Abstract: A method is provided for providing a casing in a wellbore wherein another casing of the same internal diameter may be provided in the wellbore below the casing and further providing an overlap between the casing and the other casing sufficient to provide a hydraulic seal between the two casings, the method includes the steps of: placing a casing within the wellbore wherein the casing has a smaller outside diameter than a finial inside diameter of the casing; placing an expandable mandrel within the casing, the expandable mandrel suspended from a drill string; converting the expandable mandrel to a first expansion diameter while the expandable mandrel is within the casing wherein the first expansion diameter is about the final inside diameter plus twice the thickness of the final casing; forcing the expanded mandrel through a lower portion of the casing while the expandable mandrel is of the first expansion diameter; converting the expandable mandrel to a second expansion diameter, wherein the second expansion

Abstract: An expandable mandrel is provided for plastic deformation of a tubular from an initial inside radius to an expanded inside radius around a centreline of the tubular is provided. The expandable mandrel includes: a collar having an outside radius smaller than the initial inside radius; and a plurality of deformable segments extending from the collar wherein each of the deformable segments are deformable to the expanded inside radius and when deformed to the expanded radius together form an expansion surface having gaps between the deformed segments that are not aligned with the centerline of the tubular.

Abstract: A duplex expansion apparatus for expanding a wellbore tubular to two different diameters from an initial diameter is provided. The duplex expansion apparatus includes: a first diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the internal diameter; a second diameter expansion cone that is, in a relaxed state, of a diameter less than the internal diameter and in an expanded state of a diameter greater than the diameter of the first diameter expansion cone in the expanded state; and an assembly mandrel that is capable of transferring both the first diameter expansion cone and the second diameter expansion cone into their expanded states.

Abstract: An apparatus and method for expanding a wellbore tubular such as a casing is provided. The apparatus includes: an expandable casing; a drill string extending to within the drillstring; an expansion cone suspended from the drillstring, the expansion cone having an expanded state and a collapsed state and wherein the expansion cone is deformable to the expanded state and is relaxed in the collapsed state; a seal bushing capable of sealing an annulus between the drill string and the expandable casing; a downward expansion flow path wherein fluid communication is provided between the inside of the drill string and the annulus between the drill string and the expandable casing above the expansion cone; and an upward expansion flow path wherein fluid communication is provided between the inside of the drill string and the inside of the expandable casing for upward expansion by the expansion cone.