Expandable Liner Hanger for Sealed Tubular Extension
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Solution Overview
Problem
Current methods for extending the length of tubulars in oil and gas wells, such as using liner hangers, face challenges in providing a reliable fluid-tight seal and secure coupling without mechanical or hydraulic slips, which can be inefficient and prone to leaks.
Innovation Solution
A radially expandable tubular portion with a tapered design and a securing and sealing mechanism, utilizing a hydraulically operated expansion tool to create interfacial contact and form annular shoulders for a secure and sealed connection with the existing tubular, enhancing grip through surface roughening and elastomeric coatings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If mechanically or hydraulically set slips are used to couple liner strings to existing casing, then secure coupling is achieved, but fluid-tight sealing becomes unreliable and prone to leaks
Solution Approach 1:
The invention merges the coupling function and sealing function into a single integrated expandable tubular structure. The tubular portion provides both mechanical support for coupling and fluid-tight sealing through its expandable body that creates interfacial contact with the existing casing, eliminating the need for separate slips and packer components.
Solution Approach 2:
The invention replaces the mechanical slip system with a radially expandable tubular structure that achieves both coupling and sealing through controlled expansion. The expansion creates interfacial contact between the tubular portion and existing casing, substituting mechanical biting slips with a more reliable expansion-based anchoring and sealing mechanism.
2Reliability
If separate liner hangers and packers are used to achieve coupling and sealing, then functional requirements are met, but device complexity increases
Solution Approach 1:
The invention combines the functions of liner hangers and packers into a single integrated tubular portion. This expandable tubular structure simultaneously provides mechanical coupling to the existing casing and fluid-tight sealing, eliminating the need for separate hanger and packer components and their associated installation procedures.
Solution Approach 2:
The expandable tubular portion is designed to perform multiple functions: it provides mechanical support for coupling the liner string to the casing, creates anchoring through expansion, and establishes fluid-tight sealing through interfacial contact. This multi-functional design replaces what previously required separate specialized components.
3Strength
If conventional liner hangers with slips are used, then coupling is achieved, but the process requires multiple steps reducing productivity
Solution Approach 1:
The tubular portion is pre-configured with the expandable structure and sealing surfaces before installation. Once deployed in the wellbore, it is expanded in a single operation to achieve both coupling and sealing, eliminating the need for subsequent setting operations required by conventional slips and packers.
Solution Approach 2:
The invention merges the coupling operation and sealing operation into a single expansion step. The tubular portion simultaneously achieves mechanical attachment to the casing and fluid-tight sealing through its expansion, reducing the multi-step process of conventional liner hanger installation to a single efficient operation.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution effectively extends the length of tubulars while ensuring a fluid-tight seal and secure coupling, reducing the need for mechanical slips and allowing for a one-step process, thereby improving the reliability and efficiency of well extensions.
Implementation Method 1
The tool can be arranged to radially expand the tubular portion such that plastic deformation of the tubular portion is experienced
Implementation Method 2
The tool can be arranged to radially expand the tubular portion into the existing tubular such that elastic deformation and optionally plastic deformation of the existing tubular is experienced
Implementation Method 3
The tool can be capable of applying a fluid pressure within the tubular portion in the area between the points of engagement of the tool and the inner diameter of the tubular portion. The fluid pressure can cause the tubular portion to radially expand
Implementation Method 4
The interfacial contact between the tubular portion and the existing tubular along the radially expandable part of the tubular preferably creates a fluid tight seal
Data Source
AI summary
A downhole expandable liner hanger apparatus for extending the length of an existing tubular such as a casing or liner string is described. The apparatus comprises a tubular portion and a securing and/or sealing means for securing the tubular portion to the existing tubular such as a casing string to thereby extend the length of the existing tubular and preferably simultaneously provide a sealed coupling between the tubular portion and the existing tubular. A first part or a length of the tubular portion preferably comprises a first sidewall thickness and a second part or length of the tubular portion is located adjacent the first part, where the second part comprises a second sidewall thickness, said first sidewall thickness being less than the second sidewall thickness.