Abstract: The present invention generally relates to a pipe handling system for use with a tubular joining system. In one aspect, a method of forming a string of pipe using a joining assembly at a wellbore is provided. The joining assembly includes an internal joining tool and an external joining tool. The method includes the step of picking up the pipe joint using an elevator. The method further includes the step of positioning a lower end of the pipe joint adjacent an end of a string of pipe disposed in the external joining tool. The method also includes the step of moving the internal joining tool from a first position to a second position relative to the elevator, wherein the second position is between the pipe joint and the string of pipe. The method further includes the step of forming a connection between the pipe joint and the string of pipe.

Abstract: The present invention generally relates to a pipe handling system for use with a tubular joining system (such as a welding or forging assembly) located on a drilling rig at a wellbore. In one aspect, a method of forming a string of pipe using a joining assembly at a wellbore is provided. The joining assembly includes an internal joining tool and an external joining tool. The method includes the step of picking up the pipe joint using an elevator. The method further includes the step of positioning a lower end of the pipe joint adjacent an end of a string of pipe disposed in the external joining tool. The method also includes the step of moving the internal joining tool from a first position to a second position relative to the elevator, wherein the second position is between the pipe joint and the string of pipe. The method further includes the step of forming a connection between the pipe joint and the string of pipe.

Abstract: The present invention generally provides a tubular configured to mate with a second tubular so that sealing integrity is maintained between the tubulars before, during, and after expansion of the tubulars. In one embodiment, a connector for connecting tubulars is provided. The connector includes a pin portion; a box portion, wherein the pin and the box portions are configured to mate; a sealing surface formed in an inner surface of the box portion; a seal disposed in a groove formed in an outer surface of the pin portion, wherein the seal is configured to engage with a sealing surface of the box portion upon mating of the pin and the box portions; and a bump formed on an inner surface of the pin portion, wherein the bump is substantially axially aligned with the groove and the bump is configured so that the seal remains engaged with the box portion during and after expansion of the pin and the box portions.

Abstract: A method of expanding tubing downhole comprises providing a section of expandable tubing of a first diameter, and axially compressing the tubing to induce buckling, such that the buckled portion describes a larger second diameter. The resulting diametric expansion may be utilised to anchor or seal the tubing within a larger bore. The buckled portion may be used to anchor the tubing within the wellbore prior to expansion of the length of the tubing into the wellbore.

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: The present invention relates to a method and apparatus for anchoring an expandable tubular within a wellbore prior to expanding the length of the expandable tubular into contact with the wellbore. An expandable system comprises the expandable tubular and a deployment tool, wherein the deployment tool exerts radial force against the expandable tubular to expand at least a portion of the expandable tubular into contact with the wellbore to anchor the expandable tubular prior to the expansion process. A method for anchoring an expandable tubular within a wellbore prior to the expansion process is also provided, wherein radial force expands the expandable tubular into contact with the wellbore to initially anchor the expandable tubular. A method for altering the shape of the anchor is also provided.

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: Apparatus and methods are provided for reducing drilling vibration during drilling with casing. In one embodiment, an apparatus for reducing vibration of a rotating casing includes a tubular body disposed concentrically around the casing, wherein tubular body is movable relative to the casing. Preferably, a portion of the tubular body comprises a friction reducing material. In operation, the tubular body comes into contact with the existing casing or the wellbore instead of the rotating casing. Because the tubular body is freely movable relative to the rotating casing, the rotating casing may continuously rotate even though the tubular body is frictionally in contact with the existing casing.

Abstract: The present invention relates to a method and apparatus for anchoring an expandable tubular within a wellbore prior to expanding the length of the expandable tubular into contact with the wellbore. An expandable system comprises the expandable tubular and a deployment tool, wherein the deployment tool exerts radial force against the expandable tubular to expand at least a portion of the expandable tubular into contact with the wellbore to anchor the expandable tubular prior to the expansion process. A method for anchoring an expandable tubular within a wellbore prior to the expansion process is also provided, wherein radial force expands the expandable tubular into contact with the wellbore to initially anchor the expandable tubular. A method for altering the shape of the anchor is also provided.

Abstract: An apparatus for preventing erosion of wellbore components comprises a wellscreen and a coating disposed on the wellscreen. The coating includes a metal-based coating and preferably nickel and phosphorous. The coating may also be organic-based such as phenolic resin containing ceramic or cermet. A method for fabricating an erosion and corrosion resistant wellbore component by providing the wellbore component and treating the wellbore component with erosion resistant materials. The treating step is conducted by plating the wellbore component, preferably by electroless plating. The treating step further comprises heat treatment of the wellbore component subsequent to plating. An additional step of inserting the treated wellbore component into a wellbore may also be conducted.

Abstract: A method of expanding tubing downhole comprises providing a section of expandable tubing of a first diameter, and axially compressing the tubing to induce buckling, such that the buckled portion describes a larger second diameter. The resulting diametric expansion may be utilised to anchor or seal the tubing within a larger bore. The buckled portion may be used to anchor the tubing within the wellbore prior to expansion of the length of the tubing into the wellbore.

Abstract: The present invention discloses and claims methods and apparatus for forming an opening or a window in a downhole tubular for the subsequent formation of a lateral wellbore. In one aspect of the invention, a thermite containing apparatus is run into the wellbore on a wire line and a widow is subsequently formed in casing wall. In another aspect of the invention, the apparatus includes a run-in string or drill stem with a drill bit attached to a lower end thereof. A diverter, like a whipstock is attached temporarily to the drill bit with a mechanically shearable connection. At a lower end of the whipstock, a container is formed and connected thereto. The container is designed to house a predetermined amount of exothermic material at one side thereof adjacent the portion of casing where the window or opening will be formed. A telescopic joint extends between the bottom of the container and an anchor therebelow and the telescopic joint is in an extended position when the apparatus is run into a wellbore.

Abstract: The present invention discloses and claims methods and apparatus for forming an opening or a window in a downhole tubular for the subsequent formation of a lateral wellbore. In one aspect of the invention, a thermite containing apparatus is run into the wellbore on a wire line and a widow is subsequently formed in casing wall. In another aspect of the invention, the apparatus includes a run-in string or drill stem with a drill bit attached to a lower end thereof. A diverter, like a whipstock is attached temporarily to the drill bit with a mechanically shearable connection. At a lower end of the whipstock, a container is formed and connected thereto. The container is designed to house a predetermined amount of exothermic material at one side thereof adjacent the portion of casing where the window or opening will be formed. A telescopic joint extends between the bottom of the container and an anchor therebelow and the telescopic joint is in an extended position when the apparatus is run into a wellbore.

Abstract: The present invention discloses and claims methods and apparatus for forming an opening or a window in a downhole tubular for the subsequent formation of a lateral wellbore. In one aspect of the invention, a thermite containing apparatus is run into the wellbore on a wire line and a widow is subsequently formed in casing wall. In another aspect of the invention, the apparatus includes a run-in string or drill stem with a drill bit attached to a lower end thereof. A diverter, like a whipstock is attached temporarily to the drill bit with a mechanically shearable connection. At a lower end of the whipstock, a container is formed and connected thereto. The container is designed to house a predetermined amount of exothermic material at one side thereof adjacent the portion of casing where the window or opening will be formed. A telescopic joint extends between the bottom of the container and an anchor therebelow and the telescopic joint is in an extended position when the apparatus is run into a wellbore.

Abstract: An apparatus for preventing erosion of wellbore components comprises a wellscreen and a coating disposed on the wellscreen. The coating includes a metal-based coating and preferably nickel and phosphorous. The coating may also be organic-based such as phenolic resin containing ceramic or cermet. A method for fabricating an erosion and corrosion resistant wellbore component by providing the wellbore component and treating the wellbore component with erosion resistant materials. The treating step is conducted by plating the wellbore component, preferably by electroless plating. The treating step further comprises heat treatment of the wellbore component subsequent to plating. An additional step of inserting the treated wellbore component into a wellbore may also be conducted.