Abstract: The present invention generally relates to an apparatus and method for engaging a first tubular and a second tubular in a wellbore. In one aspect, an apparatus for forming an expanded connection in a wellbore is provided. The apparatus includes a first tubular being radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular. The apparatus further includes a plurality of formations formed on an outer surface of the first tubular, the formations constructed and arranged to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path when the first tubular is expanded to engage the inner wall of the second tubular. In another aspect, an apparatus for engaging a first tubular and a second tubular in a wellbore is provided. In yet another aspect, a method of completing a wellbore is provided.

Abstract: The present invention generally relates to an apparatus and method for engaging a first tubular and a second tubular in a wellbore. In one aspect, an apparatus for forming an expanded connection in a wellbore is provided. The apparatus includes a first tubular radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular. The apparatus further includes a plurality of outwardly extending formations formed on an outer surface of the first tubular, the formations constructed and arranged to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path when the first tubular is expanded to engage the inner wall of the second tubular. In another aspect, a method of compliantly expanding a tubular into contact with a casing wall is provided. In a further aspect, an expandable apparatus for expanding a tubular is provided.

Abstract: An apparatus for expanding a portion of a tubular within a wellbore. The expansion assembly first comprises an expander tool. The expander tool is preferably a rotary expander tool which is lowered into the wellbore at the lower end of a working string. In one aspect, the rotary expander tool defines a tubular body having recesses, with each recess containing a compliant roller. The expansion assembly further comprises a chamber having a resistive medium therein. In one arrangement, the medium is a clean oil loaded into the chamber before being run into the wellbore. The fluid chamber is sized and configured to sealingly receive an elongated lower portion of the body of the expander tool. As the body of the expander tool travels into the fluid chamber, it encounters resistance from the fluid loaded therein. The fluid serves as a resistant force to the downward movement of the drill string and the expander tool during the expansion process, thereby preventing any rapid springing of the pipe string above it.

Abstract: The present invention generally relates to an apparatus for sealing a wellbore. The sealing apparatus includes an expandable tubular body having one or more sealing elements disposed thereon. In one aspect, the sealing elements include swelling and non-swelling sealing elements. Preferably, the swelling sealing elements are made of a swelling elastomer capable of swelling upon activation by an activating agent. The swelling elements may be covered with a protective layer during the run-in. When the tubular body is expanded, the protective layer breaks, thereby exposing the swelling elements to the activating agent. In turn, the swelling elements swell and contact the wellbore to form a fluid tight seal.

Abstract: An apparatus and method for expanding a lower string of casing into frictional contact with an upper string of casing, and thereby hanging the lower string of casing onto the upper string of casing is provided. The apparatus essentially defines a lower string of casing having a scribe placed into the top end thereof. The lower string of casing is run into the wellbore, and positioned so that the top end overlaps with the bottom end of an upper string of casing already cemented into the wellbore. The top end of the lower casing string is expanded below the depth of the scribe into frictional contact with the upper string of casing. At the same time, or shortly thereafter, the top end of the upper string of casing is expanded. As the portion of the lower casing string having the scribe is expanded, the casing severs into upper and lower portions. The upper portion can then be removed from the wellbore, leaving a lower string of casing expanded into frictional engagement with an upper string of casing.

Abstract: An improved expansion assembly for an expander tool is provided. The expander tool is used to expand a surrounding tubular body within a wellbore. Accordingly, a method for expanding a surrounding tubular is also provided. The expansion assembly first comprises a piston disposed within a recess of the expander tool. The top surface of the piston closely receives a pad. The pad is held in close proximity to the top surface of the piston such that it does not rotate about a shaft. This arrangement reduces the geometric size of the expansion assembly, affording a larger inner diameter for the hollow bore of the expander tool itself. At least one reinforcement member is disposed on or within the pad to strengthen the pad during an expansion operation. The reinforcement member is fabricated from a durable material, and is arranged along the pad in the area of contact with the surrounding tubular during an expansion operation.

Abstract: The present invention generally relates to a connector arrangement for connecting a first tubular to a second tubular. In particular, the present invention relates to methods and apparatus for connecting the tubulars in such a way that the connection is prevented from becoming unmade in response to expansion of the tubulars. A connector mechanically mates a box end and a pin end of the tubulars together to form the connection. Additionally, mating castellations, surface finishes on the pin end and the box end, torque screws, and a variable pitch groove can provide resistance to relative rotation between the tubulars at the connection.

Abstract: The present invention generally relates to an apparatus for use in a wellbore. The apparatus comprises a top body, a bottom body, and a sleeve mechanically connected to the top and bottom bodies. The sleeve movable between a first position to a second position, whereby in the first position, the top and bottom bodies rotate as one unit and in the second position, the top body rotates independent of the bottom body in a first direction and with the bottom body in a second direction. A method for completing a wellbore is also provided. The method comprises running an assembly and a liner disposed on a drill string into the wellbore. The assembly includes an expander tool, a hydraulically actuated swivel, and a running tool mechanically connected to the liner. The method includes rotating the assembly and the liner as one rotationally locked unit.

Abstract: The present invention provides a positive displacement apparatus for selectively translating a completion tool, such as an expander tool, downhole. The positive displacement apparatus comprises a set of three essentially concentric tubular members. The three tubulars represent (1) an outer sleeve, (2) an inner mandrel, and (3) a middle displacement piston between the sleeve and the mandrel. These three tubular members are nested within the expandable liner or other tubular to be expanded within a wellbore. A fluid transfer chamber is provided below the middle displacement piston. Rotation of the positive displacement apparatus serves to draw fluid into the fluid transfer chamber. This fluid, in turn, is pumped into a fluid transfer channel and forces the displacement piston upward between the outer sleeve and the inner mandrel. The displacement piston then acts against the rotary expander tool. In this manner, the displacement piston translates the rotary expander tool axially within the wellbore.

Abstract: The present invention provides an apparatus and method expanding a portion of a tubular. The expansion apparatus is run into a wellbore on a working string. The expansion apparatus first comprises a rotary expander for expanding an expandable tubular. The expansion apparatus further comprises a spline assembly for coupling the rotary expander to a motor disposed on the work string. The rotary expander and spline assembly have hollow bodies that allow them to encircle the work string and rotate relative thereto. The spline assembly comprises an inner sleeve and outer sleeve. The inner sleeve is attached to the motor and the outer sleeve is attached to the rotary expander. The inner and outer sleeves are coupled to each other using a spline and groove connection. The connection allows the rotary expander to be rotated by the motor, while at the same time, allow the rotary expander to move axially relative to the motor. The rotary expander comprises two rows of rollers for expansion against the tubular.

Abstract: The present invention provides an expandable tubular having improved polished bore receptacle protection. The present invention further provides methods for completing a wellbore through the use of an expandable string of casing having improved polished bore receptacle protection. In one aspect, the invention includes a liner member having an expandable section, and a polished bore receptacle positioned below the expandable section. The expandable section is run into a wellbore, and is positioned to overlap with the bottom portion of a string of casing already set within the wellbore. The expandable section is then expanded into frictional engagement with the surrounding casing. The expandable section optionally includes at least one sealing member and at least one slip member on the outer surface. In one aspect, a transition section is provided between the expandable section and the polished bore receptacle.

Abstract: An apparatus and method of creating a seal between two coaxial tubulars so as to create a hanger and a packer. A first tubular is disposed coaxially within a portion of a second, larger tubular. A portion of the first tubular is expanded into frictional contact with the second tubular, thereby creating a liner and a hanger. In one embodiment, a pattern of grooves is formed in the surface of a portion of the first tubular body. The grooves in one aspect define a continuous pattern about the circumference of the tubular body which intersect to form a plurality of substantially identical shapes, such as diamonds. The grooves serve to improve the tensile strength of the tubular body. At the same time, the grooves allow for expansion of the tubular body by use of less radial force. The grooves further provide a gripping means, providing additional frictional support for hanging the expanded tubular onto the inner surface of a surrounding second tubular.

Abstract: The present invention provides an apparatus and method for expanding a first tubular against a second tubular. In one aspect, an expander tool includes a mandrel coupled to a spline assembly such that an annular space is formed between the same. Seals are placed between the mandrel and the spline assembly to retain a fluid in the annular space. The fluid may be used to actuate one or more expander members disposed on the spline assembly. The spline assembly is movably connected to a housing, which is coupled to a torque anchor. In operation, the mandrel is rotated, which, in turn, rotates the expander members. Rotation of the mandrel also causes the spline assembly to extend axially, thereby pulling a first seal closer to a second seal. As a result, the pressure in the annular space rises due to the compression of the fluid in the annular space. The rise in pressure extends the expander members into contact with the first tubular and expands the first tubular against the second tubular.

Abstract: The present invention provides an expandable tubular having improved polished bore receptacle protection. The present invention further provides methods for completing a wellbore through the use of an expandable string of casing having improved polished bore receptacle protection. In one aspect, the invention includes a liner member having an expandable section, and a polished bore receptacle positioned below the expandable section. The expandable section is run into a wellbore, and is positioned to overlap with the bottom portion of a string of casing already set within the wellbore. The expandable section is then expanded into frictional engagement with the surrounding casing. The expandable section optionally includes at least one sealing member and at least one slip member on the outer surface. In one aspect, a transition section is provided between the expandable section and the polished bore receptacle.

Abstract: The present invention provides methods and apparatus for reducing friction and preventing galling between surfaces in a wellbore. In one aspect of the invention, mating threads are coated with fullerene to reduce galling of the threads during make up and break down. In another aspect, a fullerene is used between surfaces of an expansion tool and a tubular to be expanded in order to reduce friction and prevent galling therebetween. Preferably, the fullerene is a spherically shaped carbon 60 molecule otherwise known as buckyball or C60. The fullerene coating provides an intermediate surface between two metal surfaces, thereby preventing galling between the two surfaces. In another aspect of the invention, the fullerene is placed between the roller of an expander tool and the surface of the tubular to be expanded in order to reduce friction and galling.

Abstract: The present invention provides methods for expanding a tubular with the aid of a compressive force. A tubular, such as a string of casing, is run into a wellbore on a working string, e.g., drill pipe. A carrying mechanism such as a collet is used to releasably attach the first tubular to the working string during run-in. The tubular is then expanded into frictional engagement with another tubular therearound within the wellbore. During the expansion process, a compressive force is applied to the portion of the tubular being expanded. In one aspect of the invention, a hydraulic ram is positioned above the string of casing and is activated by the injection of fluid under pressure in order to apply the compressive force to the expandable tubular. In another aspect of the invention, the portion of casing or other expandable tubular to be expanded is pre-stressed, such as to impart a barrel shape, in order to bias the tubular to more easily buckle outwardly during expansion.

Abstract: An apparatus and method for expanding a lower string of casing into frictional contact with an upper string of casing, and thereby hanging the lower string of casing onto the upper string of casing is provided. The apparatus essentially defines a lower string of casing having a scribe placed into the top end thereof. The lower string of casing is run into the wellbore, and positioned so that the top end overlaps with the bottom end of an upper string of casing already cemented into the wellbore. The top end of the lower casing string is expanded below the depth of the scribe into frictional contact with the upper string of casing. At the same time, or shortly thereafter, the top end of the upper string of casing is expanded. As the portion of the lower casing string having the scribe is expanded, the casing severs into upper and lower portions. The upper portion can then be removed from the wellbore, leaving a lower string of casing expanded into fluid communication with an upper string of casing.

Abstract: The present invention provides a liner hanger and a method of hanging a liner in a wellbore. In one aspect, a process for setting a liner in a wellbore is provided in which a tubular having a slip formed on an outer diameter of the tubular at a first location and a preformed bypass for circulating a fluid disposed at a second location is set and expanded into substantial contact with an inner diameter of the wellbore, a casing, or another liner. In another aspect, a process for setting a liner in a wellbore is provided in which a tubular having a slip formed on an outer diameter of the tubular at a first location is placed in the wellbore, a bypass for circulating a fluid is formed downhole, the liner is set and expanded into substantial contact with an inner diameter of the wellbore, a casing, or another liner.

Abstract: An apparatus and method of creating a seal between two coaxial tubulars so as to create a hanger and a packer. A first tubular is disposed coaxially within a portion of a second, larger tubular. A portion of the first tubular is expanded into frictional contact with the second tubular, thereby creating a liner and a hanger. In one embodiment, a pattern of grooves is formed in the surface of a portion of the first tubular body. The grooves in one aspect define a continuous pattern about the circumference of the tubular body which intersect to form a plurality of substantially identical shapes, such as diamonds. The grooves serve to improve the tensile strength of the tubular body. At the same time, the grooves allow for expansion of the tubular body by use of less radial force. The grooves further provide a gripping means, providing additional frictional support for hanging the expanded tubular onto the inner surface of a surrounding second tubular.

Abstract: The present invention generally provides a running tool comprising a torque-dampening system. A first portion and a second portion of the running tool are operably related by a torsion interface. In one embodiment, the torsion interface includes a plurality of interlaced teeth disposed on the each of the first and second portions. During relative rotation of the first and second portions, the teeth engage and “ride up” on one another, thereby forcing the first and second portions in opposite axial directions. At least one of the portions houses a flow restrictor assembly adapted to restrict fluid flow from one region to another during the axial movement of the portions. Accordingly, the relative rotation between the portions is inhibited, or dampened.