Since the early years of cased hole completions, casingpatches of various designs have been used to seal off annularleaks down hole. Casing patches of prior art would typicallyrestrict the operator the ability to run large diameter toolsbelow the patch leaving the well bore with a less thandesirable tubing size for completions. Also, current designs ofcasing patches that are available are typically weaker withrespect to the pressure integrity of the patch itself.Recent interest along with the technological advances ofexpandable tubulars have led to a new design of casing patchthat permits a more desirable size of completion string. Inaddition to this, it was also realized in the design and testingphase, that a patch could be developed with pressure integritythat meet or exceed the tubing and/or casing string in which itis set.This paper will focus on the unique features of this highpressure, large thru bore expandable casing patch system fromthe initial customer contact, to the trials and tribulations of thedesign and the research and development testing process.Actual field use of the tool including applications and sizeswill also be briefly discussed, as the patch system has beendeployed in wells ranging from the Texas panhandle toWyomingWyoming1.In conclusion, this paper will discuss how thedevelopmental process of this particular tool has led themanufacturer to the design of several other new tools forvarious down hole applications.
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