A method is provided for manufacturing a segment of a drill string, such as a tubular tool, from a plurality of layers. The method includes arranging a plurality of layers based on a selected length of the segment. Each of the plurality of layers includes an aperture that is received over an alignment feature that restricts movement of the plurality of layers to two or fewer degrees of freedom. A joining process is performed to join the plurality of layers, which may include at least one replacement layer.

The invention concerns a method of applying a coating in a liquid state to wellbore tubing, such as threaded connector parts or casing sections, before running the tubing downhole. The coating only cures while running downhole. The coating is an elastic curable coating composition, comprising a curable elastic thermosetting resin, a curing agent and a water-absorbing expansion agent. During make-up of a connector, the liquid coating composition acts as lubricant. When cured, the coating will swell when contacted with a wellbore fluid to ensure leak-tightness.

The invention concerns a method of applying a coating in a liquid state to wellbore tubing, such as threaded connector parts or casing sections, before running the tubing downhole. The coating only cures while running downhole. The coating is an elastic curable coating composition, comprising a curable elastic thermosetting resin, a curing agent and a water-absorbing expansion agent. During make-up of a connector, the liquid coating composition acts as lubricant. When cured, the coating will swell when contacted with a wellbore fluid to ensure leak-tightness.

A method for casing a subsea wellbore includes running a tieback casing string into the subsea wellbore using a workstring including first, second, and third wiper plugs. The method further includes: launching a first release plug or tag into the workstring; pumping cement slurry into the workstring, thereby driving the first release plug or tag along the workstring; after pumping the cement slurry, launching a second release plug or tag into the workstring; and pumping chaser fluid into the workstring, thereby driving the release plugs or tags and cement slurry through the workstring. The release plugs or tags engage and release the respective wiper plugs from the workstring. The first wiper plug or release plug ruptures, thereby allowing the cement slurry to flow therethrough. The method further includes: stabbing the tieback casing string into a liner string; and retrieving the workstring, the workstring still including the third wiper plug.

A method for casing a subsea wellbore includes running a tieback casing string into the subsea wellbore using a workstring including first, second, and third wiper plugs. The method further includes: launching a first release plug or tag into the workstring; pumping cement slurry into the workstring, thereby driving the first release plug or tag along the workstring; after pumping the cement slurry, launching a second release plug or tag into the workstring; and pumping chaser fluid into the workstring, thereby driving the release plugs or tags and cement slurry through the workstring. The release plugs or tags engage and release the respective wiper plugs from the workstring. The first wiper plug or release plug ruptures, thereby allowing the cement slurry to flow therethrough. The method further includes: stabbing the tieback casing string into a liner string; and retrieving the workstring, the workstring still including the third wiper plug.

A packer having a thermal memory spacing system that includes a portion of the system that that selectively changes an outer diameter due. The packer may include upper and lower sealing elements, and at least one thermal memory shape material sub positioned between the sealing elements. The thermal memory shape material sub may have a first outer diameter at a first temperature and a second larger outer diameter at a second temperature. The first temperature may be greater than the second temperature. The outer diameter of the sub may be selectively increased to temporarily decrease the annular area in which debris and/or materials may collect and potentially cause the packer to become stuck within the wellbore. Prior to moving the packer to a different location, the outer diameter of the sub may be decreased to increase the annular area.

A packer having a thermal memory spacing system that includes a portion of the system that that selectively changes an outer diameter due. The packer may include upper and lower sealing elements, and at least one thermal memory shape material sub positioned between the sealing elements. The thermal memory shape material sub may have a first outer diameter at a first temperature and a second larger outer diameter at a second temperature. The first temperature may be greater than the second temperature. The outer diameter of the sub may be selectively increased to temporarily decrease the annular area in which debris and/or materials may collect and potentially cause the packer to become stuck within the wellbore. Prior to moving the packer to a different location, the outer diameter of the sub may be decreased to increase the annular area.

An apparatus for detecting over-torquing or un-torquing of a threaded connection between components in a borehole penetrating the earth includes: a string of components coupled in series by a threaded connection; a transmission line attached to each component; a signal coupler in communication with the transmission line and disposed on each component at each threaded connection, the signal coupler being configured to transmit the signal to an adjacent signal coupler on an adjacent coupled component in order to transmit a signal along the transmission line attached to the adjacent coupled component; a receiver configured to receive the signal; and a processor in communication with the receiver and configured to: (i) determine a difference between a characteristic of the signal and the characteristic of a reference signal and (ii) transmit an alert signal signifying that the threaded connection is over-torquing or un-torquing in response to the difference exceeding a threshold value.

An apparatus for detecting over-torquing or un-torquing of a threaded connection between components in a borehole penetrating the earth includes: a string of components coupled in series by a threaded connection; a transmission line attached to each component; a signal coupler in communication with the transmission line and disposed on each component at each threaded connection, the signal coupler being configured to transmit the signal to an adjacent signal coupler on an adjacent coupled component in order to transmit a signal along the transmission line attached to the adjacent coupled component; a receiver configured to receive the signal; and a processor in communication with the receiver and configured to: (i) determine a difference between a characteristic of the signal and the characteristic of a reference signal and (ii) transmit an alert signal signifying that the threaded connection is over-torquing or un-torquing in response to the difference exceeding a threshold value.

High-strength, fatigue-resistant pipe connectors suitable for use in offshore risers, tendons and pipelines, such as may be connected to floating production systems (FPSs) principally used in the production of oil and gas. The present connectors include tubular pin and box components with mating frusto-conical, concentrically-grooved mating surfaces which threadingly interlock, and non-threaded (e.g., flat) mating surfaces that seal and preload (e.g., preload at least a portion of each component in compression), via axial advancement of the pin component into the box component. In such connectors, axial movement of the pin into the mating box results the in radial expansion of the box and radial contraction of the pin until the concentric thread patterns match and interlockingly snap into the connected position.