US20080093068A1

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Publication number: US20080093068A1
Application number: US11/963,539
Authority: US
Inventors: Kevin Waddell; Lev Ring; David Brisco
Original assignee: Enventure Global Technology Inc
Current assignee: Enventure Global Technology Inc
Priority date: 2001-09-06
Filing date: 2007-12-21
Publication date: 2008-04-24
Also published as: US20080093089A1

Abstract

A system for lining a wellbore casing includes a support member, an expansion device coupled to an end of the support member, and a tubular liner coupled to the expansion device. The tubular liner includes an expandable tubular member that includes a first tubular portion, a second tubular portion, and an intermediate tubular portion coupled between the first and second tubular portions. The expandable tubular member also includes a sealing member coupled to the exterior surface of the intermediate tubular portion.

Description

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is the National Stage filing for PCT patent application serial number PCT/US02/25727, attorney docket number 25791.67.03, filed on Aug. 14, 2002, which claimed the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/317,985, attorney docket no. 25791.67, filed on Sep. 6, 2001, and U.S. provisional patent application Ser. No. 60/318,386, attorney docket no. 25791.67.02, filed on Sep. 10, 2001, the disclosures of which are incorporated herein by reference.

The present application is a continuation-in-part of U.S. utility patent application Ser. No. 10/030,593, attorney docket number 25791.25.08, filed on Jan. 8, 2002, which was the National Stage filing for PCT patent application serial number PCT/US00/18635, attorney docket no. 25791.25.02, filed on Jul. 9, 2000, which claimed the benefit of the filing dates of U.S. provisional patent application Ser. No. 60/146,203, attorney docket no. 25791.25, filed on Jul. 29, 1999, and U.S. provisional patent application Ser. No. 60/143,039, attorney docket no. 25791.26, filed on Jul. 9, 1999, the disclosures of which are incorporated herein by reference.

BACKGROUND

This invention relates generally to wellbore casings, and in particular to wellbore casings that are formed using expandable tubing.

Conventionally, when a wellbore is created, a number of casings are installed in the borehole to prevent collapse of the borehole wall and to prevent undesired outflow of drilling fluid into the formation or inflow of fluid from the formation into the borehole. The borehole is drilled in intervals whereby a casing which is to be installed in a lower borehole interval is lowered through a previously installed casing of an upper borehole interval. As a consequence of this procedure the casing of the lower interval is of smaller diameter than the casing of the upper interval. Thus, the casings are in a nested arrangement with casing diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the casings and the borehole wall to seal the casings from the borehole wall. As a consequence of this nested arrangement a relatively large borehole diameter is required at the upper part of the wellbore. Such a large borehole diameter involves increased costs due to heavy casing handling equipment, large drill bits and increased volumes of drilling fluid and drill cuttings. Moreover, increased drilling rig time is involved due to required cement pumping, cement hardening, required equipment changes due to large variations in hole diameters drilled in the course of the well, and the large volume of cuttings drilled and removed.

The present invention is directed to overcoming one or more of the limitations of the existing procedures for forming wellbore casings.

SUMMARY

According to one aspect of the present invention, a system for lining a wellbore casing is provided that includes a tubular support member defining a first passage, a tubular expansion cone defining a second passage fluidicly coupled to the first passage coupled to an end of the tubular support member and comprising a tapered end, a tubular liner coupled to and supported by the tapered end of the tubular expansion cone, and a shoe defining a valveable passage coupled to an end of the tubular liner, wherein the tubular liner includes one or more expandable tubular members that each include a tubular body comprising an intermediate portion and first and second expanded end portions coupled to opposing ends of the intermediate portion, and a sealing member coupled to the exterior surface of the intermediate portion, and one or more other tubular members coupled to the expandable tubular members, wherein the inside diameters of the other tubular members are greater than or equal to the outside diameter of the tubular expansion cone.

According to another aspect of the present invention, a method of lining a wellbore casing is provided that includes positioning a tubular liner within the wellbore casing, and radially expanding one or more discrete portions of the tubular liner into engagement with the wellbore casing.

According to another aspect of the present invention, a system for lining a wellbore casing is provided that includes means for positioning a tubular liner within the wellbore casing, and means for radially expanding one or more discrete portions of the tubular liner into engagement with the wellbore casing. In an exemplary embodiment, a plurality of discrete portions of the tubular liner are radially expanded into engagement with the wellbore casing.

According to another aspect of the present invention, an apparatus is provided that includes a subterranean formation defining a borehole, a casing positioned in and coupled to the borehole, and a tubular liner positioned in and coupled to the casing at one or more discrete locations.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1ais a cross sectional illustration of the placement of an illustrative embodiment of a system for lining a wellbore casing within a borehole having a preexisting wellbore casing.

FIG. 1bis a cross sectional illustration of the system ofFIG. 1aduring the injection of a fluidic material into the tubular support member.

FIG. 1cis a cross sectional illustration of the system ofFIG. 1bduring the pressurization of the interior portion of the shoe after sealing off the valveable fluid passage of the shoe.

FIG. 1dis a cross sectional illustration of the system ofFIG. 1cduring the continued injection of the fluidic material into the tubular support member.

FIG. 1eis a cross sectional illustration of the system ofFIG. 1dafter the completion of the radial expansion and plastic deformation of the expandable tubular members.

FIG. 1fis a cross sectional illustration of the system ofFIG. 1eafter machining the bottom central portion of the shoe.

FIG. 2 is a cross sectional illustration of an illustrative embodiment of the expandable tubular members of the system ofFIG. 1a.

FIG. 3 is a flow chart illustration of an illustrative embodiment of a method for manufacturing the expandable tubular member ofFIG. 2.

FIG. 4ais a cross sectional illustration of an illustrative embodiment of the upsetting of the ends of a tubular member.

FIG. 4bis a cross sectional illustration of the expandable tubular member ofFIG. 4aafter radially expanding and plastically deforming the ends of the expandable tubular member.

FIG. 4cis a cross sectional illustration of the expandable tubular member ofFIG. 4bafter forming threaded connections on the ends of the expandable tubular member.

FIG. 4dis a cross sectional illustration of the expandable tubular member ofFIG. 4cafter coupling sealing members to the exterior surface of the intermediate unexpanded portion of the expandable tubular member.

FIG. 5 is a cross-sectional illustration of an exemplary embodiment of a tubular expansion cone.

FIG. 6 is a cross-sectional illustration of an exemplary embodiment of a tubular expansion cone.

DESCRIPTION OF THE ILLUSTRATIVE EMBODIMENTS

Referring initially toFIG. 1a, thereference numeral10 refers, in general, to a system for lining a wellbore casing that includes atubular support member12 that defines apassage12a. Atubular expansion cone14 that defines apassage14ais coupled to an end of thetubular support member12. In an exemplary embodiment, thetubular expansion cone14 includes a taperedouter surface14bfor reasons to be described. Apre-expanded end16aof a firstexpandable tubular member16 that defines apassage16bis adapted to mate with and be supported by the taperedouter surface14bof thetubular expansion cone14. The firstexpandable tubular member16 further includes an unexpandedintermediate portion16c, anotherpre-expanded end16d, and a sealingmember16ecoupled to the exterior surface of the unexpanded intermediate portion. In an exemplary embodiment, the inside and outside diameters of the pre-expanded ends,16aand16d, of the firstexpandable tubular member16 are greater than the inside and outside diameters of the unexpandedintermediate portion16c. Anend18aof ashoe18 that defines apassage18band avalveable passage18cis coupled to thepre-expanded end16aof the firstexpandable tubular member16 by a conventional threaded connection.

Anend20aof atubular member20 that defines apassage20bis coupled to the otherpre-expanded end16dof the firstexpandable tubular member16 by a conventional threaded connection. Anotherend20cof thetubular member20 is coupled to anend22aof atubular member22 that defines apassage22bby a conventional threaded connection. Apre-expanded end24aof a secondexpandable tubular member24 that defines apassage24bis coupled to theother end22cof thetubular member22. The secondexpandable tubular member24 further includes an unexpandedintermediate portion24c, anotherpre-expanded end24d, and a sealingmember24ecoupled to the exterior surface of the unexpanded intermediate portion. In an exemplary embodiment, the inside and outside diameters of the pre-expanded ends,24aand24d, of the secondexpandable tubular member24 are greater than the inside and outside diameters of the unexpandedintermediate portion24c.

Anend26aof atubular member26 that defines apassage26bis coupled to the otherpre-expanded end24dof the secondexpandable tubular member24 by a conventional threaded connection. Anotherend26cof thetubular member26 is coupled to anend28aof atubular member28 that defines apassage28bby a conventional threaded connection. Apre-expanded end30aof a thirdexpandable tubular member30 that defines apassage30bis coupled to theother end28cof thetubular member28. The thirdexpandable tubular member30 further includes an unexpandedintermediate portion30c, anotherpre-expanded end30d, and a sealingmember30ecoupled to the exterior surface of the unexpanded intermediate portion. In an exemplary embodiment, the inside and outside diameters of the pre-expanded ends,30aand30d, of the thirdexpandable tubular member30 are greater than the inside and outside diameters of the unexpandedintermediate portion30c.

In an exemplary embodiment, the inside and outside diameters of the pre-expanded ends,16a,16d,24a,24d,30aand30d, of the expandable tubular members,16,24, and30, and the

tubular members

20,22,26, and28, are substantially equal. In several exemplary embodiments, the sealing members,16e,24e, and30e, of the expandable tubular members,16,24, and30, respectively, further include anchoring elements for engaging thewellbore casing104. In several exemplary embodiments, the tubular members,20,22,26, and28, are conventional tubular members having threaded end connections suitable for use in an oil or gas well, an underground pipeline, or as a structural support.

In an exemplary embodiment, as illustrated inFIG. 1a, thesystem10 is initially positioned in a borehole100 formed in asubterranean formation102 that includes apre-existing wellbore casing104. The borehole100 may be positioned in any orientation from vertical to horizontal. Furthermore, thewellbore casing104 may be, for example, a wellbore casing for an oil or gas well, an underground pipeline, or a structural support. In an exemplary embodiment, the upper end of thetubular support member12 may be supported in a conventional manner using, for example, a slip joint, or equivalent device in order to permit upward movement of the tubular support member andtubular expansion cone14 relative to one or more of the expandable tubular members,16,24, and30, and tubular members,20,22,26, and28.

In an exemplary embodiment, as illustrated inFIG. 1b, afluidic material106 is then injected into thesystem10, through the passages,12aand14a, of thetubular support member12 andtubular expansion cone14, respectively. Thefluidic material106 then passes into the passages,18band18c, of theshoe18 into theborehole100.

In an exemplary embodiment, as illustrated inFIG. 1c, aball108, plug or other equivalent device is then introduced into the injectedfluidic material106. Theball108 will then pass through the passages,12a,14a, and18b, of thetubular support member12, thetubular expansion cone14, and theshoe18, respectively, and will then be positioned within thevalveable passage18cof the shoe. In this manner, thevalveable passage18cof theshoe18 is closed thereby permitting thepassage18bof the shoe below thetubular expansion cone14 to be pressurized by the continued injection of thefluidic material106.

In an exemplary embodiment, as illustrated inFIG. 1d, the continued injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 and thetubular expansion cone14, respectively, pressurizes thepassage18bof theshoe18 below the tubular expansion cone thereby radially expanding and plastically deforming theexpandable tubular member16 off of the taperedexternal surface14bof thetubular expansion cone14. In particular, the intermediate nonpre-expanded portion16cof theexpandable tubular member16 is radially expanded and plastically deformed off of the taperedexternal surface14bof thetubular expansion cone14. As a result, the sealingmember16eengages the interior surface of thewellbore casing104. Consequently, the radially expandedintermediate portion16cof theexpandable tubular member16 is thereby coupled to thewellbore casing104. In an exemplary embodiment, the radially expandedintermediate portion16cof theexpandable tubular member16 is also thereby anchored to thewellbore casing104.

The continued injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 and thetubular expansion cone14, respectively, will then displace thetubular expansion cone14 upwardly into engagement with thepre-expanded end24aof the secondexpandable tubular member24.

In an exemplary embodiment, as illustrated inFIG. 1e, the continued injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 andtubular expansion cone14, respectively, will then pressurize the

passages

18b,16b,20band22bbelow the tubular expansion cone thereby radially expanding and plastically deforming the secondexpandable tubular member24 off of the taperedexternal surface14bof thetubular expansion cone14. In particular, the intermediate nonpre-expanded portion24cof the secondexpandable tubular member24 is radially expanded and plastically deformed off of the taperedexternal surface14bof thetubular expansion cone14. As a result, the sealingmember24eengages the interior surface of thewellbore casing104. Consequently, the radially expandedintermediate portion24cof the secondexpandable tubular member24 is thereby coupled to thewellbore casing104. In an exemplary embodiment, the radially expandedintermediate portion24cof the secondexpandable tubular member24 is also thereby anchored to thewellbore casing104.

The continued injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 and thetubular expansion cone14, respectively, will then displace thetubular expansion cone14 upwardly into engagement with thepre-expanded end30aof the thirdexpandable tubular member30.

The continued injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 andtubular expansion cone14, respectively, will then pressurize the

passages

18b,16b,20b,22b,24b,26b, and28bbelow the tubular expansion cone thereby radially expanding and plastically deforming the thirdexpandable tubular member30 off of the taperedexternal surface14bof thetubular expansion cone14. In particular, the intermediate nonpre-expanded portion30cof the thirdexpandable tubular member30 is radially expanded and plastically deformed off of the taperedexternal surface14bof thetubular expansion cone14. As a result, the sealingmember30eengages the interior surface of thewellbore casing104. Consequently, the radially expandedintermediate portion30cof the thirdexpandable tubular member30 is thereby coupled to thewellbore casing104. In an exemplary embodiment, the radially expandedintermediate portion30cof the thirdexpandable tubular member30 is also thereby anchored to thewellbore casing104.

In an exemplary embodiment, during the injection of thefluidic material106 through the passages,12aand14a, of thetubular support member12 and thetubular expansion cone14, respectively, thetubular support member12 andtubular expansion cone14 are displaced upwardly relative to the expandable tubular members,16,24, and30, and the tubular members,20,22,26, and28, by applying an upward axial force to the upper end of the tubular support member.

After completing the radial expansion and plastic deformation of the thirdexpandable tubular member30, thetubular support member12 and thetubular expansion cone14 are removed from thewellbore100.

In an exemplary embodiment, as illustrated inFIG. 1f, the lower central portion of theshoe18 is then removed using a conventional milling device.

tubular members

20,22,26, and28 are interleaved among the expandable tubular members,16,24, and30. As a result, because only the intermediate non pre-expanded portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, respectively, are radially expanded and plastically deformed, the tubular members,20,22,26, and28 can be conventional tubular members thereby significantly reducing the cost and complexity of thesystem10. Moreover, because only the intermediate non pre-expanded portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, respectively, are radially expanded and plastically deformed, the number and length of the interleaved tubular members,20,22,26, and28 can be much greater than the number and length of the expandable tubular members. In an exemplary embodiment, the total length of the intermediate non pre-expanded portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, is approximately 200 feet, and the total length of the tubular members,20,22,26, and28, is approximately 3800 feet. Consequently, in an exemplary embodiment, a liner having a total length of approximately 4000 feet is coupled to a wellbore casing by radially expanding and plastically deforming a total length of only approximately 200 feet.

Furthermore, the sealing

members

16e,24e, and30e, of the expandable tubular members,16,24, and30, respectively, are used to couple the expandable tubular members and the tubular members,20,22,26, and28 to thewellbore casing104, the radial gap between the tubular members, the expandable tubular members, and thewellbore casing104 may be large enough to effectively eliminate the possibility of damage to the expandable tubular members and tubular members during the placement of thesystem10 within the wellbore casing.

In an exemplary embodiment, after the sealingmember16eof theexpandable tubular member16 has been radially expanded into engagement with thewellbore casing104, the expandable tubular members,24 and30, are radially expanded and plastically deformed by injecting thefluidic material106 and applying an upward axial force to thetubular support member12 andtubular expansion cone14. In this manner, radial expansion and plastic deformation of the expandable tubular members,24 and30, may be enhanced.

In an exemplary embodiment, after the sealingmember16eof theexpandable tubular member16 has been radially expanded into engagement with thewellbore casing104, the expandable tubular members,24 and30, are radially expanded and plastically deformed by only applying an upward axial force to thetubular support member12 andtubular expansion cone14. In this manner, radial expansion and plastic deformation of the expandable tubular members,24 and30, may be provided without the further continued injection of thefluidic material106.

In an exemplary embodiment, the pre-expanded ends,16a,16d,24a,24d,30a, and30d, of the expandable tubular members,16,24, and30, respectively, and the tubular members,20,22,26, and28, have outside diameters and wall thicknesses of 8.375 inches and 0.350 inches, respectively; prior to the radial expansion, the intermediate non pre-expanded portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, respectively, have outside diameters of 7.625 inches; the tubular members,20,22,26, and28, have inside diameters of 7.675 inches; after the radial expansion, the inside diameters of the intermediate portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, are equal to 7.675 inches; and thewellbore casing104 has an inside diameter of 8.755 inches.

In an exemplary embodiment, the pre-expanded ends,16a,16d,24a,24d,30a, and30d, of the expandable tubular members,16,24, and30, respectively, and the tubular members,20,22,26, and28, have outside diameters and wall thicknesses of 4.500 inches and 0.250 inches, respectively; prior to the radial expansion, the intermediate non pre-expanded portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, respectively, have outside diameters of 4.000 inches; the tubular members,20,22,26, and28, have inside diameters of 4.000 inches; after the radial expansion, the inside diameters of the intermediate portions,16c,24c, and30c, of the expandable tubular members,16,24, and30, are equal to 4.000 inches; and thewellbore casing104 has an inside diameter of 4.892 inches.

In an exemplary embodiment, thesystem10 is used to form or repair a wellbore casing, a pipeline, or a structural support.

Referring now toFIG. 2, an exemplary embodiment of anexpandable tubular member200 will now be described. Thetubular member200 defines aninterior region200aand includes afirst end200bincluding a first threadedconnection200ba, a firsttapered portion200c, anintermediate portion200d, a secondtapered portion200e, and asecond end200fincluding a second threadedconnection200fa. Thetubular member200 further preferably includes anintermediate sealing member200gthat is coupled to the exterior surface of theintermediate portion200d.

In an exemplary embodiment, thetubular member200 has a substantially annular cross section. Thetubular member200 may be fabricated from any number of conventional commercially available materials such as, for example, Oilfield Country Tubular Goods (OCTG), 13 chromium steel tubing/casing, or L83, J55, or P110 API casing.

In an exemplary embodiment, the interior200aof thetubular member200 has a substantially circular cross section. Furthermore, in an exemplary embodiment, theinterior region200aof the tubular member includes a first inside diameter D₁, an intermediate inside diameter D_INT, and a second inside diameter D₂. In an exemplary embodiment, the first and second inside diameters, D₁and D₂, are substantially equal. In an exemplary embodiment, the first and second inside diameters, D₁and D₂, are greater than the intermediate inside diameter D_INT.

Thefirst end200bof thetubular member200 is coupled to theintermediate portion200dby the firsttapered portion200c, and thesecond end200fof the tubular member is coupled to the intermediate portion by the secondtapered portion200e. In an exemplary embodiment, the outside diameters of the first and second ends,200band200f, of thetubular member200 is greater than the outside diameter of theintermediate portion200dof the tubular member. The first and second ends,200band200f, of thetubular member200 include wall thicknesses, t₁and t₂, respectively. In an exemplary embodiment, the outside diameter of theintermediate portion200dof thetubular member200 ranges from about 75% to 98% of the outside diameters of the first and second ends,200aand200f. Theintermediate portion200dof thetubular member200 includes a wall thickness t_INT.

In an exemplary embodiment, the wall thicknesses t₁and t₂are substantially equal in order to provide substantially equal burst strength for the first and second ends,200aand200f, of thetubular member200. In an exemplary embodiment, the wall thicknesses, t₁and t₂, are both greater than the wall thickness t_INTin order to optimally match the burst strength of the first and second ends,200aand200f, of thetubular member200 with theintermediate portion200dof thetubular member200.

In an exemplary embodiment, the first and second tapered portions,200cand200e, are inclined at an angle, α, relative to the longitudinal direction ranging from about 0 to 30 degrees in order to optimally facilitate the radial expansion of thetubular member200. In an exemplary embodiment, the first and second tapered portions,200cand200e, provide a smooth transition between the first and second ends,200aand200f, and theintermediate portion200d, of thetubular member200 in order to minimize stress concentrations.

Theintermediate sealing member200gis coupled to the outer surface of theintermediate portion200dof thetubular member200. In an exemplary embodiment, theintermediate sealing member200gseals the interface between theintermediate portion200dof thetubular member200 and the interior surface of awellbore casing205 after the radial expansion and plastic deformation of theintermediate portion200dof thetubular member200. In an exemplary embodiment, theintermediate sealing member200ghas a substantially annular cross section. In an exemplary embodiment, the outside diameter of theintermediate sealing member200gis selected to be less than the outside diameters of the first and second ends,200aand200f, of thetubular member200 in order to optimally protect theintermediate sealing member200gduring placement of thetubular member200 within thewellbore casings205. Theintermediate sealing member200gmay be fabricated from any number of conventional commercially available materials such as, for example, thermoset or thermoplastic polymers. In an exemplary embodiment, theintermediate sealing member200gis fabricated from thermoset polymers in order to optimally seal the radially expandedintermediate portion200dof thetubular member200 with thewellbore casing205. In several alternative embodiments, the sealingmember200gincludes one or more rigid anchors for engaging thewellbore casing205 to thereby anchor the radially expanded and plastically deformedintermediate portion200dof thetubular member200 to the wellbore casing.

Referring toFIGS. 3, and4ato4d, in an exemplary embodiment, thetubular member200 is formed by aprocess300 that includes the steps of: (1) upsetting both ends of a tubular member instep305; (2) expanding both upset ends of the tubular member instep310; (3) stress relieving both expanded upset ends of the tubular member instep315; (4) forming threaded connections in both expanded upset ends of the tubular member instep320; and (5) putting a sealing material on the outside diameter of the non-expanded intermediate portion of the tubular member instep325.

As illustrated inFIG. 4a, instep305, both ends,400aand400b, of atubular member400 are upset using conventional upsetting methods. The upset ends,400aand400b, of thetubular member400 include the wall thicknesses to and t₂. Theintermediate portion400cof thetubular member400 includes the wall thickness t_INTand the interior diameter D_INT. In an exemplary embodiment, the wall thicknesses t₁and t₂are substantially equal in order to provide burst strength that is substantially equal along the entire length of thetubular member400. In an exemplary embodiment, the wall thicknesses t₁and t₂are both greater than the wall thickness t_INTin order to provide burst strength that is substantially equal along the entire length of thetubular member400, and also to optimally facilitate the formation of threaded connections in the first and second ends,400aand400b.

As illustrated inFIG. 4b, in

steps

310 and315, both ends,400aand400b, of thetubular member400 are radially expanded using conventional radial expansion methods, and then both ends,400aand400b, of the tubular member are stress relieved. The radially expanded ends,400aand400b, of thetubular member400 include the interior diameters D₁and D₂. In an exemplary embodiment, the interior diameters D₁and D₂are substantially equal in order to provide a burst strength that is substantially equal. In an exemplary embodiment, the ratio of the interior diameters D₁and D₂to the interior diameter D_INTranges from about 100% to 120% in order to faciliate the subsequent radial expansion of thetubular member400.

In a preferred embodiment, the relationship between the wall thicknesses t₁, t₂, and t_INTof thetubular member400; the inside diameters D₁, D₂and D_INTof thetubular member400; the inside diameter D_wellboreof the wellbore casing that thetubular member400 will be inserted into; and the outside diameter D_coneof the expansion cone that will be used to radially expand thetubular member400 within the wellbore casing is given by the following expression:

\begin{matrix} Dwellbore - 2 * t_{1} \geq D_{1} \geq \frac{1}{t_{1}} [(t_{1} - t_{INT}) * D_{cone} + t_{INT} * D_{INT}] & (1) \end{matrix}

where t₁=t₂; and
D₁=D₂.

By satisfying the relationship given in equation (1), the expansion forces placed upon thetubular member400 during the subsequent radial expansion process are substantially equalized. More generally, the relationship given in equation (1) may be used to calculate the optimal geometry for thetubular member400 for subsequent radial expansion and plastic deformation of thetubular member400 for fabricating and/or repairing a wellbore casing, a pipeline, or a structural support.

As illustrated inFIG. 4c, instep320, conventional threaded connections,400dand400e, are formed in both expanded ends,400aand400b, of thetubular member400. In an exemplary embodiment, the threaded connections,400dand400e, are provided using conventional processes for forming pin and box type threaded connections available from Atlas-Bradford.

As illustrated inFIG. 4d, instep325, a sealingmember400fis then applied onto the outside diameter of the non-expandedintermediate portion400cof thetubular member400. The sealingmember400fmay be applied to the outside diameter of the non-expandedintermediate portion400cof thetubular member400 using any number of conventional commercially available methods. In a preferred embodiment, the sealingmember400fis applied to the outside diameter of theintermediate portion400cof thetubular member400 using commercially available chemical and temperature resistant adhesive bonding.

In an exemplary embodiment, the expandable tubular members,16,24, and30, of thesystem10 are substantially identical to, and/or incorporate one or more of the teachings of, the

tubular members

200 and400.

Referring toFIG. 5, an exemplary embodiment oftubular expansion cone500 for radially expanding the

tubular members

16,24,30,200 and400 will now be described. Theexpansion cone500 defines apassage500aand includes afront end505, arear end510, and aradial expansion section515.

In an exemplary embodiment, theradial expansion section515 includes a first conicalouter surface520 and a second conicalouter surface525. The first conicalouter surface520 includes an angle of attack α₁and the second conicalouter surface525 includes an angle of attack α₂. In an exemplary embodiment, the angle of attack α₁is greater than the angle of attack α₂. In this manner, the first conicalouter surface520 radially overexpands the intermediate portions,16c,24c,30c,200d, and400c, of the tubular members,16,24,30,200, and400, and the second conicalouter surface525 radially overexpands the pre-expanded first and second ends,16aand16d,24aand24d,30aand30d,200band200f, and400aand400b, of the tubular members,16,24,30,200 and400. In an exemplary embodiment, the first conicalouter surface520 includes an angle of attack α₁ranging from about 8 to 20 degrees, and the second conicalouter surface525 includes an angle of attack α₂ranging from about 4 to 15 degrees in order to optimally radially expand and plastically deform the tubular members,16,24,30,200 and400. More generally, theexpansion cone500 may include 3 or more adjacent conical outer surfaces having angles of attack that decrease from thefront end505 of theexpansion cone500 to therear end510 of theexpansion cone500.

Referring toFIG. 6, another exemplary embodiment of atubular expansion cone600 defines apassage600aand includes afront end605, arear end610, and aradial expansion section615. In an exemplary embodiment, theradial expansion section615 includes an outer surface having a substantially parabolic outer profile thereby providing a paraboloid shape. In this manner, the outer surface of theradial expansion section615 provides an angle of attack that constantly decreases from a maximum at thefront end605 of theexpansion cone600 to a minimum at therear end610 of the expansion cone. The parabolic outer profile of the outer surface of theradial expansion section615 may be formed using a plurality of adjacent discrete conical sections and/or using a continuous curved surface. In this manner, the region of the outer surface of theradial expansion section615 adjacent to thefront end605 of theexpansion cone600 may optimally radially overexpand the intermediate portions,16c,24c,30c,200d, and400c, of the tubular members,16,24,30,200, and400, while the region of the outer surface of theradial expansion section615 adjacent to therear end610 of theexpansion cone600 may optimally radially overexpand the pre-expanded first and second ends,16aand16d,24aand24d,30aand30d,200band200f, and400aand400b, of the tubular members,16,24,30,200 and400. In an exemplary embodiment, the parabolic profile of the outer surface of theradial expansion section615 is selected to provide an angle of attack that ranges from about 8 to 20 degrees in the vicinity of thefront end605 of the expansion cone6800 and an angle of attack in the vicinity of therear end610 of theexpansion cone600 from about 4 to 15 degrees.

In an exemplary embodiment, thetubular expansion cone14 of thesystem10 is substantially identical to the

expansion cones

500 or600, and/or incorporates one or more of the teachings of theexpansion cones500 and/or600.

In several alternative embodiments, a conventional rotary expansion system such as, for example, those commercially available from Weatherford International may be substituted for, or used in combination with the

expansion cones

14,500, and/or600 above.

In several alternative embodiments, conventional expansion systems may be substituted for, or used in combination with the

expansion cones

14,500, and/or600 above.

Dwellbore - 2 * t_{1} \geq D_{1} \geq \frac{1}{t_{1}} [(t_{1} - t_{INT}) * D_{cone} + t_{INT} * D_{INT}];

wherein t₁=t₂; and wherein D₁=D₂. In an exemplary embodiment, the tapered end of the tubular expansion cone includes a plurality of adjacent discrete tapered sections. In an exemplary embodiment, the angle of attack of the adjacent discrete tapered sections increases in a continuous manner from one end of the tubular expansion cone to the opposite end of the tubular expansion cone. In an exemplary embodiment, the tapered end of the tubular expansion cone includes an paraboloid body. In an exemplary embodiment, the angle of attack of the outer surface of the paraboloid body increases in a continuous manner from one end of the paraboloid body to the opposite end of the paraboloid body. In an exemplary embodiment, the tubular liner includes a plurality of expandable tubular members, and the other tubular members are interleaved among the expandable tubular members.

A system for lining a wellbore casing has also been described that includes means for positioning a tubular liner within the wellbore casing, and means for radially expanding one or more discrete portions of the tubular liner into engagement with the wellbore casing. In an exemplary embodiment, a plurality of discrete portions of the tubular liner are radially expanded into engagement with the wellbore casing. In an exemplary embodiment, the remaining portions of the tubular liner are not radially expanded. In an exemplary embodiment, the discrete portions of the tubular liner are radially expanded by injecting a fluidic material into the tubular liner. In an exemplary embodiment, the tubular liner includes a plurality of tubular members; and wherein one or more of the tubular members are radially expanded into engagement with the wellbore casing and one or more of the tubular members are not radially expanded into engagement with the wellbore casing. In an exemplary embodiment, the tubular members that are radially expanded into engagement with the wellbore casing comprise a portion that is radially expanded into engagement with the wellbore casing and a portion that is not radially expanded into engagement with the wellbore casing.

It is understood that variations may be made in the foregoing without departing from the scope of the invention. For example, thesystem10 may be used to form or repair a wellbore casing, an underground pipeline, a structural support, or a tubing. Furthermore, thesystem10 may include one or more expandable tubular members and one or more other tubular members. In addition, thesystem10 may include a plurality of expandable tubular members, and the other tubular members may be interleaved among the expandable tubular members.

Although illustrative embodiments of the invention have been shown and described, a wide range of modification, changes and substitution is contemplated in the foregoing disclosure. In some instances, some features of the present invention may be employed without a corresponding use of the other features. Accordingly, it is appropriate that the appended claims be construed broadly and in a manner consistent with the scope of the invention.

Claims

1-48. (canceled)

49. A system for lining a wellbore casing, comprising:

a support member;

an expansion device coupled to an end of the support member; and

a tubular liner coupled to the expansion device,

wherein the tubular liner comprises:

one or more expandable tubular members that each comprise:

a first tubular portion, a second tubular portion, and an intermediate tubular portion coupled between the first and second tubular portions; and

a sealing member coupled to the exterior surface of the intermediate tubular portion, and

wherein the inside diameters of the first and second tubular portions are greater than the inside diameter of the intermediate tubular portion.

50. The system ofclaim 49, wherein the wall thicknesses of the first and second tubular portions are greater than the wall thickness of the intermediate tubular portion.

51. The system ofclaim 49, wherein each expandable tubular member further comprises:

a first tubular tapered transitionary portion coupled between the first tubular portion and the intermediate tubular portion; and

a second tubular tapered transitionary portion coupled between the second tubular portion and the intermediate tubular portion, and

wherein angles of inclination of the first and second tapered tubular transitionary portions relative to the intermediate tubular portion ranges from greater than 0 to about 30 degrees.

52. The system ofclaim 49, wherein the outside diameter of the intermediate tubular portion ranges from about 75 percent to about 98 percent of the outside diameters of the first and second tubular portions.

53. The system ofclaim 49, wherein the burst strength of the first and second tubular portions is substantially equal to the burst strength of the intermediate tubular portion.

54. The system ofclaim 49, wherein the ratio of the inside diameters of the first and second tubular portions to the interior diameter of the intermediate tubular portion ranges from greater than 100 to about 120 percent.

55. The system ofclaim 49, wherein the relationship between the wall thicknesses t₁, t₂, and t_INTof the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, the inside diameters D₁, D₂and D NT of the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, and the inside diameter D_wellboreof the wellbore casing that the expandable tubular members will be inserted into, and the outside diameter D_coneof the expansion device that will be used to radially expand the expandable tubular members within the wellbore casing is given by the following expression:

Dwellbore - 2 * t_{1} \geq D_{1} \geq \frac{1}{t_{1}} [(t_{1} - t_{INT}) * D_{cone} + t_{INT} * D_{INT}];

wherein t₁=t₂; and wherein D₁=D₂.

56. The system ofclaim 49, wherein the expansion device comprises a plurality of adjacent discrete tapered sections.

57. The system ofclaim 56, wherein an angle of attack of the adjacent discrete tapered sections increases in a continuous manner from one end of the expansion device to the opposite end of the expansion device.

58. The system ofclaim 49, wherein the expansion device comprises a paraboloid body.

59. The system ofclaim 58, wherein an angle of attack of the outer surface of the paraboloid body increases in a continuous manner from one end of the paraboloid body to the opposite end of the paraboloid body.

60. The system ofclaim 49, wherein the tubular liner comprises a plurality of expandable tubular members and one or more other tubular members, and

wherein the other tubular members are interleaved among the expandable tubular members.

61. A system for lining a wellbore casing, comprising:

an expansion device; and

a tubular liner coupled to the expansion device,

wherein the tubular liner comprises:

one or more expandable tubular members that each comprise:

62. The system ofclaim 61, wherein the burst strength of the first and second tubular portions is substantially equal to the burst strength of the intermediate tubular portion.

63. The system ofclaim 61, wherein the wall thicknesses of the first and second tubular portions are greater than the wall thickness of the intermediate tubular portion.

64. The system ofclaim 61, wherein each expandable tubular member further comprises:

65. The system ofclaim 61, wherein the outside diameter of the intermediate tubular portion ranges from about 75 percent to about 98 percent of the outside diameters of the first and second tubular portions.

66. The system ofclaim 61, wherein the ratio of the inside diameters of the first and second tubular portions to the interior diameter of the intermediate tubular portion ranges from greater than 100 to about 120 percent.

67. The system ofclaim 61, wherein the relationship between the wall thicknesses t₁, t₂, and t_INTof the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, the inside diameters D₁, D₂and D_INTof the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, and the inside diameter D_wellboreof the wellbore casing that the expandable tubular members will be inserted into, and the outside diameter D_coneof the expansion device that will be used to radially expand the expandable tubular members within the wellbore casing is given by the following expression:

Dwellbore - 2 * t_{1} \geq D_{1} \geq \frac{1}{t_{1}} [(t_{1} - t_{INT}) * D_{cone} + t_{INT} * D_{INT}];

wherein t₁=t₂; and wherein D₁=D₂.

68. A liner for lining a wellbore casing, comprising:

a sealing member coupled to the exterior surface of the intermediate tubular portion,

69. The liner ofclaim 68, wherein the burst strength of the first and second tubular portions is substantially equal to the burst strength of the intermediate tubular portion.

70. The liner ofclaim 68, wherein the wall thicknesses of the first and second tubular portions are greater than the wall thickness of the intermediate tubular portion.

71. The liner ofclaim 68, wherein each expandable tubular member further comprises:

72. The liner ofclaim 68, wherein the outside diameter of the intermediate tubular portion ranges from about 75 percent to about 98 percent of the outside diameters of the first and second tubular portions.

73. The liner ofclaim 68, wherein the ratio of the inside diameters of the first and second tubular portions to the interior diameter of the intermediate tubular portion ranges from greater than 100 to about 120 percent.

74. The liner ofclaim 68, wherein the relationship between the wall thicknesses t₁, t₂, and t_INTof the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, the inside diameters D₁, D₂and D_INTof the first tubular portion, the second tubular portion, and the intermediate tubular portion, respectively, of the expandable tubular members, and the inside diameter D_wellboreof the wellbore casing that the expandable tubular members will be inserted into, and the outside diameter D_coneof the expansion device that will be used to radially expand the expandable tubular members within the wellbore casing is given by the following expression:

Dwellbore - 2 * t_{1} \geq D_{1} \geq \frac{1}{t_{1}} [(t_{1} - t_{INT}) * D_{cone} + t_{INT} * D_{INT}];

wherein t₁=t₂; and wherein D₁=D₂.

75. An expansion device, comprising:

a paraboloid body.

76. A system for lining a wellbore casing, comprising:

an expansion device coupled to an end of the support member; and

a tubular liner coupled to the expansion device,

wherein the tubular liner comprises:

one or more expandable tubular members that each comprise:

wherein the inside diameters of the first and second tubular portions are greater than the inside diameter of the intermediate tubular portion, and

wherein the expansion device comprises a plurality of adjacent discrete tapered sections.

77. The system ofclaim 76, wherein an angle of attack of the adjacent discrete tapered sections increases in a continuous manner from one end of the expansion device to the opposite end of the expansion device.

78. A system for lining a wellbore casing, comprising:

an expansion device coupled to an end of the support member; and

a tubular liner coupled to the expansion device,

wherein the tubular liner comprises:

one or more expandable tubular members that each comprise:

wherein the expansion device comprises a paraboloid body.

79. The system ofclaim 78, wherein an angle of attack of the outer surface of the paraboloid body increases in a continuous manner from one end of the paraboloid body to the opposite end of the paraboloid body.

80. A system for lining a wellbore casing, comprising:

an expansion device coupled to an end of the support member; and

a tubular liner coupled to the expansion device,

wherein the tubular liner comprises:

one or more expandable tubular members that each comprise:

wherein the inside diameters of the first and second tubular portions are greater than the inside diameter of the intermediate tubular portion,

wherein the tubular liner comprises a plurality of expandable tubular members and one or more other tubular members, and

81. A tubular liner system, comprising:

a plurality of expandable tubular members that each comprise:

a first tubular portion, a second tubular portion, and an intermediate tubular portion coupled between the first and second tubular portions, the inside diameters of the first and second tubular portions being greater than the inside diameter of the intermediate tubular portion;

a sealing member coupled to the exterior surface of the intermediate tubular portion; and

a plurality of other tubular members interleaved among the expandable tubular members.