Expandable liner system

Abstract

A system comprises a tubular releasably coupled to a launcher. An expansion assembly is sealingly engaged with the tubular so that the expansion assembly is moved longitudinally through the tubular by applying a pressurized fluid to the launcher. The expansion assembly radially expands the tubular as it moves longitudinally therethrough. A valve is coupled to the expansion assembly and opens when fluid pressure within an unexpanded portion of the tubular exceeds fluid pressure within the launcher. An extending member is coupled to the expansion assembly and to the launcher. The extending member restricts longitudinal movement of the expansion assembly relative to the launcher once the tubular is radially expanded.

1 . A system comprising:
 a housing;   a tubular releasably coupled to said housing;   an expansion assembly sealingly engaged with said tubular so that said expansion assembly is moved longitudinally through said tubular by applying a pressurized fluid to said housing, wherein said expansion assembly radially expands said tubular as it moves longitudinally therethrough;   a valve coupled to said expansion assembly, wherein said valve opens when fluid pressure within an unexpanded portion of said tubular exceeds fluid pressure within said housing; and   a extending member coupled to said expansion assembly and said housing, wherein said extending member restricts longitudinal movement of said expansion assembly relative to said housing once said tubular is radially expanded.   
     
     
         2 . The system of  claim 1  wherein said extending member comprises a tubular mandrel. 
     
     
         3 . The system of  claim 1  wherein said extending member comprises a cable. 
     
     
         4 . The system of  claim 1  wherein said valve is a flapper valve. 
     
     
         5 . The system of  claim 1  wherein said valve is a ball valve. 
     
     
         6 . The system of  claim 1  wherein said housing is releasably coupled to said tubular by a threaded connection. 
     
     
         7 . The system of  claim 1  further comprising:
 an annulus port disposed in said housing; and 
 a sleeve moveably disposed within said housing, wherein said sleeve has a first position preventing fluid communication through said annulus port and a second position allowing fluid communication through said annulus port. 
 
     
     
         8 . The system of  claim 7  wherein said sleeve is coupled to said extending member so that said extending member moves said sleeve from the first position to the second position once said tubular is radially expanded. 
     
     
         9 . A system comprising:
 a launcher having an upper end coupled to a support member that is operable to supply pressurized fluids to said launcher;   a liner releasably coupled to a lower end of said launcher;   an expansion assembly coupled to said launcher by an extending member; wherein said expansion assembly is operable to move longitudinally through and radially expand said liner in response to pressurized fluid being supplied to said launcher, and wherein said extending member restricts longitudinal movement of said expansion assembly once said liner is radially expanded; and   a valve coupled to said expansion assembly, wherein said valve opens when fluid pressure within an unexpanded portion of said liner exceeds fluid pressure within said launcher.   
     
     
         10 . The system of  claim 9  wherein said extending member comprises a tubular mandrel. 
     
     
         11 . The system of  claim 9  wherein said extending member comprises a cable. 
     
     
         12 . The system of  claim 9  wherein said valve is a flapper valve. 
     
     
         13 . The system of  claim 9  wherein said valve is a ball valve. 
     
     
         14 . The system of  claim 1  wherein said launcher is releasably coupled to said liner by a threaded connection. 
     
     
         15 . The system of  claim 9  further comprising:
 an annulus port disposed in said launcher; and 
 a sleeve moveably disposed within said launcher, wherein said sleeve has a first position preventing fluid communication through said annulus port and a second position allowing fluid communication through said annulus port. 
 
     
     
         16 . The system of  claim 15  wherein said sleeve is coupled to said extending member so that said extending member moves said sleeve from the first position to the second position once said tubular is radially expanded. 
     
     
         17 . A method comprising:
 disposing an expansion assembly in sealing engagement with a liner that is releasably connected to a launcher;   disposing the launcher, liner, and expansion assembly in a wellbore;   applying a pressurized fluid to the launcher so as to generate a differential pressure across the expansion assembly that moves the expansion assembly downward through and radially expands the liner;   equalizing the differential pressure across the expansion assembly by opening a equalizing valve disposed in the expansion assembly;   closing the equalization valve once the differential pressure across the expansion assembly is equalized; and   applying a pressurized fluid to the launcher so as to generate a differential pressure across the expansion assembly that moves the expansion assembly downward through and continues the radial expansion of the liner.   
     
     
         18 . The method of  claim 17 , further comprising:
 restricting the movement of the expansion assembly relative to the launcher once the liner has been radially expanded.   
     
     
         19 . The method of  claim 18  wherein the movement of the expansion assembly is restricted by an extendable member that is coupled to the launcher and the expansion assembly. 
     
     
         20 . The method of  claim 17 , further comprising:
 disconnecting the launcher from the liner; and   removing the launcher and the expansion assembly from the wellbore, wherein the expansion assembly is coupled to the launcher by an extendable member.