US20090090516A1

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Publication number: US20090090516A1
Application number: US12/056,551
Authority: US
Inventors: Frank V. DeLucia; Charles A. Butterfield, Jr.; Harsh V. Chowdhary; Akindele Olufowoshe; William P. Parker
Original assignee: Enventure Global Technology Inc
Current assignee: Enventure Global Technology Inc
Priority date: 2007-03-30
Filing date: 2008-03-27
Publication date: 2009-04-09
Also published as: WO2008121753A1

Abstract

An apparatus and method according to which a tubular liner is positioned in a preexisting structure such as, for example, a wellbore, a wellbore casing, a pipeline or a structural support, and the tubular liner is anchored to the preexisting structure during radial expansion.

Description

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims benefit of U.S. provisional application Ser. No. 60/920,896 filed Mar. 30, 2007, and entitled “Tubular Liner,” which is hereby incorporated herein by reference in its entirety.

STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT

Not applicable.

BACKGROUND

1. Field of the Invention

The invention relates generally to tubular liners. More particularly, the invention relates to tubular liners positioned in preexisting structures such as, for example, wellbores, wellbore casings, pipelines and structural supports, to facilitate, for example, oil and gas exploration.

2. Background of the Invention

Conventionally, when a wellbore is created, a number of casings or tubular liners 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 tubular liner which is to be installed in a lower borehole interval is lowered through a previously installed tubular liner of an upper borehole interval. As a consequence of this procedure the tubular liner of the lower interval is of smaller diameter than the tubular liner of the upper interval. Thus, the tubular liners are in a nested arrangement with diameters decreasing in downward direction. Cement annuli are provided between the outer surfaces of the liners and the borehole wall to seal the tubular liners 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.

Conventionally, a wellbore tubular liner cannot be formed during the drilling of a wellbore. Typically, the wellbore is drilled and then a wellbore tubular liner is formed in the newly drilled section of the wellbore. This delays the completion of a well.

Embodiments of described herein are directed to overcoming one or more of the limitations of the existing procedures for forming wellbores and wellheads.

BRIEF SUMMARY OF SOME OF THE PREFERRED EMBODIMENTS

These and other needs in the art are addressed in one embodiment by a method. In an embodiment, the method comprises positioning a radially expandable tubular liner in a preexisting structure. The tubular liner comprising a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter. In addition, the method comprises radially expanding the tubular liner. Further, the method comprises a anchoring the expandable tubular member to the preexisting structure in response to radially expanding the tubular liner.

These and other needs in the art are addressed in another embodiment by a apparatus. In an embodiment, the apparatus comprises a an expandable tubular liner adapted to be positioned in a preexisting structure and radially expanded to line at least a portion of the preexisting structure. The tubular liner comprises a first portion defining a first outside diameter. In addition, the tubular liner comprises a second portion defining a second outside diameter that is greater than the first outside diameter. The second portion anchors the tubular liner to the preexisting structure in response to the radial expansion of the expandable tubular liner.

These and other needs in the art are addressed in another embodiment by a method. In an embodiment, the method comprises positioning a radially expandable tubular liner in a preexisting structure. The tubular liner comprises a first portion defining a first outside diameter and a second portion defining a second outside diameter that is greater than the first outside diameter. In addition, the method comprises radially expanding and plastically deforming the tubular liner. Further, the method comprises anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner. Still further, the method comprises sealing the interface between the tubular liner and the preexisting structure in response to radially expanding and plastically deforming the tubular liner. Anchoring the expandable tubular member to the preexisting structure in response to radially expanding and plastically deforming the tubular liner comprises at least one of the following: penetratingly engaging the preexisting structure with the second portion of the tubular liner in response to radially expanding and plastically deforming the tubular liner, compressing the second portion between the preexisting structure and the tubular liner in response to radially expanding and plastically deforming the tubular liner; and compressing the first portion around at least a portion of the second portion in response to radially expanding and plastically deforming the tubular liner. Moreover, the preexisting structure comprises one or more of the following: a wellbore, a wellbore casing, a pipeline, and a structural support.

Thus, embodiments described herein comprise a combination of features and advantages intended to address various shortcomings associated with certain prior devices. The various characteristics described above, as well as other features, will be readily apparent to those skilled in the art upon reading the following detailed description of the preferred embodiments, and by referring to the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

For a detailed description of the preferred embodiments of the invention, reference will now be made to the accompanying drawings in which:

FIG. 1 is a fragmentary cross-sectional view of an exemplary embodiment of a tubular liner including an expandable tubular member and a sleeve coupled thereto positioned within a wellbore that traverses a subterranean formation.

FIG. 2 is a fragmentary cross sectional view of the tubular liner ofFIG. 1 after positioning an expansion device within the expandable tubular member.

FIG. 3 is a fragmentary cross sectional view of the tubular liner ofFIG. 2 after operating the expansion device within the expandable tubular member to radially expand and plastically deform at least a portion of the expandable tubular member.

FIG. 4 is a fragmentary cross sectional view of the tubular liner ofFIG. 3 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the sleeve penetratingly engages the wall of the wellbore.

FIG. 5 is a fragmentary cross sectional view, not necessarily to scale, of the tubular liner ofFIG. 1 positioned within a wellbore that traverses a subterranean formation.

FIG. 6 is a fragmentary cross sectional view of the tubular liner ofFIG. 5 after positioning an expansion device within the expandable tubular member.

FIG. 7 is a fragmentary cross sectional view of the tubular liner ofFIG. 6 after operating the expansion device within the expandable tubular member to radially expand and plastically deform at least a portion of the expandable tubular member.

FIG. 8A is a fragmentary cross sectional view of the tubular liner ofFIG. 7 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the sleeve is compressed between the expandable tubular member and the wall of the wellbore.

FIG. 8B is a fragmentary cross sectional view of the tubular liner ofFIG. 7 after further operating the expansion device within the expandable tubular member to radially expand and plastically deform another portion of the expandable tubular member so that the expandable tubular member is compressed around at least a portion of the sleeve.

FIG. 9 is a perspective view, not necessarily to scale, of a tubular liner according to another exemplary embodiment.

FIG. 10 is a sectional view of the tubular liner ofFIG. 9.

FIG. 11 is an enlarged portion of the view depicted inFIG. 10.

FIG. 12 is a perspective view, not necessarily to scale, of a tubular liner according to yet another exemplary embodiment.

FIG. 13 is a sectional view of the tubular liner ofFIG. 12.

FIG. 14 is an enlarged portion of the view depicted inFIG. 13.

FIG. 15 is a perspective view, not necessarily to scale, of a tubular liner according to yet another exemplary embodiment.

FIG. 16 is a sectional view of the tubular liner ofFIG. 15.

FIG. 17 is an enlarged portion of the view depicted inFIG. 16.

DETAILED DESCRIPTION OF SOME OF THE PREFERRED EMBODIMENTS

The following discussion is directed to various embodiments of the invention. Although one or more of these embodiments may be preferred, the embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. In addition, one skilled in the art will understand that the following description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to intimate that the scope of the disclosure, including the claims, is limited to that embodiment.

Certain terms are used throughout the following description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function. The drawing figures are not necessarily to scale. Certain features and components herein may be shown exaggerated in scale or in somewhat schematic form and some details of conventional elements may not be shown in interest of clarity and conciseness.

In the following discussion and in the claims, the terms “including” and “comprising” are used in an open-ended fashion, and thus should be interpreted to mean “including, but not limited to . . . .” Also, the term “couple” or “couples” is intended to mean either an indirect or direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect connection via other devices and connections.

In an exemplary embodiment, as illustrated inFIG. 1, a tubular liner is generally referred to by thereference numeral10 and includes anexpandable tubular member12 and asleeve14 coupled thereto so that theexpandable tubular member12 extends through thesleeve14. Thesleeve14 defines an outside diameter that is greater than the outside diameter defined by theexpandable tubular member12.

During operation, in an exemplary embodiment and as illustrated inFIG. 1, thetubular liner10 is positioned within a preexisting structure such as, for example, awellbore16 that traverses asubterranean formation18.

In an exemplary embodiment, as illustrated inFIG. 2, anexpansion device20 is then positioned within theexpandable tubular member12. In several exemplary embodiments, theexpansion device20 may be positioned within theexpandable tubular member12 before, during, or after the placement of theexpandable tubular member12 within thewellbore16.

In an exemplary embodiment, as illustrated inFIG. 3, theexpansion device20 is then operated to radially expand and plastically deform at least a portion of theexpandable tubular member12 of thetubular liner10.

In an exemplary embodiment, as illustrated inFIG. 4, theexpansion device20 is then further operated to radially expand the remaining portion of theexpandable tubular member12. In response to the radial expansion of theexpandable tubular member12, thesleeve14 also radially expands and penetratingly engages the wall of thewellbore16. As a result of the penetration of thesleeve14 into the wall of thewellbore16, thetubular liner10 is anchored to thewellbore16, thereby generally preventing relative movement therebetween.

In an exemplary embodiment, as illustrated inFIG. 4, in addition to anchoring thetubular liner10 to thewellbore16 in response to the radial expansion of theexpandable tubular member12, thesleeve14 sealingly engages the interface between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16, thereby fluidicly isolating the portion of thewellbore16 below thesleeve14 from the portion of thewellbore16 above thesleeve14, and vice versa, in response to the radial expansion of theexpandable tubular member12.

In several exemplary embodiments, as a result of the anchoring of thetubular liner10 to thewellbore16, embodiments described herein offer the potential to reduce the risk of thetubular liner10 being pulled upward or downward, in response to the operation and axial movement of theexpansion device20 during the radial expansion of the portion of theexpandable tubular member12 above or below thesleeve14 and/or one or more other expandable tubular members coupled to theexpandable tubular member12 above or below thesleeve14.

In several exemplary embodiments, the ability of thetubular liner10 to be anchored to a wellbore in response to the radial expansion of theexpandable tubular member12 facilitates, for example, the formation of wellbore casings in, for example, soft formations.

In several exemplary embodiments, as a result of the anchoring of thetubular liner10 to thewellbore16 and the sealing of the interface between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16 in response to the radial expansion of theexpandable tubular member12, there is no need, or at least there is less of a need, to inject a hardenable fluidic material such as, for example, cement, into the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16 before, during or after the radial expansion of theexpandable tubular member12.

In several exemplary embodiments, before, during or after the operation of theexpansion device20, a hardenable fluidic material such as, for example, cement, is injected into the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16. As a result, an annular body of the hardenable fluidic sealing material is formed within the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16. Before, during or after the curing of the annular body of the hardenable fluidic sealing material, theexpansion device20 may be operated to radially expand and plastically deform theexpandable tubular member12.

During operation, in an exemplary embodiment and as illustrated inFIG. 5, thetubular liner10 is positioned within a preexisting structure such as, for example, awellbore22 that traverses asubterranean formation24.

In an exemplary embodiment, as illustrated inFIG. 6, theexpansion device20 is then positioned within theexpandable tubular member12. In several exemplary embodiments, theexpansion device20 may be positioned within theexpandable tubular member12 before, during, or after the placement of thetubular member12 within thewellbore22.

In an exemplary embodiment, as illustrated inFIG. 7, theexpansion device20 is then operated to radially expand and plastically deform at least a portion of theexpandable tubular member12 of thetubular liner10.

In an exemplary embodiment, as illustrated inFIG. 8A, theexpansion device20 is then further operated to radially expand the remaining portion of theexpandable tubular member12 In response to the radial expansion of theexpandable tubular member12, thesleeve14 also radially expands until thesleeve14 engages the wall of thewellbore22, at which point thesleeve14 is compressed between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22. As a result of the compression of thesleeve14 between theexpandable tubular member12 and the wall of thewellbore22, and the resulting stresses and/or frictional forces generated therebetween, thetubular liner10 is anchored to thewellbore22, thereby generally preventing relative movement therebetween.

Alternatively, in an exemplary embodiment, after operating theexpansion device20 as illustrated inFIG. 7, theexpansion device20 is then further operated to radially expand the remaining portion of theexpandable tubular member12, as illustrated inFIG. 8B. In response to the radial expansion of theexpandable tubular member12, thesleeve14 also radially expands until thesleeve14 engages the wall of thewellbore22, at which point thesleeve14 is sandwiched between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22. However, after engaging the wall of thewellbore22, thesleeve14 remains substantially intact and theexpandable tubular member12 is instead compressed around the portions of thesleeve14 not engaging the wall of thewellbore22, as shown inFIG. 8B. As a result of the sandwiching of thesleeve14 between theexpandable tubular member12 and the wall of thewellbore22, the compression of theexpandable tubular member12 around the portions of thesleeve14 not engaging the wall of thewellbore12, and the resulting stresses and/or frictional forces generated among the wall of thewellbore12, thesleeve14 and theexpandable tubular member12, thetubular liner10 is anchored to thewellbore22, thereby generally preventing relative movement therebetween.

In an exemplary embodiment, as illustrated in bothFIGS. 8A and 8B, in addition to anchoring thetubular liner10 to thewellbore22 in response to the radial expansion of theexpandable tubular member12, thesleeve14 sealingly engages the interface between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22, thereby fluidicly isolating the portion of thewellbore22 below thesleeve14 from the portion of thewellbore22 above thesleeve14, and vice versa, in response to the radial expansion of theexpandable tubular member12.

In several exemplary embodiments, as a result of the anchoring of thetubular liner10 to thewellbore22, embodiments described herein offer the potential to reduce the risk of thetubular liner10 being pulled upward or downward, in response to the operation and axial movement of theexpansion device20 during the radial expansion of the portion of theexpandable tubular member12 above or below thesleeve14 and/or one or more other expandable tubular members coupled to theexpandable tubular member12 above or below thesleeve14.

In several exemplary embodiments, as a result of the anchoring of thetubular liner10 to thewellbore22 and the sealing of the interface between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22 in response to the radial expansion of theexpandable tubular member12, there is no need, or at least there is less of a need, to inject a hardenable fluidic material such as, for example, cement, into the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22 before, during or after the radial expansion of theexpandable tubular member12.

In several exemplary embodiments, before, during or after the operation of theexpansion device20, a hardenable fluidic material such as, for example, cement, is injected into the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22. As a result, an annular body of the hardenable fluidic sealing material is formed within the annular region defined between the exterior surface of theexpandable tubular member12 and the wall of thewellbore22. Before, during or after the curing of the annular body of the hardenable fluidic sealing material, theexpansion device20 may be operated to radially expand and plastically deform theexpandable tubular member12.

During operation, in several exemplary embodiments, thesleeve14 of thetubular liner10 penetratingly engages the wall of thewellbore16 and/or22 as described above with reference toFIGS. 1,2,3 and4, is compressed between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16 and/or22 as described above with reference toFIGS. 5,6,7 and8A, and/or is sandwiched between the exterior surface of theexpandable tubular member12 and the wall of thewellbore16 and/or22 as described above with reference toFIGS. 5,6,7 and8B, thereby anchoring thetubular liner10 to thewellbore16 and/or22 and sealing the interface between the exterior of theexpandable tubular member12 and the wall of thewellbore16 and/or22.

In an exemplary embodiment, thesleeve14 is composed of one or more metallic materials. In an exemplary embodiment, thesleeve14 is composed of one or more non-metallic materials. In an exemplary embodiment, thesleeve14 is composed of a combination of one or more metallic materials and one or more non-metallic materials.

In an exemplary embodiment, thesleeve14 is composed of one or more elastomeric materials. In an exemplary embodiment, thesleeve14 is composed of a Viton® elastomer, a nitrile elastomer, a swellable elastomer, a non-swellable elastomer, and/or any combination thereof.

In an exemplary embodiment, thesleeve14 is composed of one or more composite materials. In an exemplary embodiment, thesleeve14 is composed of one or more composite materials that are sprayed onto the exterior surface of theexpandable tubular member12. In an exemplary embodiment, thesleeve14 is composed of a material that is impregnated with carbide, wire filament and/or any combination thereof. In several exemplary embodiments, thesleeve14 is composed of a material such as polyetheretherketone/PEEK or polytetrafluoroethylene/PTFE (Teflon®).

In several exemplary embodiments, thesleeve14 is composed of one or more combinations of any of the above-identified types of materials.

In an exemplary embodiment, thesleeve14 is integral with theexpandable tubular member12.

In several exemplary embodiments, thetubular liner10 further includes one or more standoffs coupled to the exterior surface of theexpandable tubular member12. In several exemplary embodiments, the standoffs are composed of one or more resilient materials.

In an exemplary embodiment, thesleeve14 includes a plurality of circumferentially-spaced fins that extend radially outward away from the exterior surface of theexpandable tubular member12. In an exemplary embodiment, thesleeve14 includes one or more spikes and/or other types of protrusions that extend radially outward away from the exterior surface of theexpandable tubular member12.

In several exemplary embodiments, in addition to thesleeve14, thetubular liner10 includes one or more other sleeves, which are substantially similar to thesleeve14 and are coupled to theexpandable tubular member12.

In several exemplary embodiments, during the operation of thetubular liner10, one or more discrete portions of theexpandable tubular member12, and thus one or more discrete portions of thetubular liner10, may be radially expanded and plastically deformed.

In several exemplary embodiments, instead of, or in addition to thewellbore16 and/or22, thetubular liner10 may be coupled to one or more other types of preexisting structures such as, for example, one or more wellbore casings, one or more pipelines, one or more structural supports, and/or any combination thereof.

In an exemplary embodiment, theexpansion device20 includes a vibration mechanism. In an exemplary embodiment, theexpansion device20 includes a vibration mechanism that travels upwards (bottom-up), as viewed in any ofFIGS. 1-8. In an exemplary embodiment, theexpansion device20 includes a vibration mechanism that travels downwards (top-down), as viewed in any ofFIGS. 1-8. In an exemplary embodiment, theexpansion device20 employs mechanical force to effect its displacement relative to theexpandable tubular member12. In an exemplary embodiment, theexpansion device20 includes a fluid-powered expansion device. In an exemplary embodiment, theexpansion device20 employs hydraulic pressure to effect its displacement relative to theexpandable tubular member12. In an exemplary embodiment, to effect the displacement of theexpansion device20 relative to theexpandable tubular member12, theexpansion device20 employs mechanical force, hydraulic pressure and/or any combination thereof.

In an exemplary embodiment, as illustrated inFIGS. 9,10 and11, a tubular liner is generally referred to by thereference numeral26 and includes anexpandable tubular member28 defining aninternal passage28a, anoutside diameter28band aninside diameter28c, and including an external threadedconnection28dat one end and an internal threaded connection28eat the other end. In an exemplary embodiment, theoutside diameter28bis about 6.010 inches and theinside diameter28cis about 5.390 inches. In an exemplary embodiment, the external threadedconnection28dis a pin connection and the internal threaded connection28eis a box connection.

Sleeves

30a,30b, and30care coupled to theexpandable tubular member28 so that theexpandable tubular member28 extends through thesleeves30a,30band30c. Thesleeves30a,30b, and30cinclude opposing tapered end portions,30aaand30ab,30baand30bb, and30caand30cb, respectively, and thesleeves30a,30b, and30care axially spaced from one another along the axial or longitudinal length of theexpandable tubular member28. In an exemplary embodiment, the axial gap between thesleeves30aand30bis about 2.0 inches, and the axial gap between the sleeves30band30cis also about 2.0 inches. Each of thesleeves30a,30b, and30cdefines anoutside diameter32 that is greater than theoutside diameter28bof theexpandable tubular member28. In an exemplary embodiment, theoutside diameter32 is about 6.337 inches. Each of thesleeves30a,30band30cdefines awall thickness34. In an exemplary embodiment, thewall thickness34 is about 0.160 inches before any radial expansion of any of thesleeves30a,30band30c. Each of thesleeves30a,30b, and30cdefines anaxial length36. In an exemplary embodiment, theaxial length36 is about 6.0 inches.

In an exemplary embodiment, thetubular liner26 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 1,2,3 and4, with thesleeves30a,30b, and30cpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member28, thereby anchoring thetubular liner26 to the wellbore and sealing the interface between the exterior surface of theexpandable tubular member28 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner26 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with thesleeves30a,30b, and30cbeing compressed between theexpandable tubular member28 and the wall of a wellbore in response to the radial expansion of theexpandable tubular member28, thereby anchoring thetubular liner26 to the wellbore and sealing the interface between the exterior surface of theexpandable tubular member28 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner26 operates in a manner substantially similar to the manner in which thetubular liner10 operates as described above with reference toFIGS. 1,2,3 and4, with thesleeves30a,30b, and30cpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member28, and also in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with thesleeves30a,30band30calso being compressed between theexpandable tubular member28 and the wall of the wellbore in response to the radial expansion of theexpandable tubular member28.

In an exemplary embodiment, as illustrated inFIGS. 12,13 and14, a tubular liner is generally referred to by thereference numeral38 and includes anexpandable tubular member40 defining aninternal passage40a, anoutside diameter40band an inside diameter40c, and including an external threadedconnection40dat one end and an internal threaded connection40eat the other end. In an exemplary embodiment, theoutside diameter40bis about 6.010 inches and the inside diameter40cis about 5.390 inches. In an exemplary embodiment, the external threadedconnection40dis a pin connection and the internal threaded connection40eis a box connection.

Sleeves

42aand42bare coupled to theexpandable tubular member40 so that theexpandable tubular member40 extends through thesleeves42aand42b. Thesleeves42aand42binclude opposing tapered end portions,42aaand42ab, and42baand42bb, respectively, and thesleeves42aand42bare axially spaced from one another along the axial or longitudinal length of theexpandable tubular member40. In an exemplary embodiment, the axial gap between thesleeves42aand42bis about 2.0 inches. Each of thesleeves42aand42bdefines anoutside diameter44 that is greater than theoutside diameter40bof theexpandable tubular member28. In an exemplary embodiment, theoutside diameter44 is about 6.337 inches. Each of thesleeves42aand42bdefines awall thickness46. In an exemplary embodiment, thewall thickness46 is about 0.160 inches before any radial expansion of any of thesleeves42aand42b. Each of thesleeves42aand42bdefines anaxial length48. In an exemplary embodiment, theaxial length48 is about 12.0 inches.

In an exemplary embodiment, thetubular liner38 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 1,2,3 and4, with thesleeves42aand42bpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member40, thereby anchoring thetubular liner38 to the wellbore and sealing the interface between the exterior surface of theexpandable tubular member40 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner38 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with thesleeves42aand42bbeing compressed between theexpandable tubular member40 and the wall of a wellbore in response to the radial expansion of theexpandable tubular member40, thereby anchoring thetubular liner38 to the wellbore and sealing the interface between the exterior surface of theexpandable tubular member40 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner38 operates in a manner substantially similar to the manner in which thetubular liner10 operates as described above with reference toFIGS. 1,2,3 and4, with thesleeves42aand42bpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member40, and also in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with thesleeves42aand42balso being compressed between theexpandable tubular member40 and the wall of the wellbore in response to the radial expansion of theexpandable tubular member28.

In an exemplary embodiment, as illustrated inFIGS. 15,16 and17, a tubular liner is generally referred to by thereference numeral50 and includes anexpandable tubular member52 defining aninternal passage52aand including an external threadedconnection52bat one end, an internal threadedconnection52cat the other end,

tubular portions

52d,52e,52f, and52g, and enlarged-diameter tubular portions52h,52iand52j. Theportion52his located between the

portions

52dand52e, the portion52iis located between the

portions

52eand52f, and the portion52jis located between the

portions

52fand52g. Each of the

portions

52d,52e,52f, and52gdefines anoutside diameter52k. Each of theportions52h,52iand52jdefines anoutside diameter52lthat is greater than theoutside diameter52k. Each of the

portions

52d,52e,52f,52g,52h,52i, and52jare integral with each other, defining aninside diameter52m.

In an exemplary embodiment, each of theportions52h,52iand52jis a machined pad. In an exemplary embodiment, each of the

portions

52d,52e,52fand52gis an external annular recess.

In an exemplary embodiment, theoutside diameter52kis about 6.00 inches and theoutside diameter52lis about 6.30 inches. In an exemplary embodiment, the axial or longitudinal length of each of theportions52h,52i, and52jis about 4.0 inches. In an exemplary embodiment, the axial or longitudinal length of each of the

portions

52eand52fis about 14.0 inches. In an exemplary embodiment, the external threadedconnection52bis a pin connection and the internal threadedconnection52cis a box connection.

In an exemplary embodiment, thetubular liner50 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 1,2,3 and4, with the enlarged-diameter portions52h,52iand52jpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member52, thereby anchoring thetubular liner50 to the wellbore and sealing the interface between theexpandable tubular member52 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner50 operates in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with the enlarged-diameter portions52h,52iand52jbeing compressed between theexpandable tubular member52 and the wall of a wellbore in response to the radial expansion of theexpandable tubular member52, thereby anchoring thetubular liner50 to the wellbore and sealing the interface between theexpandable tubular member52 and the wall of the wellbore.

In an exemplary embodiment, thetubular liner50 operates in a manner substantially similar to the manner in which thetubular liner10 operates as described above with reference toFIGS. 1,2,3 and4, with the enlarged-diameter portions52h,52iand52jpenetratingly engaging the wall of a wellbore in response to the radial expansion of theexpandable tubular member52, and also in a manner substantially similar to the manner in which thetubular liner10 operates, as described above with reference toFIGS. 5,6,7,8A and8B, with the enlarged-diameter portions52h,52iand52jalso being compressed between theexpandable tubular member52 and the wall of the wellbore in response to the radial expansion of theexpandable tubular member52.

In an exemplary experimental model, a set of calculation results are provided in Table 1 below. These calculation results are at least partially based on a tubular liner that is similar to the embodiments of

tubular liners

26,38,50 described above. These calculation results indicate that the embodiments described herein offer the potential to be anchored to at least a wellbore and/or a wellbore casing in response to the radial expansion of the

tubular liner

26,38 and/or50. These calculation results, and/or the conclusions derived therefrom, are unexpected results.

TABLE 1

External Base Casing
Nominal OD	7.625	in.
Weight	39.00	lb/ft
Nominal ID	6.625	in.
API Drift ID	6.500	in.

Launcher
Launcher OD	6.250	in.
Anchor Hanger
Set in Base Casing-Elastomer Thickness	0.230	in.
Set in Base Casing-OD	6.460	in.
Set in Open Hole-Machined Pad Thickness	0.150	in.
Set in Open Hole-OD	6.300	in.
Connection Sleeves
Set in Base Casing-Thickness	0.100	in.
Set in Base Casing-Expanded OD	6.493	in.
Set in Open Hole-Thickness	0.100	in.
Set in Open Hole-Expanded OD	6.493	in.
Pre-Expansion Connection specifications
Tension Load Rating⁽¹⁾	254,800	lb
Compressive Load Rating⁽²⁾	203,800	lb
Minimum Parting Load⁽³⁾	302,500	lb
Pure Bend Load^(2,5)	28.5°/100	ft
SET Liner Pre-Expansion

Grade

EX-80

Nominal Yield Strength	80,000	psi
Minimum Ultimate Strength	95,000	psi
Nominal OD	6.000	in.
Nominal ID	5.390	in.
API Drift ID	5.265	in.
Nominal Wall Thickness	0.305	in.
Weight	18.60	lb/ft
Internal Yield	7,120	psi
SET Liner Post-Expansion
Nominal OD	6.297	in.
Nominal ID	5.700	in.
Drift ID	5.641	in.
Nominal Wall Thickness	0.299	in.
Nominal Weight	19.14	lb/ft
Internal Yield⁽⁴⁾	6,640	psi
Collapse⁽⁴⁾	4,180	psi

Expansion Ratio

5.8%

Post-Expansion Connection Specifications
Tension Load Rating⁽¹⁾	262,400	lb
Compression Load Rating⁽²⁾	170,600	lb
Minimum Parting Load⁽³⁾	311,600	lb
Pure Bend Load^(2,5)	17.1°/100	ft

Any spatial references such as, for example, “upper,” “lower,” “above,” “below,” “between,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,”etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.

In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.

While preferred embodiments have been shown and described, modifications thereof can be made by one skilled in the art without departing from the scope or teachings herein. The embodiments described herein are exemplary only and are not limiting. Many variations and modifications of the system and apparatus are possible and are within the scope of the invention. For example, the relative dimensions of various parts, the materials from which the various parts are made, and other parameters can be varied. Accordingly, the scope of protection is not limited to the embodiments described herein, but is only limited by the claims that follow, the scope of which shall include all equivalents of the subject matter of the claims.