Abstract: A swage is made from segments that slide relatively to each other to go from a run in dimension to a maximum or built dimension when the segments move into alignment. The angle of inclination of the sliding axis between the members is less than the swaging angle for the pipe on the exterior of the segments so that once the segments are aligned and driven into a tubular for swaging they are precluded from extending into misalignment to clear an obstruction. In this manner a minimum drift is provided or the swage simply stalls. The swage in a tubular goes to the predetermined maximum dimension using the sliding surfaces that are at an angle to bear the radial reaction forces from the tubular more directly, thereby reducing the contact forces and the resulting friction. The edge connections reduce bending which can cause segment binding as the swage is built in the tubular.

Abstract: A tieback receptacle is configured with an exterior cone and externals seals with a clearance space to accept a tieback shoe that will wash over the receptacle and expand when landed and advanced over the cone. The lower end of the shoe is tapered so that the thickness opposing the upper seal adds to burst and collapse resistance while the tapered lower end allows a thicker receptacle to be used in the area of the lower seal. The expansion can be accomplished with setting down weight which can also enhance the set of the liner hanger below. Minimal expansion in the order of 3% or less is needed. Exterior slots create cement flow passages and a no-go for the stem to prevent damage to the box further below. A metal to metal seal is created at the cone that is straddled by the exterior seals on the extension.

Abstract: An expandable packer features a sealing element in an exterior recess that is straddled by projections or bumps. Upon expansion the bumps move out against the borehole wall as an anchor support. Optionally, the bumps may be covered with a sealing material and may be constructed to assist in their radial movement to the borehole wall as a result of expansion particularly if the mandrel is expanded in compression. The bumps are not necessarily expanded with the swage and their radial growth can be induced from longitudinal shrinkage resulting from radial expansion.

Abstract: The tubular string to be expanded is run in on a running string. The swage assembly has a seal from the running string to the existing tubular and the top of the tubular string to be expanded also has a similar seal against the exiting tubular. Annulus pressure around the running string drives the swage assembly to support the expanded tubular to the exiting tubular and to continue expansion to the end of the tubular. Cementing then takes place followed by reconfiguring the swage assembly to engage the liner hanger seal with the result being a monobore connection in a single trip including the cementing.

Abstract: A string to be expanded is run in with a running string that supports a swage assembly. The running string is secured to the existing tubular and the top of the string to be expanded is sealed around the supported running string. The pressure applied to the annular space above the seal drives the liner over the swage. A cement shoe is affixed to the lower end of the string that is expanded after becoming detached from the running string assembly. When the expanded liner bottoms on a support, generally the hole bottom, the cement is delivered through the shoe and the expansion of the top of the string into a recess of the string above continues. The swage assembly with the seal and the anchor are then recovered as the running string is removed during the process of expanding the top of the expanded string into the lower end recess of the existing string already in the wellbore.

Abstract: An expandable packer features a sealing element in an exterior recess that is straddled by projections or bumps. Upon expansion the bumps move out against the borehole wall as an anchor support. Optionally, the bumps may be covered with a sealing material and may be constructed to assist in their radial movement to the borehole wall as a result of expansion particularly if the mandrel is expanded in compression. The bumps are not necessarily expanded with the swage and their radial growth can be induced from longitudinal shrinkage resulting from radial expansion.

Abstract: An open hole packer uses mandrel expansion and a surrounding sealing element that can optionally have a swelling feature and further a seal enhancing feature of a ring with an internal taper to match an undercut on the mandrel exterior. As a swage progresses to the taper at the transition between the ring and the extending flat fingers, the fingers get plastically deformed in an outward radial direction to push out the sealing element. Shrinkage of the mandrel axially due to radial expansion brings a ring on the mandrel outer surface under the fingers to act as a support for the fingers against the seal which is pushed against the open hole. Mirror image orientations are envisioned to aid in retaining pressure differentials in opposed directions. Another external mandrel ring extends into the seal to keep its position during differential pressure loading.

Abstract: An open hole packer uses mandrel expansion and a surrounding sealing element that can optionally have a swelling feature and further a seal enhancing feature of a ring with an internal taper to match an undercut on the mandrel exterior. As a swage progresses to the taper at the transition between the ring and the extending flat fingers, the fingers get plastically deformed in an outward radial direction to push out the sealing element. Shrinkage of the mandrel axially due to radial expansion brings a ring on the mandrel outer surface under the fingers to act as a support for the fingers against the seal which is pushed against the open hole. Mirror image orientations are envisioned to aid in retaining pressure differentials in opposed directions. Another external mandrel ring extends into the seal to keep its position during differential pressure loading.

Abstract: An expansion and cementing assembly is run into the well as the expandable liner is made up. A work string is tagged into the expansion assembly and run to depth. Pressure drives the swage to initially expand and move uphole with the attached work string until the liner is expanded above the location of the subsequent cement placement. The assembly is then lowered to engage the guide/float shoe to perform the cementing step. The swage assembly is then released from the guide/float shoe and the balance of the expansion is performed without further expansion against the recently placed cement. The expansion assembly can start at the guide/float shoe or higher, in which case expansion can occur initially in a downhole direction and later be completed in an uphole direction. Variations without cementing are also contemplated.

Abstract: An expansion assembly is run into the well as the expandable liner is made up. A work string is tagged into the expansion assembly and run to depth. Pressure drives the swage to initially expand and move uphole with the attached work string until the liner is expanded to set at least one external packer. The balance of the expansion in the uphole direction is continued until the string is expanded into sealing support of a higher string in the wellbore and the variable swage comes out of the hole with the work string. A shoe is milled out and the process can be repeated.

Abstract: An apparatus to protect the mounting area of casing and a locating profile and optionally a sliding sleeve valve and a flow path from the outside of the valve to the annulus when subsequent attachment of an expanded liner is intended and the expanded liner is to be cemented in place. A barrier sleeve, nose, and outer sleeve define a sealed cavity having a loose incompressible material inside that covers the mounting location on the casing. A locating profile and an optional sliding sleeve valve and a flow path from the outside of the valve to the annulus can be provided. The cementing of the casing takes place through the barrier sleeve. After the cementing, the sleeve and nose are drilled out and the incompressible material is removed to the surface with the drill cuttings. A liner is inserted in the casing and is preferably expanded into sealing contact.

Abstract: The tubular string to be expanded is run in on a running string. The swage assembly has a seal from the running string to the existing tubular and the top of the tubular string to be expanded also has a similar seal against the exiting tubular. Annulus pressure around the running string drives the swage assembly to support the expanded tubular to the exiting tubular and to continue expansion to the end of the tubular. Cementing then takes place followed by reconfiguring the swage assembly to engage the liner hanger seal with the result being a monobore connection in a single trip including the cementing.

Abstract: An open hole packer uses mandrel expansion and a surrounding sealing element that can optionally have a swelling feature and further a seal enhancing feature of a ring with an internal taper to match an undercut on the mandrel exterior. As a swage progresses to the taper at the transition between the ring and the extending flat fingers, the fingers get plastically deformed in an outward radial direction to push out the sealing element. Shrinkage of the mandrel axially due to radial expansion brings a ring on the mandrel outer surface under the fingers to act as a support for the fingers against the seal which is pushed against the open hole. Mirror image orientations are envisioned to aid in retaining pressure differentials in opposed directions. Another external mandrel ring extends into the seal to keep its position during differential pressure loading.

Abstract: A string to be expanded is run in with a running string that supports a swage assembly. The running string is secured to the existing tubular and the top of the string to be expanded is sealed around the supported running string. The pressure applied to the annular space above the seal drives the liner over the swage. A cement shoe is affixed to the lower end of the string that is expanded after becoming detached from the running string assembly. When the expanded liner bottoms on a support, generally the hole bottom, the cement is delivered through the shoe and the expansion of the top of the string into a recess of the string above continues. The swage assembly with the seal and the anchor are then recovered as the running string is removed during the process of expanding the top of the expanded string into the lower end recess of the existing string already in the wellbore.

Abstract: Tubular is manufactured at a well site to a predetermined size using flat stock that is rolled into a c-shape from a plurality of feed locations. The c-shapes have open segments that are offset from each other to form the tubular shape. A binder material such as a reactive nano-foil is applied on assembly as the tubular shape is formed. The manufactured shape is reduced to a smaller dimension for run in. The cross-sectional reduced profile shape can be a smaller diameter or a crescent or an undulating shape that is triggered to revert to the original manufactured shape and size when placed downhole. The manufacturing method is capable of making continuous pipe for the length of the zone without connections. The bonding of the segments is preferably done at the time of fabrication at the well site but can also occur at least in part downhole.

Abstract: An apparatus to protect the mounting area of casing and a locating profile and optionally a sliding sleeve valve and a flow path is provided from the outside of the valve to the annulus when subsequent attachment of an expanded liner is intended and the expanded liner is to be cemented in place.

Abstract: A retaining device for a threaded connection that is expanded holds the connection together to prevent leakage. In a two step thread the retention device is located between the steps and comprises a nose in a groove that holds aligned surfaces together for a metal to metal connection and allows for relative axial movement at the same time.

Abstract: A tool for subterranean use employs relative movement between a housing and a piston by pressurizing and removing pressure in a variable volume defined between them. The variable volume is sealed with packer cups preferably with one supported from the piston and the other off the housing and in opposed orientations so that the broad surface area on each packer cup abuts the surface where relative movement takes place. The downhole tasks accomplished with the relative movement can be varied and include tubular expansion, setting packers or shifting sleeves, for example. A single or multiple packer cups are tied to a structure that needs to be driven and building pressure behind a packer cup or reducing pressure ahead of it advance the piston.

Abstract: The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. The retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. The retainer rings can also include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.

Abstract: The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. The retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. The retainer rings can also include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.