A casing patch system comprising a base tubular with two anchor/seals coupled to the base tubular and an expansion tool comprising two expansion devices positioned such that upon expansion of the first anchor/seal, the second expansion device engages the second anchor/seal, which allows reduction of the expansion forces due to sequential expansion and reduces the length of the displacement necessary for setting the casing patch, eliminating the need for resetting the thruster, which allows deployment and setting of the casing patch on a wireline. In another embodiment, the expansion device comprises two swages coupled to a shaft at a distance between them approximately equal to the length of the anchor/seal. The swage diameters are selected such that the expansion forces of the anchor/seal by front and back swages are approximately equal, resulting in significantly less expansion force compared to the expansion force necessary for expansion by a single swage, which allows a high degree of anchor/seal expansions unachievable by single swage expansion devices.

A casing patch system comprising a base tubular with two anchor/seals coupled to the base tubular and an expansion tool comprising two expansion devices positioned such that upon expansion of the first anchor/seal, the second expansion device engages the second anchor/seal, which allows reduction of the expansion forces due to sequential expansion and reduces the length of the displacement necessary for setting the casing patch, eliminating the need for resetting the thruster, which allows deployment and setting of the casing patch on a wireline. In another embodiment, the expansion device comprises two swages coupled to a shaft at a distance between them approximately equal to the length of the anchor/seal. The swage diameters are selected such that the expansion forces of the anchor/seal by front and back swages are approximately equal, resulting in significantly less expansion force compared to the expansion force necessary for expansion by a single swage, which allows a high degree of anchor/seal expansions unachievable by single swage expansion devices.

A technique facilitates actuation of a packer to a sealing and gripping position along a borehole. The packer includes a packer element structure mounted about a center structure. The packer element structure includes a sealing element mounted along an expandable base such that the sealing element may be radially expanded. Additionally, the packer includes an actuator member connected to a portion of the packer element structure via a release mechanism, e.g. a shear member. A plurality of slips may be located on the actuator member such that linear movement of the actuator member causes successive movement of the packer sealing element and then the slips in the radially outward direction. The packer may be constructed such that this sequential setting motion creates a jarring effect to ensure the slips securely bite into the surrounding wellbore surface, e.g. casing surface.

The apparatus prepares a downhole tool component, particularly a slip for a plug that seals zones in a wellbore. The apparatus includes a casing holder, a cone insert, and a cap. There is a bottom center connector to hold the cone insert within the casing holder. There are a plurality of spacing bolts, and a top center connector to hold the slip within the space between the cap, the cone insert, and the casing holder. The top center connector can adjust distance between the slip and the cone insert so that the coating on the ramp surface of the slip has a uniform thickness. The invention includes the method of using the apparatus to prepare the slip with coating of uniform thickness to removably engage another component of the apparatus.

A collet comprising a collet ring, a plurality of collet fingers, and an object seat (e.g., ball seat), wherein the object seat comprises a surface (e.g., a curved surface) configured to interface with a correspondingly sized blocking object (e.g., a ball, dart, etc.) to form a seal therebetween, wherein each of the plurality of collet fingers has a first end and a second end, wherein the first end is proximate the collet ring, and wherein the second end of at least a portion of the plurality of collet fingers comprises a key (e.g., a tab) that is configured to engage a corresponding latch of a downhole structure.

A system for establishing a bypass flow path includes a plug assembly having bypass ports extending from the exterior to the interior; a wiper dart to engage and seal the first flow path and bypass flow path, and initiate release of the plug assembly from a first position, the plug assembly having a dart nose attached to the dart body; once the plug has moved to a second position, pressure applied through the bypass ports communicates to the dart nose to cause detachment of the dart nose from the dart body; a first flow path extends through the central bore of the plug assembly when the wiper dart is not present; and a second flow path extends through the bypass ports on the plug assembly below the dart body to the detachable dart nose, once detached, the bypass flow path is established thru the bore below the dart body.

A system for establishing a bypass flow path includes a plug assembly having bypass ports extending from the exterior to the interior; a wiper dart to engage and seal the first flow path and bypass flow path, and initiate release of the plug assembly from a first position, the plug assembly having a dart nose attached to the dart body; once the plug has moved to a second position, pressure applied through the bypass ports communicates to the dart nose to cause detachment of the dart nose from the dart body; a first flow path extends through the central bore of the plug assembly when the wiper dart is not present; and a second flow path extends through the bypass ports on the plug assembly below the dart body to the detachable dart nose, once detached, the bypass flow path is established thru the bore below the dart body.

A frac dart includes a body having an outer surface and an end including at least one opening. A cutter support is mounted at the end adjacent the at least one opening. A cutter is moveably mounted at the cutter support. A counter support is slideably mounted on the outer surface, and a counter is arranged between the counter support and the cutter support. The cutter is operable to sever a portion of the counter.

Collapsible shell packers and methods of use. An example method introduces a collapsible shell packer into a wellbore; wherein the collapsible shell packer comprises a collapsible hollow, metal shell. The method further includes collapsing the collapsible hollow, metal shell by compressing the collapsible hollow, metal shell axially to expand the collapsible hollow, metal shell radially, wherein the collapsible hollow, metal shell is collapsed until a portion of the collapsible hollow, metal shell contacts an adjacent surface thereby isolating a zone.

Provided is a frac window system, a well system, and a method. The frac window system, in at least one aspect, includes an elongated tubular having a first end and a second end with an opening defined in a wall of the elongated tubular between the first end and the second end, the wall having an inner surface and an outer surface, wherein the opening in the wall is configured to align with a window of a first wellbore casing, and a spacer window sleeve positioned within the elongated tubular, the spacer window sleeve including a tubular having a first tubular end and a second tubular end with a second opening defined in a second wall of the tubular between the first tubular end and the second tubular end, the second wall having a second inner surface and a second outer surface, wherein the second opening in the second wall is configured to at least partially align with the opening in the wall of the elongated tubular.