Patents by Inventor Paul David Metcalfe
Paul David Metcalfe has filed for patents to protect the following inventions. This listing includes patent applications that are pending as well as patents that have already been granted by the United States Patent and Trademark Office (USPTO).
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Patent number: 7168497Abstract: A method of providing a downhole seal, such as a packer, in a drilled bore between inner tubing and outer tubing comprises: providing an intermediate tubing section defining a seal arrangement for engaging with the inner tubing; and radially plastically deforming the intermediate tubing section downhole to form an annular extension. The extension creates a sealing contact with the outer tubing.Type: GrantFiled: December 30, 2003Date of Patent: January 30, 2007Assignee: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Patent number: 7152684Abstract: 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.Type: GrantFiled: December 20, 2002Date of Patent: December 26, 2006Assignee: Weatherford/Lamb, Inc.Inventors: Simon John Harrall, Paul David Metcalfe, Paul Antony Rennison
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Patent number: 7140446Abstract: A tubing connection arrangement that includes two expandable tubing sections is disclosed. In one embodiment, each of the tubing sections includes a filter screen sandwiched between inner expandable tubing and outer expandable tubing. On expansion of the tubing sections, the outer tubing provides resistance to radial expansion of the inner tubing in order to ensure that the integrity between the tubing sections is maintained. The filter screen of one of the tubing sections overlaps the filter screen of the other tubing section, and the outer expandable tubing of at least one of the tubing sections extends over the overlapping filter screens.Type: GrantFiled: May 10, 2005Date of Patent: November 28, 2006Assignee: Weatherford/ Lamb, Inc.Inventor: Paul David Metcalfe
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Patent number: 7124821Abstract: 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.Type: GrantFiled: July 18, 2005Date of Patent: October 24, 2006Assignee: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Patent number: 7124830Abstract: A tubing coupling method is provided. In one aspect, the method comprises providing a length of expandable tubing and a length of larger diameter non-expanding tubing, connecting an end portion of the expandable tubing to an end portion of the non-expanding tubing, running the tubing into a bore, and expanding the expandable tubing. The expandable tubing may form part of an expandable well or sand screen, or may be an expandable bore liner.Type: GrantFiled: July 26, 2005Date of Patent: October 24, 2006Assignee: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Patent number: 7121351Abstract: The present invention generally relates to an apparatus and method for expanding a tubular body in a wellbore. In one aspect, a method includes running the tubular body into the wellbore, the tubular body having a deformed portion. The method further includes reforming the deformed portion and positioning a two-position expander in the reformed portion. Additionally, the method includes shifting the expander to a second, larger diameter position and then expanding the reformed portion by urging the expander therethrough. In another aspect, a method for completing a wellbore is provided. In yet another aspect, a formable launcher section is provided. In a further aspect, a two-position expander tool is provided. In yet another aspect, an expansion system for use in completing a wellbore is provided.Type: GrantFiled: March 24, 2004Date of Patent: October 17, 2006Assignee: Weatherford/Lamb, Inc.Inventors: Mike A. Luke, Wayne Rudd, Simon J. Harrall, David M. Haugen, Paul David Metcalfe, Frederick T. Tilton
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Patent number: 7117957Abstract: A method includes drilling and lining a wellbore, in one aspect by mounting a drill bit on a drill string including a section of expandable tubing and providing a tubing expander in the string, rotating the drill bit and advancing the drill string through a bore, and passing the expander through the expandable tubing to expand the tubing. The apparatus comprises a drill string including a section of expandable tubing, a drill bit mounted on the string, and a tubing expander mounted on the string.Type: GrantFiled: May 25, 2004Date of Patent: October 10, 2006Assignee: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Patent number: 7093653Abstract: A downhole filter comprises a tubular member having a wall defining a plurality of openings. The openings have an outer width less than an inner width. The parts of the opening defining the smaller width are defined by radially outer parts of the openings, such that particulates or sand prevented from passing through the openings will tend to be retained to the outside of the tubular member.Type: GrantFiled: October 24, 2003Date of Patent: August 22, 2006Assignee: Weatherford/LambInventors: Paul David Metcalfe, Wayne Rudd
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Patent number: 7090025Abstract: The present invention provides a method and apparatus for deforming a tubular body, running the tubular body through a restriction in a wellbore, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. In one aspect, the present invention provides a method for forming a substantially monobore well involving deforming a tubular body, running the tubular body below a restricted inner diameter portion, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. The restricted inner diameter portion may comprise a casing string previously disposed within the wellbore or a casing patch. The at least the portion of the tubular body expanded past its elastic limit may be a lower portion of the tubular body. Subsequent tubular bodies may be reformed and expanded below previous tubular bodies.Type: GrantFiled: December 1, 2003Date of Patent: August 15, 2006Assignee: Weatherford/Lamb, Inc.Inventors: David Haugen, Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton
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Patent number: 6976539Abstract: A method of installing a liner in a drilled bore below a section of bore previously lined with casing comprises the steps of: running a length of liner into the bore such that at least an upper end of the liner is positioned in overlapping relation with at least a lower end of the casing; and plastically deforming a portion of the liner such that an external face of the portion forms an interference fit with an internal face of a portion of the casing. The interference fit preferably provides both hanging support for the liner and a fluid-tight seal between the liner and casing.Type: GrantFiled: September 11, 2003Date of Patent: December 20, 2005Assignee: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Patent number: 6923261Abstract: 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.Type: GrantFiled: December 16, 2002Date of Patent: August 2, 2005Assignee: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Patent number: 6920935Abstract: A tubing coupling method is provided. In one aspect, the method comprises providing a length of expandable tubing and a length of larger diameter non-expanding tubing, connecting an end portion of the expandable tubing to an end portion of the non-expanding tubing, running the tubing into a bore, and expanding the expandable tubing. The expandable tubing may form part of an expandable well or sand screen, or may be an expandable bore liner.Type: GrantFiled: August 9, 2002Date of Patent: July 26, 2005Assignee: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Patent number: 6896057Abstract: A tubing connection arrangement that includes two expandable tubing sections is disclosed. In one embodiment, each of the tubing sections includes a filter screen sandwiched between inner expandable tubing and outer expandable tubing. On expansion of the tubing sections, the outer tubing provides resistance to radial expansion of the inner tubing in order to ensure that the integrity between the tubing sections is maintained. The filter screen of one of the tubing sections overlaps the filter screen of the other tubing section, and the outer expandable tubing of at least one of the tubing sections extends over the overlapping filter screens.Type: GrantFiled: April 19, 2004Date of Patent: May 24, 2005Assignee: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Publication number: 20040216925Abstract: A method and apparatus is provided for drilling and lining a wellbore in one downhole trip. The method comprises mounting a drill bit on a drill string including a section of expandable tubing and providing a tubing expander in the string, then rotating the drill bit and advancing the drill string through a bore, then passing the expander through the expandable tubing to expand the tubing, wherein the expandable tubing is deformed by compressive plastic deformation of the tubing with a localised reduction in wall thickness, resulting in a subsequent increase in tubing diameter, and then retrieving the drill bit from the bore through the expanded tubing.Type: ApplicationFiled: May 25, 2004Publication date: November 4, 2004Applicant: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Publication number: 20040216878Abstract: A method and apparatus is provided for drilling and lining a wellbore in one downhole trip. The method comprises mounting a drill bit on a drill string including a section of expandable tubing and providing a tubing expander in the string, then rotating the drill bit and advancing the drill string through a bore, then passing the expander through the expandable tubing to expand the tubing, wherein the expandable tubing is deformed by compressive plastic deformation of the tubing with a localised reduction in wall thickness, resulting in a subsequent increase in tubing diameter, and then retrieving the drill bit from the bore through the expanded tubing.Type: ApplicationFiled: May 25, 2004Publication date: November 4, 2004Applicant: Weatherford/Lamb, Inc.Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
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Publication number: 20040194953Abstract: Apparatus (10) for facilitating coupling and cementing of downhole tubulars (12, 28) comprises a tubing section (12, 10) for use in lining a bore. The tubing section has upper and lower ends and defines a tubing wall having cement outlets (20) spaced from the lower end of the tubing. The lower end of the tubing is selectively closed, and swab cups (22) are provided externally of the lower end of the tubing below the cement outlets (20) for restricting passage of cement.Type: ApplicationFiled: April 26, 2004Publication date: October 7, 2004Applicant: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Publication number: 20040194968Abstract: A connector arrangement for provision between the ends of two sections of expandable tubing, each expandable tubing section comprising a filter screen sandwiched between inner expandable tubing and outer expandable tubing, the filter screen of one tubing section overlapping the filter screen of the other tubing section and the outer expandable tubing of at least one of the tubing sections extending over the overlapping filter screens.Type: ApplicationFiled: April 19, 2004Publication date: October 7, 2004Applicant: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Patent number: 6789822Abstract: An expandable tubing assembly comprises a tubular connector defining overlapping longitudinal slots, the connector comprising end portions and an intermediate portion. The slots extend over the whole length of the connector, but the only slot overlap occurs in the intermediate portion. The assembly further comprises lengths of expandable tubing defining overlapping longitudinal slots and having end portions defining nodes between and beyond the ends of the tubing slots. Tubing threads are formed on the end most tubing nodes. The connector end portions define threads and are coupled with the threads formed on the nodes of the respective end portions of the tubing lengths.Type: GrantFiled: September 21, 1999Date of Patent: September 14, 2004Assignee: Weatherford/Lamb, Inc.Inventor: Paul David Metcalfe
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Publication number: 20040173360Abstract: A downhole apparatus comprises a plurality of tubing sections. Each tubing section has substantially cylindrical end portions initially of a first diameter for coupling to end portions of adjacent tubing sections. The end portions are expandable to a larger second diameter. Each tubing section also has an intermediate folded wall portions initially in a folded configuration. The intermediate folded wall portions are unfoldable to define a substantially cylindrical form of a third diameter.Type: ApplicationFiled: March 22, 2004Publication date: September 9, 2004Applicant: Weatherford/Lamb, Inc.Inventors: Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton
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Publication number: 20040159446Abstract: The present invention provides a method and apparatus for deforming a tubular body, running the tubular body through a restriction in a wellbore, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. In one aspect, the present invention provides a method for forming a substantially monobore well involving deforming a tubular body, running the tubular body below a restricted inner diameter portion, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. The restricted inner diameter portion may comprise a casing string previously disposed within the wellbore or a casing patch. The at least the portion of the tubular body expanded past its elastic limit may be a lower portion of the tubular body. Subsequent tubular bodies may be reformed and expanded below previous tubular bodies.Type: ApplicationFiled: December 1, 2003Publication date: August 19, 2004Applicant: Weatherford/Lamb, Inc.Inventors: David Haugen, Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton