Abstract: An apparatus for use in a well includes a tubular mandrel configured to connect to a downhole assembly. An outer hub is configured to attach to a wellhead and has a bore therethrough. An inner housing is disposed on the tubular mandrel and configured to attach the outer hub to the wellhead. A clutch assembly is disposed within the bore of the outer hub and movable between a locked position and an unlocked position, wherein the tubular mandrel is rotatable relative to the inner housing to operate the downhole assembly in the unlocked position.

Abstract: A method of cutting a tubular includes providing a rotatable cutting tool in the tubular, the cutting tool having a blade with a cutting structure thereon; extending the blade relative to the cutting tool; rotating the cutting tool relative to the tubular; guiding the cutting structure into contact with the tubular; cutting the tubular using the blade; and limiting extension of the blade. A rotatable blade for cutting a tubular includes a blade body extendable from a retracted position; a cutting structure disposed on a leading edge of the blade body, the cutting structure configured to cut the tubular; a stop on a first surface of the blade body; and an initial engagement point on a second surface of the blade body, the initial engagement point configured to guide the cutting structure into contact with the tubular.

Abstract: Methods and apparatus for releasing a lead mill of a BHA from a whipstock in a wellbore include slideably releasing the BHA from the whipstock without relative rotation and without destruction of a retractable bolt. A system includes: a bias mechanism; a retractable bolt at least partially disposed in the bottom hole assembly and biased to a retracted position by the bias mechanism; and a retraction actuator capable of selectably opposing the bias of the retractable bolt. A method includes: coupling a whipstock to a BHA with a retention system, including: a retractable bolt biased to retract into the BHA; and a retraction actuator configured to resist the bias of the retractable bolt; and after the whipstock and BHA have been disposed in a wellbore, activating the retraction actuator so that retraction of the retractable bolt ensues.

Abstract: A method of cutting a tubular includes disposing a rotatable cutter assembly in the tubular, the cutter assembly including a blade having a cutting portion; engaging the tubular using a trailing cutting structure of the cutting portion; engaging the tubular using an intermediate cutting structure of the cutting portion; forming a window in the tubular; and longitudinally extending the window using a leading cutting structure of the cutting portion. A rotatable blade includes a blade body extendable from a retracted position; and a cutting portion on the blade body having: a trailing cutting structure configured to engage the tubular, an intermediate cutting structure configured to engage the tubular while the trailing cutting structure engages the tubular, a leading cutting structure configured to engage an exposed wall thickness of the tubular; and an integral stabilizer disposed on at least a portion of an outer surface of the blade body.

Abstract: A method of manufacturing a gripping element can include depositing a gripping element material, and thereby gradually building up the gripping element and forming a gripping surface thereon, the gripping surface being configured to grippingly engage a well surface. A gripping system can include at least one extendable gripping element configured to grip a well surface, and the gripping element including a gripping element material enclosing one or more voids in the gripping element. Another gripping system can include at least one extendable gripping element having a gripping surface configured to grip a well surface, and the gripping element including at least two gripping element materials deposited to form the gripping element. Properties or characteristics may gradually change or vary from one gripping element material to another gripping element material in the gripping element. The gripping element materials may each include the same basic matrix material.

Abstract: A method of manufacturing a seal element can include depositing a seal element material from an instrument at a location of the seal element, and depositing another seal element material from the instrument at another location of the seal element, the seal element materials being different from each other. A sealing system can include a seal element, the seal element having at least one seal element material about at least one void in the seal element, the seal element material enclosing the void. Another sealing system can include a seal element, the seal element having multiple different seal element materials deposited at respective multiple different locations in the seal element. Properties or characteristics may gradually change or vary from one seal element material to another seal element material in the seal element. The seal element materials may each include the same basic matrix material.

Abstract: A method and apparatus for cutting and pulling a casing string from a well. a downhole casing pulling tool includes a tubular housing having a bore therethrough, a packer assembly configured to isolate an annulus between a casing and the tool, a slip assembly configured to engage the casing, and a piston assembly disposed in the bore of the tubular housing. The piston assembly is configured to operate an actuator, wherein the actuator is configured to operate at least one of the packer assembly and the slip assembly and modify a fluid pressure in the bore of the tubular housing.

Abstract: An apparatus for use in a well includes a tubular mandrel configured to connect to a downhole assembly. An outer hub is configured to attach to a wellhead and has a bore therethrough. An inner housing is disposed on the tubular mandrel and configured to attach the outer hub to the wellhead. A clutch assembly is disposed within the bore of the outer hub and movable between a locked position and an unlocked position, wherein the tubular mandrel is rotatable relative to the inner housing to operate the downhole assembly in the unlocked position.

Abstract: A method of cutting a tubular includes disposing a rotatable cutter assembly in the tubular, the cutter assembly including a blade having a cutting portion; engaging the tubular using a trailing cutting structure of the cutting portion; engaging the tubular using an intermediate cutting structure of the cutting portion; forming a window in the tubular; and longitudinally extending the window using a leading cutting structure of the cutting portion. A rotatable blade includes a blade body extendable from a retracted position; and a cutting portion on the blade body having: a trailing cutting structure configured to engage the tubular, an intermediate cutting structure configured to engage the tubular while the trailing cutting structure engages the tubular, a leading cutting structure configured to engage an exposed wall thickness of the tubular; and an integral stabilizer disposed on at least a portion of an outer surface of the blade body.

Abstract: A method of cutting a tubular includes providing a rotatable cutting tool in the tubular, the cutting tool having a blade with a cutting structure thereon; extending the blade relative to the cutting tool; rotating the cutting tool relative to the tubular; guiding the cutting structure into contact with the tubular; cutting the tubular using the blade; and limiting extension of the blade. A rotatable blade for cutting a tubular includes a blade body extendable from a retracted position; a cutting structure disposed on a leading edge of the blade body, the cutting structure configured to cut the tubular; a stop on a first surface of the blade body; and an initial engagement point on a second surface of the blade body, the initial engagement point configured to guide the cutting structure into contact with the tubular.

Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.

Abstract: An energized composite metal to metal seal. A sealing device includes a metal seal with a metal sealing surface facing radially outward, and another metal sealing surface facing radially inward; and a nonmetal seal including a nonmetal sealing surface positioned proximate one metal sealing surface and facing radially outward, and another nonmetal sealing surface positioned proximate the other metal sealing surface and facing radially inward. A method of sealing between a housing assembly and a closure member includes applying a pressure differential across the sealing device while the sealing device seals between the housing assembly and the closure member, and the pressure differential increasing contact pressure in a metal to metal seal between the housing assembly and a metal sealing surface on the metal seal, and increasing contact pressure in a metal to metal seal between the closure member and another metal sealing surface on the metal seal.

Abstract: A well system can include a flow control device which regulates flow of a fluid from an interior of the device outwardly through an exit port, and a deflector which outwardly overlies the exit port and provides fluid communication between the exit port and an annulus formed radially between the deflector and a wellbore lining. The deflector can diffuse the flow of the fluid prior to impingement on the wellbore lining. A flow control assembly can include a flow control device which regulates flow of a fluid from an interior of the device outwardly through an exit port, and a deflector which outwardly overlies the exit port, the deflector including at least one opening, and the opening being circumferentially offset relative to the exit port. A form of an interior surface of the deflector and/or an exterior surface of the flow control device can diffuse the flow of the fluid.

Abstract: A well system can include a flow control device which regulates flow of a fluid from an interior of the device outwardly through an exit port, and a deflector which outwardly overlies the exit port and provides fluid communication between the exit port and an annulus formed radially between the deflector and a wellbore lining. The deflector can diffuse the flow of the fluid prior to impingement on the wellbore lining. A flow control assembly can include a flow control device which regulates flow of a fluid from an interior of the device outwardly through an exit port, and a deflector which outwardly overlies the exit port, the deflector including at least one opening, and the opening being circumferentially offset relative to the exit port. A form of an interior surface of the deflector and/or an exterior surface of the flow control device can diffuse the flow of the fluid.

Abstract: A well tool having an enhanced performance packing element assembly. A well tool includes a packing element assembly for sealingly engaging a surface, the assembly including a packing element having at least one circumferential variation. Another well tool includes a packing element assembly including a packing element and a backup ring, the packing element being configured to bias the backup ring into contact with a surface opposite a circumferential portion of the backup ring, while another circumferential portion does not contact the surface. A method of setting a well tool includes providing a packing element assembly with multiple packing elements, and setting the well tool by squeezing fluid from between the packing elements via a gap, and then closing off the gap.

Abstract: Embodiments of the present invention provide methods for manufacturing an even-wall rotor or stator that do not suffer from drawbacks of the prior art. Even-wall rotors or stators produced according to those methods are also provided. In one embodiment, a method for manufacturing a rotor or stator for use in a mud motor is provided. The method includes providing a vacuum chamber; providing a metal electrode at least partially disposed in the vacuum chamber; providing a mold disposed in the vacuum chamber; and melting a portion of the electrode with a direct current arc, the molten metal flowing into the mold ring.

Abstract: An energized composite metal to metal seal. A sealing device includes a metal seal with a metal sealing surface facing radially outward, and another metal sealing surface facing radially inward; and a nonmetal seal including a nonmetal sealing surface positioned proximate one metal sealing surface and facing radially outward, and another nonmetal sealing surface positioned proximate the other metal sealing surface and facing radially inward. A method of sealing between a housing assembly and a closure member includes applying a pressure differential across the sealing device while the sealing device seals between the housing assembly and the closure member, and the pressure differential increasing contact pressure in a metal to metal seal between the housing assembly and a metal sealing surface on the metal seal, and increasing contact pressure in a metal to metal seal between the closure member and another metal sealing surface on the metal seal.

Abstract: Some embodiments of the present invention generally provide an apparatus that may be used in a coiled tubing drillstring and that can switch between effectively straight drilling and curved drilling without halting drilling. Methods for steering a coiled tubing drillstring are also provided. In one embodiment, an apparatus for use in drilling a wellbore is provided. The apparatus includes a mud motor; a housing; an output shaft; and a clutch actuatable between two positions. The clutch is configured to rotationally couple the mud motor to the output shaft when the clutch is in a first position as a result of fluid being injected through the clutch at a first flow rate, and rotationally couple the output shaft to the housing when the clutch is in a second position as a result of fluid being injected through the clutch at a second flow rate.

Abstract: A well tool having an enhanced performance packing element assembly. A well tool includes a packing element assembly for sealingly engaging a surface, the assembly including a packing element having at least one circumferential variation. Another well tool includes a packing element assembly including a packing element and a backup ring, the packing element being configured to bias the backup ring into contact with a surface opposite a circumferential portion of the backup ring, while another circumferential portion does not contact the surface. A method of setting a well tool includes providing a packing element assembly with multiple packing elements, and setting the well tool by squeezing fluid from between the packing elements via a gap, and then closing off the gap.

Abstract: Method, apparatus and article of manufacture for monitoring and characterizing the operation of a transducer (i.e., motor or pump) downhole. In particular, transducer RPMs are determined by analysis of acoustic information. An acoustical source (signal generator) located on a downhole tool (e.g., a drill string) creates acoustic energy which is received and processed by a receiving unit, which may be located at the surface of a wellbore. The acoustical source is operably connected to the transducer, so that the frequency of the signal produced by the acoustical source corresponds to the speed of the transducer. The acoustic signal of the acoustical source may then be isolated from other acoustical energy produce by downhole equipment, such as a drill bit. Having determined transducer speed by isolation of the acoustic signal, other operating parameters may be determined. Illustrative operating parameters include torque, flow, pressure, horsepower, and weight-on-bit.