Abstract: Devices and methods for setting a packer inside a wellbore with little appreciable reduction of the useable area of the wellbore. The outer casing or liner of the wellbore contains one or more integrated casing coupler joints having an increased diameter chamber portion. A large bore packing element is carried within the increased diameter chamber portion. The packing element may be selectively actuated to form a seal against an interior tubular member. Because the packing element is located within the chamber portion of the casing coupler, the packer may be set while saving useable cross-sectional area within the casing.

Abstract: Systems and methods for increasing fluid flow characteristics within a hydrocarbon production tubing string within a wellbore. An expansion member is passed through the interior flowbore of one or more production tubing string members. The expansion member smoothes the interior surface of the flowbore and may radially expand the interior surface of the flowbore.

Abstract: A screen section is made with variable resistance to flow in the screen material to balance the flow along the screen length. In one variation different discrete zones have screens configured for different percentages of open area while all have the same particle filtration capability. In another variation discrete portions have differing amounts of overlapping screen portions so as to balance flow without affecting the particle size screened. The cross-sectional shape of a wire wrap underlayment for the screen is made closer to trapezoidal to decrease the angle of opening for the incoming flow paths toward the base pipe. In this manner flow resistance is reduced and flow is increased due to reduced turbulence.

Abstract: An apparatus and method for perforating a liner, fracturing a formation, and injection or producing fluid, all in one trip with a single tool. The tool has a plurality of outwardly telescoping elements (12, 14) for perforation and fracturing. The tool also has a mechanical control device for selectively controlling the fracturing of the formation and the injection or production of fluids through the telescoping elements.

Abstract: One or more valves can be run into a string to land near associated ports in the string for injection or/and production service. When multiple valves are installed they can be initially configured to balance flow into or from a zone. The position of each valve can be altered without removal from the string preferably by a wireline shifting tool. One or more valves can also be removed and replaced when worn preferably using a wireline run tool. The valves can come with an integral sand control feature to facilitate production. Sensors to monitor well conditions and to transmit data to the surface can also be incorporated into the valve module.

Abstract: An apparatus for screening earth formation components includes: a base pipe configured to allow the passage of formation fluid therethrough; and a foam layer disposed radially outwardly of the base pipe and configured to allow the passage of formation fluid therethrough and minimize the passage of formation solids therethrough, the foam layer including a plurality of hollow structures forming windows therebetween. A method of manufacturing an apparatus for screening earth formation components is also disclosed.

Abstract: A screen section has a valve assembly to control flow through it. The valve is open and has a closure spring held compressed by a shape memory material that responds to the presence of a specific well fluid or fluids so that its property changes to allow the spring to deliver the stored potential energy to the valve member to close it when the specific well fluid or fluids are detected. The preferred material is a shape memory polymer that, for example, is sensitive to the presence of water or methane and gets softer to release the potential energy source to operate the downhole tool.

Abstract: A downhole arrangement including an outer housing, an inner housing disposed within the outer housing and defining with the outer housing a chamber, a turbine disposed within the chamber, and one or more nozzles disposed at the chamber capable of exhausting steam into the chamber. A method for moving a target fluid within a wellbore.

Abstract: A fracturing operation is done in open hole. The annular space is spanned by telescoping members that are located behind isolation valves. A given bank of telescoping members can be uncovered and the telescoping members extended to span the annular space and engage the formation in a sealing manner. Pressurized fracturing fluid can be pumped through the telescoped passages and the portion of the desired formation fractured. In a proper formation, cementing is not needed to maintain wellbore integrity. In formations that need annular space isolation, the string in a preferred embodiment can have an external material that grows to seal the annular space in lieu of a traditional cementing operation.

Abstract: A fracturing operation is done in open hole without annular space isolation. The annular space is spanned by telescoping members that are located behind isolation valves. A given bank of telescoping members can be uncovered and the telescoping members extended to span the annular space and engage the formation in a sealing manner. Pressurized fracturing fluid can be pumped through the telescoped passages and the portion of the desired formation fractured. In a proper formation, cementing is not needed to maintain wellbore integrity. The telescoping members can optionally have screens. Normally, the nature of the formation is such that gravel packing is also not required. A production string can be inserted into the string with the telescoping devices and the formation portions of interest can be produced through the selectively exposed telescoping members.

Abstract: A screen section is made with variable resistance to flow in the screen material to balance the flow along the screen length. In one variation different discrete zones have screens configured for different percentages of open area while all have the same particle filtration capability. In another variation discrete portions have differing amounts of overlapping screen portions so as to balance flow without affecting the particle size screened. The cross-sectional shape of a wire wrap underlayment for the screen is made closer to trapezoidal to decrease the angle of opening for the incoming flow paths toward the base pipe. In this manner flow resistance is reduced and flow is increased due to reduced turbulence.

Abstract: A flow conduit may have at least one orifice is in the vicinity of a flow source. The source is at least partially covered (and flow blocked by) an optional temporary coating or barrier. The flow pathway between the orifice and the source is temporarily blocked with a degradable material or barrier. The material disintegrates (e.g. under the influence of time or temperature) to optionally produce a product that removes the temporary coating in the area adjacent the barrier. The method is useful in one non-limiting context of recovering hydrocarbons where the flow conduit is the casing or liner of the well and the flow source is a subterranean reservoir where the temporary coating is a filter cake.

Abstract: An assembly method for a downhole screen is disclosed. In the preferred embodiment, the filtration layer is slipped over a perforated base pipe and an expansion technique is used to increase the base pipe diameter to the point where, preferably, an interference fit exists. The expansion can be fully underneath the filtration layer or can be done in discrete zones. The finished assembly can still be expanded further downhole, such as, for example, in open hole completions. An outer protective shroud can be employed over the filtration layer when the expansion of the base pipe occurs.

Abstract: A packer or bridge plug uses a sealing element made from a shape memory polymer (SMP). The packer element receives heat or other stimulus to soften the SMP while the element is compressed and retained. While so retained, the heat or other stimulus is removed to allow the SMP to get stiff so that it effectively seals a surrounding tubular. High expansion rates are possible as the softness of the material under thermal input allows it to be reshaped to the surrounding tubular or to the surrounding open hole from a smaller size during run in and to effectively retain a sealed configuration after getting stiff on reduction in its core temperature while longitudinally compressed. The SMP or equivalent material whose modulus is changeable can be covered on the outside, the inside or both with an elastic material that protects the SMP and enhances the seal in the wellbore and against the mandrel.

Abstract: Devices and methods for setting a packer inside a wellbore with little appreciable reduction of the useable area of the wellbore. The outer casing or liner of the wellbore contains one or more integrated casing coupler joints having an increased diameter chamber portion. A large bore packing element is carried within the increased diameter chamber portion. The packing element may be selectively actuated to form a seal against an interior tubular member. Because the packing element is located within the chamber portion of the casing coupler, the packer may be set while saving useable cross-sectional area within the casing.

Abstract: A packer or bridge plug uses a sealing element made from a shape memory polymer (SMP). The packer element receives heat to soften the SMP while the element is compressed and retained. While so retained, the heat is removed to allow the SMP to get stiff so that it effectively seals a surrounding tubular. High expansion rates are possible as the softness of the material under thermal input allows it to be reshaped to the surrounding tubular from a smaller size during run in and to effectively retain a sealed configuration after getting stiff on reduction in its core temperature while longitudinally compressed.

Abstract: An isolation assembly for downhole injection use is described that features at least one isolation device mounted on a tubular so that when injection fluid changes the tubular temperature which can cause a length change in the tubular, an anchor for the tubular is provided to resist such a dimension change. The result is that the isolation device such as a packer can be left undamaged and retaining its sealing integrity. The anchor can be an inflatable or telescoping pistons disposed to grab in open hole. When using telescoping pistons, their placement on the liner and their pattern can meet the desired locations where grip is enhanced. Use of cement inflatable anchors is contemplated as an alternative.

Abstract: A coupler for gravel packing completions comprising an annular member having an upper end, a lower end, at least one flange disposed along an inner wall surface of the annular member intermediate the upper and lower ends, and at least one deformable portion is disclosed. The coupler may be used to connect one or more screens to a base pipe in a gravel packing completion by deforming the deformable portion such as by passing a swage over the outer wall surface of the annular member. In a similar manner, the coupler may also be used to connect a gravel packing completion component, such as an inflow control device to the base pipe of the gravel packing completion, to contemporaneously connect a screen section and a gravel packing completion component to the base pipe.

Abstract: A liner rotates a bit to make more hole. The liner has openings with inserts in them to lend torque resistance to the liner. The inserts have a passage with a send control media in the passage and a seal so that the liner can hold pressure for run in to get proper circulation through the bit. When sufficient hole is made, the liner is hung off an existing cemented tubular and the seal for the passages with the sand control media is removed by a variety of techniques so that the formation can be produced in a single trip.

Abstract: A screen assembly has a material that conforms to the borehole shape after insertion. The assembly comprises a compliant layer that takes the borehole shape on expansion. The outer layer is formed having holes to permit production flow. The selected conforming material swells with heat, and in one non-limiting embodiment comprises a shape memory foam that is thermoset or thermoplastic. Heat is provided by supplying a fuel (including an oxidant) to a catalyst in close proximity to the compliant layer so that the product from the catalytic reaction is heated steam which contacts and deploys the conforming material. The base pipe can have a screen over it to act as an underlayment for support of the conforming layer or alternatively for screening.