Abstract: A system includes an inner string assembly disposed within an outer casing. The inner string assembly includes a seal member in sealing engagement with the outer casing. An expansion sleeve is coupled to an end of the outer casing. An expandable liner is coupled to the expansion sleeve. A cone assembly is coupled to the inner string assembly and positioned proximate to the expansion sleeve when the inner string is in a running position.

Abstract: A system and method for lining a section of a wellbore with an expandable tubular element. The system comprises an elongate drill string having a force multiplier near a lower end thereof, which is housed within the expandable tubular element. An expander for expanding the tubular element is arranged at a lower end of the force multiplier. Anchoring means are provided at the exterior of the tubular element for anchoring the tubular element in the wellbore. Pulling the expander through the expandable tubular using the force multiplier may be combined with pulling the drill string upwards. A sudden drop of the hydraulic pressure in the force multiplier drops will confirm fixation of the anchoring means in the wellbore wall.

Abstract: A system including a housing having an upper end in fluid communication with a source of pressurized fluid and a lower end releasably coupled to an expandable tubular. A piston is disposed within and sealingly engaged with the housing. An expansion cone is coupled to the piston and is operable to radially expand the expandable tubular as it moves longitudinally therethrough. A pressure chamber is disposed within the housing and defined by the piston and the expansion cone. A first pressure relief port is disposed within the housing and is operable to allow fluid communication between the pressure chamber and an annulus external to the housing. A second pressure relief port is disposed within the expansion cone and is operable to allow fluid communication between the pressure chamber and a portion of the expandable tubular below the expansion cone.

Abstract: The present invention provides a system for anchoring an expandable tubular to a borehole wall. The system comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, said second end being movable relative to the outside of the tubular. Said support member includes a ramp surface that tapers in the direction of said anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with said ramping surface.

Abstract: The present invention provides a system for anchoring an expandable tubular to a borehole wall. The system comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, said second end being movable relative to the outside of the tubular. Said support member includes a ramp surface that tapers in the direction of said anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with said ramping surface.

Abstract: A system for anchoring an expandable tubular to a borehole wall comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, the second end being movable relative to the outside of the tubular. The support member includes a ramp surface that tapers in the direction of the anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with the ramping surface.

Abstract: A method of removing an unexpanded shoe comprises disposing a tool in a wellbore. The tool includes a latch assembly and a mill body. The latch assembly is engaged with a shoe assembly that is coupled to the wellbore by a tubular having an expanded portion and an unexpanded portion. The mill body is rotated relative to the latch assembly so as to mill the unexpanded portion of the tubular until the shoe assembly is uncoupled from the wellbore. The tool and the shoe assembly are then pulled through the expanded portion and out of the wellbore.

Abstract: A method is provided of radially expanding a tubular element (56) in a well-bore using an expander located in the tubular element, the expander (40) comprising an expansion member (48) and a plurality of segments (50) spaced in circumferential direction around the expansion member, the segments being movable between a radially retracted position and a radially expanded position by axial movement of the expansion member relative to the segments. The method includes a plurality of successive expansion cycles, wherein each expansion cycle comprises the steps of: (a) moving the expander (40) in axially forward direction through the tubular element (56) whereby the segments (56) are in the radially retracted position; and (b) radially expanding the tubular element by moving the segments to the radially expanded position by axially moving the expansion member relative to the segments.

Abstract: An expansion cone comprising a cone body having a first expansion surface with a diameter that increases from a leading edge to a first expansion diameter. A resilient sleeve disposed on an actuation mandrel that is coupled to the cone body. Movement of the actuation mandrel relative to the cone body moves an outer surface of the resilient sleeve to a second expansion diameter that is greater than the first expansion diameter.

Abstract: A system for anchoring an expandable tubular to a borehole wall. The system comprises a support member having a first end fixed relative to the outside of the tubular and a second end comprising a ramping surface. An anchor member has a first end fixed relative to the outside of the tubular and a second end extending toward the support member, the second end being movable relative to the outside of the tubular. The support member includes a ramp surface that tapers in the direction of the anchor member. Expansion of the portion of the expandable tubular between the first support end and the first anchor end causes the axial device length to shorten, wherein the difference in length is sufficient to cause the second anchor end to move radially outward and engage the borehole wall as a result of engagement with the ramping surface.

Abstract: A system comprising a housing having an upper end in fluid communication with a source of pressurized fluid and a lower end releasably coupled to an expandable tubular. A piston is disposed within and sealingly engaged with the housing. An expansion cone is coupled to the piston and is operable to radially expand the expandable tubular as it moves longitudinally therethrough. A pressure chamber is disposed within the housing and defined by the piston and the expansion cone. A first pressure relief port is disposed within the housing and is operable to allow fluid communication between the pressure chamber and an annulus external to the housing. A second pressure relief port is disposed within the expansion cone and is operable to allow fluid communication between the pressure chamber and a portion of the expandable tubular below the expansion cone.

Abstract: A downhole releasable tubular connection includes a joint between two tubing strings, wherein one of the two tubing strings is radially expanded and plastically deformed by an expansion device. When the expansion device is moved adjacent to the joint, a threaded connection mechanism in the joint reacts to the radially outward forces of the expansion device and releasably expands, thereby decoupling the tubing strings.

Abstract: A system comprising a first expandable tubular section and a first expansion bridge coupled to an inner surface of the first expandable tubular section. A base pipe is coupled to the first expandable tubular section and to a second expandable tubular section. A second expansion bridge is coupled to an inner surface of the second expandable tubular section. The system also comprises an expansion cone disposed within and translatable relative to the first expandable section. The expansion cone has an expansion diameter greater than an inner diameter of the first and second expansion bridges and less than an inner diameter of the base pipe.

Abstract: A geometrically optimized expansion cone for radially expanding a tubular member. In some embodiments, the expansion cone includes an annular body having an outer surface. The outer surface includes a linear surface having a constant diameter, a curvilinear surface extending from the linear surface, a recessed surface having a diameter less than the diameter of the curvilinear surface, and a chamfer between the recessed surface and the curvilinear surface. The diameter of the linear surface is substantially equal to an inner diameter of the tubular member after expansion, while the chamfer has a maximum diameter less than an inner diameter of the tubular member prior to expansion. The curvilinear surface has a diameter defined by a radius of curvature which is tangent to the chamfer at the maximum diameter and tangent to the linear surface.

Abstract: An expandable tubular liner includes a first tube, a second tube, a mechanical coupling for coupling the first and second tubes, and an insert coupled to the mechanical coupling. The insert is capable of forming a metallurgical bond with at least one of the tubes when energy is injected into the insert.

Abstract: A radial expansion system.

Abstract: An apparatus for radially expanding and plastically deforming a tubular member includes a support member with a fluid passage. A mandrel is movably coupled to the support member and includes an expansion cone operable to radially expand and plastically deform the tubular member when moved relative to the tubular member. A pressure chamber is positioned between the support member and the mandrel, and the pressure chamber is fluidicly coupled to the fluid passage. A releasable support is coupled to the support member and operable to selectively couple the support member to the tubular member.

Abstract: Methods and apparatus for radially expanding and plastically deforming an expandable tubular include a resilient launcher. The resilient launcher includes a launcher portion and a sleeve portion. An inner diameter of the sleeve portion is smaller than an inner diameter of the launcher portion. An expansion cone is disposed in the launcher portion of the resilient launcher. The expandable tubular is disposed around the sleeve portion and above the launcher portion of the resilient launcher. The launcher portion comprises a port that is sealable below the expansion cone.

Abstract: A system for expanding a tubular member. In some embodiments, the system includes an expansion assembly disposed in sealingly engagement within the tubular member, a shoe assembly releasably coupled within the tubular member, and a chamber disposed therebetween. The expansion assembly has a flowbore and a openable port. The shoe assembly includes a flowbore extending therethrough, the flowbore in fluid communication with the flowbore of the expansion assembly and having a valveable passage. When the valveable passage is closed, the port is adapted to open, whereby the chamber is fluidicly coupled to the flowbore of the expansion assembly. When the valveable passage is open, the port remains closed, whereby the chamber is fluidicly isolated from the flowbore of the expansion assembly.

Abstract: Methods and apparatus for radially expanding and plastically deforming an expandable tubular member using a lower expansion cone and an upper expandable cone. The apparatus includes an expandable tubular, a support member releasably secured to the expandable tubular, and an extendable section below where the support member is releasably anchored. An upper expandable cone is attached to the extendable section and in a retracted state and an anchor is disposed below the upper expandable cone. The anchor is releasable from below the upper expandable cone. A lower expansion cone is disposed below the anchor. An expansion sleeve is disposed in the lower end of the expandable tubular. The lower expansion cone is configured to expand the expansion sleeve radially outward to an outer diameter greater than the inside diameter of the expandable tubular when axially displaced downward by the extendable section.