Abstract: A method of installing an expandable tubular assembly in a wellbore, the tubular assembly including a plurality of expandable tubular elements, comprising: installing a first tubular element in the wellbore; installing a second tubular element in the wellbore such that an end part of the second tubular element extends into an end part of the first tubular element, arranging a radially deformable body around the overlapping portion; and radially expanding the end part of the second tubular element against the end part of the first tubular element such that the end part of the first tubular element becomes radially expanded and the deformable body becomes radially deformed, wherein a body of cement is present between the first tubular element and the wellbore wall, and wherein the deformable body is a fluidic volume that is pumped between the first tubular element and the wellbore wall before hardening of the cement.

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: 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 system is provided for expanding a tubular element extending into a wellbore formed in an earth formation. The system includes an expander arranged to expand the tubular element by virtue of axial movement of the expander through the tubular element, an activating system for inducing the expander to move through the tubular element, the activating system including at least one activating tool, and a control system for controlling the activating system, including a remote control unit and for each activating tool a respective controller. The remote control unit is arranged to transmit an acoustic signal to an acoustic conductor selected from the tubular element and another elongate member extending into the borehole, each controller being arranged to receive the acoustic signal from the acoustic conductor and to control the corresponding activating tool upon receipt of the acoustic signal.

Abstract: A method of forming a wellbore casing within a borehole that traverses a subterranean formation includes the steps of assembling a tubular liner by coupling a threaded portion of a first tubular member to a threaded portion of a second tubular member and coupling a tubular sleeve to the threaded portions of the first and second tubular members. The method further includes positioning the wellbore casing within the borehole and radially expanding and plastically deforming the wellbore casing assembly within the borehole. The step of coupling the tubular sleeve through the threaded portions of the and second tubular members includes applying impulsive magnetic energy to the tubular sleeve.

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: A wellhead isolation tool including a mandrel and a centralizing device. The centralizing device will align the tool so that the lower end of the mandrel sealingly engages the production casing. The mandrel has an open bore for allowing service tools to pass therethrough.

Abstract: A seal arrangement comprises an expandable inner tubular and an outer tubular. The inner tubular comprises an axially extending lip seal. Expansion of the inner tubular serves to energise the lip seal, a free end of which will be urged into contact with the outer tubular.

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: Expandable casing has an expandable slip used for completion of a mono-diameter wellbore. The expandable casing is run through the upper casing and has an upper end that overlaps a lower end of the upper casing to form a fluid flow path between the expandable casing and the upper casing. The operator expands the overlapping portion of the expandable casing to an intermediate position, causing the expandable slip to anchor the expandable casing to the upper causing without blocking the flow path. Cement is then pumped up around the outside of the expandable casing and wellbore fluid displaced by the cement and excess cement are permitted to flow through the fluid flow path and up the upper casing. After sufficient cement is in place, the expandable casing is further expanded, compressing the expandable slip into to the inner wall of the upper casing and sealing off the fluid flow path.

Abstract: There are disclosed methods and apparatus for expanding tubing downhole. In one embodiment, there is disclosed a method of expanding downhole tubing such as a liner (10), the method comprising the steps of locating the liner (10) in a borehole (12), expanding a part (16) of the liner (10) in the borehole (12), locating an expansion device such as an expandable cone (18) in said expanded part (16) of the liner (10), and translating the cone (18) relative to the liner (10) to expand a further part (20) of the liner (10).

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: A apparatus and method for radially expanding and plastically deforming a tubular member. The apparatus includes a tubular support member, an expansion device coupled to the tubular support member, a tubular expansion launcher that receives and mates with the expansion device, an expandable tubular member coupled to an end of the tubular expansion launcher; and one or more cup seals coupled to the tubular support member.

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

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

Abstract: A 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 system for radially expanding a tubular member.

Abstract: An expander system for radially expanding a tubular element having an unexpanded portion of a first inner diameter, the expander system including an expander movable between a radially retracted mode and a radially expanded mode, the expander being operable to expand the tubular element from the first inner diameter to a second inner diameter larger than the first inner diameter by movement of the expander from the radially retracted mode to the radially expanded mode thereof, wherein the expander has a contact section of a diameter larger than the first inner diameter when the expander is in the radially retracted mode, and wherein the contact section is arranged to prevent axial movement of the expander through the unexpanded portion of the tubular element when the expander is in the radially retracted mode.

Abstract: A compliant, integrated, fastening and sealing system located on either end of cladding or on a liner hanger. It features protrusions in opposed directions whose contact edges are preferably hardened. The protrusions penetrate the surrounding tubular on expansion of the smaller tubular. Seals are included adjacent the protrusions so that seals between adjacent protrusions get forced toward each other upon flexing of the projections that penetrate the surrounding tubular. The attachment configuration is particularly suited for use with fixed swages or variable swages with limited dimensional adjustability when precise ID of host casing or open hole is unknown.

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: There is disclosed an expandable seal for sealing at least part of a wall of a well borehole, an expandable seal assembly comprising at least two such expandable seals, and a method of sealing at least part of a well borehole using such a seal. In one embodiment, the expandable seal (32) comprises an expandable tubular support member (34) and an inflatable seal element (36) mounted externally of the expandable tubular support member (34) for inflation radially outwardly into sealing engagement with at least part of a wall (50) of a well borehole (10). There is also disclosed a sealing apparatus for sealing at least one flow port in an expandable downhole tubular, in one embodiment, the sealing apparatus (332) comprising a sealing member (384) coupled to an expandable tubular (334), the sealing member (384) including a deformable portion (387) movable between a closed position preventing fluid flow through a flow port (356) and an open position permitting fluid flow through the flow port (356).

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

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: A method of lining a drilled bore comprises running a tubular into a drilled bore and then corrugating the tubular in the bore. The tubular may also be expanded in the bore. In other aspects of the invention the tubular is corrugated prior to running into the bore and may be rotated as it is run into the bore.

Abstract: A method of expanding tubing comprises applying a varying fluid pressure across the wall of the tubing. The variation in pressure may be achieved by varying one or both of the fluid pressure within the tubing and the fluid pressure externally of the tubing. A body of varying volume may be located in a volume of fluid associated with the tubing. Alternatively, the volume of a body of fluid associated with the tubing may be varied by movement of a wall portion defining a boundary of the volume, which wall portion may be associated with an oscillator or a percussive or hammer device. In other embodiments a pressurised fluid source may be provided, and the fluid may be supplied at varying pressure from the source. An increase in pressure within the tubing may be accompanied by a reduction in pressure externally of the tubing.

Abstract: A system for lining a wellbore casing includes a support member, an expansion device coupled to an end of the support member, and a tubular liner coupled to the expansion device. The tubular liner includes an expandable tubular member that includes a first tubular portion, a second tubular portion, and an intermediate tubular portion coupled between the first and second tubular portions. The expandable tubular member also includes a sealing member coupled to the exterior surface of the intermediate tubular portion.

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

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

Abstract: 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: The invention relates to a tubing expansion tool including an expansion member which is movable between a first configuration and a larger expansion configuration for expanding tubing, and to a corresponding method. In one embodiment of the invention, a tubing expansion tool (10) is disclosed for expanding a length of expandable tubing such as expandable sand exclusion tubing (12). The tool (10) comprises an expansion member (16) adapted for movement between a first configuration and a larger expansion configuration, and means (17) for exerting a cyclical expansion force on the expansion member (16).

Abstract: An apparatus and a method for expanding a downhole tubular. The apparatus includes a mandrel defining at least one curved support surface. The apparatus further includes an expansion member defining a curved bearing surface for contact with the support surface and corresponding to the mandrel support surface. The expansion member is movable relative to the mandrel, whereby the surfaces are in contact and movable over one another to move the expansion member from a smaller diameter first configuration towards a larger diameter second configuration.

Abstract: A control sub for use with a hydraulically operated downhole tool. In an embodiment, the sub comprises an outer sleeve connected to a work string and an inner sleeve slidably engaged to the outer sleeve by matching hex profiles, connected to the downhole tool. Radial ports in the outer sleeve provide selective circulation of fluid from the tool and by closing these ports with the sleeve fluid pressure in to the downhole tool can be controlled. Closure is effected by setting down weight on the sub against the tool. An indexing mechanism is also described to keep the tool in a configuration, which maintains pressure on the tool. The sub is suitable for use with an expander tool.

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

Abstract: A method for lining tubular includes positioning an expandable liner in a wellbore at a depth of one or more perforations using a downhole depth locator tool. The expandable liner is expanded in the wellbore to line the one or more perforations.

Abstract: A method of sealing an expandable tubular within a bore comprises the steps of providing an expandable tubular describing a first diameter and having a sealing medium on its outer surface, running the tubular into a bore and expanding the tubular within the bore to describe a second larger diameter, and activating the sealing medium to facilitate provision of a seal between the tubular and the bore.

Abstract: A casing apparatus is provided to install a hard, pressure-resistant seal along a wall of a well in situ. The casing apparatus includes a moving device and a deformable tubular sleeve having a first end and a second end and. The moveable element is radially inflatable and movable inside the deformable tubular sleeve along a longitudinal axis of the deformable tubular sleeve. When the moving device is radially inflatable to an inflated condition and is moved from the first end to the second end, the moving device deforms the deformable tubular sleeve radially against the wall and progressively from the first end to the second end. A force of deforming the tubular sleeve applied by the inflated moving device is adjustable by changing the inflated condition of the moving device during the deformation process.

Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.

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

Abstract: The end of an expandable liner hanger (120) provides a receptacle for another tubular liner (135).

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

Abstract: A drilling assembly (2) comprises upper (4) and lower (6) drill strings with a fluid passage (80) therethrough for distributing fluid to a bottom hole assembly (10). The upper drill string (4) has an upper end (11) connectable to a drilling apparatus (13) and fluid source (16) and a lower end (18) with an attached casing expander unit (20) that communicates the fluid passage (80) of the upper (4) and lower (6) drill strings. An upper end (22) of the lower drill string (6) is formed from a casing string (24) telescoped over the casing expander unit. A constriction (31) connects the casing string (24) with the rest of the lower drill string (6). A flow restriction device (35) in the lower drill string acts to control fluid flow through the fluid passage.

Abstract: A well completion having an expandable tubular. The expandable tubular having a tubular base and a conforming layer. The conforming layer being radially expandable singularly or in combination with expansion of the tubular base. The expandable tubular being perforated or non-perforated.

Abstract: Improved casing strings, and methods of using improved casing strings in subterranean operations, are provided. An example of a method is a method of cementing a pipe string in a subterranean formation. Another example of a method is a method of cementing a pipe string in a well bore. An example of an apparatus is an improved pipe string comprising at least one pipe section; and a delivery system of an activator; wherein the delivery system of an activator is disposed adjacent an outer surface of the at least one pipe section.

Abstract: A method and apparatus for expanding tubulars is disclosed. In an embodiment, a tubular expansion apparatus includes an expansion swage. In addition, the tubular expansion apparatus includes an actuator. Moreover, the tubular expansion apparatus includes at least two anchors. The tubular expansion apparatus further includes at least one anchor longitudinally moveable relative to the other anchor while both anchors are engaged with the inner diameter of the tubular.

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

Abstract: Apparatus and methods of expanding tubular members are disclosed. In one embodiment, the apparatus includes a vibrating device that is capable of imparting a longitudinal and/or lateral and/or oblique vibration to a tubular member or string as it is being run into a borehole or wellbore. In another embodiment, the vibrating device imparts a longitudinal and/or lateral and/or oblique vibration to a tubular member and/or expander device, as the tubular member is being radially expanded by the expander device.

Abstract: Methods and apparatus for expanding tubulars are disclosed. The tubulars 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 and apparatus for tubular expansion are disclosed. In an embodiment, an apparatus for radially expanding a tubular comprises at least two expansion swages. At least one expansion swage is axially movable relative to other expansion swages. In addition, the apparatus includes sealing means capable of providing fluid tight pressure chambers between the expansion swages and an expanded portion of the tubular.

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

Abstract: The present disclosure addressed apparatus and methods for forming an annular isolator in a borehole after installation of production tubing. Annular seal means are carried in or on production tubing as it is run into a borehole. In conjunction with expansion of the tubing, the seal is deployed to form an annular isolator. An inflatable element carried on the tubing may be inflated with a fluid carried in the tubing and forced into the inflatable element during expansion of the tubing. Reactive chemicals may be carried in the tubing and injected into the annulus to react with each other and ambient fluids to increase in volume and harden into an annular seal. An elastomeric sleeve, ring or band carried on the tubing may be expanded into contact with a borehole wall and may have its radial dimension increased in conjunction with tubing expansion to form an annular isolator.