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.

Abstract: A tubing coupling method is provided. In one aspect, the method comprises providing a length of expandable tubing and a length of larger diameter non-expanding tubing, connecting an end portion of the expandable tubing to an end portion of the non-expanding tubing, running the tubing into a bore, and expanding the expandable tubing. The expandable tubing may form part of an expandable well or sand screen, or may be an expandable bore liner.

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 expanding wellbore junction system, apparatus and methods are provided for forming a sealed wellbore intersection in a subterranean well. In one described method, an expandable wellbore junction is expanded within an under-reamed cavity in a wellbore. Intersecting tubular legs of the wellbore junction are then drifted using a drifting apparatus. A deflection device may be used to direct a drift of the drifting apparatus into a selected one of the wellbore junction legs.

Abstract: A method for securing and sealing one tubular to another downhole facilitates cementing prior to sealing and allows for suspension of one tubular in the other by virtue of pipe expansion techniques.

Abstract: A casing liner and method for lining a casing affixed in a well bore. The casing liner having a plurality of grooves and ridges arranged longitudinally and in an alternating relationship about the exterior surface of the casing liner to increase stress storage upon the casing liner being radially reduced in size and thereby decrease the expansion rate of the casing liner and facilitate installation of the casing liner into the casing.

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 method of connecting a first pipe to a second pipe having an end part fitting into an end part of the first pipe, comprising arranging the end part of the second pipe within the end part of the first pipe, arranging a sleeve of a deformable material between said end parts, and radially expanding the end part of the second pipe towards the end part of the first pipe so as to bias the sleeve between said end parts.

Abstract: A slotting geometry for a metal pipe for use in fabricating slotted liners. The slotting geometry includes one or more integral substantially continuous unslotted helical coils extending around a peripheral sidewall for sustantially the entire length of a tubular body. There are helical regions between the coils containing slots arranged to create generally trapezoidally shaped elongated struts joining the edges of adjacent coils. Ends of the tubular body have unslotted connecting portions, thereby facilitating connection with the tubular body. Slotted liners fabricated using this slotting geometry have the capability of having their outer diameter expanded or contracted. This has utility when inserting or removing the slotted liners iinto a well bore. By expanding or contracting the outer diameter, the slots can be made to be sider or narrower, this has utility in controlling slot width.

Abstract: The present invention relates to methods and apparatus for expanding tubulars in a wellbore. In one aspect of the invention, an expansion tool with hydraulically actuated, radially expandable members is disposed on a string of coil tubing. In another aspect of the invention the apparatus is utilized to expand a tubular lining a lateral wellbore into contact with a window of a larger tubular lining a central wellbore.

Abstract: A method of streamlining expansion of long lengths of tubulars or screen is disclosed. In one embodiment, the expansion assembly is coupled with a length of pipe that acts as a weight and has a length longer than the anticipated section to be expanded. There is a stinger that fits into the pipe above the anchor and a seal to maintain sealing contact despite the downhole advance of the expansion assembly following each stroke of the expansion device and advance of a swage. By sequentially applying and removing pressure, the desired length is expanded downhole. Alternatively, coiled tubing is connected to the expansion assembly and weights that are above it and is paid out into the well as the expansion assembly descends after each stroke.

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 tubing connection arrangement that includes two expandable tubing sections is disclosed. In one embodiment, each of the tubing sections includes a filter screen sandwiched between inner expandable tubing and outer expandable tubing. On expansion of the tubing sections, the outer tubing provides resistance to radial expansion of the inner tubing in order to ensure that the integrity between the tubing sections is maintained. The filter screen of one of the tubing sections overlaps the filter screen of the other tubing section, and the outer expandable tubing of at least one of the tubing sections extends over the overlapping filter screens.

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.

Abstract: An apparatus including a support member, the support member including a first fluid passage, a mandrel coupled to the support member, the mandrel including: a second fluid passage, a tubular member coupled to the mandrel, and shoe coupled to the tubular liner, the shoe including a third fluid passage, and a drilling assembly coupled to the shoe, wherein the first, second and third fluid passages and the drilling assembly are operably coupled.

Abstract: A splicing system that accommodates the splicing of tubing having internal power cable. The splice system is amenable to use in subterranean environments where sections of continuous tubing are spliced along with the splicing of internal power cable. The splice technique comprises utilization of an expandable connector that permits lineal movement of the internal segments of power cable.

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: The present invention provides apparatus and methods for expanding an expandable sand screen in the wellbore and then fracturing the wellbore. In one aspect of the invention, an expandable sand screen includes a perforated inner pipe and outer shroud. The outer shroud includes a plurality of longitudinal channels that retain their general shape after the expandable sand screen is expanded. In the expanded state, the channels provide a fluid conduit along an area between the screen and the wall of the wellbore. In a subsequent fracturing operation, slurry travels along the conduits permitting communication of the fracturing slurry with hydrocarbon bearing formations.

Abstract: An expanding screen has an associated spirally wrapped exterior control line. The control line rests in a spiral trough made up in an exterior perforated jacket. The trough can be made by a pair of ridges disposed substantially parallel to each other or by an ordered spacing of raised dimples in the outer perforated jacket to create spiral troughs. At the screen connections centralizers having a spiral path or paths within can serve a dual function of locating the screen prior to expansion and protecting the control line in the joint area. A fiber optic cable can be placed in the control line.

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: Apparatus and methods are disclosed for anchoring a first conduit to a second conduit. The first conduit is typically an expandable conduit whereby at portion of the first conduit is expanded by applying a radial force thereto to provide an anchor and/or seal between the first and second conduits. An inflatable device is provided that can be used to provide a temporary anchor while the first (expandable) conduit is radially expanded. An expander device that is capable of applying a radial expansion force to the first conduit is optionally attached to the inflatable device.

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: The present invention provides a cement shoe assembly for use on a string of tubulars in a well. In one aspect of the invention, the cement shoe assembly includes a housing having a lower portion with an enlarged inside diameter and a drillable cement shoe disposed therein. The shoe includes a weakened portion of material adjacent the enlarged inside diameter portion of the housing and ensures that as a cutting tool passes through the housing, all portions of the cement shoe are removed from the enlarged inside diameter portion, leaving a connection surface clear of debris for a subsequent tubular string. When a smaller tubular is expanded into the enclosed diameter portion of the housing, a connection is made therebetween without enlarging the outer diameter of the housing.

Abstract: A method of attaching a tubular to an existing tubular in a well without reducing the inside diameter of the well is described. A shoe is attached to the lower end of the existing lowermost casing or tubular, generally prior to the casing being cemented or otherwise secured in the wellbore. The shoe has a diameter larger than the inside diameter of the casing or tubular to which it is attached. Subsequently, a liner is run in until its top end is in the enlarged diameter region of the shoe. A hanger can be optionally used. The liner is expanded into the enlarged diameter so that the net result is that the inside diameter in the wellbore is not reduced by the addition of the liner.

Abstract: An improved expansion assembly for an expander tool is provided. The expander tool is used to expand a surrounding tubular body within a wellbore. Accordingly, a method for expanding a surrounding tubular is also provided. The expansion assembly first comprises a piston disposed within a recess of the expander tool. The top surface of the piston closely receives a pad. The pad is held in close proximity to the top surface of the piston such that it does not rotate about a shaft. This arrangement reduces the geometric size of the expansion assembly, affording a larger inner diameter for the hollow bore of the expander tool itself. At least one reinforcement member is disposed on or within the pad to strengthen the pad during an expansion operation. The reinforcement member is fabricated from a durable material, and is arranged along the pad in the area of contact with the surrounding tubular during an expansion operation.

Abstract: The present invention generally relates to an apparatus for use in a wellbore. In one aspect, the apparatus includes a first tubular having a connection portion at the end thereof and a second tubular having a mating connection portion at an end thereof. The connection portion and mating connection portion are constructed and arranged to form a connection between the tubulars. The apparatus further includes a swelling elastomer disposable between the connection portion and the mating connection portion, the swelling elastomer expandable upon contact with an activating agent. In another aspect, the invention provides a method for utilizing an expandable connection in a wellbore.

Abstract: A mono-diameter wellbore casing.

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: 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: 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 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: Embodiments of the present invention generally provide methods and apparatus for forming a tubular-lined wellbore which does not decrease in diameter with increasing depth or length. Methods and apparatus for forming a substantially monobore well while drilling with casing are provided. In one aspect, a portion of a second casing is expanded into a portion of a first casing having a larger inner diameter than the remaining portion of the first casing string. In another aspect, the portion of the second casing is expanded into a portion of the first casing having a compressible member therearound. In another aspect, a lined lateral wellbore may be constructed by forming a lateral wellbore extending from a main wellbore lined with casing. A diameter of at least a portion of the lateral wellbore may be expanded. An expandable tubular element may be run into lateral wellbore and expanded to have an inner diameter equal to or larger than an inner diameter of the main wellbore casing.

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 method of providing a liner which can be rolled up on a reel for convenient transport and which can be unrolled into the bore of an oil or gas well and expanded to the approximate bore size of the casing size which the liner was run through and is collapsed in a way which allows sealing and stripping with a blowout preventer for well control protection during running and providing smooth surface support wedging without the need for marking the pipe with slip teeth.

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 system for lining a wellbore casing.

Abstract: A slip for an expanding hanger or patch is disclosed. The slip is mounted over the hanger body and has an internal profile that nests within a mating profile on the exterior of the hanger. When a compressive force is applied to the hanger, it shrinks longitudinally and as a result the slip is cammed radially to the extent the inside diameter of the surrounding tubing permits. When the swage is advanced, the diameter of the hanger increases forcing the slip into preferably penetrating contact with the inside wall of the surrounding tubular.

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

Abstract: The present invention provides an apparatus and method expanding a portion of a tubular. The expansion apparatus is run into a wellbore on a working string. The expansion apparatus first comprises a rotary expander for expanding an expandable tubular. The expansion apparatus further comprises a spline assembly for coupling the rotary expander to a motor disposed on the work string. The rotary expander and spline assembly have hollow bodies that allow them to encircle the work string and rotate relative thereto. The spline assembly comprises an inner sleeve and outer sleeve. The inner sleeve is attached to the motor and the outer sleeve is attached to the rotary expander. The inner and outer sleeves are coupled to each other using a spline and groove connection. The connection allows the rotary expander to be rotated by the motor, while at the same time, allow the rotary expander to move axially relative to the motor. The rotary expander comprises two rows of rollers for expansion against the tubular.

Abstract: Methods and apparatus for shaping pipes, tubes, liners, or casing at downhole locations in wells. Use is made of rollers bearing radially outwards against the inside wall of the pipe (etc.), the rollers being rolled around the pipe to cause outward plastic deformation which expands and shapes the pipe to a desired profile. Where one pipe is inside another, the two pipes can be joined without separate components (except optional seals). Landing nipples and liner hangers can be formed in situ. valves can be deployed to a selected downhole location and there sealed to the casing or liner without separate packers. Casing can be deployed downhole in reduced-diameter lengths and then expanded to case a well without requiring larger diameter bores and casing further uphole. The invention enables simplified downhole working, and enables a well to be drilled & produced with the minimum downhole bore throughout its depth, obviating the need for large bores.

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: A multilateral junction comprises a primary leg and one or more lateral legs. Each end of the primary leg and each lateral leg has an inflatable element therein. A method for installing a multilateral junction includes running a deformed junction to depth and serially or collectively inflating an inflatable element in each leg of said junction to reform said junction.

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.