Abstract: There is disclosed a method of lining a drilled bore (10) and bore-lining tubing (12). The method comprises providing a first tubular (16); locating the first tubular (16) in the bore (10); providing an expandable, second tubular (22); locating the second tubular (22) in the bore (10) overlapping the first tubular (16); expanding a portion (24) of the second tubular (22) to create a coupling (29) including a flow passage (26) between the first tubular and the second tubular (16,22).

Abstract: An expansion mandrel includes a lubrication system for lubricating the trailing edge portion of the interface between the expansion mandrel and a tubular member during the radial expansion of the tubular member.

Abstract: This invention relates to a slotted expandable centraliser. In preferred embodiments, the centraliser is adapted to be used in conjunction with slotted casing, and can expand with the casing when an expander cone is propelled through the casing.

Abstract: Tools for expanding downhole tubulars into each other or in open hole are disclosed. One embodiment uses a movable cone biased by Bellville washers to move longitudinally against such bias and allow collets to move radially in or out to a predetermined maximum diameter. A release system allows collet retraction to avoid hang up on removal. In an alternate embodiment, more suitable for open hole applications, pressurized gas pushes a movable cone longitudinally against the collets. A stationary cone is on the opposite side of the collets from the movable cone. The collet rides out or in between the cones and raises the gas pressure when forced in. A pressure actuated release allows the lower cone to shift downwardly to allow the collets to retract for removal.

Abstract: Methods of expanding well tools, which permit operation of the well tools after expansion, are provided. In a described example, a cementing tool includes a valve and a packer. After the cementing tool is expanded, the valve is selectively opened and closed, and the packer is sealingly engaged in a wellbore.

Abstract: The present invention provides an encapsulation for housing instrumentation lines, control lines, or instruments downhole. In one use, the encapsulation resides between an expandable downhole tool, such as an expandable sand screen, and the wall of the well bore. The encapsulation is specially profiled to allow the downhole tool to be expanded into the wall of the wellbore without leaving a channel outside of the tool through which formation fluids might vertically migrate. The encapsulation is useful in both cased hole and open hole completions.

Abstract: The present invention provides apparatus and methods for expanding tubulars in a wellbore. In one aspect, a process of sealing an annular area in a wellbore is provided in which a tubular having perforations at a predetermined location and a sleeve concentrically covering substantially all of the perforations is expanded into substantial contact with an inner diameter of a tubular, such as a casing or a liner. In another aspect, a process of sealing an annular area in a wellbore is provided in which a tubular having perforation at a predetermined location and a sleeve concentrically coving substantially all of the perforations is expanded into substantial contact with a junction between two tubulars, such as a liner and a casing, or between two liners.

Abstract: An expandable packer or anchor is disclosed. It features a gripping device integral to or mounted in a sleeve over the mandrel and mating undulating surfaces to help maintain grip under changing load conditions. Upon expansion, pressure on a sealing element is enhanced by nodes to increase internal pressure as it engages an outer tubular. Adjacent retaining rings limit extrusion and enhance grip. A gripping device, such as wickers on slips, preferably digs into the outer tubular. The expansion is preferably by pressure and can incorporate pressure intensifiers delivered by slick line or wire line. Release is accomplished by a release tool, which is delivered on slick line or wire line. It stretches the anchor or packer longitudinally, getting it to retract radially, for release. The release tool can be combined with packers or anchors that have a thin walled feature in the mandrel, to release by pulling the mandrel apart.

Abstract: The present invention provides a recess within an expandable downhole tubular, such as an expandable sand screen. The recess resides within the wall, such as the outer shroud of an expandable sand screen. The recess serves as a housing for instrumentation lines, fiber optics, control lines, or downhole instrumentation. By placing the lines and instrumentation within a wall of the expandable downhole tool, the tool can be expanded into the wall of the wellbore without leaving a channel outside of the tool through which formation fluids might vertically migrate. The recess is useful in both cased hole and open hole completions. In one embodiment, the recess serves as a housing for an encapsulation which itself may house instrumentation lines, control lines, and downhole instrumentation.

Abstract: An apparatus for radially expanding tubular members.

Abstract: The present invention provides apparatus and methods for completing a wellbore using expandable tubulars. In one aspect, the invention includes a tubular member with an expandable portion at a lower end constructed and arranged to be expanded into contact with a previously expanded liner. At an upper end of the tubular is a polish bore receptacle permitting the tubular to be tied back to the surface of the well with production tubing. In another aspect, the invention provides a method of completing a well comprising expanding a liner top into a cased wellbore to hang the liner and, thereafter running a tubular member into the wellbore.

Abstract: Tools for expanding downhole tubulars into each other or in open hole are disclosed. One embodiment uses a movable cone biased by Bellville washers to move longitudinally against such bias and allow collets to move radially in or out to a predetermined maximum diameter. A release system allows collet retraction to avoid hang up on removal. In an alternate embodiment, more suitable for open hole applications, pressurized gas pushes a movable cone longitudinally against the collets. A stationary cone is on the opposite side of the collets from the movable cone. The collet rides out or in between the cones and raises the gas pressure when forced in. A pressure actuated release allows the lower cone to shift downwardly to allow the collets to retract for removal.

Abstract: A wellbore expandable connection, which includes a tubular pin member having an outwardly facing tapered threaded section and a tubular box member having an inwardly facing tapered threaded section. The threaded sections form a connection of a predetermined integrity when the tubular pin member is mated with the tubular box member. The integrity of the connection is substantially maintained during radial expansion of the connection.

Abstract: The present invention provides an apparatus and methods for seating a whipstock. The apparatus comprises an expandable seat, or nipple, configured to receive a whipstock. The seat is run into a cased wellbore, and is set by expanding it into frictional contact with the inner surface of the casing. Thereafter, a whipstock is seated onto the seat. The seat includes a keyway configured to receive an orientation member extending from the whipstock. In this manner, the orientation of the seat can be determined. An orientation member of the whipstock can be adjusted to properly orient the face of the whipstock in the seat, and the whipstock lowered onto the seat so that it automatically seats in the proper direction. The whipstock then serves as a diverter tool for drilling a lateral wellbore such as a horizontal well.

Abstract: A tool is provided for preventing the rotation of a downhole tool or rotary pump stator, the tool comprising a tubular housing and a jaw which is biased radially outwardly from the tool to engage the casing wall for arresting tool rotation and providing significant stabilization of a rotary pump. In doing so, the tool housing moves oppositely to rest against the casing opposite the jaw. The tool housing and the downhole tool are thereby restrained and stabilized by the casing wall. The tool's jaw is released by opposite tool rotation. Preferably, the jaw is biased outwardly from the tool housing to a casing-engaging position by a torsional member, housed along the axis of the hinge of the jaw. The tool is released from the casing by opposite tool rotation which increasingly compresses the jaw toward the housing, twisting the torsional member into torsion, which then acts to urge the jaw outwardly again. Overextension of the jaw during assembly is prevented using cooperating stops in the jaw and the housing.

Abstract: An expandable packer or anchor is disclosed. It features a gripping device integral to or mounted in a sleeve over the mandrel and mating undulating surfaces to help maintain grip under changing load conditions. Upon expansion, pressure on a sealing element is enhanced by nodes to increase internal pressure as it engages an outer tubular. Adjacent retaining rings limit extrusion and enhance grip. A gripping device, such as wickers on slips, preferably digs into the outer tubular. The expansion is preferably by pressure and can incorporate pressure intensifiers delivered by slick line or wire line. Release is accomplished by a release tool, which is delivered on slick line or wire line. It stretches the anchor or packer longitudinally, getting it to retract radially, for release. The release tool can be combined with packers or anchors that have a thin walled feature in the mandrel, to release by pulling the mandrel apart.

Abstract: Methods and apparatus for suppression of wave energy within a fluid-filled borehole using a low pressure acoustic barrier. In one embodiment, a flexible diaphragm type device is configured as an open bottomed tubular structure for disposition in a borehole to be filled with a gas to create a barrier to wave energy, including tube waves. In another embodiment, an expandable umbrella type device is used to define a chamber in which a gas is disposed. In yet another embodiment, a reverse acting bladder type device is suspended in the borehole. Due to its reverse acting properties, the bladder expands when internal pressure is reduced, and the reverse acting bladder device extends across the borehole to provide a low pressure wave energy barrier.

Abstract: A method of manufacturing an expandable slotted tube fabricated from at least one tubular element and at least two annular elements connected to the opposite ends of the tubular element by means of butt joints wherein axially extending slots are formed at a uniform angular spacing around the periphery of the tube and in longitudinally overlapping relation characterized by cutting said annular elements in a pattern of overlapping positionally fixed slots in accordance with invariable parameters which are pre-determined relative to the dimensions of said annular elements and cutting in said tubular element a pattern of slots that is variable in accordance with measured parameters of the tube so as to achieve the required overlap between said positionally fixed and variable slots. A machine for carrying out the method is also described.

Abstract: The present invention provides an encapsulation for housing instrumentation lines, control lines, or instruments downhole. In one use, the encapsulation resides between an expandable downhole tool, such as an expandable sand screen, and the wall of the wellbore. The encapsulation is specially profiled to allow the downhole tool to be expanded into the wall of the wellbore without leaving a channel outside of the tool through which formation fluids might vertically migrate. The encapsulation is useful in both cased hole and open hole completions.

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.

Abstract: A wellbore anchoring device for anchoring a down-hole tool within a string of casing is provided, comprising an expandable cone having at least one annular integral shoulder, defining the large end of at least one conical annular recess on an outer surface of the cone, and at least one resilient slip positioned within the at least one annular recess, wherein axial travel of the at least one slip relative to the cone is actively limited by engagement with at least one integral shoulder on the cone.

Abstract: A substantially constant force actuator that is applicable to centralizers, anchors and tractors for use in wells and is applicable to lifting devices such as jacks and load supporting devices. One or more sets of linkage arms are angularly movable by the force of one or more force transmitting members from a minimum angle with the force transmitting members at maximum spacing to a maximum angle with the force transmitting members at minimum spacing to impart a substantially constant force to an object or surface, with the direction of the force being substantially perpendicular to the direction of relative linear movement of the force transmitting members. With the linkage arms at their minimum angles, movement control elements on at least one of the force transmitting members react with guide surfaces of the linkage arms to achieve angular linkage movement and to develop a substantially constant force during angular linkage movement.

Abstract: A six-bar linkage mechanism for conforming to the configuration of a tractored surface having a central link defined by a tool body and a saddle link spaced from the central link and movable for conforming with the tractored surface. A pair of front links each having pivotal connection with respective ends of the saddle link and having linearly movable pivotal connection with the central link to permit angular and spacing changes of the saddle link relative to the central link. A pair of centralizer links are located between the front links and have pivotal connections with the saddle link and pivotal connections with the central link. One of the pivotal connections is linearly movable on the central link. For tractor tools, when the tractored surface is a wellbore or well pipe, a plurality of six-bar linkages radiate from a tool body for surface conforming traction with the tractored surface.

Abstract: The present invention relates to a method of regulating the flow rate of formation fluids produced from a determined zone of an underground well whose cased wall is provided with orifices through which said formation fluids can pass, said method consisting in applying a tubular structure along the casing in said zone, which tubular structure prevents the fluids from flowing directly while also preserving a flow path along which the fluids can flow via the annular space outside the tubular structure so as to generate head loss. The invention also relates to a device for implementing said method, which device is essentially constituted by a radially-expandable tubular structure that can be applied against the inside wall of the casing, the structure being provided with means for preserving the flow of the fluids via a path running along the casing and along the structure, in order to generate head loss.

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 mono-diameter wellbore casing.

Abstract: A packer element has a biasing member incorporated with it. The element is either fabricated with the biasing element in a relaxed condition and then the element is stretched prior to insertion downhole or the element is created around the stressed biasing member and is held in that position until allowed to relax downhole. In either event the release of the element increases its diameter while shortening its length. Preferably, an advancing swage triggers the release to allow the element to expand as much as it can go or to the maximum relaxed diameter, whichever is larger. The swage then, preferably, drives the relaxed element toward the borehole wall or the casing.

Abstract: An improved method for completing wells, such as hydrocarbon wells, is provided. In one aspect, methods are provided for deploying an expandable tubular, such as an expandable sand screen, in a hydrocarbon well. According to methods of the present invention, a sand screen is lowered into a wellbore. Thereafter, cement is injected into the wellbore so as to place a column of cement in the annular region between the tubular and the surrounding formation. The cement is then treated so as to imbue greater permeability and/or porosity characteristics. The cement serves to reinforce the sand screen, providing it with both improved physical strength and improved sand filtering ability. At the same time, the sand screen serves to reinforce and strengthen the cement sheath placed in the wellbore.

Abstract: An apparatus and method for forming or repairing a wellbore casing by radially expanding a tubular liner.

Abstract: A wellhead is formed by extruding a plurality of tubular liners off of a mandrel into contact with an outer casing. The first tubular liner and mandrel are positioned within the wellbore with the tubular liner in an overlapping relationship with the outer casing. At least a portion of the tubular liner is extruded off of the mandrel into contact with the interior surface of the outer casing. The first tubular liner is extruded off of the mandrel by pressurizing an interior portion of the first tubular liner. Subsequent tubular liners are positioned in concentric overlapping relation and similarly extruded off of a mandrel into at least partial contact with the interior surface of the outer casing.

Abstract: A system for forming a patch in a well at a location along a tubular string which has lost sealing integrity includes a central patch body 60, an upper expander body 52 carrying an upper seal 50 or 56, and a lower expander body 98 carrying a lower seal 102, 104. The running tool includes an inner mandrel 14 axially moveable relative to the central patch body, and one or more pistons 20, 30, 20A axially moveable relative to the inner mandrel in response to fluid pressure within the running tool. Top expander 48 is axially moveable downward relative to the upper expander body in response to movement of the one or more pistons. The expander sleeves may remain downhole to radially support the downhole tubular.

Abstract: An anchor system for high expansion applications is described. It features a gripping member that holds together a pair of links. The movement of the links is regulated to assure the gripping member moves into proper contact with the casing. Meshing gears or a pin and slot can do this, for example. The gripping member is shaped such that it can still transmit load through the links even if the pin connections fail. The gripping member is preferably contoured to the shape of the casing inner wall to enhance grip.

Abstract: A method and apparatus for propelling a tool having a body within a passage. The tool includes a gripper including at least a gripper portion which can assume a first position that engages an inner surface of the passage and limits relative movement of the gripper portion relative to the inner surface. The gripper portion can also assume a second position that permits substantially free relative movement between the gripper portion and the inner surface of the passage. The tool includes a propulsion assembly for selectively continuously moving the body of the tool with respect to the gripper portion while the gripper portion is in the first position. This allows the tool to move different types of equipment within the passage. For example, the tool advantageously may be used in drilling processes to provide continuous force to a drill bit. This enables the drilling of extended horizontal boreholes.

Abstract: The present invention provides apparatus and a method of anchoring an expandable conduit. A formation is provided on an outer surface of the conduit, the formation comprising a number of bands of a friction and/or sealing material. When the expandable conduit is radially expanded, the friction and/or sealing material engages a second conduit in which the expandable conduit is located. The engagement of the friction and/or sealing material provides an anchor for the expandable conduit.

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.

Abstract: An apparatus and method for completing an interval of a wellbore while drilling comprises a drill string (52) having a drill bit (30) mounted on the lower end thereof. A completion assembly (50) is positioned around a section of the drill string (52) such that when the wellbore (32) is extended by rotating the drill bit (30) and advancing the drill string (52), the completion assembly (50) does not rotate. The advancement of the drill string (52) and rotation of the drill bit (30) is ceased when the completion assembly (50) has reached the desired interval of the wellbore (32). Thereafter, the drill string (52) is disconnected from the drill bit (30) for retrieval to the surface leaving the completion assembly (50) and the drill bit (30) downhole.

Abstract: The present invention provides apparatus and methods for completing a wellbore using expandable tubulars. In one aspect, the invention includes a tubular member with an expandable portion at a lower end constructed and arranged to be expanded into contact with a previously expanded liner. At an upper end of the tubular is a polish bore receptacle permitting the tubular to be tied back to the surface of the well with production tubing. In another aspect, the invention provides a method of completing a well comprising expanding a liner top into a cased wellbore to hang the liner and, thereafter running a tubular member into the wellbore.

Abstract: A particulate screen suitable for use in a wellbore. The particulate screen is expandable and may be at least partially formed of a bistable tubular. Also, a filter media may be combined with the bistable tubular to limit influx of particulates.

Abstract: A method of expanding tubing comprises the steps: providing a length of expandable tubing; locating an expansion tool, such as a cone, in the tubing; and applying impulses to the tool to drive the tool through the tubing and expand the tubing to a larger diameter. The tubing may be located downhole and may have a solid wall or a slotted wall.

Abstract: A system for forming a patch in a well at a location along a tubular string which has lost sealing integrity includes a central patch body 60, an upper expander body 52 carrying an upper seal 50 or 56, and a lower expander body 98 carrying a lower seal 102, 104. The running tool includes an inner mandrel 14 axially moveable relative to the central patch body, and one or more pistons 20, 30, 20A axially moveable relative to the inner mandrel in response to fluid pressure within the running tool. Top expander 48 is axially moveable downward relative to the upper expander body in response to movement of the one or more pistons, and a bottom expander 120 is axially moveable upward relative to a lower expander body. After the upper expander body and a lower expander body have been moved radially outward into sealing engagement with a downhole tubular string, the running tool is retrieved to the surface.

Abstract: An anchoring tool is provided for preventing rotation of a tubing string relative to a surrounding well casing in both right and left hand directions of rotation. The tool includes tubular housing for connection in line with the tubing string. A gripping member is supported alongside the housing for rotation about an anchor axis lying substantially parallel to the housing. The gripping member has a profile which increases in radial dimension from a first gripping portion to a second gripping portion thereof. The first gripping portion and the second gripping portion being arranged to grip the surrounding well casing in a retracted position and an extended position respectively. Rotation of the housing with the tubing string relative to the well casing rotates the gripping member in relation to the housing to vary an overall diameter of the anchoring tool within the well casing, thereby preventing further rotation.

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: The present invention includes a method and apparatus for setting a liner in a wellbore and then expanding a screen in the wellbore in a single trip. In one aspect of the invention, a liner and expandable screen is provided with a slip assembly to fix the liner in the wellbore. An expansion tool and work sting is run into the wellbore in the liner. After the liner is set, the expansion tool is used to expand the screen. In another embodiment, an annular area between the expansion tool and work string is utilized in order to set the slips. Thereafter, cup packers used in forming the annulus are lifted from the liner prior to expanding the screen.

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: (1) A steel pipe that is expanded radially in a state wherein it was inserted in a well such as an oil well, characterized in that the non-uniform wall thickness ratio E0 (%) before expanding satisfies the following expression {circle over (1)}.

Abstract: An expandable packer or anchor is disclosed. It features a gripping device integral to or mounted in a sleeve over the mandrel. Upon expansion, a sealing element engages an outer tubular and the gripping device, such as wickers on slips, preferably digs into the outer tubular. The expansion is preferably by pressure and can incorporate pressure intensifiers delivered by slick line or wire line. Release is accomplished by a release tool, which is delivered on slick line or wire line. It stretches the anchor or packer longitudinally, getting it to retract radially, for release. The release tool can be combined with packers or anchors that have a thin walled feature in the mandrel, to release by pulling the mandrel apart.

Abstract: A method of expanding tubing comprises the steps: providing a length of expandable tubing; locating an expansion tool, such as a cone, in the tubing; and applying impulses to the tool to drive the tool through the tubing and expand the tubing to a larger diameter. The tubing may be located downhole and may have a solid wall or a slotted wall.

Abstract: A system for forming a patch in a well at a location along a tubular string which has lost sealing integrity includes a central patch body 60, an upper expander body 52 carrying an upper seal 50 or 56, and a lower expander body 98 carrying a lower seal 102, 104. The running tool includes an inner mandrel 14 axially moveable relative to the central patch body, and one or more pistons 20, 30, 20A axially moveable relative to the inner mandrel in response to fluid pressure within the running tool. Top expander 48 is axially moveable downward relative to the upper expander body in response to movement of the one or more pistons, and a bottom expander 120 is axially moveable upward relative to a lower expander body. After the upper expander body and a lower expander body have been moved radially outward into sealing engagement with a downhole tubular string, the running tool is retrieved to the surface.

Abstract: A tool is provided for preventing the rotation of a downhole tool or rotary pump stator, the tool comprising a tubular housing and a jaw which is biased radially outwardly from the tool to engage the casing wall for arresting tool rotation and providing significant stabilization of a rotary pump. In doing so, the tool housing moves oppositely to rest against the casing opposite the jaw. The tool housing and the downhole tool are thereby restrained and stabilized by the casing wall. The tool's jaw is released by opposite tool rotation. Preferably, the jaw is biased outwardly from the tool housing to a casing-engaging position by a torsional member, housed along the axis of the hinge of the jaw. The tool is released from the casing by opposite tool rotation which increasingly compresses the jaw toward the housing, twisting the torsional member into torsion, which then acts to urge the jaw outwardly again.

Abstract: A well logging instrument is disclosed which includes a housing operatively coupled to a well logging conveyance and movable within the wellbore. The housing has therein a formation testing system and an axial extension mechanism. The axial extension mechanism controllably extends and retracts to allow the formation testing system to perform tests and take samples in an axially fixed position in the wellbore while the housing moves through the wellbore.