Abstract: Pipe-in-pipe composite tubular structure having between layers a hardenable filling material associating the layers to enhance the structure mechanical performance mostly in collapse. Prior to harden the filling material, the composite tubular structure can be longitudinally deployable between a folded configuration and a deployed configuration, and has a radial dimension increasing between the folded configuration and the deployed configuration. Such structure is well fitted to be used in oil-well downhole structure and casings or underwater pipeline/flowline.

Abstract: A downhole contraction joint. The downhole contraction joint can include at least one anti-rotation assembly. The anti-rotation assembly can include a first tubular member at least partially disposed within a second tubular member. An axial slot can be formed through at least a portion of the first tubular member, and at least one key can be at least partially disposed within the second tubular member and the axial slot. The downhole contraction joint can also have at least one resetting assembly disposed at a first end of the anti-rotation assembly. The resetting assembly can include a c-ring secured to the second tubular member. The first tubular member can be secured to the lock ring, and the lock ring can be aligned with the c-ring. The downhole contraction joint can also include at least one control line assembly disposed about a portion of the anti-rotation assembly.

Abstract: An assembly for use in a wellbore formed in an earth formation, comprising an expandable tubular element and an outer structure having first and second portions arranged at a distance from each other, the portions being restrained to the tubular element in a manner that the distance changes as a result of radial expansion of the tubular element, the outer structure further having a third portion arranged to move radially outward upon said change in distance between the first and second portions, wherein said radially outward movement of the third portion is larger than the radially outward movement of the tubular element as a result of radial expansion of the tubular element.

Abstract: A method for radially expanding a tubular element in a wellbore and providing a control line that extends along the tubular element comprises (a) inducing the wall of the tubular element to bend radially outward and in axially reverse direction so as to form an expanded tubular section extending around a remaining tubular section of the tubular element, wherein said bending occurs in a bending zone of the tubular element, (b) increasing the length of the expanded tubular section by inducing the bending zone to move in axial direction relative to the remaining tubular section, wherein said wall includes a material that is plastically deformed in the bending zone during the bending process so that the expanded tubular section retains an expanded shape as a result of said plastic deformation, and (c) extending the control line along the tubular element.

Abstract: A system is provided for drilling a borehole into an earth formation, comprising a casing arranged in the borehole, a drill string extending through the interior of the casing to a lower end portion of the borehole, and a body of drilling fluid extending into the casing, the casing having an inner surface susceptible of wear due to frictional contact with an outer surface of the drill string during drilling of the borehole with the drill string. The system further comprises means for reducing wear of the inner surface of the casing, the means including at least one of a hardened layer at the inner surface of the casing, a friction-reducing layer at the outer surface of the drill string, and a lubricating compound contained in the body of drilling fluid.

Abstract: A tubular sleeve overlaps the threaded connection between a pair of adjacent tubular members that are to receive an expansion device for radial expansion and plastic deformation of the threaded tubular connection.

Abstract: An actuator includes a tubular configured to longitudinally expand in response to radial expansion of at least a portion of the tubular.

Abstract: Apparatus for expanding first and second portions of a downhole tubular in a single trip comprises a support and first and second expansion devices. The first expansion device is mounted on the support and is operable to expand a first portion of tubular. The second expansion device is mounted to a second portion of tubular and is adapted to be engaged by the support following the expansion of the first portion of tubular, and is then used to expand the second portion of tubular.

Abstract: The present invention generally relates to a swage assembly that is movable from a compliant configuration having a first shape to a substantially non-compliant configuration having a second shape. In one aspect, an expansion swage for expanding a wellbore tubular is provided. The expansion swage includes a body and a solid cone disposed on the body. The expansion swage further includes a deformable cone disposed on the body, wherein the solid cone is made from a first material and the deformable cone is made from a second material and wherein the deformable cone is movable relative to the body when the expansion swage is in a compliant configuration. In another aspect, a method of expanding a wellbore tubular is provided.

Abstract: A method and apparatus of expanding tubing. The method may include expanding a first portion of an expandable tubing into contact with a surrounding tubing using an upper expander; expanding a second portion of the expandable tubing that extends beyond the surrounding tubing using a lower expander; and further expanding the first portion of the expandable tubing using the lower expander, thereby expanding the surrounding tubing. The apparatus may include a fluted expander coupled to a first end of the expandable tubing; and a collapsible cone disposed inside the expandable tubing.

Abstract: An expandable casing with enhanced collapse resistance and sealing capability. An expandable tubular for use in a subterranean well includes multiple recesses extending into a wall of the tubular, with the recesses being longitudinally spaced apart along the wall. A method of expanding tubulars in a subterranean well includes the steps of: expanding a tubular in the well, the tubular including multiple recesses extending into a wall of the tubular; and after the expanding step, allowing the wall of the tubular to retract radially inward more at each of the recesses than between the recesses.

Abstract: Methods relate to tubulars that may be part of a tubular string for isolating one or more zones within a wellbore. In one embodiment, the tubular string includes a first expandable zone isolation unit disposed on a first side of a zone to be isolated, a second expandable zone isolation unit disposed on a second side of the zone to be isolated, and a perforated tubular disposed in fluid communication with a producing zone. The tubular string may be expanded using an expansion assembly having a first expander for expanding the first and second expandable zone isolation units and a second expander for expanding the at least one perforated tubular. Tags or markers along the tubular string may indicate locations where expansion is desired such that connections or connectors between joints are not expanded.

Abstract: A method of repairing a damaged portion of a casing in a wellbore includes running a bottom hole assembly (BHA) into the wellbore on a conveyance and locating the BHA proximate the damaged portion. The method further includes engaging an inner wall of the casing with a friction member, rotating the conveyance thereby rotating a portion of the BHA, maintaining a portion of the BHA stationary with the friction member. The method further includes pulling the inner string, thereby engaging the inner wall of the casing with an anchor of the BHA and disconnecting a frangible connection with the anchor. An inner string is coupled to an expansion member and pulling the inner string and thereby the expansion member through an expandable tubular expands the expandable tubular into engagement with the inner wall of the casing thereby repairing the damaged portion.

Abstract: An apparatus to protect the mounting area of casing and a locating profile and optionally a sliding sleeve valve and a flow path is provided from the outside of the valve to the annulus when subsequent attachment of an expanded liner is intended and the expanded liner is to be cemented in place.

Abstract: The present invention generally relates to a swage assembly that is movable from a compliant configuration having a first shape to a substantially non-compliant configuration having a second shape. In one aspect, an expansion swage for expanding a wellbore tubular is provided. The expansion swage includes a body and a solid cone disposed on the body. The expansion swage further includes a deformable cone disposed on the body, wherein the solid cone is made from a first material and the deformable cone is made from a second material and wherein the deformable cone is movable relative to the body when the expansion swage is in a compliant configuration. In another aspect, a method of expanding a wellbore tubular is provided.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member with a fluid passage. A mandrel is movably coupled to the support member and includes an expansion cone operable to radially expand and plastically deform the tubular member when moved relative to the tubular member. A pressure chamber is positioned between the support member and the mandrel, and the pressure chamber is fluidicly coupled to the fluid passage. A releasable support is coupled to the support member and operable to selectively couple the support member to the tubular member.

Abstract: A downhole apparatus having a radially expanding portion and a support structure are described. The support structure comprises an attachment means for coupling to the apparatus and a support portion configured to be deployed from a first unexpanded condition to a second expanded condition by expansion of the apparatus. In one aspect of the invention, the downhole apparatus is expanded by exposing the swellable material to at least one predetermined fluid, and the support structure abuts the swellable material in its expanded form. A method of use and its application to a well packer, a hanging member, an anchor and a centralising apparatus are described.

Abstract: Disclosed herein is a completion device that includes an interior layer that swells when exposed to a wellbore fluid; and an exterior layer encasing the interior layer and configured to be impermeable to the wellbore fluid at temperatures below an activation depth temperature, and configured to be permeable to the wellbore fluid at temperatures above the activation depth temperature. Also disclosed herein is a method of deploying a completion device that includes encasing an interior layer of the device in a temperature-sensitive exterior layer that is impermeable to a fluid in the wellbore at temperatures below an activation depth temperature; attaching the device on a tube string; inserting the tube string into the wellbore; creating a leak path in the temperature-sensitive exterior layer in response to the device being exposed to the activation depth temperature in the wellbore; and swelling the interior layer with the wellbore fluid.

Abstract: A cladding method for sealing a leak in a casing, a pipeline, a borehole, or a well downhole using a liner having a tube with a first diameter, a plurality of circumferential grooves, and a plurality of seals in the grooves extending beyond the first diameter. The cladding method has at least the steps of fastening the liner in a fastening mechanism of an expansion tool, inserting the liner having a first part and a second part into the casing outside the leak, positioning an expansion mechanism of the expansion tool at the first part of the liner, expanding the first part of the liner until the seals in the grooves of the first part of the liner are pressed against the casing and fasten the first part to the casing, releasing the liner so that the liner is free of the tool and the liner is held in place by the seals in the first part of the liner, and expanding all the way through the liner by expanding also the second part of the liner to abut the casing for sealing the leak.

Abstract: Systems and methods for increasing fluid flow characteristics within a hydrocarbon production tubing string within a wellbore. An expansion member is passed through the interior flowbore of one or more production tubing string members. The expansion member smoothes the interior surface of the flowbore and may radially expand the interior surface of the flowbore.

Abstract: Casing deformation and control for inclusion propagation in earth formations. A method of forming at least one inclusion in a subterranean formation includes the steps of: installing a liner within a casing section in a wellbore intersecting the formation; and expanding the liner and the casing section, thereby applying an increased compressive stress to the formation. Another method of forming the inclusion includes the steps of: installing an expansion control device on a casing section, the device including at least one latch member; expanding the casing section radially outward in a wellbore, the expanding step including widening at least one opening in a sidewall of the casing section, and displacing the latch member in one direction; and preventing a narrowing of the opening after the expanding step, the latch member resisting displacement thereof in an opposite direction.

Abstract: Methods and apparatus for radially expanding and plastically deforming an expandable tubular include a resilient launcher. The resilient launcher includes a launcher portion and a sleeve portion. An inner diameter of the sleeve portion is smaller than an inner diameter of the launcher portion. An expansion cone is disposed in the launcher portion of the resilient launcher. The expandable tubular is disposed around the sleeve portion and above the launcher portion of the resilient launcher. The launcher portion comprises a port that is sealable below the expansion cone.

Abstract: A downhole releasable tubing connection includes a joint between two tubing strings, wherein one of the two tubing strings is radially expanded and plastically deformed by an expansion device. When the expansion device is moved adjacent to the joint, a mechanism in the joint reacts to the radially outward forces of the expansion device and releasably expands, separates, breaks, or otherwise provides a release between the two tubing strings. One tubing string and the expansion device can then be removed to the surface of the well bore while the expanded tubing remains installed in the well bore.

Abstract: Embodiments of the present invention provide an apparatus and method for expanding a tubular. In one aspect, embodiments of the prevent invention provide an expander tool having at least two expansion members radially extendable from the expander tool into contact with a surrounding inside surface of the tubular, the at least two expansion members radially extendable at different times and axially spaced after radially extending. In another aspect, embodiments include a method for isolating a first portion of a wellbore from a second portion of a wellbore comprising locating an expandable tubular within the wellbore between the first and second portions, the expandable tubular having a weakened portion therein, isolating the first portion from the second portion of the wellbore, and expanding the expandable tubular proximate to the weakened portion to sever the expandable tubular.

Abstract: Systems and methods for drainage of a heavy oil reservoir via a horizontal wellbore. A method of improving production of fluid from a subterranean formation includes the step of propagating a generally vertical inclusion into the formation from a generally horizontal wellbore intersecting the formation. The inclusion is propagated into a portion of the formation having a bulk modulus of less than approximately 750,000 psi. A well system includes a generally vertical inclusion propagated into a subterranean formation from a generally horizontal wellbore which intersects the formation. The formation comprises weakly cemented sediment.

Abstract: A method of expanding a tubular downhole comprises mounting a sensing device in a downhole tubular to be expanded, expanding at least a portion of the tubular and then engaging the sensing device with a retrieving device. The sensing device is then translated through the expanded tubular.

Abstract: The invention comprises using a tube having a ductile and radially expansible upper portion, provided at the base thereof with a seal that is also radially expansible under the action of the weight of the tube, the latter being thus sized so that when its base abuts the bottom of the well, the upper portion is located above a fractured area to be isolated, the procedure comprising the following steps: the tube is inserted into the well so that the base thereof bears against the bottom, triggering the radial expansion of the seal; using an expansion tool, the upper portion of the tube is radially expanded beyond its yield strength in order to apply the same tightly against the wall of the well above the fractured area. The invention can be used in the petroleum industry.

Abstract: A downhole axial expansion or telescoping tool includes radially expandable tubular members. The tubular members are relatively moveable before and after radial expansion, and include an intermediate layer therebetween of a non-metal or non-cladding material. The intermediate layer may provide any one or more of lubricity, load transfer, sealing, and shape retention during and after radial expansion.

Abstract: The present invention provides a system for anchoring an expandable tubular to a borehole wall. The system comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, said second end being movable relative to the outside of the tubular. Said support member includes a ramp surface that tapers in the direction of said anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with said ramping surface.

Abstract: A filament wound composite tube is inserted into a non-metallic mandrel below the core to support the core when holding pressure in the top annulus. The tube has a close-fit tolerance to the inner surface of the mandrel. The tube is secured in place with pins through a mule shoe, such that the bore of the tube is not impeded. Alternately, a retainer with wickers is disposed in the mandrel below the core to support the core when holding pressure in the top annulus. The wickers are biased to engage with an inner surface of the mandrel, holding the insert in place under pressure. Axial movement of the core downward further engages the wickers with the mandrel, helping to support the load.

Abstract: A downhole apparatus having a radially expanding portion and a support structure are described. The support structure comprises an attachment means for coupling to the apparatus and a support portion configured to be deployed from a first unexpanded condition to a second expanded condition by expansion of the apparatus. In one aspect of the invention, the downhole apparatus is expanded by exposing the swellable material to at least one predetermined fluid, and the support structure abuts the swellable material in its expanded form. A method of use and its application to a well packer, a hanging member, an anchor and a centralising apparatus are described.

Abstract: There is disclosed a connector for tubing, in particular, expandable tubing sections. There is also disclosed a method of sealing a connection between tubing sections, in particular, expandable tubing sections. In one embodiment of the invention, a connector (10) is disclosed which is suitable for coupling expandable tubing sections (11,13) together. The connector (10) comprises first and second portions (12,14) adapted to be provided on respective expandable tubing sections (11, 13), at least one of the portions (12,14) including a seal profile (16) which is adapted to be urged into sealing engagement with the other portion (12,14) on expansion thereof.

Abstract: A downhole apparatus is described comprising a main body coupled with a well tubing and a swellable mantle disposed on the main body. The swellable mantle expands upon contact with at least one predetermined fluid, and the main body comprises at least one opening for fluid flow between an exterior of the main body and the bore. An insert permits the passage of fluid, through the swellable mantle, between the exterior of the apparatus and the opening. In one aspect of the invention a screen filters solids between the exterior of the apparatus and the bore, and a swellable mantle comprises a first region which allows the passage of fluid between the exterior of the apparatus and the main body and a second region, circumferentially adjacent the first region, which substantially prevents passage of fluid. Corresponding well completion and production methods are also described.

Abstract: The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. The retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. The retainer rings can also include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member. In some embodiments, the apparatus includes a tubular support, sliding sleeve, rupture disc, and expansion cone. The tubular support has a first internal passage, wherein the sliding sleeve is disposed, and a flow passage, wherein the rupture disc is seated. The sliding sleeve has a second internal passage and is moveable by fluid pressure between first and second positions. In the first position, the second internal passage is fluidicly coupled with a first annulus surrounding the tubular support. In the second position, the second internal passage is fluidicly isolated from the first annulus. The rupture disc fluidicly isolates the first internal passage from a second annulus surrounding the tubular support and is adapted to rupture, whereby the first internal passage and the second annulus are fluidicly coupled. The expansion cone is disposed in the second annulus and moveable under pressure from fluid in the second annulus.

Abstract: Apparatus, systems, and methods may operate to couple a tubular member to a bottom hole assembly, dispose at least one adjustable stabilizing member on the tubular member, and control at least one of a radial extension of the adjustable stabilizing member and an axial position of the adjustable stabilizing member relative to the bottom hole assembly to adjust a borehole trajectory, wherein the adjustable stabilizing member is adjustable in both radial and axial directions. Additional apparatus, systems, and methods are disclosed.

Abstract: A downhole swaging system includes, a tubular having an area of strength with a different resistance to swaging as compared to areas of the tubular outside of the area of strength, and a swaging tool. The swaging tool has a first swage, and a second swage with an adjustable swaging dimension, the second swage is in functional communication with the first swage such that the adjustable swaging dimension is adjusted in response to the first swage encountering a change in resistance to swaging.

Abstract: Devices, systems and related methods control a flow of a fluid between a wellbore tubular and a formation using a flow control device having a flow space formed therein; and a flow control element positioned in flow space. The flow control element may be configured to flex between a first radial position and a second radial position to in response to a pressure differential along the flow space.

Abstract: A swage is made from segments that slide relatively to each other to go from a run in dimension to a maximum or built dimension when the segments move into alignment. The angle of inclination of the sliding axis between the members is less than the swaging angle for the pipe on the exterior of the segments so that once the segments are aligned and driven into a tubular for swaging they are precluded from extending into misalignment to clear an obstruction. In this manner a minimum drift is provided or the swage simply stalls. To facilitate building the swage in a tubular to the predetermined maximum dimension, the sliding surfaces are configured at an angle to bear the radial reaction forces from the tubular more directly thereby reducing the contact forces and the resulting friction. The edge connections are also configured to reduce bending which can cause segment binding as the swage is built in the tubular.

Abstract: A method and a device for establishing an underground borehole (10) and setting a casing (6) in the borehole (10), wherein the running tool (1) including a drilling tool (14), an expandable casing (6), an expansion tool (32) and a packer (30) which is arranged to seal against the wall of the borehole (10), is placed at the bottom of the borehole (10), whereupon the borehole (10) is drilled to the necessary length in order then to set the expandable casing (6), and in subsequent operations the casing is reinforced and a completion string is run, having built-in cables for downhole control and monitoring.

Abstract: A casing patch includes a deformable seal configurable to a deformed and undeformed position for sealing and unsealing respectively with a target stub and a pressure based subsystem in operable communication with the deformable seal. The patch may also contain a stop ring to prevent overcompression of the seal.

Abstract: A recess shoe system includes a recess shoe an insert sleeve disposed radially inwardly adjacent of the recess shoe in a portion of the recess shoe. The insert sleeve includes a ring and a plurality of fingers extending from the ring, the fingers being radially outwardly deflectable in response to a radially outwardly directed force. The force is generated by a swage in a swaging position acting on an inside dimension of the insert sleeve, and the insert sleeve is radially inwardly retractable when the radially outwardly directed force is removed such that the fingers of the insert sleeve define a tubular structure having an outside dimension smaller than an outside dimension of the swage in the swaging position and method.

Abstract: There is disclosed an improved expandable centraliser (20;120;220;320), which may optionally also be adjustable, and a related downhole assembly and a method of completing a well. Previous art has suffered from a number of problems and essentially attempted to mitigate the effect of pipe expansion, i.e. using tension caused in the centraliser body. The centraliser (20;120;220;320) of the invention uses the expansion of the tubing to cause compressive forces, which are exerted over known distances to energise blades of the centraliser by using relative motion caused by said expansion. The expandable centraliser (20;120;220;320) comprises at least one first member (30;130;230;330), and at least one second member (35;135;235;335), wherein, in use, relative circumferential motion of the at least one first and second members (30,35;130,135;230,235;330,335) causes radial motion of at least one portion (40;140;240;340) of the expandable centraliser (20;120;220;320).

Abstract: An anchoring and expanding unit comprising an anchoring device (20, 20?) and an expanding device (30, 30?), reciprocally removably constrained, the anchoring device (20, 20?) being of the expandable type, wherein the expanding device (30, 30?) includes a series of expanding means (33a, 33b) which can be extracted and blocked in at least two different operative positions, wherein the expanding means (33a, 33b) protrude radially from the expanding device (30, 30?).

Abstract: A method and device for a running tool for drilling or cleaning and setting a lining and a completion string in an underground borehole, The running tool comprising a drilling tool, an expandable casing, an expansion tool, a packer arranged to seal against the wall of the borehole, and at least one conduit extending up to the surface. The drilling tool is releasably connected to the lower portion of the expanding casing, and the expansion tool and the packer are releasably connected to the upper portion of the expanding casing. The running tool is arranged to communicate with the surface through at least one pipe conduit.

Abstract: A system comprising a first expandable tubular section and a first expansion bridge coupled to an inner surface of the first expandable tubular section. A base pipe is coupled to the first expandable tubular section and to a second expandable tubular section. A second expansion bridge is coupled to an inner surface of the second expandable tubular section. The system also comprises an expansion cone disposed within and translatable relative to the first expandable section. The expansion cone has an expansion diameter greater than an inner diameter of the first and second expansion bridges and less than an inner diameter of the base pipe.

Abstract: A tool 10 is provided for radially expanding a downhole tubular C, and includes a central tool mandrel 12, a tubular expander 48 at the lower end of the tubular, and a downhole actuator 15 for forcibly moving the expander axially within the downhole tubular. Slips 20 are positioned for securing the tool within a well, so that the slips may be set, and the tool subsequently stroked to move the expander 48 and radially expand a length of the tubular. Upward pull on the work string may expand long portions of the downhole tubular. Buttress threads 43 preferably support the tubular expander on the downhole tubular when run in the well.

Abstract: A method and apparatus for expanding a tubular member.

Abstract: The expandable casing packing element systems for cased and open-hole wellbores include an expandable casing member having a sealing device comprising a sealing element disposed between at least two retainer rings. The retainer rings have flat cross-sections and the sealing element is forced radially outward by the expansion of the expandable casing against the two retainer rings such that the sealing element protrudes outwardly beyond the retainer rings and engages the wall of a wellbore in three locations. The retainer rings can also include flares that extend outwardly from the body of the expandable casing to which they are attached. As the expandable casing is expanded, the flares are forced inward to compress the sealing element which is then extruded radially outward through a gap between the two retainer rings to engage and seal off the wellbore.

Abstract: The inventions provide apparatus and methods for radially expanding a tubular deployed in a subterranean well by moving an expansion tool axially through the well. An expansion tool apparatus may have wear faces attached to at least a portion of the outer periphery of a mandrel for contacting the interior surface of the pipe, tube, or screen during expansion. According to another aspect of the invention, an expansion tool has a controlled egress seal between the outer surface of the tool and the inside surface of the expandable tubular. According to another aspect of the invention, an automatically variable diameter expansion tool is provided having a variable diameter cone, which expands, and contracts based on input from one or more sensors. According to another aspect of the invention, an apparatus and method for expanding a length of screen assembly in a subterranean wellbore is provided.