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).

  • Patent number: 7168497
    Abstract: 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: Grant
    Filed: December 30, 2003
    Date of Patent: January 30, 2007
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Patent number: 7152684
    Abstract: 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: Grant
    Filed: December 20, 2002
    Date of Patent: December 26, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Simon John Harrall, Paul David Metcalfe, Paul Antony Rennison
  • Patent number: 7140446
    Abstract: 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: Grant
    Filed: May 10, 2005
    Date of Patent: November 28, 2006
    Assignee: Weatherford/ Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Patent number: 7124821
    Abstract: 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: Grant
    Filed: July 18, 2005
    Date of Patent: October 24, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Patent number: 7124830
    Abstract: 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: Grant
    Filed: July 26, 2005
    Date of Patent: October 24, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Patent number: 7121351
    Abstract: 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: Grant
    Filed: March 24, 2004
    Date of Patent: October 17, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Mike A. Luke, Wayne Rudd, Simon J. Harrall, David M. Haugen, Paul David Metcalfe, Frederick T. Tilton
  • Patent number: 7117957
    Abstract: 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: Grant
    Filed: May 25, 2004
    Date of Patent: October 10, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Patent number: 7093653
    Abstract: 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: Grant
    Filed: October 24, 2003
    Date of Patent: August 22, 2006
    Assignee: Weatherford/Lamb
    Inventors: Paul David Metcalfe, Wayne Rudd
  • Patent number: 7090025
    Abstract: 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: Grant
    Filed: December 1, 2003
    Date of Patent: August 15, 2006
    Assignee: Weatherford/Lamb, Inc.
    Inventors: David Haugen, Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton
  • Patent number: 6976539
    Abstract: 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: Grant
    Filed: September 11, 2003
    Date of Patent: December 20, 2005
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Patent number: 6923261
    Abstract: 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: Grant
    Filed: December 16, 2002
    Date of Patent: August 2, 2005
    Assignee: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Patent number: 6920935
    Abstract: 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: Grant
    Filed: August 9, 2002
    Date of Patent: July 26, 2005
    Assignee: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Patent number: 6896057
    Abstract: 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: Grant
    Filed: April 19, 2004
    Date of Patent: May 24, 2005
    Assignee: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Publication number: 20040216925
    Abstract: 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: Application
    Filed: May 25, 2004
    Publication date: November 4, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Publication number: 20040216878
    Abstract: 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: Application
    Filed: May 25, 2004
    Publication date: November 4, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventors: Paul David Metcalfe, Neil Andrew Abercrombie Simpson
  • Publication number: 20040194968
    Abstract: 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: Application
    Filed: April 19, 2004
    Publication date: October 7, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Publication number: 20040194953
    Abstract: 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: Application
    Filed: April 26, 2004
    Publication date: October 7, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Patent number: 6789822
    Abstract: 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: Grant
    Filed: September 21, 1999
    Date of Patent: September 14, 2004
    Assignee: Weatherford/Lamb, Inc.
    Inventor: Paul David Metcalfe
  • Publication number: 20040173360
    Abstract: 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: Application
    Filed: March 22, 2004
    Publication date: September 9, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventors: Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton
  • Publication number: 20040159446
    Abstract: 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: Application
    Filed: December 1, 2003
    Publication date: August 19, 2004
    Applicant: Weatherford/Lamb, Inc.
    Inventors: David Haugen, Simon John Harrall, Paul David Metcalfe, Frederick T. Tilton