Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.

Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.

Abstract: The present disclosure addresses apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. A first deployable annular isolator is carried on tubing as it is positioned in a borehole. An annular isolator forming material is placed in the annulus around the first deployable isolator. The first isolator is then deployed into the material in the annulus to form a combined isolator. The annular isolator forming material is carried in a compartment in the tubing and forced from the compartment into the annulus. A second deployable isolator may be deployed before placing the material in the annulus to resist annular flow of the material before the first isolator is deployed. The second isolator may be deployed by material from the compartment. A second compartment may be provided to deploy the first isolator.

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

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: The present inventions relate to improved apparatus and methods for radially expanding tubulars, such as tubing, casing and sand-control screen assemblies in a subterranean oil or gas well, and more specifically, to a variable diameter expansion tool for expanding downhole tubulars to varying diameters. In general, the inventions provide apparatus and methods for radially expanding a tubular, such as pipe, tubing, screen or screen assembly, deployed in a subterranean well by moving an expansion tool axially through the well. An automatically infinitely variable-diameter expansion cone tool is provided. A variable-diameter cone is provided, movable between an expanded position and a retracted position. The cone is enlarged to its expanded position and advanced through expandable components until a restriction is reached. At the restriction, the variable-diameter cone automatically retracts enough to allow the tool to continue advancing through the wellbore.

Abstract: An expandable well screen provides increased collapse, torsional and tensile strength. In a described embodiment, an expandable well screen includes a generally tubular base pipe and an external filtering media. The well screen is configured to have sufficient torsional and tensile strength for conveyance and positioning in a wellbore, while also having sufficient strength to prevent collapse when the screen is radially expanded.

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.

Abstract: A well completion system for creating a seal between a production tubing (30) and a well casing (34) positioned within a wellbore (32) comprises a production packer (46) that includes a section of the production tubing (30) and at least one seal element (60). The production tubing (30) is then positioned within the well casing (34) that lines the wellbore (32). An expander member (56) that is positioned within the production tubing (30) then travels longitudinally through the production packer (46) to expand the section of the production tubing (30) downhole that includes the seal element (60). This expansion creates a sealing and gripping relationship between the production tubing (30) and the well casing (34).

Abstract: A well tool assembly interconnection method is provided. In a described embodiment, a continuous tubing string has connectors positioned corresponding to desired locations for tool assemblies in a well. The tubing string is wrapped on a reel and transported to a well. As the tubing string is deployed from the reel into the well, the tool assemblies are interconnected between the connectors. A tool assembly having sensors embedded in a sidewall thereof is also provided.

Abstract: An expandable float shoe and associated methods are provided. In a described embodiment, an expandable float shoe is attached to a leg of an expandable wellbore junction. The float shoe and leg are radially compressed, such as by folding along their axial lengths. The wellbore junction is conveyed into a well and expanded by applying pressure therein. The float shoe expands outward, along with the leg of the wellbore junction.

Abstract: A well tool assembly interconnection method is provided. In a described embodiment, a continuous tubing string has connectors positioned corresponding to desired locations for tool assemblies in a well. The tubing string is wrapped on a reel and transported to a well. As the tubing string is deployed from the reel into the well, the tool assemblies are interconnected between the connectors.

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Abstract: A method of regulating flow through a first tubular structure in a well provides flow control by use of an expandable second tubular structure inserted into the first tubular structure and deformed therein. In a described embodiment, a liner has sealing material externally disposed thereon. Expansion of the liner within a screen assembly may be used to sealingly engage the liner with one or more well screens of the screen assembly, and may be used to regulate a rate of fluid flow through one or more of the well screens.

Abstract: The inventions provide apparatus and methods for radially expanding a tubular deployed in a subterranean well by moving an expansion tool axially through the well. An expansion tool apparatus may have wear faces attached to at least a portion of the outer periphery of a mandrel for contacting the interior surface of the pipe, tube, or screen during expansion. According to another aspect of the invention, an expansion tool has a controlled egress seal between the outer surface of the tool and the inside surface of the expandable tubular. According to another aspect of the invention, an automatically variable diameter expansion tool is provided having a variable diameter cone, which expands, and contracts based on input from one or more sensors. According to another aspect of the invention, an apparatus and method for expanding a length of screen assembly in a subterranean wellbore is provided.

Abstract: An expandable well screen provides increased collapse, torsional and tensile strength. In a described embodiment, an expandable well screen includes a generally tubular base pipe and an external filtering media. The well screen is configured to have sufficient torsional and tensile strength for conveyance and positioning in a wellbore, while also having sufficient strength to prevent collapse when the screen is radially expanded.

Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.

Abstract: An expandable float shoe and associated methods are provided. In a described embodiment, an expandable float shoe is attached to a leg of an expandable wellbore junction. The float shoe and leg are radially compressed, such as by folding along their axial lengths. The wellbore junction is conveyed into a well and expanded by applying pressure therein. The float shoe expands outward, along with the leg of the wellbore junction.