System for lining a wellbore casing

Abstract

A system for lining a wellbore casing.

1 . A system for lining a wellbore casing, comprising: 
 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 comprises an expandable tubular member that comprises: 
 first and second tubular portions;  
 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;  
 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 inside diameter of the first tubular portion is greater than the inside diameter of the second tubular portion.  
   
   
   
       2 . The system of  claim 1  wherein the inside diameter of the first tubular portion is about 5% greater than the inside diameter of the second tubular portion.  
   
   
       3 . The system of  claim 1  wherein the wall thicknesses of the first and second tubular portions are greater than the wall thickness of the intermediate tubular portion.  
   
   
       4 . The system of  claim 1  wherein the 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;    wherein the 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.    
   
   
       5 . The system of  claim 1  wherein the outside diameter of the intermediate tubular portion ranges from about 75 percent to about 98 percent of the outside diameters of the second tubular portion.  
   
   
       6 . The system of  claim 1  wherein the burst strength of the first and second tubular portions is substantially equal to the burst strength of the intermediate tubular portion.  
   
   
       7 . The system of  claim 1  wherein the ratio of the inside diameter of the second tubular portion to the interior diameter of the intermediate tubular portion ranges from greater than 100 to about 120 percent.  
   
   
       8 . The system of  claim 1  wherein the tapered end of the tubular expansion cone comprises a plurality of adjacent discrete tapered sections.  
   
   
       9 . The system of  claim 8  wherein 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.  
   
   
       10 . The system of  claim 1  wherein the tapered end of the tubular expansion cone comprises a paraboloid body.  
   
   
       11 . The system of  claim 10  wherein 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.  
   
   
       12 . The system of  claim 1  wherein the tubular liner comprises a plurality of expandable tubular members and a plurality of other tubular members, and wherein the other tubular members are interleaved among the expandable tubular members.  
   
   
       13 . A method of lining a wellbore casing, comprising: 
 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;    wherein the tubular liner comprises an expandable tubular member that comprises: 
 first and second tubular portions;  
 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;  
 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 inside diameter of the first tubular portion is greater than an inside diameter of the second tubular portion.  
   
   
   
       14 . The method of  claim 13  wherein the inside diameter of the first tubular portion is about 5% greater than an inside diameter of the second tubular portion.  
   
   
       15 . The method of  claim 13  wherein a plurality of discrete portions of the tubular liner are radially expanded into engagement with the wellbore casing.  
   
   
       16 . The method of  claim 15  wherein the remaining portions of the tubular liner are not radially expanded.  
   
   
       17 . The method of  claim 15  wherein the discrete portions of the tubular liner are radially expanded by injecting a fluidic material into the tubular liner.  
   
   
       18 . The method of  claim 13  wherein the tubular liner comprises a plurality of expandable tubular members, wherein one or more of the expandable tubular members are radially expanded into engagement with the wellbore casing, and wherein a plurality of the expandable tubular members are not radially expanded into engagement with the well bore casing.  
   
   
       19 . A system for lining a wellbore casing, comprising: 
 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;    wherein the tubular liner comprises an expandable tubular member that comprises: 
 first and second tubular portions;  
 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;  
 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 inside diameter of the first tubular portion is greater than the inside diameter of the second tubular portion.  
   
   
   
       20 . The system of  claim 19  wherein the inside diameter of the first tubular portion is about 5% greater than the inside diameter of the second tubular portion.  
   
   
       21 . The system of  claim 19  wherein a plurality of discrete portions of the tubular liner are radially expanded into engagement with the wellbore casing.  
   
   
       22 . The system of  claim 21  wherein remaining portions of the tubular liner are not radially expanded.  
   
   
       23 . The system of  claim 21  wherein the discrete portions of the tubular liner are radially expanded by injecting a fluidic material into the tubular liner.  
   
   
       24 . The system of  claim 19  wherein the tubular liner comprises a plurality of tubular members, wherein one or more of the tubular members are radially expanded into engagement with the wellbore casing, and wherein a plurality of the tubular members are not radially expanded into engagement with the wellbore casing.  
   
   
       25 . An apparatus, comprising: 
 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;    wherein the tubular liner comprises a radially expanded and plastically deformed tubular member that comprises: 
 first and second tubular portions;  
 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 that engages the interior surface of the casing;  
 wherein the intermediate tubular portion is radially expanded and plastically deformed;  
 wherein the first and second tubular portions are not radially expanded and plastically deformed; and  
 wherein the first tubular portion is greater in diameter than the second tubular portion.  
   
   
   
       26 . The apparatus of  claim 25  wherein the inside diameter of the first tubular portion is about 5% greater than an inside diameter of the second tubular portion.  
   
   
       27 . The system of  claim 25  wherein the tubular liner comprises a plurality of radially expanded and plastically deformed tubular members.  
   
   
       28 . 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 that comprises: 
 a first expandable tubular member that comprises: 
 first and second tubular portions;  
 a first intermediate tubular portion coupled between the first and second tubular portions; and  
 a first sealing member coupled to the exterior surface of the first intermediate tubular portion;  
 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 inside diameter of the first tubular portion is greater than an inside diameter of the second tubular portion; and  
 one or more second expandable tubular members that each comprise:  
 third and fourth tubular portions;  
 a second intermediate tubular portion coupled between the third and fourth tubular portions; and  
 a second sealing member coupled to the exterior surface of the second intermediate tubular portion;  
 wherein the inside diameters of the first, second, third and fourth tubular portions are greater than the inside diameters of the first and second intermediate tubular portions.  
 
   
   
   
       29 . The system of  claim 28  wherein the inside diameter of the first tubular portion is about 5% greater than an inside diameter of the second tubular portion.  
   
   
       30 . The system of  claim 28  wherein the wall thicknesses of the first, second, third and fourth tubular portions are greater than the wall thicknesses of the first and second intermediate tubular portions.  
   
   
       31 . The system of  claim 28  wherein the first expandable tubular member further comprises: 
 a first tubular tapered transitionary portion coupled between the first tubular portion and the first intermediate tubular portion; and    a second tubular tapered transitionary portion coupled between the second tubular portion and the first intermediate tubular portion;    wherein the angles of inclination of the first and second tapered tubular transitionary portions relative to the first intermediate tubular portion ranges from greater than 0 to about 30 degrees.    
   
   
       32 . The system of  claim 31  wherein each of the second expandable tubular members further comprise: 
 a third tubular tapered transitionary portion coupled between the third tubular portion and the second intermediate tubular portion; and    a fourth tubular tapered transitionary portion coupled between the fourth tubular portion and the second intermediate tubular portion;    wherein the angles of inclination of the third and fourth tapered tubular transitionary portions relative to the second intermediate tubular portion ranges from greater than 0 to about 30 degrees.    
   
   
       33 . The system of  claim 28  wherein the outside diameters of the first and second intermediate tubular portions each range from about 75 percent to about 98 percent of the outside diameters of the second, third and fourth tubular portions.  
   
   
       34 . The system of  claim 28  wherein the burst strength of the first, second, third and fourth tubular portions is substantially equal to the burst strength of the first and second intermediate tubular portions.  
   
   
       35 . The system of  claim 28  wherein the ratio of the inside diameters of the second, third and fourth tubular portions to the interior diameters of the first and second intermediate tubular portions ranges from greater than 100 to about 120 percent.  
   
   
       36 . The system of  claim 28  wherein the expansion device comprises a plurality of adjacent discrete tapered sections.  
   
   
       37 . The system of  claim 36  wherein the 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.  
   
   
       38 . The system of  claim 28  wherein the expansion device comprises an paraboloid body.  
   
   
       39 . The system of  claim 38  wherein 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.  
   
   
       40 . A liner for lining a wellbore casing, comprising: 
 a first tubular portion;    a second tubular portion;    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;    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 inside diameter of the first tubular portion is greater than the inside diameter of the second tubular portion.    
   
   
       41 . The liner of  claim 40  wherein the inside diameter of the first tubular portion is about 5% greater than the inside diameter of the second tubular portion.  
   
   
       42 . The liner of  claim 40  wherein the wall thicknesses of the first and second tubular portions are greater than the wall thickness of the intermediate tubular portion.  
   
   
       43 . The liner of  claim 40  further comprising: 
 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;    wherein the 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.    
   
   
       44 . The liner of  claim 40  wherein the outside diameter of the intermediate tubular portion ranges from about 75 percent to about 98 percent of the outside diameter of the second tubular portion.  
   
   
       45 . The liner of  claim 40  wherein the ratio of the inside diameter of the second tubular portion to the interior diameter of the intermediate tubular portion ranges from greater than 100 to about 120 percent.  
   
   
       46 . A method of lining a wellbore casing, comprising: 
 positioning a tubular liner within the wellbore casing, wherein the tubular liner comprises first and second discrete portions coupled by a conventional threaded connection; and    radially expanding the first and second discrete portions of the tubular liner, including the conventional threaded connection, providing a fluid tight seal between the radially expanded first and second discrete portions.    
   
   
       47 . The method of  claim 46  wherein radially expanding the first and second discrete portions of the tubular liner and the conventional threaded connection includes radially expanding a diameter of an inner passage extending through the first and second discrete portions and the conventional threaded connection up to about 5%.  
   
   
       48 . A system for lining a wellbore casing, comprising: 
 means for positioning a tubular liner within the wellbore casing, wherein the tubular liner comprises first and second discrete portions coupled by a conventional threaded connection; and    means for radially expanding the first and second discrete portions of the tubular liner, including the conventional threaded connection, providing a fluid tight seal between the radially expanded first and second discrete portions.    
   
   
       49 . The system of  claim 48  wherein the radially expanding means includes is configured to radially expand a diameter of an inner passage extending through the first and second discrete portions and the conventional threaded connection up to about 5%.  
   
   
       50 . A liner for lining a wellbore casing, comprising: 
 a first tubular portion; and    a second tubular portion;    wherein the first and second tubular portions are coupled by a conventional threaded connection;    wherein the first and second tubular portions and the conventional threaded connection are radially expanded up to about 5%; and    wherein a fluid tight seal is provided between the radially expanded first and second tubular portions by the radially expanded conventional threaded connection.