Abstract: An expandable tubular member.

Abstract: A wellbore system is disclosed, comprising a wellbore extending into an earth formation, the wellbore containing a body of fluid, and an expandable tubular element arranged in the wellbore, whereby a lower end portion of the wall of the tubular element is bent radially outward and in axially reverse direction so as to define an expanded tubular section extending around a remaining tubular section of the tubular element. The expanded tubular section is axially extendable by downward movement of the remaining tubular section relative to the expanded tubular section. The body of fluid is located in the remaining tubular section, and a fluid conduit extends from the body of fluid to a location above the remaining tubular section, the fluid conduit being movable in upward direction relative to the remaining tubular section.

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: Methods and apparatus are provided for performing an expedited shoe test using an expandable casing portion as an annular fluid barrier. Further provided are methods and apparatus for successfully recovering from a failed expansion so that a shoe test can be completed without replacement of the expandable casing portion. In one recovery method, a selectively actuatable fluid circulation tool is provided to further expand the expandable portion or perform a cementing operation. Additionally, methods and apparatus are provided to drill a wellbore and form an annular fluid barrier in a single trip.

Abstract: An apparatus and method for radially expanding and plastically deforming a tubular member. The apparatus includes a support member, an expansion device coupled to the support member and at least one of a cutting device coupled to the support member, an actuator coupled to the support member, a sealing assembly, or a packer assembly coupled to the support member. The apparatus may further include a gripping device for coupling the tubular member to the support member. The expansion device may be used for radially expanding and plastically deforming the tubular member which may be coupled to the support member. The cutting device may be used for cutting the tubular member. The actuator may be used for displacing the expansion device relative to the support member. The sealing assembly may be used for sealing an annulus defined between the support member and the tubular member.

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: A system for radially expanding an expandable tubular within a wellbore to form a wellbore casing. In some embodiments, the system includes a support member insertable within and displaceable relative to the expandable tubular, an expansion cone coupled to the support member, a tubular sleeve translatably disposed about the support member, an annular chamber between the tubular sleeve and the expandable tubular, and a tubular piston disposed in the annular chamber, the tubular piston dividing the annular chamber into a first chamber and a second chamber. The support member has a tubular body with an axial flowbore, a first radial passage, and a second radial passage. The tubular sleeve has a third and a fourth radial passage. The flowbore is in fluid communication with the first chamber when the first and third radial passages are aligned, and with the second chamber when the second and fourth radial passages are aligned.

Abstract: A method for expanding a tubular member in a wellbore includes applying a downward force to an expansion cone through a work string to anchor the tubular member in the wellbore and pulling upwards on the expansion cone with the work string to expand the tubular member. The expansion cone is disposed in a launcher portion connected to the tubular member being expanded.

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: An apparatus for radially expanding and plastically deforming a tubular member.

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 tubular element can be expanded using an expander tool that includes a flexible sleeve having an outer diameter less than or equal to the inner diameter of the tubular element, a cone expander section on which the sleeve is mounted and an elongate mandrel. The cone expander section includes a first cone having a first narrow end that fits inside the sleeve and that increases in diameter from the first narrow end to a maximum at a base that is greater than the inner diameter of the sleeve but less than the inner diameter of the tubular element. The expander tool can be positioned at a predetermined location in the tubular element, fixed in place, and the expander section can be urged through the sleeve to expand the sleeve and thus the tubular element.

Abstract: Downhole apparatus comprises a base pipe and a plurality of non-concentric pressure deformable chambers mounted externally on the pipe. The chambers may be inflated to increase the diameter of the apparatus and engage and support a surrounding bore wall.

Abstract: An apparatus for controlling a flow of a fluid into a wellbore tubular includes a flow path associated with a production control device; an occlusion member positioned along the flow path that selectively occludes the flow path, and a reactive media disposed along the flow path that change a pressure differential across at least a portion of the flow path by interacting with a selected fluid. The reactive media may be a water swellable material or an oil swellable material. The reactive media may be selected or formulated to change a parameter related to the flow path. Illustrative parameters include, but are not limited to, (i) permeability, (ii) tortuosity, (iii) turbulence, (iv) viscosity, and (v) cross-sectional flow area.

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: A wellbore tubular has openings in its wall. An outer sleeve has ridges on which openings are located so that they communicate with the tubular openings. The tubular can be expanded to plant the ridges against the formation while any space between the ridges and the borehole wall can be used for pumping cement without fouling the aligned openings between the tubular and the sleeve. Optionally the sleeve can swell with or without tubular expansion. The openings can be initially sealed for delivery to the desired location and then opened using well or added fluids or well conditions.

Abstract: A sampling system and method for use in pipes or in boreholes beneath the earth's surface, including the use of flexible borehole liners, the liners provided with a diffusion barrier to prevent contamination of fluid samples obtained by the system and method. There is provided a flexible diffusion barrier in the construction of a flexible fluid sampling liner, so as to nearly eliminate concern for diffusion transport into or out of the liner. The flexible diffusion barrier may be incorporated into and constructed with known devices, called spacers, in use with flexible borehole liners. The diffusion barrier according to the present disclosure is attached or secured by a suitable means to the interior surface, or the exterior surface, or both surfaces, of the flexible borehole liner. In one embodiment, a spacer with a diffusion barrier prevents both the diffusion into the liner, and the diffusion out of the liner, in the interval subtended by the spacer length.

Abstract: Systems and methods for running downhole equipment with hydraulic control systems. A downhole running tool can have a body having an annulus formed therethrough. A latch member can be disposed on a first portion of the body. A reset member can be disposed on a second portion of the body. A conduit can be formed within a sidewall of the body. The conduit can be located between the first and second portions of the body. A pressure relief port can be disposed at a first end of the conduit; and a first flow port can be disposed at a second end of the conduit. The pressure relief port and first flow port can be in communication with an outer diameter of the body.

Abstract: A hydraulically powered downhole tool includes a tool mandrel (20) having an interior bore (22), and a plurality of pistons (26) each axially movable relative to the tool mandrel and mechanically interconnected by an outer sleeve (24) exterior of the tool mandrel. A plurality of mandrel sections and a plurality of outer sleeve sections each have a lower end for interconnection with an upper end of a corresponding member. A retainer (28), (29) is provided for supporting each outer sleeve section above a respective lower sleeve section, thereby exposing mandrel sections for vertical assembly.

Abstract: A tubular sleeve is coupled to and overlaps the threaded connection between a pair of adjacent tubular members.

Abstract: An expandable downhole tool features a mandrel that is expanded from within by a swage or other technique. The expansion of the mandrel advances an exterior ring or comparable slidably mounted object against an exterior sleeve that can be impervious or porous. The ring engages a ratchet mechanism to hold its position with respect to the mandrel as the swage advances through the mandrel and expands the ring and the exterior sleeve. The locking of the ring to the mandrel keeps the exterior sleeve from springing back longitudinally as the expansion is concluded.

Abstract: Systems, apparatus and well intervention methods are described. Tubular member radial expansion apparatus includes a support member having forward and rearward ends; a drive unit and an expansion member disposed on the support member providing force for propelling the expansion member through an expandable tubular and expanding it, the drive unit disposed rearward of the expansion member; front and rear anchors disposed on the support member for engaging the expandable tubular's ID to provide reaction forces to propagate the expansion member through the expandable tubular, the rear anchor positioned behind the drive unit and providing its reaction force after the front anchor has exited the expandable tubular; a casing lock disposed on the support member and positioned between the expansion member and the front anchor, securing the expandable tubular to the support member during running-in-hole (RIH); and a valve attached to the forward end of the expandable 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: An apparatus for the radial expansion and plastic deformation of a tubular member.

Abstract: An apparatus to protect the mounting area of casing and a locating profile and optionally a sliding sleeve valve and a flow path 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. A barrier sleeve, nose, and outer sleeve define a sealed cavity having a loose incompressible material inside that covers the mounting location on the casing. A locating profile and an optional sliding sleeve valve and a flow path from the outside of the valve to the annulus can be provided. The cementing of the casing takes place through the barrier sleeve. After the cementing, the sleeve and nose are drilled out and the incompressible material is removed to the surface with the drill cuttings. A liner is inserted in the casing and is preferably expanded into sealing contact with the mounting location on the casing.

Abstract: An expansion joint with one or more communication medium bypass paths is described herein. At least some illustrative embodiments include a first axially flexible cylinder, one or more additional axially flexible cylinders positioned within the first cylinder, and first and second annular members each positioned at a opposite ends of, and each coupled to, the first cylinder and the one or more additional cylinders (the first and second annular members each including one or more apertures through each member). All cylinders concurrently extend and contract in axial length when the first and second annular members are respectively moved away from and towards each other. Annular spaces formed by each of the one or more additional cylinders and an externally adjacent cylinder, together with corresponding apertures of each of the first and second annular members, each provides at least one path for at least one communication medium.

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: Embodiments of the present invention provide apparatus and methods of forming a lateral wellbore wherein the monobore characteristic is maintained. In one embodiment, a method of completing a lateral wellbore comprises inserting a first tubular into a main wellbore; forming one or more oversized portions on the first tubular; and intersecting the lateral wellbore with the main wellbore. The method further includes inserting a second tubular into the lateral wellbore, wherein a portion of the second tubular is positioned adjacent the one or more oversized portions and expanding the portion of the second tubular adjacent the one or more oversized portions.

Abstract: An apparatus for running a liner into a wellbore may include an inner string, a device coupled to the inner string that is operable to engage the interior of the liner and facilitates running of the liner into the wellbore, and a control mechanism operable to control fluid communication between the interior of the liner and the wellbore. A method of running a liner into a wellbore may include the steps of positioning an inner string into the liner, wherein the inner string includes a device operable to engage the interior of the liner, engaging the interior of the liner, and supplying a fluid pressure to move the liner relative to the inner string to advance the liner into the wellbore.

Abstract: The invention relates to a method of radially expanding a tubular element. The method comprises 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 an unexpanded section of the tubular element, said wall having a resistance to radially outward bending and a resistance to stretching in circumferential direction. Said wall is provided with at least one of primary means for increasing the resistance to radially outward bending of the wall, and secondary means for reducing the resistance to stretching in circumferential direction of the wall.

Abstract: The present invention generally relates to an expandable liner hanger capable of being expanded into a surrounding casing. In one aspect, an expandable tubular system is provided. The system includes an expandable tubular. The system further includes an expansion swage for expanding the expandable tubular, wherein the expansion swage is deformable from a compliant configuration to a smaller substantially non-compliant configuration. Additionally, the system includes a restriction member disposed on an exterior surface of the expandable tubular, wherein expansion of the expandable tubular in the location of the restriction member deforms the expansion swage from the compliant configuration to the smaller substantially non-compliant configuration. In another aspect, a method of expanding a liner hanger using a cone is provided.

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: Submersible pump power cable is inserted into a length of tubing. The device comprises an anchoring system attachable to the cable affixed to the tubing inner surface. The anchoring system includes an anchoring sleeve slideable over the cable and insertable into the tubing. Coiling the tubing with the cable and anchoring system inside energizes the sleeve into an anchoring configuration to anchor the cable within the tubing. The anchoring system continues to anchor the cable after uncoiling the tubing and inserting it into a wellbore.

Abstract: Apparatus, such as a liner, adapted to be hung in a downhole tubular such as casing is described. The apparatus includes one or more circumferentially distributed abrasive portions, arranged to be movable radially outwards by a dimple former or an expander. In an embodiment, the abrasive portions are provided on disks moveable in recesses in the outer diameter of the apparatus being hung. In an embodiment, the apparatus is hung by operating a dimple former provided on the running tool.

Abstract: The present invention generally relates to methods and systems for mitigating trouble zones in a wellbore in a preferred pressure condition and completing the wellbore in the preferred pressure condition. In one aspect, a method of reinforcing a wellbore is provided. The method includes locating a valve member within the wellbore for opening and closing the wellbore. The method further includes establishing a preferred pressure condition within the wellbore and closing the valve member. The method also includes locating a tubular string having an expandable portion in the wellbore and opening the valve member. Additionally, the method includes moving the expandable portion through the opened valve member and expanding the expandable portion in the wellbore at a location below the valve member. In another aspect, a method of forming a wellbore is provided. In yet another aspect, a system for drilling a wellbore is provided.

Abstract: A method and apparatus for completing a well through expansion of tubing enable construction of the well or at least part of the well with a mono-diameter or substantially no inside diameter reduction with subsequent casings/liners. Prior to lining an extended section of the borehole, forming a discrete enlarged portion of the extended section with a relatively larger inner diameter than the remainder of the extended section of the borehole occurs where overlapping tubing sections are to be located. For some embodiments, an open-hole clad expanded in the enlarged portion of the extended section of the borehole provides an inner surface for receiving a bottom of a first expanded liner and optionally a top of a second expanded liner.

Abstract: An expander is provided for radially expanding a tubular element, the expander having an axially forward direction and being provided with thrust means for exerting a thrust force to the expander to move the expander in axially forward direction through the tubular element. The expander comprises an adjustable cone having an expander surface tapering radially inward in the axially forward direction, the adjustable cone being movable between a radially expanded mode and a radially collapsed mode. The expander further comprises adjusting means for moving the adjustable cone from the collapsed mode to the expanded mode by the action of said thrust force exerted to the thrust means.

Abstract: Expandable tubulars for use in geologic structures, including methods for expanding the expandable tubulars, and methods of manufacturing them, include the use of an expansive energy storage component, which provides a self-expanding feature for the expandable tubulars.

Abstract: A swellable packer construction for continuous or segmented tubing. A method of constructing a swellable packer on a continuous tubular string includes the steps of: attaching a swellable seal material to the tubular string to thereby form the packer; and then wrapping the tubular string with the packer on a spool. A swellable packer includes a tubular body portion for incorporation into a tubular string, and a seal material wrapped about the body portion, the seal material being swellable in response to contact with a fluid. A method of constructing a swellable packer for a tubular string includes the steps of: wrapping a seal material about a tubular body portion to thereby form the packer; and then swelling the seal material in response to contact with a fluid. A continuous tubular string includes a seal material attached to a body portion of the tubular string to thereby form a swellable packer; and the packer wrapped with the tubular string on a spool.

Abstract: A geometrically optimized expansion cone for radially expanding a tubular member. In some embodiments, the expansion cone includes an annular body having an outer surface. The outer surface includes a linear surface having a constant diameter, a curvilinear surface extending from the linear surface, a recessed surface having a diameter less than the diameter of the curvilinear surface, and a chamfer between the recessed surface and the curvilinear surface. The diameter of the linear surface is substantially equal to an inner diameter of the tubular member after expansion, while the chamfer has a maximum diameter less than an inner diameter of the tubular member prior to expansion. The curvilinear surface has a diameter defined by a radius of curvature which is tangent to the chamfer at the maximum diameter and tangent to the linear surface.

Abstract: A mono-diameter wellbore casing is formed by radially expanding a first tubular liner off of a mandrel into contact with a second tubular liner. The first and second tubular liners are positioned within the wellbore in an overlapping relationship. The overlapping portions of the tubular liners include thin wall portions with compressible annular members that are expanded into contact with each other.

Abstract: An expandable tubular includes a plurality of leaves formed from sheet material that have curved surfaces. The leaves extend around a portion or fully around the diameter of the tubular structure. Some of the adjacent leaves of the tubular are coupled together. The tubular is compressed to a smaller diameter so that it can be inserted through previously deployed tubular assemblies. Once the tubular is properly positioned, it is deployed and coupled or not coupled to a previously deployed tubular assembly. The inventive tubular is useful for all types of wells and boreholes.

Abstract: Nested articulated split rings move relatively to each other to enlarge their outer dimension for a grip on a surrounding tubular or the wellbore. The rings can be articulated to enlarge their outside dimension with relative movement that can be initiated by dimensional expansion from within the tubular or manipulation of the tubular that creates the desired relative movement. The relative movement can be locked in after it is made to secure the grip. Different shape profiles that magnify the radial outer dimension in excess of the percentage dimensional change in the underlying tubular are contemplated.

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

Abstract: Radially expanding a tubular such as a liner or casing, especially in a downward direction. 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. One or more anchoring devices, which may be radially offset, are used to substantially prevent the tubular from moving during expansion thereof.

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: Flow control for increased permeability planes in unconsolidated formations. A well system includes a casing expansion device interconnected in a casing string for initiating an inclusion propagated into a formation surrounding the casing string. The device has at least one opening in a sidewall for fluid communication between the inclusion and an interior of the casing string. A flow control device is retrievably installed in the expansion device and controls flow between the formation and an interior of the casing string. A method of controlling flow of fluid between a formation and an interior of a casing string includes the steps of interconnecting a casing expansion device in the casing string; expanding the device to thereby initiate propagation of an inclusion into the formation; and installing a flow control device in the expansion device to thereby control flow between the inclusion and the casing string interior.

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: A method is provided of expanding a tubular element from a first inner diameter to a second inner diameter larger than the first inner diameter. The method comprises the steps of: a) installing a sleeve of flexible material in the tubular element; b) installing an expander in the tubular element, the expander being suitable to radially expand the sleeve to an outer diameter larger than said first inner diameter by moving the expander in axial direction through the sleeve; and c) moving the expander in axial direction through the sleeve thereby radially expanding the tubular element from the first inner diameter to the second inner diameter.

Abstract: An expandable tubular member.