WELLBORE LINER SYSTEM

Abstract: Wellbore apparatus having a tubular member (202) with a top end, a bottom end, a hollow portion, and a window (214) therethrough, a sleeve (240) positioned within the hollow portion of the tubular member (202), the sleeve (240) having a top end and a bottom end, a diverter apparatus (212) within or outside the tubular member (202) and, optionally, below the bottom end of the sleeve (240), the sleeve movable so that the diverter (212) directs the sleeve (240) to the window (214) and through the window into a bore (258) extending beyond the window, and the window having an edge therearound to which the top end of the sleeve is weldable to sealingly secure the sleeve (240) at the window (214).

Description: WELLBORE LINER SYSTEM This invention is directed to a wellbore liner system, and in particular to a method for installing a sleeve in a lateral wellbore. The prior art discloses a wide variety of wellbore milling systems and methods and a wide variety of systems and methods for re-establishing a pathway through a main wellbore after lining a lateral wellbore with a liner. Many such prior art systems and methods require a guide for a milling system so that the milling system mills back through the liner rather than entering the liner itself and milling in the wrong location. Without such a guide a lateral liner can be damaged by the wrongly located milling system, and the pathway through the main wellbore will not be re-established. According to a first aspect of the present invention there is provided a wellbore apparatus comprising: a tubular member having a window therethrough; a diverter apparatus located within or below the tubular member; a sleeve movable through the tubular member so that the diverter apparatus directs the sleeve through the window into a bore extending beyond the window; and a welding apparatus; wherein the window has an edge therearound to which the top end of the sleeve is weldable by the welding apparatus to sealingly secure the sleeve at the window. Thus a sleeve can be inserted into a lateral wellbore without leaving behind a liner which needs to be cut away to allow re-entry into the primary wellbore. Further preferred features are set out in claim 2 et seq. Some preferred embodiments of the invention will now be described by way of example only and with reference to the accompanying drawings, in which: Fig. 1 A shows in a side cross-section view a prior art wellbore extending down from an earth surface into the earth; Fig. IB shows in side cross-section view of a lateral wellbore extending from the wellbore of Fig. 1 A; Fig. 1C is a side cross-section view of a liner with a part installed in the lateral wellbore of Fig. IB; Figs. 2A, 2B, and 2E are side cross-section views of a liner system according to the present invention; Fig. 2C shows cross-section views along the length of the system as illustrated in Fig. 2B; Fig. 2D is a cross-section view along line 2D-2D of Fig. 2B; Fig. 2E shows a sleeve of the system of Fig. 2 A installed in a wellbore; and Fig. 2F is a side cross-section view of a system according to the present invention. Referring now to Fig. 1A, a main wellbore W extends down into an earth formation F and is cased with a string of casing C. Such wellbores and the drilling of them are old and well-known, as are the systems, tubulars, and methods for casing them. Fig. IB shows the results of well-known window milling methods that have created a window D and well-known drilling methods that have produced a lateral bore L. Fig. 1C shows a liner assembly 10 installed in part of the main wellbore W and part extending into the lateral bore L. The part of the liner assembly 10 may extend to any desired length into the lateral base L, including substantially all of the length of the lateral bore L. A suitable support 12 holds the liner assembly 10 in place. In one aspect, the support 12 is an external casing packer, but it may be a liner hanger, tubing hanger, pack off or any support that supports the liner assembly 10. In another aspect, a non- sealing support or supports may be used if no sealing between the exterior of the liner assembly 10 and the casing interior is desired. A tubular liner 14 may be made from any suitable material such as metal (steel, aluminium, zinc, alloys thereof), composite, flbreglass, or plastic. Preferably, the tubular liner 14 is bendable sufficiently for a lower portion 16 to bend and enter into the lateral bore L. In one aspect a bent tubular or bent sub 18 is connected at the end of the lower portion 16 of tubular liner 14 to facilitate initial entry of the tubular liner 14 into the lateral bore L. Optional seals 13 seal the annular space between a casing 38 and tubular members 14. Optionally, an orienting apparatus 20 (including but not limited to a measurement- hile-drilling device) may be used connected to the tubular liner 14 for correcting positioning and orienting of the bent sub 18 and of the tubular liner 14. Such an arrangement means that if access to the primary wellbore is required it is necessary to drill through the liner 14. Fig. 2A shows a system 200 with a tubular member 202 having a top end 204 with an anchor 206 and a bottom end 208 with a plug, (preferably drillable) 210. An anchor may be provided at the end 208. A bar, whipstock, or diverter 212 is secured at a lower end of a pre-formed or pre-machined window 214 to and within the tubular member 202. A sleeve 220, e.g. a liner or wellbore tubular, (made e.g. of metal, brass, bronze, zinc, zinc alloy, aluminium, aluminium alloy, fibreglass, or composite) is releasably secured in or is inserted into and through the tubular member 202. The sleeve 220 is moved down to contact the diverter 212 which urges the sleeve 212 to a position as shown in Fig. 2B (e.g. into an already underreamed formation portion or into a lateral bore extending from a main wellbore). When the sleeve 220 is in the position shown in Fig. 2B an activatable sealing material 222 disposed around the edge of the window 214 is activated to effect sealing securement of the sleeve 220 at the window 214. Preferably a flange 224 formed of or secured to the sleeve 220 extends interiorly beyond the edge of the window 214 to facilitate sealing of the sleeve at the window and to serve as a stop and locking device. Any suitable stored energy medium may be used as the sealing material 222, including, but not limited to, thermite and other iron oxide-aluminium compounds which react to form a metal seal or weld between parts and which are activated by heat with suitable initiation devices as are well known in the art indicated schematically by the device 221, Fig. 2E. In one aspect, not shown, the sleeve 220 has an open lower end. As shown in Figs. 2A and 2B a pressure-containing drillable shoe or end cap 226 seals off the sleeve's bottom end. In one aspect the diverter 212 is replaceable or removable in the wellbore or at the surface. The sleeve 220 may be any desired length. As shown in Fig. 2E a sleeve 240 (like the sleeve 220) with a flange 241 has been installed at a pre-formed window 244 of a tubular body 246 installed in a casing 248 of a wellbore 250 extending from an earth surface down in an earth formation 252 and sealed in place with sealing material 243. A top anchor 254 anchors the top of the tubular body 246 in casing 248. A diverter 242 secured within the body 246 (removable or not) has urged the sleeve 240 into an underreamed part of the formation 252 and a liner 256 has been inserted into and through the sleeve 240. The liner 256 (any desired length) extends down into a lateral wellbore 258. A liner hanger or packoff liner hanger 260 is at the top of the liner 256. The liner may be cemented into place with cement 262. An anchor 255 anchors the bottom of the tubular body 246. Alternatively a plug may be used instead of, or in addition to, the anchor 255. A system with a sleeve as shown in Fig. 2A or 2E may be run in a well and set, or bridged, across an already milled and under-reamed portion of casing. The sleeve is then pushed down to the diverter and forced out the pre-machined window in the tool body. In this position, the flange on the sleeve is adjacent to a shoulder in the pre- machined window and positioned in place. The stored energy medium reaction is then initiated creating a pressure-containing seal between the flange and the tool body. At this point, a lateral open hole may be drilled or an existing lateral open hole may be lengthened. An additional length of liner may be run into the drilled open hole and hung off the sleeve and then cemented into place. Alternatively, the lateral open hole is first drilled and then an entire liner string with a flange on top (like, e.g. the flange 241, Fig. 2E) is run into place. A seal is then activated (as with the systems of Figs. 2A and 2E with sealing material 222 or 243). If desired, the liner is then cemented in place. In another embodiment, a system as in Figs. 2A or 2E is run into a new well (without a sleeve or liner in place within the tool body) by placing the tool body directly in a new casing string while running in hole, with slight modifications (e.g. no anchors or plugs are needed) to the tool body. The aforementioned procedures are then followed, with the absence of section milling and under-reaming. As shown in Fig. 2F a sleeve 260 (like the sleeves 220, 240) with a flange 261 has been installed at a pre-formed window 264 of a tubular body 266 installed in a casing 268 of a wellbore 270 extending from an earth surface down in an earth formation 227 and sealed in place with sealing material, as described above or, alternatively by welding with a welding apparatus WA which is used either before installation of a top anchor 274 or is movable through the top anchor 274 after it is installed. Any suitable known welding apparatus, machine or device may be used for the welding apparatus WA. Suitable examples include apparatus for electron beam welding, laser welding, or rod or wire feed welding. The advantage of welding is that the welding apparatus can be inserted into the wellbore after the sleeve, and the sleeve does not need to include the stored energy medium around the top. In one embodiment the top anchor 274 anchors the top of the tubular body 266 in casing 268. A diverter 262 secured within the body 266 (removable or not) has urged the sleeve 260 into an underreamed part of the formation 272 and a liner 276 has been inserted into and through the sleeve 260. The liner 276 (any desired length) extends down into a lateral wellbore 278. A liner hanger or packoff liner hanger 280 is then installed at the top of the liner 276. The liner may be cemented into place with cement 282. An anchor 275 anchors the bottom of the tubular body 266. Alternatively a plug may be used instead of, or in addition to, the anchor 275. Alternatively, the welding apparatus may be run into the wellbore on new casing being installed in the wellbore. Optionally the diverter 262 is positioned outside the body 266 and/or below it, and/or below a bottom end of the sleeve 260. In one aspect a system with a sleeve as shown in Fig. 2F is run in a well and set, or bridged, across an already milled and under-reamed portion of casing. The sleeve is then pushed down to the diverter and forced out the pre-machined window in the tool body. In this position, the flange on the sleeve is adjacent to a shoulder in the pre- machined window and positioned in place. The sleeve is then sealingly welded in place with the welding apparatus WA (which, e.g. is run in the hole on a wireline WL). Alternatively the welding apparatus WA may be run in the hole on coiled tubing, on a cable, on a rope, or any other suitable means. Optionally, a stored energy medium reaction is initiated creating a pressure-containing seal between the flange and the tool body. A lateral open hole may then be drilled or an existing lateral open hole may be lengthened. An additional length of liner may be run into the drilled open hole and hung off the sleeve and then cemented into place. Alternatively, the lateral open hole is first drilled and then an entire liner string with a flange on top is run into place. A seal is then made. If desired, the liner is then cemented in place. In another embodiment, a system as in Fig. 2F is run into a new well (without a sleeve or liner in place within the tool body) by placing the tool body directly in a new casing string while running in hole, with slight modifications (e.g. no anchors or plugs are needed) to the tool body. The aforementioned procedures are then followed, with the absence of section milling and under-reaming. In another embodiment the system does not include sealing material 222 disposed around the edge of the window 214 when the sleeve 220 is inserted through the tubular member 202. Instead, the sealing material 222 is formed into a cord and initiated, then fed into position around the window 214. Any suitable known method for feeding the cord into position may be used.

Claims: CLAIMS: 1. A wellbore apparatus comprising: a tubular member having a window therethrough; a diverter apparatus located within or below the tubular member; a sleeve movable through the tubular member so that the diverter apparatus directs the sleeve through the window into a bore extending beyond the window; and a welding apparatus; wherein the window has an edge therearound to which the top end of the sleeve is weldable by the welding apparatus to sealingly secure the sleeve at the window. 2. A wellbore apparatus as claimed in claim 1, wherein the sleeve has a flange for securement around the edge of the window. 3. A wellbore apparatus as claimed in claim 1 or 2, wherein the sleeve is weldable to the edge of the window. 4. A wellbore apparatus as claimed in any preceding claim, further comprising an end cap closing off the bottom end of the sleeve. 5. A wellbore apparatus as claimed in claim 4, wherein the end cap is made of drillable material. 6. A wellbore apparatus as claimed in any preceding claim, wherein the bore is an underreamed bore in a formation. 7. A wellbore apparatus as claimed in any preceding claim, wherein the bore is a lateral wellbore extending from a main wellbore and the tubular member is disposable in the main wellbore so that the diverter can divert the sleeve through the window into the lateral wellbore. 8. A wellbore apparatus as claimed in any preceding claim, further comprising anchor apparatus for anchoring the tubular member in a bore. 9. A wellbore apparatus as claimed in claim 8, wherein the anchor apparatus includes an anchoring device at the top of the tubular. 10. A wellbore apparatus as claimed in claim 8, wherein the anchor apparatus includes an anchoring device at the bottom of the tubular. 11. A wellbore apparatus as claimed in claim 1, further comprising a plug closing off the bottom end of the tubular member. 12. A wellbore apparatus as claimed in claim 11 wherein the plug is made of drillable material. 13. A wellbore apparatus as claimed in any preceding claim, further comprising a liner, the top end of which is positioned within the bottom end of the sleeve. 14. A wellbore apparatus as claimed in claim 13, further comprising a liner hanger securing the liner to the sleeve. 15. A wellbore apparatus as claimed in claim 13 or 14, wherein the liner is disposed in a lateral wellbore extending from a main wellbore and the liner is cemented in place in the lateral wellbore. 16. A method for installing a sleeve in a lateral bore extending from a main earth bore, the method comprising: introducing a wellbore apparatus as claimed in any preceding claim into the main earth bore adjacent an opening into the lateral bore; moving the sleeve to co-act with the diverter, moving the sleeve into the lateral bore, and effecting a seal around the edge of the window by welding the top end of the sleeve to the edge of the window. 17. A method as claimed in claim 16, further comprising anchoring the tubular member in the main bore. 18. A method as claimed in claim 16 or 17, further comprising moving a liner into the lateral bore so that its top end is positioned within the bottom end of the sleeve. 19. A method as claimed in claim 18, further comprising securing the liner in place with a liner hanger. 20. A method as claimed in claim 19, further comprising cementing the liner in the lateral bore. 21. A wellbore apparatus comprising: a tubular member with a window therethrough; a diverter located within or below the tubular member; a sleeve movable so that the diverter directs the sleeve through the window into a bore extending beyond the window so that the top end of the sleeve contacts the edge of the window; a cord of activatable sealing material movable to contact the edge of the window; and an initiation device for activating the activatable sealing material. 22. A method for installing a sleeve in a lateral bore extending from a main bore, the method comprising: introducing a wellbore apparatus as claimed in claim 33 into the main bore so that the window is adjacent an opening of the lateral bore; moving the sleeve to co-act with the diverter; moving the sleeve into the lateral bore; moving the cord to dispose activatable sealing material around the edge of the window; and effecting a seal around the edge of the window by activating the activatable sealing material. 3. A liner system for lining a bore, the liner system comprising a liner string, a top flange on the liner string for abutting an edge of a window in a tubular, and a welding apparatus for welding the flange to the edge of the window.

Inventors: BAILEY THOMAS, BARRY ANDREW ARTHUR, BLIZZARD WILLIAM ALLAN JR, CARTER THURMAN BEAMER, HAUGEN DAVID MICHAEL, JOHNSON MONTE IRA, KUCK MARC DAVID, MCCLUNG GUY LAMONTE, ROBERTS JOHN DOUGLAS, ROBERTSON ROBERT EUGENE, SINGLETON TEME FORREST, SPIELMAN WILLIAM ALAN, BAILEY, THOMAS, BARRY, ANDREW, ARTHUR, BLIZZARD, WILLIAM, ALLAN, JR., CARTER, THURMAN, BEAMER, HAUGEN, DAVID, MICHAEL, JOHNSON, MONTE, IRA, KUCK, MARC, DAVID, MCCLUNG, GUY, LAMONTE, ROBERTS, JOHN, DOUGLAS, ROBERTSON, ROBERT, EUGENE, SINGLETON, TEME, FORREST, SPIELMAN, WILLIAM, ALAN
Applicants: HARDING RICHARD PATRICK, WEATHERFORD LAMB, HARDING, RICHARD, PATRICK, WEATHERFORD/LAMB, INC.
Application year: 2001
Main classification: E21B41
IPC codes: E21B41