Abstract: An apparatus in a drill string comprises an internally upset drill pipe. The drill pipe comprises a first end, a second end, and an elongate tube intermediate the first and second ends. The elongate tube and the ends comprising a continuous an inside surface with a plurality of diameters. A conformable metal tube is disposed within the drill pipe intermediate the ends thereof and terminating adjacent to the ends of the drill pipe. The conformable metal tube substantially conforms to the continuous inside surface of the metal tube. The metal tube may comprise a non-uniform section which is expanded to conform to the inside surface of the drill pipe. The non-uniform section may comprise protrusions selected from the group consisting of convolutions, corrugations, flutes, and dimples. The non-uniform section extends generally longitudinally along the length of the tube. The metal tube may be adapted to stretch as the drill pipes stretch.

Abstract: An apparatus (200) and method for repairing an opening (130) in a wellbore casing (110). The apparatus (200) and method couple a floating tubular (250) member in opposing relation to the opening (130) in the wellbore casing (110).

Abstract: There are disclosed methods and apparatus for expanding downhole tubing. In one embodiment, there is disclosed a method of expanding tubing comprising providing an assembly 40 comprising a section of expandable tubing (42) and an expansion device in the form of an expansion mandrel (44) located at least partially externally of the tubing (42), running the assembly (40) into a bore, translating the expansion mandrel (44) relative to the tubing (42) to expand an end section of the tubing (42), and further translating the expansion mandrel (44) relative to the tubing (42) to expand a further section of the tubing (42).

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 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: An apparatus and method for coupling a tubular member to a preexisting structure.

Abstract: A well having a bore hole extending from surface to an underground formation, a casing arranged in the borehole, a tubing hanger supported on the top of the casing, a packer arranged in the casing at a predetermined depth, and a tubing extending from the tubing hanger to the packer, wherein the tubing includes a tubing section that consists of a tubular body of elastomeric material that is reinforced by axially extending reinforcement strands arranged in the tubular body.

Abstract: An apparatus in a drill string comprises an internally upset drill pipe. The drill pipe comprises a first end, a second end, and an elongate tube intermediate the first and second ends. The elongate tube and the ends comprising a continuous an inside surface with a plurality of diameters. A conformable spirally welded metal tube is disposed within the drill pipe intermediate the ends thereof and terminating adjacent to the ends of the drill pipe. The conformable metal tube substantially conforms to the continuous inside surface of the metal tube. The metal tube may comprise a non-uniform section which is expanded to conform to the inside surface of the drill pipe. The non-uniform section may comprise protrusions selected from the group consisting of convolutions, corrugations, flutes, and dimples. The non-uniform section extends generally longitudinally along the length of the tube.

Abstract: An apparatus for radially expanding tubular members including a segmented expansion cone.

Abstract: An apparatus for expanding a tubular member.

Abstract: A tubular liner including a first tubular portion, a second tubular portion, and an intermediate tapered tubular portion coupled to, and positioned between, the first and second tubular portions.

Abstract: The present invention provides for a seal assembly that maintains a seal under various conditions by providing a source of stored energy that can be used to insure contact forces are maintained.

Abstract: A mono-diameter wellbore casing. A tubular liner and an expansion cone are positioned within a new section of a wellbore with the tubular liner in an overlapping relationship with a pre-existing casing. A hardenable fluidic material is injected into the new section of the wellbore below the level of the expansion cone and into the annular region between the tubular liner and the new section of the wellbore. The inner and outer regions of the tubular liner are then fluidicly isolated. A non hardenable fluidic material is then injected into a portion of an interior region of the tubular liner to pressurize the portion of the interior region of the tubular liner below the expansion cone. The tubular liner is then extruded off of the expansion cone. The overlapping portion of the pre-existing casing and the tubular liner are then radially expanded using an expansion cone.

Abstract: An expansion apparatus for expanding a portion of a tubular comprises at least two expansion members adapted for selective deployment against a wall of a tubular. The expansion apparatus may be controlled to select a first expansion member to be deployed and the apparatus operated to expand a section of the tubular. The deployed expansion member may then be inactivated or retracted, such that the expansion member is no longer deployed against the wall of the tubular or is otherwise rendered inoperative, and a second expansion member can then be deployed and a further section of the tubular expanded.

Abstract: An apparatus and method for coupling a tubular member to a preexisting structure. The tubular member is anchored to the preexisting structure and an expansion member is displaced relative to the tubular member to radially expand the tubular member.

Abstract: Apparatus and methods are described that are particularly suited for creating a seal in a borehole annulus. In one embodiment, an outer surface 10s of an expandable conduit 10 is provided with a formation 20 that includes an elastomeric material (e.g. a rubber) that can expand and/or swell when the material comes into contact with an actuating agent (e.g. water, brine, drilling fluid etc). The expandable conduit 10 is located inside a second conduit (e.g. a pre-installed casing, liner or open borehole) and radially expanded. The actuating agent can be naturally occurring in the borehole or can be injected or pumped therein to expand or swell the elastomeric material to create the seal.

Abstract: Apparatus for and method of radial expansion of a tubular member, with embodiments of the apparatus including an expander device, for example an expansion cone, which has a driver device either attached to it or integral therewith. The driver device can be a pump for example, where the pump creates a differential pressure across the expander device to cause it to move.

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: (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 around (1)}. E0?30/(1+0.018?){circle around (1)} Wherein ? is the pipe expansion ratio (%) calculated by the following expression {circle around (2)}. ?=[(inner diameter of the pipe after expanding?inner diameter of the pipe before expanding)/inner diameter of the pipe before expanding]×100{circle around (2)} (2) A steel pipe that should be expanded radially in a state wherein it is inserted in a well, such as an oil well, characterized in that the eccentric non-uniform wall thickness ratio is 10% or less. When the embedding-expanding method is performed with use of the steel pipe of (1) or (2), lowering of collapse strength of the expanded steel pipe is prevented and bending thereof can be decreased.

Abstract: A casing junction member connects in a well between a main casing and a lateral branch casing. The junction member has an upper end section which connects to the main casing extending above the member. It has a lower end section that is coaxial and connects into the main casing below the junction member. The junction member has a lateral section which extends downward for connecting to lateral branch casing. The junction between the main section and the lateral section has enlarged sections that are formed by opposed cones. A removable or drillable closure member blocks the lateral passage while in the collapsed and expanded positions. The casing junction uses internal fluid pressure to move from collapsed position to expanded position.

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Abstract: The present disclosure addresses apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. A first deployable annular isolator is carried on tubing as it is positioned in a borehole. An annular isolator forming material is placed in the annulus around the first deployable isolator. The first isolator is then deployed into the material in the annulus to form a combined isolator. The annular isolator forming material is carried in a compartment in the tubing and forced from the compartment into the annulus. A second deployable isolator may be deployed before placing the material in the annulus to resist annular flow of the material before the first isolator is deployed. The second isolator may be deployed by material from the compartment. A second compartment may be provided to deploy the first isolator.

Abstract: The present invention provides methods and compressible foamed sealing compositions for sealing expandable pipe in well bores. The compressible sealant compositions for sealing expandable pipe are basically comprised of a hydraulic cement, a rubber latex, a rubber latex stabilizer, a gas and a mixture of foaming and foam stabilizing surfactants.

Abstract: A borehole may be drilled utilizing the bottom hole assembly 10, 50 with a downhole motor 14, which may offset at a selected bend angle. A gauge section 34 is secured to the bit 16 has a uniform diameter bearing surface along an axial length of at least 60% of the bit diameter. The axial spacing between the bend and the bit face is controlled to less than fifteen times the bit diameter. After drilling a section of the well with the BHA according to the present invention, a tubular may be inserted in the well by passing the tubular through an upper tubular, then the inserted tubular expanded while downhole to a diameter substantially equal to the expanded tubular.

Abstract: An expandable well screen having a temporary sealing substance. In a described embodiment, a method of installing a well screen in a subterranean well includes the steps of: providing the screen including a temporary sealing substance preventing fluid flow through a wall of the screen; positioning the screen in a wellbore of the well; expanding the screen in the wellbore; and degrading the sealing substance, thereby permitting fluid flow through the screen wall.

Abstract: A mono-diameter wellbore casing. The mono-diameter wellbore casing is formed by plastically deforming and radially expanding a first tubular member within a wellbore. A second tubular member is then plastically deformed and radially expanded in overlapping relation to the first tubular member. The second tubular member and the overlapping portion of the first tubular member are then radially expanded again.

Abstract: A device for expansion and calibration of profile pipes, such as profile liners, with cylindrical threaded ends in their installation in a well. The device has a plurality of in-series connected mandrel assemblies, each of which has a housing with a central straight-through channel and inclined slots, in which rains are fastened and hinge-connected through pushers, tightened with respect to the housing, with a spring-loaded rod, accommodated in the central straight-through channel of the housing. Rods of an upper mandrel assembly are spring-loaded for holding the rams in nonoperating position, and rods of a lower assembly are spring-loaded for holding the rams in operating position. The lower mandrel assembly is provided with a choke. The Maximum diameter of a circle circumscribed about each mandrel assembly in its working position decreases from the upper assembly to the lower one.

Abstract: A mono-diameter wellbore casing. The mono-diameter wellbore casing is formed by plastically deforming and radially expanding a first tubular member within a wellbore. A second tubular member is then plastically deformed and radially expanded in overlapping relation to the first tubular member. The second tubular member and the overlapping portion of the first tubular member are then radially expanded again.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, a plurality of pressure chambers defined by and positioned between the support member and the expansion device fluidicly coupled to the first fluid passage, and one or more releasable supports coupled to the support member adapted to support the tubular member positioned below the expansion device.

Abstract: A tie back assembly that uses expansion for connection and sealing is disclosed. The male component does not have any wall portions removed to hold a resilient seal. A seal is an option as anchoring and sealing can be accomplished by the expansion alone. The pressure rating of the connection is not reduced by material removed to accommodate a seal. A variety of expansion techniques can be used and the expansion can be done in a single trip with the insertion of the tie back assembly into the receptacle or in a separate trip.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member comprising a fluid passage, an expansion device for radially expanding and plastically deforming the tubular member movably coupled to the support member for longitudinal displacement relative to the support member, a plurality of pressure chambers defined by and positioned between the support member and the expansion device fluidicly coupled to the first fluid passage, one or more releasable supports coupled to the support member adapted to support the tubular member positioned above the expansion device.

Abstract: A device for forming a wellbore casing in a borehole, according to which the device includes a support member including a first fluid passage, and an expansion cone coupled to the support member. The support member includes a second fluid passage, which is fluidicly coupled to the first fluid passage. The device further includes an expandable tubular liner movably coupled to the expansion cone, and an expandable shoe coupled to the expandable tubular liner.

Abstract: A technique utilizes blocking members to resist contraction of expandables in wellbore environments. The technique comprises an expandable having a wall with a plurality of expandable cells. A plurality of blocking members cooperate with at least some of the cells to resist contraction of the expandable device once transitioned to a desired expanded state.

Abstract: A tool for radially expanding casing having a tool body that includes a proximal end, a distal end, and an outer surface. The tool includes at least one hydraulic channel disposed axially. The at least one hydraulic channel transmits hydraulic pressure from behind the expansion tool forward in the direction of travel of the expansion tool.

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. A method comprises providing a tubular string having a non-porous tubular portion and a porous tubular portion, and installing the tubular string within a wellbore such that the porous tubular portion is located adjacent a fluid-producing formation within the wellbore. In another embodiment, an apparatus comprises a drill string comprising a non-porous tubular portion and a porous tubular portion, and an earth removal member operatively connected to a lower end of the drill string.

Abstract: Composite tubulars that have not been polymerized and are thus flexible enough to be coiled are delivered into a wellbore and expanded. The expansion occurs from an external catalyst such as heat or releases the internal catalyst and allows the expanded tubular to become rigid. Optionally, healing agents can be imbedded in the tubular wall to be released to seal subsequently forming cracks.

Abstract: Apparatus and methods for radially expanding a tubular such as a drill pipe, liner, casing or the like. The apparatus includes at least one driver device such as a piston that is typically fluid-actuated, and an expander device is attached to the or each driver device. Actuation of the or each driver device causes movement of the expander device to expand the tubular. In certain embodiments, one or more anchoring devices are used to substantially prevent the tubular from moving during expansion thereof.

Abstract: An apparatus suitable for use in a wellbore comprises an expandable bistable device. An exemplary device has a plurality of bistable cells formed into a tubular shape. Each bistable cell comprises at least two elongated members that are connected to each other at their ends. The device is stable in a first configuration and a second configuration.

Abstract: A mono-diameter wellbore casing. A tubular liner and an expansion cone are positioned within a new section of a wellbore with the tubular liner in an overlapping relationship with a pre-existing casing. A hardenable fluidic material is injected into the new section of the wellbore below the level of the expansion cone and into the annular region between the tubular liner and the new section of the wellbore. The inner and outer regions of the tubular liner are then fluidicly isolated. A non hardenable fluidic material is then injected into a portion of an interior region of the tubular liner to pressurize the portion of the interior region of the tubular liner below the expansion cone. The tubular liner is then extruded off of the expansion cone. The overlapping portion of the pre-existing casing and the tubular liner are then radially expanded using an expansion cone.

Abstract: An expander tool for expanding a first tubular into a second surrounding tubular within a wellbore. The expander tool first comprises a body. Within the body is an expansion member capable of being actuated outwardly from the body when expansion of the first tubular is desired. In one aspect, the expander tool is a rotary expander tool, and the expansion members define a plurality of rollers. The expander tool further comprises at least one sensor for sensing a downhole condition during expansion of the tubular. The sensors in one aspect include at least one tool for sensing wall dimensions of the first tubular such as inner diameter or wall thickness. Examples include sonic logs, caliper logs, and electromagnetic wall thickness tools. A depth gauge may also be included. In one aspect, a data transmission device is provided between a surface server and the sensors downhole. In this way, the operator at the surface can monitor progress of the expansion operation downhole.

Abstract: Methods of and apparatus for drilling, casing and/or completing a borehole wherein one or more portions of the borehole are drilled into a formation at a single diameter along the entire length or depth of the or each portion of the borehole. An expandable tubular member is then located within the or each portion of the borehole and radially expanded in the or each portion to line and/or case it or them. Optionally, a corrosion resistant member and/or a service string can be located in the borehole. An advantage of certain embodiments is that a single diameter borehole is formed along the entire length or depth thereof.

Abstract: Apparatus for and a method of expanding tubulars, and particularly tubulars or a string of tubulars that have one or more per orated portions and one or more non-perforated portions. In one embodiment, the apparatus (150) includes an inflatable element (e.g. a packer 152) that has a shaft (156) rotatably coupled thereto so that the shaft (156) can rotate relative to the inflatable element (152). An expansion cone (158) is threadedly engaged with a threaded portion (156t) of the shaft (156) so that it moves along the threaded portion (156t) upon rotation of the shaft (156) relative to the cone (158).

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 mono-diameter wellbore casing. The mono-diameter wellbore casing is formed by plastically deforming and radially expanding a first tubular member within a wellbore. A second tubular member is then plastically deformed and radially expanded in overlapping relation to the first tubular member. The second tubular member and the overlapping portion of the first tubular member are then radially expanded again.

Abstract: An apparatus and method for forming or repairing a wellbore casing, a pipeline, or a structural support. An expandable tubular member is radially expanded and plastically deformed by an expansion cone that is displaced by hydraulic pressure. Before or after the radial expansion of the expandable tubular member, a sliding sleeve valve within the apparatus permit a hardenable fluidic sealing material to be injected into an annulus between the expandable tubular member and a preexisting structure.

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: A system for lining a section of a wellbore with an expandable tubular element is provided. The system includes an elongate string extending into the wellbore, the string being provided with the tubular element in the unexpanded form thereof whereby the tubular element surrounds a lower portion of the string. The string is further provided with an expander arranged at a lower end part of the tubular element and anchoring means for anchoring an upper end part of the tubular element in the wellbore.

Abstract: A mono-diameter wellbore casing. The mono-diameter wellbore casing is formed by plastically deforming and radially expanding a first tubular member within a wellbore. A second tubular member is then plastically deformed and radially expanded in overlapping relation to the first tubular member. The second tubular member and the overlapping portion of the first tubular member are then radially expanded again.

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.

Abstract: An expandable device, such as a sand screen, is used in a wellbore. The expandable device comprises an expandable base pipe and a filter layer that facilitates expansion of the device while maintaining filtering capability.