Novel expandable liner hanger platform for advanced liner drilling and reaming

A novel bottom-up method for expanding liner hangers has been developed and field proven. Unlike conventional top-down expansion systems, this approach leverages a controlled combination of applied pressure, liner weight, and overpull to achieve reliable expansion from the bottom upward. By expanding in this direction, the system inherently eliminates common failure mechanisms such as liner buckling and hydro-locking, while simplifying deployment and improving operational robustness. The design incorporates both primary and secondary hydraulic expansion methods and intentionally removes all mechanical actuation components and moving parts, resulting in a simple, reliable system with minimal operational complexity.

The bottom-up expansion methodology supports a fully modular liner hanger architecture. The lengths of both the sealing and anchoring sections can be customized to meet or exceed API 19LH gas-tight sealing requirements while providing hanging capacities greater than the liner’s tensile capacity. The use of long, modular expansion sections also enables the post- expanded inner diameter (ID) to function as a polished bore receptacle (PBR). For the first time, the functions of a liner hanger, liner-top packer, and PBR are integrated into a single, continuous solid steel tubular, eliminating interfaces that traditionally limit pressure integrity and mechanical strength.

Using the post-expanded ID as a PBR removes unsupported burst and collapse regions between the axial positions of the seal stem and liner-top packing elements. This architecture maximizes both burst and collapse resistance and provides a continuous pressure-rated bore through the liner top. The absence of moving parts, combined with the use of wrapped and bonded elastomer sealing elements, allows the system to tolerate high circulation rates, elevated torque and rotation speeds, and substantial set-down weights. These characteristics make the system particularly well suited for drilling liner applications and challenging wellbore conditions.

Multiple field case studies validate the system’s performance across a wide range of demanding environments. In wells experiencing massive lost circulation, liners were successfully reamed through lost circulation material (LCM), cemented, and installed without compromising hanger performance or sealing integrity. Additional case studies include extended-reach horizontal wells in which liners up to four miles in length were installed in lateral sections without floating the liners into the wellbore. In these applications, high set-down weights combined with high applied torque were used to mechanically work the liners to bottom. Following installation, these wells were successfully hydraulically fractured with up to 100 stages, demonstrating the system’s ability to withstand severe axial, torsional, and pressure loads.

These field results confirm that the bottom-up expanded liner hanger system provides a robust, mechanically efficient, and operationally flexible solution for modern well construction, including severe loss environments, long lateral wells, and high-intensity completion operations.