement to set so that the inflatable packer and the valve apparatus effectively seal off the borehole to fluid flow.