Abstract: A lateral exit in a casing is formed by starting with a shaped charge to produce a semi-circular cut of about 180 degrees in the casing. A spreader tool pushes in opposed directions at opposed ends of the cut making some of the casing wall at the cut curl inwardly. A wedge shaped tool is advanced behind the curled metal to force it to collapse on itself to create a long tapered ramp that act as would a whipstock. A one trip operation is contemplated. The drill is then guided by the doubled and tapered casing wall right into the formation without having to mill a window in the casing wall.

Abstract: A connection to a stub downhole is accomplished in a variety of ways. A string has a tapered lower end inserted into the stub and expansion occurs from within the tapered lower end into the stub to leave a connection without reduction of the internal diameter. An overshot fitting can be lowered outside the stub and the stub expanded from within against the overshot. Both options in a single tool can be used to get sealing around the inside and the outside of the stub. An adjustable swage can be used with the overshot configuration where the overshot has an internal groove. The adjustable swage expands from within the stub into the surrounding groove in the overshot.

Abstract: A release mechanism for a downhole tool is actuated by radial movement of a locking member. The locking member provided as much as full circumferential support in the locked position and once released can be prevented from re-gripping the previously connected elements. Illustrative examples of the mechanism for radial movement for release comprise sleeves that expand and radially oriented pistons. Shear pins or collets are not used to hold the components together in the preferred embodiment. Internal pressure fluctuations before initiating the release sequence will not cause unwanted release. The mechanism is applicable to a variety of downhole tools and is illustrated in the context of a hydraulic release.

Abstract: Apparatus and method for monitoring the wear of a downhole tool, and providing indication of the degree of wear to an operator at the well surface. A pressurized fluid path within the cutting element matrix can exhibit a pressure drop when wear of the matrix progresses into the fluid path, or rotating torque can exhibit a drop when wear of the matrix progresses to wear pads within the cutting element matrix. Other wear indicators can also be built into the cutting element matrix. Progression of wear down to the indicator can be directly measured at the well surface, or relayed to the surface via a downhole communication system.

Abstract: Milling in casing that is over 4½ inches is done with coiled tubing that is anchored against torque reaction. An improved debris catcher is part of the bottom hole assembly to capture cuttings from the milling. A thruster can be used to maintain weight on the mill during the milling. The coiled tubing supports a mud motor to drive the mill. Return fluid is separated from the cuttings and returned to the surface.

Abstract: A method of repairing tubulars downhole is described. A swage is secured to a force magnification tool, which is, in turn, supported by an anchor tool. Applied pressure sets the anchor when the swage is properly positioned. The force magnification tool strokes the swage through the collapsed section. The anchor can be released and weight set down on the swage to permit multiple stroking to get through the collapsed area. The swage diameter can be varied.

Abstract: The invention allows running, in one trip, a packer-setting tool, a whip-stock, and a window-milling system into the wellbore. Between the whipstock and the packer is a packer-setting tool. A flow passage extends through a portion of the whipstock into the setting tool. One or more seals are located between the whipstock and the setting tool if below the packer to be set there are already perforations which could result in fluid losses if they are pressurized. If there are uphole perforations which will cause fluid losses, one or more seals are disposed above the milling string. When both lower and upper seals are used below the whipstock and above the milling string, the zone between the seals is isolated in the wellbore, and pressure goes through the tubing, exits the tubing between the seals, and reenters into the lower end of the whipstock where it communicates with the setting tool for hydraulically setting the packer to support the whipstock.

Abstract: A retrieval tool for whipstocks is disclosed. A latch is retractable into the tool upon application of hydraulic pressure. A locking pin securely fastens the whipstock and retrieving tool together. The hydraulic pressure acts a cleaning force on the top of the whipstock and the retrieving slot to facilitate engagement. The offset stabilizer, when oriented opposite the lug on the retrieving tool, creates a force in the direction of the lug, whereby latching the retrieving tool will start. A joint of drillpipe or heavyweight drillpipe is run above the eccentric stabilizer. An offset stabilizer is provided to ensure proper initial orientation and avoid sticking the tool. The latch can firmly grip lugs within a slot in the whipstock. A overshot design is also disclosed using a similar hydraulically actuated latch assembly where the latch grabs the whipstock without having to use an opening therein, if for any reason the opening has been fouled with debris or damaged due to milling.

Abstract: A downhole tool for making up threaded connections between lower and upper tubulars within a well bore includes a lower anchoring member, an upper anchoring member, and a drive member including a movable piston assembly. A plurality of straight splines on the piston assembly and mating splines on a housing rotatable with the lower anchoring member allow axial movement while preventing rotational movement of the piston assembly with respect to the lower anchoring member during the tool driving stroke. The helical drive component on the piston assembly and a mating driven component rotatable with the upper anchoring member cooperate to rotate the upper anchoring member and thus the upper tubular to make up the downhole threaded connection. According to the method of the present invention, the upper and lower anchoring members are each secured to a respective tubular, and fluid pressure is increased to drive the piston assembly downward, thereby rotating the upper tubular.