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

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

Abstract: The present invention provides an encapsulation for housing instrumentation lines, control lines, or instruments downhole. In one use, the encapsulation resides between an expandable downhole tool, such as an expandable sand screen, and the wall of the wellbore. The encapsulation is specially profiled to allow the downhole tool to be expanded into the wall of the wellbore without leaving a channel outside of the tool through which formation fluids might vertically migrate. The encapsulation is useful in both cased hole and open hole completions.

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

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

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

Abstract: The invention is a multipurpose system for reeling tubing secured to a platform made of a reel support frame removeably secured to a platform, a reel containing tubing removeably secured to the reel support frame, a reel drive for rotating the reel disposed on the reel support frame, a tower for suspending the straightener and the guide, a support frame attached to the tower, a guide disposed on the support frame for receiving tubing from the reel and ending the tubing forming bent tubing, a straightener disposed on the support frame for receiving the bent tubing and forming straightened tubing, a rotating connection for connecting the support frame to the tower, a tensioner frame removeably mounted on the platform, and a tensioner secured to the tensioner frame for receiving the straightened tubing, supporting the straightened tubing and moving the straightened tubing.

Abstract: An apparatus and methods are provided for monitoring a well and for obtaining fluid samples from below the ground. The apparatus includes a single-piece, extruded plastic well stock that extends from the surface of the ground to the lowest sampling depth. Plural sampling intervals are defined between the surface and the lowest sampling depth. Sampling intervals are defined by isolating sections of the borehole by using packers that seal the annular space between the well stock and the borehole. The well stock includes plural longitudinal chambers. Inlet holes are put into the well stock so that inlets for each interval admit fluid to only one longitudinal chamber. Inert sealant is injected below inlets to prevent fluid from spreading below a desired level. Instructions are placed into the longitudinal chambers to monitor fluids in the chambers or to retrieve samples, or alternatively, the well stock can be removed to obtain samples.

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

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

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

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

Abstract: The disclosure describes a spoolable compliant guide, a system including a spoolable compliant guide and injector and methods for using the compliant guide, where the guide is designed to connect at one end to the injector and at its other end to a remote installation having a seal and to allow coiled tubing to be inserted into the installation through the seal. Because the guide permits a substantial distance to exist between the injector and the installation seal and functions as a crimp or band resistor for the coiled tubing, the guide enables the injector to be conveniently positioned remote from the installation such as a wellhead and assumes a compliant shape between the injector and the installation allowing dynamic relative movement between them without the use of heave compensators. Thus, for subsea installations, the injector, its control system and coiled tubing reels can all be located on the water's surface for ease of access and maintenance.

Abstract: An apparatus and method used for sealing a wellbore. The apparatus includes a swelling elastomer disposed around an outer surface of the tubular body. The swelling elastomer is isolated from wellbore fluid in an annulus. However, upon the application of an outwardly directed force to an inner surface of the tubular body, the tubular body expands radially outward causing the swelling elastomer to contact the wellbore while exposing the swelling elastomer to an activating agent via the one or more apertures, thereby causing the swelling elastomer to create a pressure energized seal with one or more adjacent surfaces in the wellbore.

Abstract: Apparatus for and method of radial expansion of a tubular member, with embodiments of the apparatus including an expander device, for example an expansion cone, which has a driver device either attached to it or integral therewith. The driver device can be a pump for example, where the pump creates a differential pressure across the expander device to cause it to move.

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

Abstract: The present invention provides apparatus and a method of anchoring an expandable conduit. A formation is provided on an outer surface of the conduit, the formation comprising a number of bands of a friction and/or sealing material. When the expandable conduit is radially expanded, the friction and/or sealing material engages a second conduit in which the expandable conduit is located. The engagement of the friction and/or sealing material provides an anchor for the expandable conduit.

Abstract: 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 wellhead has, instead of a conventional Christmas tree, a spool tree in which a tubing hanger is landed at a predetermined angular orientation. As the tubing string can be pulled without disturbing the tree, many advantages follow, including access to the production casing hanger for monitoring production casing annulus pressure, and the introduction of larger tools into the well hole without breaching the integrity of the well.

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: An apparatus and method of creating a seal between two coaxial tubulars so as to create a hanger and a packer. A first tubular is disposed coaxially within a portion of a second, larger tubular. A portion of the first tubular is expanded into frictional contact with the second tubular, thereby creating a liner and a hanger. In one embodiment, a pattern of grooves and profile cuts are formed in the surface of a portion of the first tubular body. The grooves in one aspect define a continuous pattern about the circumference of the tubular body which intersect to form a plurality of substantially identical shapes, such as diamonds. The grooves and profile cuts serve to improve the tensile strength of the tubular body. At the same time, the grooves and profile cuts allow for expansion of the tubular body by use of less radial force.

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

Abstract: The present invention provides methods and apparatus for reducing friction and preventing galling between surfaces in a wellbore. In one aspect of the invention, a titanium carbide is disposed between surfaces of an expansion tool and a tubular to be expanded. The titanium carbide coating acts as a lubricant to reduce friction and prevent galling therebetween.

Abstract: A system for lining a wellbore casing.

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

Abstract: A method and apparatus is provided for drilling and lining a wellbore in one downhole trip. The method comprises mounting a drill bit on a drill string including a section of expandable tubing and providing a tubing expander in the string, then rotating the drill bit and advancing the drill string through a bore, then passing the expander through the expandable tubing to expand the tubing, wherein the expandable tubing is deformed by compressive plastic deformation of the tubing with a localised reduction in wall thickness, resulting in a subsequent increase in tubing diameter, and then retrieving the drill bit from the bore through the expanded tubing.

Abstract: The present invention generally relates to an apparatus and method for engaging a first tubular and a second tubular in a wellbore. In one aspect, an apparatus for forming an expanded connection in a wellbore is provided. The apparatus includes a first tubular radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular. The apparatus further includes a plurality of outwardly extending formations formed on an outer surface of the first tubular, the formations constructed and arranged to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path when the first tubular is expanded to engage the inner wall of the second tubular. In another aspect, a method of compliantly expanding a tubular into contact with a casing wall is provided. In a further aspect, an expandable apparatus for expanding a tubular is provided.

Abstract: A method and apparatus is provided for drilling and lining a wellbore in one downhole trip. The method comprises mounting a drill bit on a drill string including a section of expandable tubing and providing a tubing expander in the string, then rotating the drill bit and advancing the drill string through a bore, then passing the expander through the expandable tubing to expand the tubing, wherein the expandable tubing is deformed by compressive plastic deformation of the tubing with a localised reduction in wall thickness, resulting in a subsequent increase in tubing diameter, and then retrieving the drill bit from the bore through the expanded tubing.

Abstract: The present invention generally relates to an apparatus and method for engaging a first tubular and a second tubular in a wellbore. In one aspect, an apparatus for forming an expanded connection in a wellbore is provided. The apparatus includes a first tubular being radially expandable outward into contact with an inner wall of a second tubular upon the application of an outwardly directed force supplied to an inner surface of the first tubular. The apparatus further includes a plurality of formations formed on an outer surface of the first tubular, the formations constructed and arranged to provide a frictional relationship between the first tubular and the second tubular while leaving a fluid path when the first tubular is expanded to engage the inner wall of the second tubular. In another aspect, an apparatus for engaging a first tubular and a second tubular in a wellbore is provided. In yet another aspect, a method of completing a wellbore is provided.

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

Abstract: A tubing expander (10) comprises a body (12) carrying a plurality of radially movable piston-mounted rollers (24) and associated sleeves (16) mounted about the body (12) and being radially supported by the rollers (12). The expander (10) is positioned in a length of cubing of a first diameter, the pistons (28) extended, and the expander (10) rotated such that the sleeves (16) roll around the inner surface of the tubing and expand the tubing to a larger second diameter.

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

Abstract: A connector arrangement for provision between the ends of two sections of expandable tubing, each expandable tubing section comprising a filter screen sandwiched between inner expandable tubing and outer expandable tubing, the filter screen of one tubing section overlapping the filter screen of the other tubing section and the outer expandable tubing of at least one of the tubing sections extending over the overlapping filter screens.

Abstract: An apparatus suitable for use in a wellbore comprises an expandable bistable device. An exemplary device has a plurality of bistable cells formed into a tubular shape. Each bistable cell comprises at least two elongated members that are connected to each other at their ends. The device is stable in a first configuration and a second configuration.

Abstract: An improved V-style gripper block to better accommodate a variable outer diameter material (e.g. cable, plastic, wire, or pipe). The gripper block comprises a block body being connectable to a gripper chain in an injector apparatus, a gripper plate having arcuate and/or angled gripping surfaces for engaging tubing of various outer diameters, and a flex layer disposed between the gripper plate and the block body to allow the gripping surface of the gripper plate to move relative to the block body to which it is attached. This relative movement allows the gripping surface of the gripper block to rapidly conform to changes in the outer diameter of coiled tubing. In various embodiments, the flex layer may be formed of elastomeric materials including natural or synthetic rubber; an encapsulated gel or liquid within a flexible membrane; or mechanical means such as springs.

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

Abstract: This invention relates to an elongated wireline entry device (10) which allows a wirelein tool or coiled tubing with a tool attached to be inserted in a well bore without disconneciton form the drill string appended thereto without introducing bending moments into the threaded connectiosn (101, 106, 202) attached to the drill string because the pin and box connectiosn of the tool are in axial, longitudinal alignment. The absence of these bending moments is required to suspend long pendular, and therefore heavy, drill strings forr htthis device without failure. The angle between the longitudinal ayes of the longitudinal passage and the wireline passage in the wireline entry device is at most 4.0°.

Abstract: A technique utilizes blocking members to resist contraction of expandables in wellbore environments. The technique comprises an expandable having a wall with a plurality of expandable cells. A plurality of blocking members cooperate with at least some of the cells to resist contraction of the expandable device once transitioned to a desired expanded state.

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

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

Abstract: An apparatus and method for completing an interval of a wellbore while drilling comprises a drill string (52) having a drill bit (30) mounted on the lower end thereof. A completion assembly (50) is positioned around a section of the drill string (52) such that when the wellbore (32) is extended by rotating the drill bit (30) and advancing the drill string (52), the completion assembly (50) does not rotate. The advancement of the drill string (52) and rotation of the drill bit (30) is ceased when the completion assembly (50) has reached the desired interval of the wellbore (32). Thereafter, the drill string (52) is disconnected from the drill bit (30) for retrieval to the surface leaving the completion assembly (50) and the drill bit (30) downhole.

Abstract: The present invention provides a method and apparatus for deforming a tubular body, running the tubular body through a restriction in a wellbore, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. In one aspect, the present invention provides a method for forming a substantially monobore well involving deforming a tubular body, running the tubular body below a restricted inner diameter portion, reforming the tubular body, and expanding at least a portion of the tubular body past its elastic limit. The restricted inner diameter portion may comprise a casing string previously disposed within the wellbore or a casing patch. The at least the portion of the tubular body expanded past its elastic limit may be a lower portion of the tubular body. Subsequent tubular bodies may be reformed and expanded below previous tubular bodies.

Abstract: A coiled tubing injector apparatus for use in inserting coiled tubing into a well, temporarily suspending the coiled tubing, and removing the coiled tubing from the well is described. The apparatus includes a base with a pair of spaced-apart carriages extending upwardly therefrom. The base is part of a frame positioned above a wellhead. The carriages each have a gripper chain drive system rotatably mounted thereon and movable therewith. An actuation and linkage system allows the carriages to move toward and away from one another in a lateral or transverse direction with respect to the superstructure and the base. Thus, the gripper chain systems comprises gripper chains that can be engaged or disengaged from the coiled tubing extending through the apparatus. A wetting fluid basin is positioned below the gripper chains, and support guides engage the coiled tubing below the gripper chains to prevent buckling of the coiled tubing.

Abstract: The invention concerns a method for enhancing resistance to external pressure to a pipe installed in a previously cased borehole, which offers a passage through its opening of reduced size. Said method consists in lowering the pipe in a first shape (2) whereof the dimensions are smaller than the reduced opening, in deforming it to convert it from the first shape in a second shape substantially cylindrical (3) having a dimension larger than the reduced opening and characterized by the expansion of the cylindrical pipe of the second form by displacement of an expansion mandrel through the pipe, the peripheral expansion lying between 2 and 10% of the value of the initial perimeter.

Abstract: An apparatus suitable for use in a wellbore comprises an expandable bistable device. An exemplary device has a plurality of bistable cells formed into a tubular shape. Each bistable cell comprises at least two elongated members that are connected to each other at their ends. The device is stable in a first configuration and a second configuration.

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

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

Abstract: A multi-layer deformable composite construction. In a described embodiment, a method of expanding a structure in a wellbore includes the steps of: positioning the structure in an unexpanded configuration in the wellbore, the structure including a wall made up of multiple layers; expanding the structure to an expanded configuration while permitting relative displacement between the layers; and then preventing relative displacement between the layers.

Abstract: The present invention provides a method and apparatus for regulating pressure within a closed expansion system. In one aspect of the invention, the apparatus comprises an expander tool comprising a first pressure regulation system disposed within an expansion chamber. The first pressure regulation system comprises two valves which regulate pressure within the expansion system during run-in. In another aspect of the invention, the apparatus comprises an expander tool comprising an expansion chamber in fluid communication with a second pressure regulation system. The second pressure regulation system regulates pressure during the expansion of a tubular. The second pressure regulation system comprises a frangible member and a valve in series, and optionally a pressure regulator downstream of the frangible member and valve in series. In another aspect of the invention, a method is provided for regulating pressure during the expansion process using the first and/or second pressure regulation system.

Abstract: A continuous well string injection unit, comprising a pair of motor driven continuous chains mounted opposed to each for gripping coiled rod between them. Plural links are connected end to end in each one of the pair of motor driven continuous chains, in which each link comprises a connected yoke and a neck, the neck of each link being sized to fit within the yoke of a succeeding link in the motor driven continuous chain with consecutive links connected by a pin extending through the neck of one link and the yoke of the next succeeding link. A method of injecting coiled rod into a well is also provided.