Abstract: A method of expanding tubing downhole comprises the steps of: providing tubing (14;44) of a first diameter; running the tubing into a bore (10;40); expanding a first section of the tubing to a second diameter, and expanding a second section of the tubing to a third diameter.

Abstract: An expansion cone for radially expanding tubular members.

Abstract: There is disclosed, in one embodiment of the invention an expandable downhole tubular (10) comprising an expandable inner support tube (14) an expandable outer tube (18); and a filter tube (22) located between said inner support tube (14) and said outer tube (18), the filter tube (22) comprising at least one filter portion (24) and at least one extendable portion (28) coupling axial edges of said filter portion (24), said extendable portion (28) being extendable to accommodate circumferential expansion of said filter tube (22).

Abstract: Aspects of the invention relate to apparatus and methods for remedial and repair operations downhole. Certain embodiments of apparatus include a lightweight expandable member (22) that can be radially expanded to increased its inner and outer diameters using an inflatable element (34). The lightweight member (22) can be used to repair a fautly safety vavle flapper (12) for example. The invention also relates to lateral tubular adapter apparatus and a method of hanging a lateral from a cased borehole.

Abstract: A method of isolating a section of a drilled bore containing a problem zone comprises: providing a section of tubing; locating the tubing in the section of the bore; and expanding the tubing and forming at least an outer portion of the tubing to conform to irregularities in the bore wall, to isolate the problem zone. The tubing may feature a formable outer section, and the expansion of the tubing may be achieved using a compliant rotary expander.

Abstract: An improved system and method is disclosed for expanding a fluid permeable tubular downhole in an open hole completion. A high quality borehole is first drilled using a bottomhole assembly having a long gauge bit and a short bit-to-bend ratio. A fluid-permeable tubular is then inserted into an open-hole portion of the wellbore and preferably expanded in place. The expandable tubular may include an external filtering medium. Hydrocarbons may pass from the formation through the expanded fluid permeable tubular and into the borehole, to be recovered.

Abstract: An assembly and methods for constructing a MONOWELL includes a monodiameter casing disposed in a monodiameter wellbore having diametric efficiency with a monobore production delivery system disposed within the monodiameter casing. An assembly for constructing a monodiameter wellbore includes a bottomhole assembly having a overgauge hole drilling member, a directional steering assembly, a measurement while drilling tool, and a logging while drilling tool; a work string attached to the bottomhole assembly and extending to the surface; drilling fluids flowing through the work string and bottomhole assembly; chemical casing casing the borehole; expandable casing disposed in the wellbore; and a sealing composition disposed between the expandable casing and the wellbore.

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 method of applying an axial force to a first piston positioned within a first piston chamber including applying an axial force to the first piston using a second piston positioned within the first piston chamber.

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: A wellbore system having a borehole extending into an earth formation, a tubular element extending into the borehole whereby a cylindrical wall surrounds the tubular element in a manner that an annular space is formed between the tubular element and the cylindrical wall, at least one seal member arranged in the annular space, each seal member being movable between a retracted mode in which the seal member has a first volume and an expanded mode in which the seal member has a second volume larger than the first volume, wherein the seal member in the expanded mode thereof seals the annular space, and wherein the seal member includes a material which swells upon contact with a selected fluid so as to move the seal member from the retracted mode to the expanded mode thereof.

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: At least a first expandable tubular and a second expandable tubular are connected to each other by a connector system. The connector system is expandable and utilizes a plurality of extensions that may be used to create an interlocking engagement. The system design enables both the tubulars and the connector system to be expanded to an increased diameter.

Abstract: An expandable sand control screen (100) that is positionable within a wellbore comprises a fluid permeable generally tubular member (102) that is expanded downhole. A filtering assembly is disposed exteriorly of the generally tubular member (102). The filtering assembly includes a filter medium (106) that prevents the flow of particulate material of a predetermined size therethrough but allows the flow of production fluids therethrough. The filtering assembly also includes a compliable member (118) that has a thickness that is radially variable downhole. During or after expansion of the expandable sand control screen (100), the radial variability of the thickness of the compliable member (118) allows the expandable sand control screen (100) to comply with any irregularities in the wellbore profile, thereby preventing any void regions between the expandable sand control screen (100) and the wellbore.

Abstract: A method of selecting tubular members.

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: An apparatus and method for repairing a wellbore casing (100). An opening (115) in a wellbore casing (100) is located using a logging tool (310). An expandable tubular member (370) is then positioned in opposition to the opening (115) in the wellbore casing (100). The expandable tubular member (370) is then radially expanded into intimate contact with the wellbore casing (100).

Abstract: An apparatus for radially expanding tubular members.

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

Abstract: A technique for deploying expandables is provided. The technique comprises actuating an expansion tool such that the expansion tool imparts an outwardly directed radial force on an expandable tubular. More specifically, the expansion tool imparts radial expansion forces against an interior surface of the tubular thereby allowing the tubular to be deployed in a wellbore environment.

Abstract: An expansion cone 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: A method for expanding tubulars including providing an expandable tubing and a larger diameter tubing, wherein the larger diameter tubing has an expandable, tapering end portion; coupling an end portion of the expandable tubing to the expandable tapering end portion of the larger diameter tubing; running the connected tubing into a bore; and expanding the expandable tubing. Prior to the expanding of the expandable tubing, a wall thickness of the end portion of the expandable tubing coupled to the expandable tapering end portion of the larger diameter tubing is less than a wall thickness of another end portion of the expandable tubing.

Abstract: The present invention provides methods and apparatus for expanding a first, smaller diameter tubular into frictional contact with a second, larger diameter tubular or wellbore. In an embodiment, annular formations formed on an inner surface of a split ring engage an outer surface of the smaller tubular. In one aspect, the smaller diameter tubular is provided with an annular recess there around, the annular recess including recessed grooves formed there around. Therefore, the split ring is disposable within the annular recess and the annular formations formed on the split ring are constructed and arranged to fit within the recessed grooves of the annular recess of the tubular. An outer surface of the split ring is provided with teeth or some other grip-enhancing material or formation. The split ring also includes a split portion permitting the ring to expand in diameter as that portion of the tubular is expanded in diameter.

Abstract: A screen that conforms to the borehole shape after expansion is disclosed. The screen comprises a compliant outer layer that takes the borehole shape on expansion. The outer layer is formed having holes to permit production flow. The material that is selected preferably swells with prolonged contact to well fluids to further close off annular gaps after expansion. In an alternative embodiment, the screen is not expanded and the swelling of the material alone closes off annular gaps. The outer sleeve is placed over the screen and the screen is placed on a base pipe and initially expanded from within the base pipe to secure the components of the screen assembly for running downhole, while minimizing or eliminating any welding among the layers. A variety of expansion tools can be used to expand the screen or screens downhole.

Abstract: A structural support.

Abstract: There is provided a method of radially expanding a tubular element extending into a wellbore, the tubular element having a first section to be expanded to a first diameter and a second section to be expanded to a second diameter, the first diameter being larger than the second diameter. The method involves arranging an expander in the wellbore, the expander including a first expander member and a second expander member, wherein the first member has a larger outer diameter than the second member, said members being releasably interconnected. The expander is moved through the first tubular section thereby expanding the first tubular section to the first diameter, whereafter the second expander member is released from the first expander member. The second expander member is then moved through the second tubular section so as to expand the latter to the second diameter.

Abstract: The present invention provides methods and apparatus for cutting tubulars in a wellbore. In one aspect of the invention, a cutting tool having radially disposed rolling element cutters is provided for insertion into a wellbore to a predetermined depth where a tubular therearound will be cut into an upper and lower portion. The cutting tool is constructed and arranged to be rotated while the actuated cutters exert a force on the inside wall of the tubular, thereby severing the tubular therearound. In one aspect, the apparatus is run into the well on wireline which is capable of bearing the weight of the apparatus while supplying a source of electrical power to at least one downhole motor which operates at least one hydraulic pump. The hydraulic pump operates a slip assembly to fix the downhole apparatus within the wellbore prior to operation of the cutting tool. Thereafter, the pump operates a downhole motor to rotate the cutting tool while the cutters are actuated.

Abstract: A method of lining and drilling a bore (10) comprises the steps of mounting a first section of bore-lining tubing (20) on the lower end portion of a drill string (18). The method also includes running the drill string and tubing into a bore having an unlined section and an existing tubing lined section, locating the first tubing section (20) in the unlined section, uncoupling the first tubing section (20) from the drill string (18), and drilling the bore beyond the first tubing section.

Abstract: A method of installing an internal latch profile in an existing tubular string does not require the use of a packer. In a described embodiment, a method of latch installation includes the step of deforming an interior surface of the tubular string after the tubular string is positioned in a well. In another described embodiment, a method of latch installation includes the step of cutting into the interior surface of the tubular string.

Abstract: A first tubular is disposed coaxially within a portion of a second, larger tubular. A portion of the first tubular is expanded into frictional contact with the second tubular, thereby creating a liner and a hanger. In one embodiment, a pattern of grooves and profile cuts are formed in the surface of a portion of the first tubular body. The grooves in one aspect define a continuous pattern about the circumference of the tubular body which intersect to form a plurality of substantially identical shapes, such as diamonds. The grooves and profile cuts serve to improve the tensile strength of the tubular body. At the same time, the grooves and profile cuts allow for expansion of the tubular body by use of less radial force. The grooves and profile cuts further provide additional frictional support for hanging the expanded tubular onto the inner surface of a surrounding second tubular.

Abstract: A connector arrangement used for connecting a first tubular to a second tubular. The first tubular member has at least one circumferential ring profile, and the second tubular member has a corresponding number of matching circumferential ring profiles. When the ring profiles of the two tubulars are mated and interlocked, they form separate and independent fluid seals as well as a mechanical lock able to hold the tubulars together during future expansion of the entire tubular and joint. Further, selecting properties of the tubulars such as yield strength and modulus of elasticity or constraining a diameter of one of the tubulars during expansion or compression forms a tight connection due to elastic recovery of the tubulars.

Abstract: A sand control screen assembly (60) comprises a base pipe (62) having at least one opening (64) that allows fluid flow therethrough and a filter medium (66) positioned about the exterior of the base pipe (62) that allows fluid flow therethrough and prevents particulate flow therethrough. An inflatable seal member (72) is disposed within the at least one opening (64) of the base pipe (62) and controls fluid flow through the at least one opening (64). An inflation fluid source (74) is in fluid communication with the inflatable seal member (72) and provides an inflation fluid to the inflatable seal member (72) to selectively urge the inflatable seal member (72) into sealing engagement with the at least one opening (64).

Abstract: The present invention generally relates to a sealing apparatus for isolating a wellbore. In one aspect, the present invention provides an expandable sealing apparatus having an expandable tubular and a sealing element disposed around the tubular. A chamber for maintaining a fluid is defined between the sealing element and the tubular. The sealing apparatus also includes a self-isolating layer disposed in the chamber, wherein the self-isolating layer is adapted and arranged to regulate fluid flow through the chamber. Fluid supplied to the chamber may inflate the sealing element, thereby urging the sealing element into contact with the wellbore. When the pressure in the tubular is released, the pressure in the chamber causes the self-isolating layer to close off, thereby retaining the pressure in the chamber.

Abstract: The present invention generally relates to a connector arrangement for connecting a first tubular to a second tubular. In particular, the present invention relates to methods and apparatus for connecting the tubulars in such a way that the connection is prevented from becoming unmade in response to expansion of the tubulars. A connector mechanically mates a box end and a pin end of the tubulars together to form the connection. Additionally, mating castellations, surface finishes on the pin end and the box end, torque screws, and a variable pitch groove can provide resistance to relative rotation between the tubulars at the connection.

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 comprises locating an expansion tool in a section of tubing to be expanded, applying a fluid pressure to the tubing to create a fluid pressure expansion force and induce a hoop stress in the tubing, and applying a mechanical expansion force to the tubing via the expansion tool. The combined fluid pressure expansion force and mechanical expansion force is selected to be sufficient to induce expansion of the tubing.

Abstract: An apparatus and methods for preventing the accumulation of unwanted materials in an enlarged inner diameter portion of a casing or housing. In one aspect of the invention, a sleeve is disposed in the housing to isolate an annular area defined by the outer surface sleeve and the wall of the enlarged inner diameter portion. The sleeve prevents unwanted materials from being disposed in the annular area. The sleeve can later be expanded into the enlarged inner diameter portion, removed from the wellbore or destroyed. In another aspect of the invention, the sleeve is provided and disposed to cover the enlarged inner diameter portion. By covering the enlarged inner diameter portion, unwanted material is prevented from accumulating at said portion and from interfering with the expansion of the next casing into said portion to form a monobore. The sleeve can be made from materials that are dissolvable, elastically deformable, or retrievable.

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: The present invention provides apparatus and methods for completing a wellbore using expandable tubulars. Particularly, the invention relates to a system of completing a wellbore through the expansion of tubulars. More particularly, embodiments of the present invention relate to the concurrent expansion of a first and second tubular, wherein the first tubular contains a polished bore receptacle configured to sealingly receive a portion of the second tubular thereby providing a sealable connection therebetween.

Abstract: An apparatus comprising a first tubular member; a second tubular member positioned within and coupled to the first tubular member; a first annular piston chamber defined by the space between the first and second tubular members; an annular piston movably coupled to the second tubular member and positioned within the first annular piston chamber; and a third tubular member for receiving the first and second tubular members coupled to the first tubular member. The third tubular member comprises a radially expandable and plastically deformable tubular member.

Abstract: In one variation, a tool is disclosed that can run cladding into casing where the cladding interior is closed off by opposed cup seals and access to the volume between the cup seals exists through the tool body. “Cladding” comprises sleeves, scrolls, casing, tubing and liner strings. Pressure is applied to the interior of the cladding to expand it into gripping and sealed contact with the casing. An exterior gripping surface can be provided on the cladding to enhance grip upon expansion. The tool can be repositioned to expand lengths of cladding including tubing or casing.

Abstract: A tool and method for treating an open hole just before expanding a screen into position is described. The swage is hydraulically driven and permits flow through it and out lateral ports to impact the borehole wall. A cup seal assembly below and a packer up above insure that the fluid impacts the borehole wall with sufficient force to dislodge the mud cake. Another feature of the invention is that the surface treatment and screen expansion can be done in one trip. The pressurized fluid that drives the swage also provides the fluid energy to prepare the borehole wall just before the screen is expanded against it.

Abstract: A method of coupling first and second tubulars (12,14) comprises providing a first tubular having a first yield strength and a second tubular having a higher second yield strength. A portion of the first tubular is located within and overlapping a portion of the second tubular and the first tubular is expanded sufficient to expand the second tubular, at least the first tubular being expanded beyond its yield point. Following expansion, a degree of elastic contraction of the tubulars is permitted, sufficient to provide interference between the tubulars.

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 generally relates to methods of connecting two expandable tubulars. In one aspect, the method includes flash welding the ends of the expandable tubulars together. Thereafter, the connected tubulars are lowered into the wellbore for expansion. The flash welding process provides a highly reliable joint for expansion. In another aspect, the present invention provides a method for expanding a non-uniform tubular. In one embodiment, the non-uniform tubular is formed by connecting two misaligned tubulars.

Abstract: The present invention generally relates to methods of connecting two expandable tubulars. In one aspect, the method includes flash welding the ends of the expandable tubulars together. Thereafter, the connected tubulars are lowered into the wellbore for expansion. The flash welding process provides a highly reliable joint for expansion.

Abstract: Embodiments of the present invention generally relate to a joint used with expandable sand screens and other expandable tubulars that permits elongation or contraction of the expandable tubulars during a tubular expansion operation within a wellbore. In one aspect, a connection assembly for use with expandable tubulars is provided. The connection assembly includes a first expandable tubular axially fixable at one end within a wellbore and a second expandable tubular axially fixable at one end within the wellbore. The second expandable tubular has an opposite end adapted to receive an opposite end of the first expandable tubular to provide a joint between the tubulars. The connection assembly further includes a releasable connection between the opposite ends of the tubulars for selectively permitting axial movement of the opposite ends relative to each other. In another aspect, a method for joining a first expandable tubular and a second expandable tubular is provided.