Abstract: An expandable seal features a ring structure with internal and external seal. The seals are mounted in grooves and extend beyond a base outer dimension on the ring on the inside and the outside surfaces. Bumps are positioned in axial alignment with the seals but in opposition to each seal so that the exterior seal has a bump axially aligned but on the inside of the ring and the inner seal has a bump axially aligned and on the outside surface of said ring. The bumps have end transitions to the base dimension to create a volume for the seal material to travel axially when radially expanded from a mandrel extending within for effective seal containment. Seal rings can be stacked to adjust to dimensional irregularities in the surrounding tubular or the mandrel and to back each other up in the event of seal failure in any one seal ring.

Abstract: A tool allows in a single trip advancing the liner while more hole is made until the liner is properly positioned. Slips are actuated into the inside of the liner to grasp it as a swage is released to move to support the liner to the surrounding tubular. With the liner supported in the hole, the running tool can be picked up to test the release feature and then set down again for cementing. The tool is then picked up higher to release a flapper and re-pressurized to set a seal adjacent the support previously engaged by swage operation. The flapper has a rupture disc blown and the tool is removed. The tool has an emergency release.

Abstract: A CNC machining method that incorporates a dimensional probe that allows inspection after stages of machining to determine actual dimensions with respect to the target dimension allows for corrective measures before advancing to the next step of the process so as to reduce the number of rejects at the end of the machining process. In making a tubular thread that involves initially machining a taper followed by the thread form, the probe and the various cutters are oriented against gauge blocks supported in the chuck jaws. The probe is used to dimensionally inspect the taper that is cut as an initial step before the thread form is produced. Inspection using the probe takes place upon machining the taper and after the thread form is cut using the probe integrated into the machine.

Abstract: An expandable tubular pin and box connection is described having a feature of trapping the pin nose after preferably deforming the pin nose plastically in an outward direction away from the longitudinal axis of the connection. The box end is held away from the pin wall before expansion so that its tendency to curl inwardly upon expansion causes it to bend against the pin wall for sealing with it. The thread profile is also optimized to reduce flank separation as a result of expansion.

Abstract: A tool is provided that allows in a single trip advancing the liner while more hole is made until the liner is properly positioned. Slips are actuated into the inside of the liner to grasp it as a swage is released to move to support the liner to the surrounding tubular. With the liner supported in the hole, the running tool can be picked up to test the release feature and then set down again for cementing. The tool is then picked up higher to release a flapper and re-pressurized to set a seal adjacent the support previously engaged by swage operation. The flapper has a rupture disc blown and the tool is removed. An emergency release is provided.

Abstract: A one trip system for expanding a tubular that is solid or perforated or a screen comprises a downhole assembly that features a hydraulic anchor that can be set, released and repositioned to repeat the process. The anchor is small enough to go through the tubular or screen after initial expansion. The anchor's maximum extension is designed to avoid overstressing the already expanded tubular or screen. An expansion tool is hydraulically driven with the initial portion of the stroke delivering an enhanced force. The expansion tool initially supports the tubular or liner but subsequently releases during the first stroke, after the tubular or screen is fully supported.

Abstract: A compliant swage has the ability to change shape to allow clearance of an obstruction while permitting expansion to go on in other areas removed from the obstruction. A series of segments move with respect to each other longitudinally to change overall size. The segments have an additional degree of freedom to change from a round profile of varying diameter to an oblong, elliptical, or an irregular shape so as to compensate in the portion that encounters an obstruction to let the swage pass while at the same time permitting the intended maximum expansion in other portions where conditions permit such expansion.

Abstract: A compliant swage has the ability to change shape to allow clearance of an obstruction while permitting expansion to go on in other areas removed from the obstruction. A series of segments move with respect to each other longitudinally to change overall size. The segments have an additional degree of freedom to change from a round profile of varying diameter to an oblong, elliptical, or an irregular shape so as to compensate in the portion that encounters an obstruction to let the swage pass while at the same time permitting the intended maximum expansion in other portions where conditions permit such expansion.

Abstract: A one trip system for expanding a tubular that is solid or perforated or a screen is disclosed. The downhole assembly features a hydraulic anchor that can be set, released and repositioned to repeat the process is used. The anchor is small enough to go through the tubular or screen after initial expansion. The anchor's maximum extension is designed to avoid overstressing the already expanded tubular or screen. An expansion tool is hydraulically driven with the initial portion of the stroke delivering an enhanced force. The expansion tool initially supports the tubular or liner but subsequently releases during the first stroke, after the tubular or screen is fully supported.