Abstract: A tool for expanding a liner in a wellbore includes a cone assembly that is moveable between a retracted position and an extended position. The tool also includes a jack assembly that is operable by fluid pressure to move the cone assembly from the retracted position to the extended position. The fluid pressure is also applied to expansion cup seals to generate axial load that urges the cone assembly to move through the expandable liner and radially expand of the expandable liner. A latch assembly axially fixes the liner while the cone assembly moves to the extended position. Once the cone assembly is fully moved to the extended position, the latch assembly releases the liner, allowing the cone assembly to move through the liner and radially expand the liner.

Abstract: A tool for expanding a liner in a wellbore includes a cone assembly that is moveable between a retracted position and an extended position. The tool also includes a jack assembly that is operable by fluid pressure to move the cone assembly from the retracted position to the extended position. The fluid pressure is also applied to expansion cup seals to generate axial load that urges the cone assembly to move through the expandable liner and radially expand of the expandable liner. A latch assembly axially fixes the liner while the cone assembly moves to the extended position. Once the cone assembly is fully moved to the extended position, the latch assembly releases the liner, allowing the cone assembly to move through the liner and radially expand the liner.

Abstract: A safety joint having threads with a first handedness, for example right-handed threads, to connect the safety joint to an upper drill pipe portion and a lower drill pipe portion. The safety joint includes a releasable threaded connection having a second handedness inverse of the first handedness. The safety joint also includes a hydraulically actuated piston sleeve that locks rotation across the releasable threaded connection. Disconnecting the upper drill pipe portion from the lower drill pipe portion is achieved by moving the piston sleeve to a position wherein the piston sleeve does not transmit rotation across the releasable threaded connection, and rotating the upper drill pipe portion in the first handedness direction to unscrew the releasable threaded connection.

Abstract: An expansion system is assembled by coupling a piston assembly and a solid cone assembly to an adjustable cone assembly within an expandable tubular having inner sleeve disposed in a portion thereof. The expansion system is run into a wellbore. The piston assembly is activated to move the solid cone assembly downward through the inner sleeve so as to expand the inner sleeve and the portion of the expandable tubular having the inner sleeve. The adjustable cone assembly is shifted from a retracted position to an expansion position within the inner sleeve. The adjustable cone assembly is moved upward through expandable tubular while leaving the solid cone assembly and the inner sleeve coupled to expandable tubular. The solid cone assembly and the inner sleeve may be drilled or milled.

Abstract: An apparatus for expanding tubular members in a wellbore, such as casing, liners, sand screens, or other expandable tubular members, includes a first downhole tubular member, a second downhole tubular member that is radially expandable, and a sealed releasable connection coupling the first and second downhole tubular members. The sealed releasable connection is configured to decouple the first and second downhole tubular members by expansion of the second downhole tubular member. The sealed releasable connection had a metal-to-metal seal formed between the first and second downhole tubular members.

Abstract: A safety joint having threads with a first handedness, for example right-handed threads, to connect the safety joint to an upper drill pipe portion and a lower drill pipe portion. The safety joint includes a releasable threaded connection having a second handedness inverse of the first handedness. The safety joint also includes a hydraulically actuated piston sleeve that locks rotation across the releasable threaded connection. Disconnecting the upper drill pipe portion from the lower drill pipe portion is achieved by moving the piston sleeve to a position wherein the piston sleeve does not transmit rotation across the releasable threaded connection, and rotating the upper drill pipe portion in the first handedness direction to unscrew the releasable threaded connection.

Abstract: An expandable tubular having a receptacle at its lower end is installed in a wellbore. An axial force is generated on a solid cone assembly to push the solid cone assembly. The solid cone assembly includes a cone body formed from a drillable material, the cone body having an expansion surface, a first expansion profile formed in a first portion of the expansion surface, and a second expansion profile formed in a second portion of the expansion surface. The second expansion profile includes one or more facets. The facets of the second expansion profile engage the receptacle, providing a rotational lock to the cone body. After expansion of the expandable tubular, the cone body may be drilled or milled.

Abstract: An apparatus for expanding tubular members in a wellbore, such as casing, liners, sand screens, or other expandable tubular members, includes a first downhole tubular member, a second downhole tubular member that is radially expandable, and a sealed releasable connection coupling the first and second downhole tubular members. The sealed releasable connection is configured to decouple the first and second downhole tubular members by expansion of the second downhole tubular member. The sealed releasable connection had a metal-to-metal seal formed between the first and second downhole tubular members.

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: An expansion system is assembled by coupling a piston assembly and a solid cone assembly to an adjustable cone assembly within an expandable tubular having inner sleeve disposed in a portion thereof. The expansion system is run into a wellbore. The piston assembly is activated to move the solid cone assembly downward through the inner sleeve so as to expand the inner sleeve and the portion of the expandable tubular having the inner sleeve. The adjustable cone assembly is shifted from a retracted position to an expansion position within the inner sleeve. The adjustable cone assembly is moved upward through expandable tubular while leaving the solid cone assembly and the inner sleeve coupled to expandable tubular. The solid cone assembly and the inner sleeve may be drilled or milled.

Abstract: A threaded connection comprising a pin member formed on an end of a first tubular member. The pin member includes an inner seal pin portion, a threaded pin portion, and an outer seal pin portion. The inner seal pin portion has an inner diameter that is greater than an inner diameter of the outer seal pin portion. A box member is formed on an end of a second tubular member. The box member includes an inner seal box portion, a threaded box portion, and an outer seal box portion. The inner seal box portion has an outer diameter that is greater than an outer diameter of the outer seal box portion. The inner seal pin portion sealingly engages the inner seal box portion and the outer seal pin portion sealingly engages the outer seal box portion when the threaded pin portion is engaged with the threaded box portion.

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 method of expanding a tubular member by assembling an expansion system having an expansion cone and an expansion sleeve and coupling a tubular member to the expansion system so that the expansion sleeve is at least partially disposed within the tubular member. The expansion system and tubular member are then disposed in a wellbore and the expansion cone is translated relative to the expansion sleeve and tubular member so as to radially expand the tubular member into engagement with the wellbore and the expansion system is removed from the wellbore. The tubular member is expanded to an inside diameter equal to an expansion diameter of the expansion cone plus twice a thickness of the expansion sleeve.

Abstract: A method of expanding a tubular member by assembling an expansion system having an expansion cone and an expansion sleeve and coupling a tubular member to the expansion system so that the expansion sleeve is at least partially disposed within the tubular member. The expansion system and tubular member are then disposed in a wellbore and the expansion cone is translated relative to the expansion sleeve and tubular member so as to radially expand the tubular member into engagement with the wellbore and the expansion system is removed from the wellbore. The tubular member is expanded to an inside diameter equal to an expansion diameter of the expansion cone plus twice a thickness of the expansion sleeve.

Abstract: A threaded connection comprising a pin member formed on an end of a first tubular member. The pin member includes an inner seal pin portion, a threaded pin portion, and an outer seal pin portion. The inner seal pin portion has an inner diameter that is greater than an inner diameter of the outer seal pin portion. A box member is formed on an end of a second tubular member. The box member includes an inner seal box portion, a threaded box portion, and an outer seal box portion. The inner seal box portion has an outer diameter that is greater than an outer diameter of the outer seal box portion. The inner seal pin portion sealingly engages the inner seal box portion and the outer seal pin portion sealingly engages the outer seal box portion when the threaded pin portion is engaged with the threaded box portion.

Abstract: An expansion system including a mandrel slidably coupled to plurality of primary cone segments that are interleaved with a plurality of secondary cone segments. The expansion system has a the first position wherein the primary cone segments and secondary cone segments are in a retracted position, a second position wherein the primary cone segments are in an expanded position and the secondary cone segments are in a retracted position, and a third position wherein the primary cone segments and the secondary cone segments are in an expanded position. When the expansion assembly is disposed within a tubular member and in the second position, the primary cone segments expand the tubular member into a tri-lobe cross-sectional shape.

Abstract: An expandable tubular member comprises a first portion having a first inner diameter and a first wall thickness. A second portion of the expandable tubular member has an increased inner diameter and an increased wall thickness. A transition portion of the expandable tubular member is defined by a wall thickness that varies non-linearly between the first wall thickness and the increased wall thickness.

Abstract: An expansion system including a mandrel slidably coupled to plurality of primary cone segments that are interleaved with a plurality of secondary cone segments. The expansion system has a the first position wherein the primary cone segments and secondary cone segments are in a retracted position, a second position wherein the primary cone segments are in an expanded position and the secondary cone segments are in a retracted position, and a third position wherein the primary cone segments and the secondary cone segments are in an expanded position. When the expansion assembly is disposed within a tubular member and in the second position, the primary cone segments expand the tubular member into a tri-lobe cross-sectional shape.