Patent ID: 12252961

DETAILED DESCRIPTION

In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily, but may be, to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results. Moreover, all statements herein reciting principles and aspects of the disclosure, as well as specific examples thereof, are intended to encompass equivalents thereof. Additionally, the term, “or,” as used herein, refers to a non-exclusive or, unless otherwise indicated.

Unless otherwise specified, use of the terms “connect,” “engage,” “couple,” “attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described.

Unless otherwise specified, use of the terms “up,” “upper,” “upward,” “uphole,” “upstream,” or other like terms shall be construed as generally away from the bottom, terminal end of a well, regardless of the wellbore orientation; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical or horizontal axis. Unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water, such as ocean or fresh water.

As can be appreciated, liner hangers (e.g., expanded liner hangers) should support the substantial weight of the attached tubing string below. For deep and extra-deep wells, subsea wells, etc., the tubing string places substantial axial load on the hanging mechanism engaging the liner hanger to the casing. There is a need for improved methods and apparatus providing a liner hanger having an anchoring mechanism and sealing mechanism capable of supporting the substantial axial loads imparted by longer and heavier liner strings. Furthermore, there is a need in certain situations to improve performance of liner hanger designs that have failed to achieve adequate axial load holding in an uphole direction when placed in collapse by pressure from downhole.

Additionally, the industry is currently employing high grade steels (e.g., with minimum yield strengths of 125 ksi, 140 ksi, 150 ksi, etc.), as well as increased wall thickness, for the wellbore tubular in many high pressure/high temperature applications. The present disclosure has recognized that the higher minimum yield strength and increased wall thickness leads to various problems. For example, the present disclosure has recognized that in such situations traditional anchoring ridges (e.g., with minimum yield strengths of 110 ksi or less) are unable to bite in the wellbore tubular, as well as are unable to deform the wellbore tubular (e.g., into a wave form), when expanded. Accordingly, the traditional anchoring ridges, particularly when used with high grade steel wellbore tubulars, can only rely on the metal-to-metal friction between the anchoring ridges and the wellbore tubular as the anchoring means. Unfortunately, in certain applications the metal-to-metal friction fails to provide the required anchoring capacity. Moreover, the traditional anchoring ridges, again particularly when used with high grade steel wellbore tubulars, fail to provide the necessary high pressure seal (e.g., from below).

The present disclosure has recognized, for the first time, that axial load performance of liner hangers can be improved by localized hardening of the one or more of the anchoring ridges. For example, the localized hardening of the one or more of the anchoring ridges allows the one or more ridges to expand, which would not be as possible if the entire continuous anchoring ridge was hardened. In at least one embodiment, one or more of the anchoring ridges are locally hardened, such that the locally hardened sections would have a minimum yield strength of at least 175 ksi, if not at least 200 ksi or at least 250 ksi. For example, in one or more embodiments one or more of the anchoring ridges are locally hardened, such that the locally hardened sections would have a minimum yield strength at least as high as the hardness of carburized steel (e.g., 300 ksi).

In at least one embodiment, one or more of the anchoring ridges are locally hardened using an additive manufacturing technique. For example, one or more of the anchoring ridges may be locally hardened using a direct metal deposition process, for example employing robotic arm(s) to deposit a thin metal having a minimum yield strength of at least 175 ksi to localized regions of the anchoring ridge.

In at least one other embodiment, one or more of the anchoring ridges are locally hardened using carburization. The term carburization (e.g., including carburizing, carburising, carburisation, etc.), as used herein, means a heat treatment process in which iron or steel absorbs carbon while the metal is heated in the presence of a carbon-bearing material, such as charcoal or carbon monoxide. The intent is to make the metal harder. Depending on the amount of time and temperature, the affected area can vary in carbon content. Longer carburizing times and higher temperatures typically increase the depth of carbon diffusion. Furthermore, when the iron or steel is cooled rapidly by quenching, the higher carbon content on the outer surface becomes hard due to the transformation from austenite to martensite, while the core remains soft and tough as a ferritic and/or pearlite microstructure.

The number of anchoring ridges having the locally hardened surface for a given design may vary. In at least one embodiment, one or more of the anchoring ridges have the locally hardened surface. In yet another embodiment, at least 20 percent of the anchoring ridges have the locally hardened surface, if not at least 50 percent of the anchoring ridges. In yet another embodiment, at least 75 percent of the anchoring ridges have the locally hardened surface, if not 100 percent.

The present disclosure has further recognized, for the first time, that axial load performance of liner hangers can be improved by replacing one or more of the continuous (e.g., circular) anchoring ridges with a ring of discrete slip teeth, each having a minimum yield strength of at least 175 ksi, if not at least 200 ksi, if not at least 250 ksi, or up to 300 ksi or above. In certain embodiments, less than all of the continuous anchoring ridges are replaced with the ring of discrete slip teeth. For example, the uphole and downhole most continuous anchoring ridges could be replaced with the ring of discrete slip teeth, every other continuous anchoring ridge replaced with the ring of discrete slip teeth, etc. Accordingly, the ring(s) of discrete slip teeth could be used to improve the anchoring capacity (e.g., the number of rings of discrete slip teeth could be chosen based upon the anchor load requirements of the well system), whereas the continuous anchoring ridges could be used for sealing capacity (e.g., the number of continuous anchoring ridges could be chosen based upon the sealing requirements of the well system).

In at least one embodiment, the discrete slip teeth may be placed within one or more shallow grooves in the radially expandable tubular. In one or more embodiments, the discrete slip teeth are each individually press fit within the one or more shallow grooves. In one or more other embodiments, the plurality of discrete slip teeth are coupled to a C-ring that is press fit within the one or more grooves. In yet another embodiment, the plurality of discrete slip teeth are coupled to each other using an elastic material that would hold the plurality of discrete slip teeth within the one or more shallow grooves. In even yet another embodiment, the plurality of slip teeth are coupled to an open end ring by way of inward pointing slender beams, the inward pointing slender beams holding the plurality of slip teeth within the one or more shallow grooves. Nevertheless, other coupling mechanisms, including adhesives and/or spot welds could be used to maintain the plurality of slip teeth within the one or more shallow grooves.

The embodiments disclosed above have been shown to greatly improve the anchoring capacity of the expandable liner hanger assembly. For example, finite element analysis (FEA) simulation of the embodiments discloses show that the anchoring capacity may be improved by at least 30%. Accordingly, a 1.5 m expandable liner hanger assembly according to the present disclosure could provide the same anchoring capacity as a 4 m traditional expandable liner hanger assembly.

FIG.1illustrates one embodiment of a well system100designed, manufactured and/or operated according to one or more embodiments of the disclosure. The well system100, in at least one embodiment, includes a wellbore110extending through one or more hydrocarbon bearing subterranean formations115. Further to the embodiment ofFIG.1, a wellbore tubular120(e.g., casing string in the illustrated embodiment) has been installed and cemented within the wellbore110. The wellbore tubular110may comprise many different materials and minimum yield strengths and remain within the scope of the disclosure. Nevertheless, the present disclosure is particularly useful when the wellbore tubular110comprises a high grade steel. For instance, the wellbore tubular may have a minimum yield strength of at least 125 ksi in one embodiment, at least 140 ksi in another embodiment, at least 150 ksi in yet another embodiment, etc., and remain within the scope of the disclosure.

In the illustrated embodiment, a liner hanger system130(e.g., expandable liner hanger system) is positioned within the wellbore110. The liner hanger system130, in at least one embodiment, includes an expandable cone (not shown), as well as an expandable liner hanger assembly135disposed thereabout. In at least one embodiment, the expandable liner hanger assembly135includes a radially expandable tubular140. In the illustrated embodiment, the radially expandable tubular140defines an interior passageway and an exterior surface. In accordance with one embodiment, the expandable liner hanger assembly135additionally includes one or more continuous anchoring ridges145extending radially outward from the radially expandable tubular140. In accordance with one embodiment of the disclosure, the radially expandable tubular140is configured to move from an initial state (as shown) wherein the one or more continuous anchoring ridges145are not in contact with the wellbore tubular120, to an expanded state (e.g., shown inFIG.2) wherein the one or more anchoring ridges145are in gripping engagement with the wellbore tubular120.

Further to the embodiment ofFIG.1, at least one of the one or more continuous anchoring ridges145has a plurality of localized hardened sections150placed circumferentially there around. Without limitation, the plurality of localized hardened sections150might have a minimum yield strength of at least 175 ksi, if not at least 200 ksi or at least 250 ksi. For example, in one or more embodiments, the plurality of locally hardened sections could have a minimum yield strength at least as high as the hardness of carburized steel (e.g., 300 ksi). The plurality of localized hardened sections150may be manufactured using any of the processes disclosed above, or any other known or hereafter discovered process.

As shown, the expandable liner hanger assembly135may be hung, extending downhole from a lower end of wellbore tubular120. An annulus170may be created between the wellbore tubular120and the liner hanger system130. In embodiments, the liner hanger system130can support additional wellbore casing, operational tubulars or tubing strings, completion strings, downhole tools, etc., for positioning at greater depths.

As used herein, the terms “tubular,” “liner,” and “casing” are used generally to describe tubular wellbore items, used for various purposes in wellbore operations. Tubulars, liners, and casings can be made from various materials (metal, plastic, composite, etc.), can be expanded or unexpanded as part of an installation procedure, and can be segmented or continuous. It is not necessary for a tubular, liner or casing to be cemented into position. Any type of tubular, liner, or casing may be used in keeping with the principles of the present invention.

As further illustrated inFIG.1, the liner hanger system130may seal and secure an upper end of expandable liner hanger assembly135near a lower end of the wellbore tubular120. Alternatively, the liner hanger system130may seal and secure the upper end of expandable liner hanger assembly135above a window (not shown) formed through a sidewall of the wellbore tubular120, with the expandable liner hanger assembly135extending outwardly through the window into a branch or lateral wellbore. Thus, it will be appreciated that many different configurations and relative positions of the wellbore tubular120and the liner hanger system130are possible.

In embodiments, as also shown inFIG.1, a setting tool175may be connected proximate the expandable liner hanger assembly135on work string180. Work string180may convey the setting tool175, expandable liner hanger assembly135(e.g., including the radially expandable tubular140and the one or more continuous anchoring ridges145) into the wellbore110, conduct fluid pressure and flow, transmit torque, tensile and compressive force, etc. Setting tool175may facilitate conveyance and installation of radially expandable tubular140and the one or more continuous anchoring ridges145, in part by using the torque, tensile and compressive forces, fluid pressure and flow, etc., as delivered by work string180.

InFIG.1, the expandable liner hanger assembly135is additionally illustrated with one or more sealing members155and one or more anchoring ridges160positioned on and attached to the expandable liner hanger assembly135. In at least one embodiment, the one or more anchoring ridges function as a primary metal-to-metal seal, whereas the one or more sealing members155function as a secondary seal. Additionally, in certain embodiments the radially expandable tubular140and the one or more continuous anchoring ridges145may also provide a sealing function. In accordance with one embodiment, the one or more anchoring ridges160may be standard anchoring ridges (e.g., that might not contain the plurality of localized hardened sections150), but may be used in conjunction with the one or more continuous anchoring ridges145having the plurality of localized hardened sections150. In embodiments, when the expandable liner hanger assembly135is expanded, such as with an expansion cone, into anchoring and sealing engagement with wellbore tubular120, the one or more continuous anchoring ridges145having the plurality of localized hardened sections150, the one or more sealing members155, and the one or more anchoring ridges160engage the interior of wellbore tubular120. In at least one embodiment, the one or more continuous anchoring ridges145having the plurality of localized hardened sections150and the one or more anchoring ridges160provide an anchoring function, whereas each of the one or more continuous anchoring ridges145having the plurality of localized hardened sections150, the one or more sealing members155, and the one or more anchoring ridges160provide a sealing function to one degree or another. These elements are discussed more fully below.

FIG.2illustrates an elevational view, with cut-away and partial cross-section, of an embodiment of the well system100ofFIG.1, with the expandable liner hanger assembly135in the expanded state. Accordingly, the one or more continuous anchoring ridges145having the plurality of localized hardened sections150are in gripping engagement with the wellbore tubular120. In at least one embodiment, as shown, the one or more continuous anchoring ridges145may have at least four localized hardened sections150placed circumferentially there around. In at least one embodiment, the at least four localized hardened sections150are placed circumferentially equidistance there around. In at least one other embodiment, the one or more continuous anchoring ridges145may have at least eighteen localized hardened sections150placed circumferentially there around, if not placed circumferentially equidistance there around. In yet another embodiment, the one or more continuous anchoring ridges145may have at least twenty-four localized hardened sections150placed circumferentially there around, if not placed circumferentially equidistance there around.

In the illustrated embodiment, the plurality of localized hardened sections150are a plurality of localized hardened layers placed circumferentially there around. In accordance with this embodiment, the plurality of localized hardened layers may have a thickness of 0.25 μm or less. In yet another embodiment, the plurality of hardened layers may have a thickness ranging from 0.025 μm to 0.076 μm.

In the illustrated embodiment, a plurality of ductile sections210are placed between the plurality of localized hardened sections150. The plurality of ductile sections210, in at least one embodiment, comprise the same material as the radially expandable tubular140, but have not been locally hardened like the localized hardened sections150. In yet another embodiment, the plurality of ductile sections210comprise a different material and minimum yield strength than the radially expandable tubular140and/or the localized hardened sections150. In at least one embodiment, the plurality of localized hardened sections150have a hardened section minimum yield strength at least 10% greater than a ductile section minimum yield strength of the plurality of ductile sections210. In yet another embodiment, the plurality of localized hardened sections150have a hardened section minimum yield strength at least 50% greater than a ductile section minimum yield strength of the plurality of ductile sections210. In yet even another embodiment, the plurality of localized hardened sections150have a hardened section minimum yield strength at least 100% greater than a ductile section minimum yield strength of the plurality of ductile sections210.

FIG.3illustrates a perspective view of expandable liner hanger assembly135ofFIGS.1and2with one or more (e.g., two) continuous anchoring ridges145extending radially outward from the radially expandable tubular140. As shown inFIG.3, the one or more continuous anchoring ridges145have a plurality of localized hardened sections150placed circumferentially there around. In this embodiment, the radially expandable tubular140and the one or more continuous anchoring ridges145comprise the same material. Nevertheless, the plurality of localized hardened sections150provide the necessary minimum yield strength required to grip the wellbore tubular. The expandable liner hanger assembly135ofFIG.3additionally includes the plurality of ductile sections210.

FIG.4Aillustrates a cross-section of an expandable liner hanger assembly400designed, manufactured and/or operated, as might exist in its initial (e.g., non-expanded or run-in-hole) state. The expandable liner hanger assembly400, in the illustrated embodiment ofFIG.4A, includes at least eighteen localized hardened sections420placed circumferentially around a radially expandable tubular410. In the illustrated embodiment, the expandable liner hanger assembly400includes at least twenty-four localized hardened sections420placed circumferentially equidistance apart. Further to the embodiment ofFIG.4A, individual ones of ductile sections430are placed between the plurality of localized hardened sections420. Further to the embodiment ofFIG.4A, in at least one embodiment, the plurality of ductile sections430are radially outside of the plurality of hardened sections420when the radially expandable tubular400is in the initial state.

In the illustrated embodiment, each of the localized hardened sections420extend circumferentially around the radially expandable tubular410by an angle (β), wherein the plurality of ductile sections430each extend circumferentially around the radially expandable tubular410an angle (Ω). In at least one embodiment, the angle (β) is 20 degrees or less, if not 10 degrees or less. In at least one other embodiment, the angle (Ω) is 10 degrees or less, if not 5 degrees or less. For example, a ratio of the angle (β) to the angle (Ω), in at least one embodiment, ranges from 4:1 to 1:1.

FIG.4Billustrates a cross-section of the expandable liner hanger assembly400ofFIG.4A, as it might exist in its expanded state. In at least one embodiment, as shown, the plurality of ductile sections430are no longer radially outside of the plurality of hardened sections420when the expandable liner hanger assembly400is in the expanded state.

FIG.4Cillustrates a cross-section of an expandable liner hanger assembly400cdesigned, manufactured and/or operated, as might exist in its initial (e.g., non-expanded or run-in-hole) state. The expandable liner hanger assembly400c, in the illustrated embodiment ofFIG.4A, includes a single hardened section420cplaced circumferentially around a radially expandable tubular410. In the illustrated embodiment, the single hardened section420cis set up as a C-ring with a cutout440, which would allow the single hardened section420cto expand.

FIG.4Dillustrates a cross-section of the expandable liner hanger assembly400cofFIG.4C, as it might exist in its expanded state.

FIG.5illustrates an alternative embodiment of a well system500designed, manufactured and/or operated according to one or more embodiments of the disclosure. The well system500is similar in many respects to the well system100ofFIG.1. Accordingly, like reference number have been used to indicated similar, if not identical, features. The well system500differs, for the most part, from the well system100, in that it employs a different expandable liner hanger assembly535from the expandable liner hanger assembly135ofFIG.1. For example, the expandable liner hanger assembly535does not include the one or more continuous anchoring ridges145having the plurality of localized hardened sections150placed circumferentially there around. In contrast, the expandable liner hanger assembly535ofFIG.5includes a shallow groove542located in the exterior surface of its radially expandable tubular540, and a plurality of discrete slip teeth545placed within the shallow groove542circumferentially around the radially expandable tubular540. The plurality of discrete slip teeth545of the embodiment ofFIG.5provide the same function as the one or more continuous anchoring ridges145having the plurality of localized hardened sections150placed circumferentially there around, which is to grip the wellbore tubular120when moved from the initial state to the expanded state.

In the illustrated embodiment ofFIG.5, each of the plurality of discrete slip teeth545has a minimum yield strength of at least 175 ksi. In yet another embodiment, each of the plurality of discrete slip teeth545has a minimum yield strength of at least 200 ksi, and in yet another embodiment each of the plurality of discrete slip teeth545has a minimum yield strength of at least 250 ksi, if not 300 ksi or more.

In the illustrated embodiment ofFIG.5, the expandable liner hanger assembly535includes at least four discrete slip teeth545placed circumferentially around the radially expandable tubular540in a given shallow groove542. For example, the at least four discrete slip teeth545may be placed circumferentially equidistance around the radially expandable tubular540for a given shallow groove542. In yet another embodiment, the expandable liner hanger assembly535includes at least eighteen discrete slip teeth545placed circumferentially (e.g., circumferentially equidistance) around the radially expandable tubular in a given shallow groove542. In even yet another embodiment, the expandable liner hanger assembly535includes at least twenty-four discrete slip teeth545placed circumferentially (e.g., circumferentially equidistance) around the radially expandable tubular in a given shallow groove542.

In certain embodiments, the radially expandable tubular540may include a plurality of spaced apart shallow grooves542. In such an embodiment, a first set of plurality of discrete slip teeth could be positioned in a first shallow groove, and a second set of plurality of discrete slip teeth could be positioned in a second shallow groove, such as shown inFIG.5.FIG.5further illustrates four different shallow grooves542, two of which include sets of plurality of discrete slip teeth, and two of which have yet to include sets of plurality of discrete slip teeth.FIG.5additionally illustrates that one or more continuous anchoring ridges160may be positioned between the first and second sets of plurality of discrete slip teeth.

FIG.6illustrates an elevational view, with cut-away and partial cross-section, of an embodiment of the well system500ofFIG.5, with the expandable liner hanger assembly535in the expanded state. Accordingly, the plurality of discrete slip teeth545are in gripping engagement with the wellbore tubular120.

In certain embodiments, the plurality of discrete slip teeth545are individually press fit within the shallow grooves. Nevertheless, in the embodiment ofFIG.5, the plurality of discrete slip teeth545are coupled to each other using an elastic material610that holds the plurality of discrete slip teeth545within the shallow groove while the expandable liner hanger535is being run in hole, and until it is moved to the expanded state.

FIG.7illustrates a perspective view of expandable liner hanger assembly535ofFIGS.5and6with a first shallow groove542aincluding a first set of plurality of discrete slip teeth545aand a second shallow groove542bincluding a second set of plurality of discrete slip teeth545b.FIG.7further illustrates a first elastic material610athat holds the first plurality of discrete slip teeth545awithin the first shallow groove542a, and a second elastic material610bthat holds the second plurality of discrete slip teeth545bwithin the first shallow groove542b.

FIG.8Aillustrates a cross-section of an expandable liner hanger assembly800designed, manufactured and/or operated, as might exist in its initial (e.g., non-expanded or run-in-hole) state. The expandable liner hanger assembly800, in the illustrated embodiment, includes at least eighteen discrete slip teeth820placed within the shallow groove circumferentially around the radially expandable tubular810. In the illustrated embodiment, the expandable liner hanger assembly800includes at least twenty-four discrete slip teeth820placed circumferentially equidistance apart. Further to the embodiment ofFIG.8A, elastic material830holds the plurality of discrete slip teeth820within the shallow groove.

In the illustrated embodiment, each of the discrete slip teeth820extend circumferentially around the radially expandable tubular by an angle (Γ). In at least one embodiment, the angle (Γ) is 30 degrees or less. In yet another embodiment, the angle (Γ) is 20 degrees or less, if not 10 degrees or less or 5 degrees or less.

FIG.8Billustrates a cross-section of the expandable liner hanger assembly800ofFIG.8A, as it might exist in its expanded state.

FIG.9illustrates a perspective view of an expandable liner hanger assembly935, for example similar to the expandable liner hanger535ofFIGS.5and6, but employing an open end ring910and inward pointing slender beams920coupled to ones of the discrete slip teeth545to hold the plurality of discrete slip teeth545within the shallow groove.

FIG.10Aillustrates a perspective view of an expandable liner hanger assembly1035, for example similar to the expandable liner hanger ofFIGS.5and6, but employing a C-ring1010attached to the discrete slip teeth545to hold the plurality of discrete slip teeth545within the shallow groove.

FIGS.10B and10Cillustrate cross-sectional views of different embodiments of the C-ring1010b,1010c, respectively, having the discrete slip teeth545attached thereto, as might be designed, manufactured and/or employed according to the present disclosure.

Generally, in the downhole setting, elements with pressure from above (uphole) are typically “boosted” or enhanced because of the pressure on the inner diameter of the liner hanger. Elements with pressure from below (downhole) are typically placed in collapse, thus reducing the contact stress and liner hanger performance when reacting to load from below (downhole). The pressure from below (downhole) may be sealed off by placing one or more sealing members1110on the bottom of expandable liner hanger1100—thus limiting the influence of collapse pressure—as illustrated inFIG.11A. Further, trapped pressure from expansion of expandable liner hanger1100, which would have a negative influence in the annular space between sealing members1110, may be avoided—thus avoiding decreased performance of one or more anchoring ridges1120. This may be due to fluid being able to communicate through stress-relief features in the one or more anchoring ridges1120. Therefore, stress-relief features may provide stress relief and fluid communication. In another embodiment, as illustrated inFIG.11Banother sealing sub-assembly may be placed above the one or more anchoring ridges1120as well, thereby limiting the ability of pressure to reduce contact stress against the wellbore tubular. In certain scenarios, pressures may be directed from below (downhole) or above (uphole) and/or combined with varying internal pressures—all of which may impact the contact stress that expandable liner hanger1100has against the inner diameter of wellbore tubular. It should be noted, however, that the one or more anchoring ridges1120, to one degree or another, may also provide a sealing function.

Turning toFIG.12A, illustrated is one embodiment of an expandable liner hanger assembly1200ahaving a continuous anchoring ridge1210adesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12A, the continuous anchoring ridge1210aincludes a localized hardened section1220apositioned only on its top surface. The continuous anchoring ridge1210a, in the illustrated embodiment, includes two inward angled sidewalls and a flat top surface.

Turning toFIG.12B, illustrated is an alternative embodiment of an expandable liner hanger assembly1200bhaving a continuous anchoring ridge1210bdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12B, the continuous anchoring ridge1210bincludes a localized hardened section1220bpositioned on its top surface and partially along its two inward angled sidewalls.

Turning toFIG.12C, illustrated is an alternative embodiment of an expandable liner hanger assembly1200chaving a continuous anchoring ridge1210cdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12C, the continuous anchoring ridge1210cincludes a localized hardened section1220cpositioned on its top surface and entirely along its two inward angled sidewalls.

Turning toFIG.12D, illustrated is an alternative embodiment of an expandable liner hanger assembly1200dhaving a continuous anchoring ridge1210ddesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12D, the continuous anchoring ridge1210dincludes two inward angled sidewalls, two vertical sidewalls, and a flat top surface, and the localized hardened section1220dis positioned on its top surface and partially along its two sidewalls.

Turning toFIG.12E, illustrated is an alternative embodiment of an expandable liner hanger assembly1200ehaving a continuous anchoring ridge1210edesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12E, the continuous anchoring ridge1210eincludes two vertical sidewalls and a flat top surface, and the localized hardened section1220eis positioned on its top surface and partially along its vertical two sidewalls.

Turning toFIG.12F, illustrated is an alternative embodiment of an expandable liner hanger assembly1200fhaving a continuous anchoring ridge1210fdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12F, the continuous anchoring ridge1210fincludes two outward angled sidewalls and a flat top surface, and the localized hardened section1220fis positioned on its top surface and partially along its two outward angled sidewalls.

Turning toFIG.12G, illustrated is an alternative embodiment of an expandable liner hanger assembly1200ghaving a continuous anchoring ridge1210gdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12G, the continuous anchoring ridge1210gincludes two inward differently angled sidewalls, two vertical sidewalls, and a flat top surface, and the localized hardened section1220gis positioned on its top surface and partially along its two inward angled sidewalls.

Turning toFIG.12H, illustrated is an alternative embodiment of an expandable liner hanger assembly1200hhaving a continuous anchoring ridge1210hdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12H, the continuous anchoring ridge1210hincludes two inward angled sidewalls, and a concave top surface, and the localized hardened section1220his positioned on its concave top surface and partially along its two sidewalls.

Turning toFIG.12I, illustrated is an alternative embodiment of an expandable liner hanger assembly1200ihaving a continuous anchoring ridge1210idesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12I, the continuous anchoring ridge1210iincludes two inward angled sidewalls forming a triangle, and the localized hardened section1220gis positioned partially along its two inward angled sidewalls.

Turning toFIG.12J, illustrated is an alternative embodiment of an expandable liner hanger assembly1200jhaving a continuous anchoring ridge1210jdesigned, manufactured, and placed according to one or more embodiments of the disclosure. In the embodiment ofFIG.12J, the continuous anchoring ridge1210jincludes a circular cross-section, and the localized hardened section1220gis positioned on a top of the circular cross-section. It should be noted that the shapes of the continuous anchoring ridges illustrated inFIGS.12A through12Jare equally suitable for the plurality of discrete slip teeth disclosed above.

Turning toFIG.13, illustrated is an alternative embodiment of a well system1300including an expandable linger hanger assembly1335designed, manufactured and/or operated according to one or more embodiments of the disclosure. The expandable linger hanger assembly1335is similar in many respects to the expandable linger hanger assembly135ofFIG.2. Accordingly, like reference numbers have been used to indicate similar, if not identical, features. The expandable liner hanger assembly1335differs, for the most part, from the expandable linger hanger assembly135, in that the expandable liner hanger assembly1335includes one or more stress-relief features1310defined thereon. In embodiments, a stress-relief groove or similar feature may be provided to support plastic expansion. Stress-relief features1310may be notches or cut-outs spaced circumferentially on one or more anchoring ridges145, as shown. Further, stress-relief features1310may be created through milling. Those of skill in the art will recognize other stress-relief features and geometries as well. Stress-relief features1310may also allow for fluid communication between one or more anchoring ridges145.

Aspects disclosed herein include:A. An expandable liner hanger assembly, the expandable liner hanger assembly including: 1) a radially expandable tubular defining an interior passageway and an exterior surface; and 2) one or more continuous anchoring ridges extending radially outward from the radially expandable tubular, at least one of the one or more continuous anchoring ridges having a plurality of localized hardened sections placed circumferentially there around, the radially expandable tubular configured to move from an initial state wherein the one or more continuous anchoring ridges are not in contact with a wellbore tubular to an expanded state wherein the one or more continuous anchoring ridges are in gripping engagement with the wellbore tubular.B. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; 2) wellbore tubular positioned within the wellbore; and 3) an expandable liner hanger assembly positioned within the wellbore tubular, the expandable liner hanger assembly including: a) a radially expandable tubular defining an interior passageway and an exterior surface; and b) one or more continuous anchoring ridges extending radially outward from the radially expandable tubular, at least one of the one or more continuous anchoring ridges having a plurality of localized hardened sections placed circumferentially there around, the radially expandable tubular configured to move from an initial state wherein the one or more continuous anchoring ridges are not in contact with the wellbore tubular to an expanded state wherein the one or more continuous anchoring ridges are in gripping engagement with the wellbore tubular.C. An expandable liner hanger assembly, the expandable liner hanger assembly including: 1) a radially expandable tubular defining an interior passageway and an exterior surface, the radially expandable tubular having a shallow groove located in the exterior surface; and 2) a plurality of discrete slip teeth placed within the shallow groove circumferentially around the radially expandable tubular, the radially expandable tubular configured to move from an initial state wherein the plurality of discrete slip teeth are not in contact with a wellbore tubular to an expanded state wherein the plurality of discrete slip teeth are in gripping engagement with the wellbore tubular.D. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; 2) wellbore tubular positioned within the wellbore; and 3) an expandable liner hanger assembly positioned within the wellbore tubular, the expandable liner hanger assembly including: a) a radially expandable tubular defining an interior passageway and an exterior surface, the radially expandable tubular having a shallow groove located in the exterior surface; and b) a plurality of discrete slip teeth placed within the shallow groove circumferentially around the radially expandable tubular, the radially expandable tubular configured to move from an initial state wherein the plurality of discrete slip teeth are not in contact with a wellbore tubular to an expanded state wherein the plurality of discrete slip teeth are in gripping engagement with the wellbore tubular.

Aspects A, B, C and D may have one or more of the following additional elements in combination: Element 1: wherein the at least one of the one or more continuous anchoring ridges has at least four localized hardened sections placed circumferentially there around. Element 2: wherein the at least four localized hardened sections are placed circumferentially equidistance there around. Element 3: wherein the at least one of the one or more continuous anchoring ridges has at least eighteen localized hardened sections placed circumferentially there around. Element 4: wherein the at least eighteen localized hardened sections are placed circumferentially equidistance there around. Element 5: wherein the at least one of the one or more continuous anchoring ridges has a plurality of ductile sections placed between the plurality of localized hardened sections. Element 6: wherein the at least eighteen localized hardened sections each extend circumferentially around the radially expandable tubular an angle (β) of 10 degrees or less. Element 7: wherein the plurality of ductile sections each extend circumferentially around the radially expandable tubular an angle (Ω) of 5 degrees or less. Element 8: wherein a ratio of the angle (β) to the angle (Ω) ranges from 4:1 to 1:1. Element 9: wherein the plurality of localized hardened sections have a hardened section minimum yield strength at least 10% greater than a ductile section minimum yield strength of the plurality of ductile sections. Element 10: wherein the plurality of localized hardened sections have a hardened section minimum yield strength at least 50% greater than a ductile section minimum yield strength of the plurality of ductile sections. Element 11: wherein the plurality of localized hardened sections have a hardened section minimum yield strength at least 100% greater than a ductile section minimum yield strength of the plurality of ductile sections. Element 12: wherein the plurality of ductile sections are radially outside of the plurality of hardened sections when the radially expandable tubular is in the initial state. Element 13: wherein the plurality of localized hardened sections are a plurality of localized hardened layers placed circumferentially there around. Element 14: wherein the plurality of hardened layers have a thickness of 0.25 μm or less. Element 15: wherein the plurality of hardened layers have a thickness ranging from 0.025 μm to 0.076 μm. Element 16: wherein each of the plurality of discrete slip teeth has a minimum yield strength of at least 175 ksi. Element 17: wherein each of the plurality of discrete slip teeth has a minimum yield strength of at least 200 ksi. Element 18: wherein each of the plurality of discrete slip teeth has a minimum yield strength of at least 250 ksi. Element 19: wherein the plurality of discrete slip teeth are at least four discrete slip teeth placed circumferentially around the radially expandable tubular. Element 20: wherein the at least four discrete slip teeth are placed circumferentially equidistance around the radially expandable tubular. Element 21: wherein the plurality of discrete slip teeth are at least eighteen discrete slip teeth placed circumferentially around the radially expandable tubular. Element 22: wherein the at least eighteen discrete slip teeth are placed circumferentially equidistance around the radially expandable tubular. Element 23: wherein the at least eighteen discrete slip teeth each extend circumferentially around the radially expandable tubular an angle (Γ) of 10 degrees or less. Element 24: wherein the plurality of discrete slip teeth are each individually press fit within the shallow groove. Element 25: wherein the plurality of discrete slip teeth are configured as a C-ring that is press fit within the shallow groove. Element 26: wherein the plurality of discrete slip teeth are coupled to each other using an elastic material that holds the plurality of discrete slip teeth within the shallow groove. Element 27: wherein the plurality of discrete slip teeth are coupled to an open end ring by way of inward pointing slender beams, the inward pointing slender beams holding the plurality of discrete slip teeth within the shallow groove. Element 28: wherein the shallow groove is a first shallow groove and the plurality of discrete slip teeth are a first set of plurality of discrete slip teeth, and further including a second shallow groove located in the exterior surface and a second set of plurality of discrete slip teeth placed within the second shallow groove circumferentially around the radially expandable tubular. Element 29: further including one or more continuous anchoring ridges extending radially outward from the radially expandable tubular. Element 30: wherein the one or more continuous anchoring ridges are positioned between the first set of plurality of discrete slip teeth and the second set of plurality of discrete slip teeth.

Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.