Apparatus and methods for separating and joining tubulars in a wellbore

An apparatus for cutting a tubular in a wellbore, the apparatus comprising:

• a rotatable cutting tool having a body with at least one opening formed in a wall thereof and at least one cutter assembly disposed within the body, the assembly including at least one hydraulically actuatable, radially extendable cutter arranged to contact the inside wall of the tubular therearound;
• a housing disposed above the cutter member, the housing including:
• a hydraulically actuatable slip assembly disposed therein and having slip members extending radially from the housing to engage the wall of a tubular therearound;
• at least one pump therein for actuating the slip assembly and the cutting tool;
• at least one source of pressurizable fluid in communication with the cutting tool, the slip assembly and the at least one pump;
• at least one electrical motor for operating the at least one pump and for providing rotation to the cutting tool.

An apparatus for setting a liner in a wellbore, comprising:

• a run-in string disposable in the wellbore, the run-in string having a bearing disposed therearound, the bearing providing a support for an upper end of a section of liner;
• a rotatable cutting tool disposed in the run-in string within the liner portion, the cutting tool having a body with at least one opening formed in a wall thereof and at least one cutter assembly disposed within the body, the assembly including at least one hydraulically actuatable, radially extendable cutter arranged to contact the inside wall of the liner therearound, thereby severing the liner into an upper and a lower portion;
• and
• an expansion tool disposed on the run-in string below the cutting tool, the expansion tool having a body with at least one opening formed in a wall thereof and at least one roller assembly disposed within the body, the assembly including at least one hydraulically actuatable, radially extendable roller arranged to contact the inside wall of the liner therearound and, through radial force and rotational movement, expand the liner therearound.

A method of setting a liner in a wellbore comprising:

• running an apparatus into a wellbore, the apparatus including a liner bearingly supported in the wellbore by a run-in string, the run-in string having a cutter and an expander disposed thereon below the bearing;
• expanding a predetermined portion of the liner into a portion of casing fixed in the wellbore, whereby after expanding, the liner is supported in the wellbore by interference between the liner and the casing;
• cutting the liner with the cutter;
• and
• removing the apparatus including an upper portion of the liner from the wellbore.

A tubular section for expanding into a larger diameter tubular in a wellbore, the section comprising:

• an outer circumferential portion expandable into a tubular therearound in a frictional relationship;
• and
• at least one aperture formed in the tubular section and spaced a first longitudinal distance from the outer circumferential portion, the at least one aperture providing a fluid flow path between the an inside and outside of the tubular;
• whereby, the tubular section and the larger diameter tubular are sealable through expansion of the tubular section.

A method of joining two tubulars in a wellbore comprising:

• disposing a smaller diameter tubular coaxially within a larger diameter tubular;
• expanding the smaller diameter tubular circumferentially in an area of at least two formations formed on an outer surface thereof, whereby the weight of the smaller diameter tubular is borne by the larger diameter tubular;
• circulating fluid between the tubulars along areas defined between the formations;
• expanding a second area of the smaller diameter tubular having at least one circumferential groove formed therearound with a sealing element therein, whereby an annular area defined between the annulus is sealed to the passage of fluid smaller and larger diameter tubulars is sealed.