Abstract: An apparatus for radially expanding and plastically deforming a tubular member. In some embodiments, the apparatus includes a support member and an adjustable expansion device coupled thereto. The adjustable expansion device includes a tubular support member with a plurality of circumferentially spaced apart inclined surfaces, a plurality of circumferentially spaced apart expansion segments movably coupled to the tubular support member, and an actuator for displacing the expansion segments relative to the tubular support member to thereby displace each of the expansion segments onto corresponding inclined surfaces.

Abstract: An apparatus for providing zonal isolation in a wellbore includes a plurality of interlocking sealing elements having anchor elements at the opposing ends. Each anchor element sealingly engages a wellbore tubular whereas the interlocking sealing elements do not engage any portion of wellbore therebetween. In one exemplary application utilizes a wellhead and lubricator positioned over a wellbore under pressure and a conveyance device for conveying equipment into the wellhead. The first anchor, the second anchor and the plurality of interlocking sealing elements are separately conveyed into the wellbore with the conveyance device and sequentially assembled in the wellbore to provide zonal isolation.

Abstract: A downhole tool is provided that includes a grip assembly for contacting a well formation. The grip assembly includes a gripper body; and a centralizer that is attached to and radially expandable with respect to the gripper body and that has a geometry which is lockable by a locking device. The grip assembly also includes a force amplifier in force transmitting relation with the centralizer, wherein the force amplifier transfers a force in a first direction to a much larger force in a second direction when the centralizer is locked by the locking device.

Abstract: A bottom plug and a method of using a bottom plug for forming a mono diameter wellbore casing is provided that includes an expandable packer initially attached below an expansion device. A packer setting mechanism is coupled between the expansion device and the expandable packer for expanding the expandable packer and sealingly setting it in an expanded portion of the wellbore casing. A release mechanism is coupled between the expansion device and the expandable bottom packer for releasing expandable bottom packer from the expansion device. Fluid is pumped into the wellbore casing between the cone and the set expandable bottom packer to facilitate forcing the expansion device into and through an unexpanded portion of the wellbore casing, thereby expanding the casing.

Abstract: A packer device includes a central packer mandrel and a radially surrounding expansion mandrel. At least one slip mandrel carrying wickers surrounds the expansion mandrel and is secured in place upon the expansion mandrel by an annular retaining ring. The slip mandrel is secured to the retaining ring by screw connectors that pass through the slip mandrel and into retainer segments. The retaining ring is clamped between the slip mandrel and segments. Additionally, the packer device carries a fluid seal that is made up of a thermoplastic material with elastomeric energizing elements.

Abstract: An oil country tubular good for expansion according to the invention is expanded in a well. The oil country tubular good for expansion according to the invention is formed of duplex stainless steel having a composition containing, in percentage by mass, 0.005% to 0.03% C, 0.1% to 1.0% Si, 0.2% to 2.0% Mn, at most 0.04% P, at most 0.015% S, 18.0% to 27.0% Cr, 4.0% to 9.0% Ni, at most 0.040% Al, and 0.05% to 0.40% N, and the balance consisting of Fe and impurities, a structure including an austenite ratio in the range from 40% to 90%. The oil country tubular good for expansion according to the invention has a yield strength from 256 MPa to 655 MPa, and a uniform elongation more than 20%. Therefore, the oil country tubular good for expansion according to the invention has a high pipe expansion characteristic.

Abstract: A method of lining a drilled bore comprises running an expandable first tubular into a bore and locating a portion of the first tubular in an unlined section of the bore and another portion of the first tubular overlapping a portion of an existing second tubular. The first tubular is secured relative to the second tubular while retaining the provision of fluid outlets to permit displacement of fluid from an annulus between the first tubular and the bore wall. An expansion device is then run through the first tubular to expand the first tubular to a larger diameter. Cement is then circulated into the annulus between the expanded first tubular and the bore wall. The fluid outlets are then closed.

Abstract: A method and apparatus includes providing an element formed of a superplastic material to perform a predetermined downhole task. In another arrangement, a method and apparatus includes a flowable element and a deformable element that can be expanded by flowing the flowable element.

Abstract: A method of expanding a tubular element is provided, the tubular element having a first portion to be expanded to a first inner diameter and a second portion to be expanded to a second inner diameter larger than the first inner diameter. The method comprising: a) arranging an expandable sleeve of selected wall thickness in said second tubular element portion; b) positioning an expander in the tubular element; c) operating the expander so as to expand said first tubular element portion to the first inner diameter, and operating the expander so as to expand the sleeve to an inner diameter substantially equal to the second inner diameter minus double the wall thickness of the sleeve; and d) retrieving the sleeve from the tubular element.

Abstract: A tool 10 is provided for radially expanding a downhole tubular C, and includes a central tool mandrel 12, a tubular expander 48 at the lower end of the tubular, and a downhole actuator 15 for forcibly moving the expander axially within the downhole tubular. Slips 20 are positioned for securing the tool within a well, so that the slips may be set, and the tool subsequently stroked to move the expander 48 and radially expand a length of the tubular. Upward pull on the work string may expand long portions of the downhole tubular. Buttress threads 43 preferably support the tubular expander on the downhole tubular when run in the well.

Abstract: An apparatus for expanding a tubular member comprising a support member, an expansion device for radially expanding the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, at least one pressure chamber defined by and positioned between the support member and expansion device, and one or more releasable supports coupled to the support member adapted to support the tubular member, wherein the releasable supports are positioned above the expansion device.

Abstract: A downhole tool with a mandrel that is expanded downhole is further actuated due to relative longitudinal movement between the mandrel and a member that accommodates radial expansion without undergoing as much shrinkage as the expanded mandrel or any shrinkage at all. In a packer application, the packer can be set in open hole or cased hole and the relative longitudinal movement that results from mandrel expansion leaves a residual longitudinal compressive force on the sealing element and a tensile reaction force on the underlying mandrel.

Abstract: The invention involves the use of a base pipe perforated only in a specific section under each screen section. Inflow comes through an outer shroud that is optional and goes through the screen material and into an annular space between the screen material and the unperforated base pipe. After traveling longitudinally in that annular space, the flow must go through a restriction that preferably comprises a porous media in a passage defined outside the still unperforated base pipe. After passing through the porous media in a particular screen section, the flow can pass through openings in the base pipe. A surrounding ring preferably protects the porous media during run in and expansion and can also optionally create additional resistance to flow to work in tandem with the porous media. Other flow restricting techniques in place of the porous media are contemplated.

Abstract: A method of expanding tubing such as a section of casing includes locating the casing in a bore and expanding a portion of the casing to engage the bore wall using an expansion tool having at least one radially movable expansion member. The expansion member may be in the form of a roller of a rotary expander. The method additionally includes subsequently expanding a further portion of the casing by advancing a cone expander through the casing.

Abstract: A method and apparatus for forming an elastic memory foam into an expansion element with an outer diameter larger than a borehole, heating the expansion element to its transition temperature and compressing it to a smaller run-in diameter, cooling the compressed expansion element below its transition temperature and running it into the borehole, then raising the expansion element to its transition temperature to cause it to expand and seal against the borehole wall. Expansion can be enhanced by expanding a mandrel on which the expansion element is formed.

Abstract: A packer device includes a central packer mandrel and a radially surrounding expansion mandrel. At least one slip mandrel carrying wickers surrounds the expansion mandrel and is secured in place upon the expansion mandrel by an annular retaining ring. The slip mandrel is secured to the retaining ring by screw connectors that pass through the slip mandrel and into retainer segments. The retaining ring is clamped between the slip mandrel and segments. Additionally, the packer device carries a fluid seal that is made up of a thermoplastic material with elastomeric energizing elements.

Abstract: An expandable tubular element for use in a wellbore formed in an earth formation, the tubular element having a first radially expandable tube and a second radially expandable tube. The tubes are arranged in a manner that an end portion of the second tube extends into an end portion of the first tube, wherein a selected one of the end portions has a reduced resistance to radial expansion per unit length compared to a remainder portion of the tube to which the selected end portion pertains.

Abstract: A method of forming a seal between two tubular members comprising providing a first tubular member having an internal surface and an external surface describing a first diameter, with a recess in the external surface at a seal portion of the first tubular member. A deformable circumferentially extending sealing member is located in the recess, the sealing member describes an external diameter no greater than the first diameter. The first tubular member is located within a second tubular member and the seal portion of the first tubular member is expanded such that the sealing member engages an inner surface of the second tubular member.

Abstract: A compliant, integrated, fastening and sealing system located on either end of cladding or on a liner hanger. It features protrusions in opposed directions whose contact edges are preferably hardened. The protrusions penetrate the surrounding tubular on expansion of the smaller tubular. Seals are included adjacent the protrusions so that seals between adjacent protrusions get forced toward each other upon flexing of the projections that penetrate the surrounding tubular. The attachment configuration is particularly suited for use with fixed swages or variable swages with limited dimensional adjustability when precise ID of host casing or open hole is unknown.

Abstract: A mono-diameter wellbore casing. A tubular liner and an expansion cone are positioned within a new section of a wellbore with the tubular liner in an overlapping relationship with a pre-existing casing. A hardenable fluidic material is injected into the new section of the wellbore below the level of the expansion cone and into the annular region between the tubular liner and the new section of the wellbore. The inner and outer regions of the tubular liner are then fluidicly isolated. A non hardenable fluidic material is then injected into a portion of an interior region of the tubular liner to pressurize the portion of the interior region of the tubular liner below the expansion cone. The tubular liner is then extruded off of the expansion cone. The overlapping portion of the pre-existing casing and the tubular liner are then radially expanded using an expansion cone.

Abstract: A packer device includes a central packer mandrel and a radially surrounding expansion mandrel that can expand radially. At least one slip mandrel carrying wickers surrounds the expansion mandrel and a plurality of axial slots are disposed within the slip mandrel.

Abstract: A radially expandable tool is provided that includes a tool body and a radially moveable member coupled to the tool body and in force receiving relation to a constant force actuator. The radially moveable member is movable by the constant force actuator from an closed position to a plurality of radially expanded open positions, which includes a fully open position. The constant force actuator includes an opening arm having a force transmission member; and a movement control guide in force reacting engagement with the force transmission member. The tool also includes a linear force generator; which applies a linear force to the constant force actuator, which the actuator transfers to a radial force perpendicular to the linear force.

Abstract: A borehole seismic acquisition tool configured for release from a stuck position within a borehole having a tool body with at least one sensor package, an anchoring arm, and anchoring arm linkage adapted to connect the anchoring arm to the tool body. The anchoring arm linkage includes a weakpoint mechanism adapted to break in response to a minimum threshold amount of breaking force being applied upon the weakpoint mechanism. The anchoring arm includes a first end adapted for contacting a borehole wall surface and a second end pivotally attached to the anchoring arm linkage. The anchoring arm also includes a movable cam removably secured to the first end via a first connector pin. The cam being at least partially rotatable about the first connector pin and configured and arranged to rotate against the borehole wall by a pulling force at a top portion of the borehole seismic acquisition tool.

Abstract: A system and method for assembly of downhole equipment in a subterranean well. In a described embodiment, a method of assembling an apparatus in a subterranean well includes the steps of: positioning an expandable shell in the well; expanding the shell in the well; and then interconnecting multiple portions of the apparatus to each other within the expanded shell.

Abstract: The invention features the use of a shape memory material in a downhole application to provide an energy source for at least in part setting the tool. In a specific application the springs that set slips for a liner hanger are made from the shape memory material and easily pre-compressed below the transition temperature when the material has low modulus of elasticity. The tool is run into position where a heat source such as well fluids or a heater can bring the springs above the transition temperature to store a force. The tool is then independently released to allow the stored force to set the tool.

Abstract: Grip between a tubular being expanded and the surrounding tubular is enhanced by disposing a wire in a groove. The wire is preferably harder than the surrounding tubular so that it can dig in upon expansion. The wire is mounted in the groove so that it is not stretched due to the expansion and for that reason doesn't increase the effort required for the expansion. The wire can take the shape of the groove that it is in or it can have some other shape. The wire can be solid or hollow and can be in segments such as rings or can be a longer continuously extending wire in a groove that, for example, can be helically disposed on the tubular being expanded or even on a sleeve surrounding it.

Abstract: An adjustable swage features an ability to enhance a radial collapse force when an obstruction in a tubular is encountered to allow radial contraction so that the obstruction can be cleared. The movable segments are configured to elastically bend on high loading so as to create additional radial component force to aid the adjustable swage in reducing its size to clear the obstruction.

Abstract: A method of manufacturing an expandable slotted tube fabricated from at least one tubular element and at least two annular elements connected to the opposite ends of the tubular element by means of butt joints wherein axially extending slots are formed at a uniform angular spacing around the periphery of the tube and in longitudinally overlapping relation characterized by cutting said annular elements in a pattern of overlapping positionally fixed slots in accordance with invariable parameters which are pre-determined relative to the dimensions of said annular elements and cutting in said tubular element a pattern of slots that is variable in accordance with measured parameters of the tube so as to achieve the required overlap between said positionally fixed and variable slots. A machine for carrying out the method is also described.

Abstract: A method for manufacturing a wellscreen and a wellscreen that have the mechanical properties of a direct-wrap wellscreen and the precise slot tolerance of a slip-on wellscreen are provided. In one embodiment, a method for manufacturing a wellscreen for use in a wellbore is provided. The method includes disposing a filter subassembly on a base pipe sized so that there is annulus between the base pipe and the filter subassembly. The filter subassembly includes a length of wire wrapped and welded along a plurality of rods so that a slot is defined between adjacent coils of wire. The method further includes expanding the base pipe so that the slot is not substantially altered, thereby substantially reducing or eliminating the annulus.

Abstract: A method and apparatus for forming an elastic memory foam into an expansion element with an outer diameter larger than a borehole, heating the expansion element to its transition temperature and compressing it to a smaller run-in diameter, cooling the compressed expansion element below its transition temperature and running it into the borehole, then raising the expansion element to its transition temperature to cause it to expand and seal against the borehole wall. Expansion can be enhanced by expanding a mandrel on which the expansion element is formed.

Abstract: A tubular liner including a first tubular portion, a second tubular portion, and an intermediate tapered tubular portion coupled to, and positioned between, the first and second tubular portions.

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: An apparatus for radially expanding and plastically deforming a tubular member includes a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member comprising an expansion cone, at least one pressure chamber defined by and positioned between the support member and expansion device fluidicly coupled to the first fluid passage, and one or more releasable supports coupled to the support member adapted to support the tubular member, wherein the releasable supports are positioned above the expansion device.

Abstract: A device for expansion and calibration of profile pipes, such as profile liners, with cylindrical threaded ends in their installation in a well. The device has a plurality of in-series connected mandrel assemblies, each of which has a housing with a central straight-through channel and inclined slots, in which rains are fastened and hinge-connected through pushers, tightened with respect to the housing, with a spring-loaded rod, accommodated in the central straight-through channel of the housing. Rods of an upper mandrel assembly are spring-loaded for holding the rams in nonoperating position, and rods of a lower assembly are spring-loaded for holding the rams in operating position. The lower mandrel assembly is provided with a choke. The Maximum diameter of a circle circumscribed about each mandrel assembly in its working position decreases from the upper assembly to the lower one.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, a plurality of pressure chambers defined by and positioned between the support member and the expansion device fluidicly coupled to the first fluid passage, and one or more releasable supports coupled to the support member adapted to support the tubular member positioned below the expansion device.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, a plurality of pressure chambers defined by and positioned between the support member and the expansion device fluidicly coupled to the first fluid passage, one or more releasable supports coupled to the support member adapted to support the tubular member positioned above the expansion device.

Abstract: A mono-diameter wellbore casing. A tubular liner and an expansion cone are positioned within a new section of a wellbore with the tubular liner in an overlapping relationship with a pre-existing casing. A hardenable fluidic material is injected into the new section of the wellbore below the level of the expansion cone and into the annular region between the tubular liner and the new section of the wellbore. The inner and outer regions of the tubular liner are then fluidicly isolated. A non hardenable fluidic material is then injected into a portion of an interior region of the tubular liner to pressurize the portion of the interior region of the tubular liner below the expansion cone. The tubular liner is then extruded off of the expansion cone. The overlapping portion of the pre-existing casing and the tubular liner are then radially expanded using an expansion cone.

Abstract: A wellhead is formed by extruding a plurality of tubular liners off of a mandrel into contact with an outer casing. The first tubular liner and mandrel are positioned within the wellbore with the tubular liner in an overlapping relationship with the outer casing. At least a portion of the tubular liner is extruded off of the mandrel into contact with the interior surface of the outer casing. The first tubular liner is extruded off of the mandrel by pressurizing an interior portion of the first tubular liner. Subsequent tubular liners are positioned in concentric overlapping relation and similarly extruded off of a mandrel into at least partial contact with the interior surface of the outer casing.

Abstract: A one trip system for expanding a tubular that is solid or perforated or a screen comprises a downhole assembly that features a hydraulic anchor that can be set, released and repositioned to repeat the process. The anchor is small enough to go through the tubular or screen after initial expansion. The anchor's maximum extension is designed to avoid overstressing the already expanded tubular or screen. An expansion tool is hydraulically driven with the initial portion of the stroke delivering an enhanced force. The expansion tool initially supports the tubular or liner but subsequently releases during the first stroke, after the tubular or screen is fully supported.

Abstract: A ported expandable tubing having an outer valve sleeve which closes the ports upon tubing expansion. An elastomeric sealing member may be carried between the tubing and the valve sleeve to improve closing of the ports. The elastomeric sealing member may be shaped and positioned to operate as a check valve before tubing expansion. Various fluids may be flowed from the ported tubing into a borehole, or from the borehole into the ported tubing, before tubing expansion. After expansion, the ports are closed by residual clamping forces between the sleeve and tubing. By applying sufficient internal pressure to overcome the clamping forces, fluids can be flowed from the tubing into the borehole after expansion.

Abstract: A method of lining a drilled bore comprises running an expandable first tubular into a bore and locating a portion of the first tubular in an unlined section of the bore and another portion of the first tubular overlapping a portion of an existing second tubular. The first tubular is secured relative to the second tubular while retaining the provision of fluid outlets to permit displacement of fluid from an annulus between the first tubular and the bore wall. An expansion device is then run through the first tubular to expand the first tubular to a larger diameter. Cement is then circulated into the annulus between the expanded first tubular and the bore wall. The fluid outlets are then closed.

Abstract: A wellhead is formed by extruding a plurality of tubular liners off of a mandrel into contact with an outer casing. The first tubular liner and mandrel are positioned within the wellbore with the tubular liner in an overlapping relationship with the outer casing. At least a portion of the tubular liner is extruded off of the mandrel into contact with the interior surface of the outer casing. The first tubular liner is extruded off of the mandrel by pressurizing an interior portion of the first tubular liner. Subsequent tubular liners are positioned in concentric overlapping relation and similarly extruded off of a mandrel into at least partial contact with the interior surface of the outer casing.

Abstract: A method is provided for providing a casing in a wellbore including placing a casing within the wellbore wherein the casing has a smaller outside diameter than a final inside diameter of the casing, placing an expandable mandrel within the casing, the expandable mandrel suspended from a drill string, converting the expandable mandrel to a first expansion diameter while the expandable mandrel is within the casing wherein the first expansion diameter is about the final inside diameter plus twice the thickness of the final casing; forcing the expanded mandrel through a lower portion of the casing while the expandable mandrel is of the first expansion diameter; converting the expandable mandrel to a second expansion diameter, wherein the second expansion diameter is about the final inside diameter, and forcing the expanded mandrel through an upper portion of the casing while the expandable mandrel is of the second expansion diameter.

Abstract: A compliant swage has the ability to change shape to allow clearance of an obstruction while permitting expansion to go on in other areas removed from the obstruction. A series of segments move with respect to each other longitudinally to change overall size. The segments have an additional degree of freedom to change from a round profile of varying diameter to an oblong, elliptical, or an irregular shape so as to compensate in the portion that encounters an obstruction to let the swage pass while at the same time permitting the intended maximum expansion in other portions where conditions permit such expansion.

Abstract: A method of isolating a section of downhole tubing comprises: running a length of expandable tubing (20) into a tubing-lined borehole (12, 14) and positioning the expandable tubing (20) across a section of tubing to be isolated; deforming at least portions of the expandable tubing (36, 40) to increase the diameter of the portions to sealingly engage the tubing (14) and to isolate the tubing section.

Abstract: An expansion-set fluid production assembly transfers well fluids from a casing string 12 to a production tubing string 112. A tubular anchor 72 and tubular expander 70 may be positioned downhole on a running tool at a desired depth along the casing string 12. An actuator assembly 10 may forcibly move the tubular expander 70 into the tubular anchor 72, expanding the tubular anchor 72 to seal and secure the tubular anchor 72 against the casing string 12. The running tool actuator assembly 10 may be removed, leaving the expanded tubular anchor 72 and tubular expander 70 downhole. A seal nipple 122 may be sealed with the tubular expander 70 and to the production tubing string 112. Fluids may then be recovered from the wellbore through the casing string 12, through the fluid production assembly, and into the production tubing string 112.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member including a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, at least one pressure chamber defined by and positioned between the support member and expansion device fluidicly coupled to the first fluid passage, and releasable supports coupled to the support member adapted to support the tubular member, wherein the releasable supports are positioned above and below the expansion device.

Abstract: An apparatus and method for expanding a wellbore tubular such as a casing is provided. The apparatus includes: an expandable casing; a drill string extending to within the drillstring; an expansion cone suspended from the drillstring, the expansion cone having an expanded state and a collapsed state and wherein the expansion cone is deformable to the expanded state and is relaxed in the collapsed state; a seal bushing capable of sealing an annulus between the drill string and the expandable casing; a downward expansion flow path wherein fluid communication is provided between the inside of the drill string and the annulus between the drill string and the expandable casing above the expansion cone; and an upward expansion flow path wherein fluid communication is provided between the inside of the drill string and the inside of the expandable casing for upward expansion by the expansion cone.

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: An expander for radially expanding a tubular element by axial movement of the expander through the tubular element is provided. The expander comprising an expander member having a front part of a first cross-sectional size; a rear part of a second cross-sectional size larger than the first cross-sectional size; and an intermediate part arranged between said front part; and, rear part and having a cross-sectional size varying between said first and second cross-sectional sizes. The expander member is provided with fluid supply means for supplying pressurized fluid to the inner surface of the tubular element at a location opposite the intermediate part when the expander member is arranged in the tubular element.