The present disclosure relates generally to expandable liner hanger systems, and, more specifically, to a setting tool including a collapsible cone for an expandable liner hanger system.
Expandable liner hanger systems operate, for example, by utilizing a setting tool to promote the expansion of a liner hanger, thus connecting the liner hanger to a casing string disposed within a wellbore. In order to effectuate the expansion of the liner hanger, an expansion cone is displaced axially through the liner hanger, thus engaging the interior of the liner hanger to radially expand the exterior thereof. The forces required to expand a liner hanger in this manner, which can be considerable, are a function of the geometry, material properties, and friction reducing coatings applied to the expansion cone and/or the liner hanger.
Certain differences in hardness and/or other basic metallurgical properties between the liner hanger and the expansion cone can help to mitigate galling between the respective contacting surfaces thereof, even if the friction reducing coating(s) becomes compromised. Accordingly, conventional liner hangers are manufactured with highly ductile low alloy steel, the expansion of which can be effectuated using an expansion cone manufactured with, for example, D2 tool steel. However, some liner hangers incorporate nickel and chromium-based alloys to provide corrosion resistance within the wellbore. Conventional expansion cones do not have the proper material properties to effectively expand such nickel and chromium-based liner hangers. Further, the use of more effective materials is often prohibitively expensive because of the geometry of conventional expansion cones.
Moreover, conventional expansion cones are often difficult or impossible to remove from the liner hanger once the liner hanger has been expanded. Although collapsible expansion cones exist to address this issue, such collapsible expansion cones often incorporate a collet feature that permits the expansion cone to bend radially inward from the interior of the liner hanger. However, the machined slits of the collet feature create high contact stresses along the respective edges of the slits, which stresses can cause damage to, among other things, the friction reducing coating(s) applied to the liner hanger and/or the expansion cone.
Furthermore, some expansion cones require a sealing interface between the expansion cone and the interior of the liner hanger so that the expansion cone may be actuated by a fluid pressure. The machined slits associated with conventional collapsible expansion cones necessitate the use of a “lead cone” that has no slits, surface features, or other geometry that could create a leak path. Such a “lead cone” necessarily has a smaller diameter than the collapsible expansion cone, thereby reducing the effective axial force imparted to the setting tool by the fluid pressure.
Therefore, what is needed is an apparatus, method, or system that addresses one or more of the foregoing issues, among others.
Various embodiments of the present disclosure will be understood more fully from the detailed description given below and from the accompanying drawings of various embodiments of the disclosure. In the drawings, like reference numerals may indicate identical or functionally similar elements.
This disclosure may repeat reference numerals and/or letters in the various examples or Figures. This repetition is for the purpose of simplicity and clarity and does not in itself dictate a relationship between the various embodiments and/or configurations discussed. Further, spatially relative terms, such as beneath, below, lower, above, upper, uphole, downhole, upstream, downstream, and the like, may be used herein for ease of description to describe one element or feature's relationship to another element(s) or feature(s) as illustrated, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure, the uphole direction being toward the surface of the wellbore, the downhole direction being toward the toe of the wellbore. Unless otherwise stated, the spatially relative terms are intended to encompass different orientations of the apparatus in use or operation in addition to the orientation depicted in the Figures. For example, if an apparatus in the Figures is turned over, elements described as being “below” or “beneath” other elements or features would then be oriented “above” the other elements or features. Thus, the exemplary term “below” can encompass both an orientation of above and below. The apparatus may be otherwise oriented (rotated 90 degrees or at other orientations) and the spatially relative descriptors used herein may likewise be interpreted accordingly.
Moreover, even though a Figure may depict a horizontal wellbore or a vertical wellbore, unless indicated otherwise, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in wellbores having other orientations including vertical wellbores, horizontal wellbores, slanted wellbores, multilateral wellbores or the like. Likewise, unless otherwise noted, even though a Figure may depict an offshore operation, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in onshore operations. Further, unless otherwise noted, even though a Figure may depict a cased-hole wellbore, it should be understood by those skilled in the art that the apparatus according to the present disclosure is equally well suited for use in open-hole wellbore operations.
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The collapsible expansion cone 58 extends circumferentially about the cone mandrel 56 and is adapted to be engaged by the cone mandrel 56 when the cone mandrel 56 is displaced in an axial direction 64. As a result, the cone mandrel 56 is adapted to urge the collapsible expansion cone 58 in the axial direction 64 so that the collapsible expansion cone 58 engages the reduced diameter portion 52 of the hanger body 48. The collapsible expansion cone 58 is thus adapted to be displaced relative to the hanger body 48 to engage, and radially expand, the reduced diameter portion 52 of the hanger body 48, as will be discussed in further detail below.
The cone retainer 60 extends circumferentially about, and is connected to, the cone mandrel 56. Once the reduced diameter portion 52 of the hanger body 48 has been radially expanded by the collapsible expansion cone 58, the cone mandrel 56 is adapted to be displaced in an axial direction 66, which is opposite the axial direction 64, and relative to the collapsible expansion cone 58. As a result, the cone mandrel 56 is adapted to slide axially in relation to the collapsible expansion cone 58. Moreover, the cone retainer 60 is adapted to engage the collapsible expansion cone 58, thereby urging the collapsible expansion cone 58 in the axial direction 66 and relative to the hanger body 48.
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As the collapsible expansion cone 58 slidably engages the hanger body 48, the tapered external annular surface 82 and the cone crest 84 impart radial force to the interior of the reduced diameter portion 52, causing the exterior of hanger body 48 to expand radially. In several exemplary embodiments, the uniform cross-section of the collapsible expansion cone 58 is fully supported radially by the cone mandrel 56 during the expansion of the hanger body 48. Moreover, the relatively larger wall thickness of the cone mandrel 56 at the end portion 68b of the tapered annular surface 68 supports the cone crest 84 during the radial expansion of the hanger body 48. The radial expansion of the hanger body 48 causes the exterior of the reduced diameter portion 52 to be urged into engagement with the interior of the casing string 40. Consequently, the contact elements 54 are expanded into engagement with the interior of the casing string 40. The contact elements 54 form a frictional interface with the interior of the casing string 40 when the reduced diameter portion 52 is expanded, thus connecting the hanger body 48 to the casing string 40. In several exemplary embodiments, the contact elements 54 are, include, or are part of a cylindrical seal made of a rubber material and adapted to form a frictional interface with the interior of the casing string 40 when the reduced diameter portion 52 is expanded. In several exemplary embodiments, the contact elements 54 are, include, or are part of a plurality of casing slips adapted to engage, or “bite” into, the interior of the casing string 40 when the reduced diameter portion 52 is expanded. In several exemplary embodiments, the contact elements 54 are integrally formed with the hanger body 48 and are designed to sealingly engage the interior of the casing string 40 when the hanger body 48 is expanded.
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In several exemplary embodiments, by eliminating the need for irregular surface features associated with expansion cones that incorporate, for example, collet features, the collapsible expansion cone 58 prevents, or at least reduces, damage to any friction reducing coatings applied to the hanger body 48 and/or the collapsible expansion cone 58. In several exemplary embodiments, the collapsible expansion cone 58 provides additional structural resistance to hoop or radial stress patterns imparted thereto during the expansion of the hanger body 48 as compared to conventional expansion cones incorporating, for example, a collet feature. In several exemplary embodiments, the collapsible expansion cone 58 provides a sealing interface with the interior of the hanger body 48 that is coincident with the cone crest 84, thus increasing the axial force imparted to the setting tool 50 by the hydraulic fluid pressure within the annular space 94 as compared to an expansion cone having, for example, a collet feature that requires a “lead cone” for effective expansion.
In several exemplary embodiments, the collapsible expansion cone 58 has an uninterrupted and/or uniform circumferential wall thickness that operates to reduce the stress transferred to the cone mandrel 56 during expansion of the hanger body 48. In several exemplary embodiments, the collapsible expansion cone 58 has a uniform cross-section that optimizes the material properties of the collapsible expansion cone 58 after the case hardening and/or the heat treatment thereof.
In several exemplary embodiments, the collapsible expansion cone 58 defines a continuous, slit-less, circumferentially-extending body. In several exemplary embodiments, every cross-section of the collapsible expansion cone 58 that is taken along a plane in which the longitudinal axis of the collapsible expansion cone 58 extends is substantially identical.
In several exemplary embodiments, the collapsible expansion cone 58 provides a simple, cost-effective, and easy-to-manufacture expansion cone that prevents, or at least reduces, damage to the expanded hanger body 48 during extrication of the setting tool 50. In several exemplary embodiments, the collapsible expansion cone 58 is a disposable, one-time use expansion cone that mitigates the risk associated with the expansion of nickel alloy and/or high-chromium alloy hanger bodies.
The present disclosure introduces an expandable liner hanger system, including a setting tool, including a cone mandrel defining a tapered external annular surface and adapted to be displaced in first and second axial directions; an expansion cone extending about the cone mandrel and defining a tapered internal annular surface adapted to be engaged by the tapered external annular surface when the cone mandrel is displaced in the first axial direction; and a cone retainer extending from the cone mandrel and adapted to engage the expansion cone when the cone mandrel is displaced in the second axial direction and relative to the expansion cone; and a hanger body adapted to be radially expanded by the expansion cone when the cone mandrel and the expansion cone are displaced in the first axial direction and relative to the hanger body; wherein, when the cone retainer engages the expansion cone, the tapered internal annular surface is disengaged from the tapered external annular surface, thus enabling the expansion cone to bell radially inward. In an exemplary embodiment, when the hanger body is radially expanded by the setting tool, the hanger body is adapted to fixedly engage a casing string disposed within a wellbore. In an exemplary embodiment, the expandable liner hanger further includes a liner string connected to the hanger body and adapted to extend into the wellbore beyond the casing string when the hanger body fixedly engages the casing string. In an exemplary embodiment, the expansion cone includes a contact ring adapted to be engaged by the cone retainer when the cone mandrel is displaced in the second axial direction and relative to the expansion cone; and a frusto-conical member connected to the contact ring and defining a cone crest that is adapted to slidably engage, and radially expand, the hanger body when the expansion cone is displaced in the first axial direction and relative to the hanger body. In an exemplary embodiment, the tapered external annular surface of the cone mandrel defines first and second end portions; the cone mandrel defines a first wall thickness at the first end portion and a second wall thickness at the second end portion; and the first wall thickness of the cone mandrel is greater than the second wall thickness of the cone mandrel. In an exemplary embodiment, when the hanger body is radially expanded by the expansion cone, the first wall thickness of the cone mandrel is adapted to support a portion of the expansion cone, including at least the cone crest. In an exemplary embodiment, the cone mandrel further defines an external annular groove and an annular contact surface extending between the external annular groove and the tapered external annular surface; and the external annular groove accommodates the cone retainer, thus trapping the expansion cone axially between the cone retainer and the tapered external annular surface. In an exemplary embodiment, when the cone mandrel is displaced in the second axial direction and relative to the expansion cone, the annular contact surface slidably engages the contact ring and the tapered internal annular surface is disengaged from the tapered external annular surface. In an exemplary embodiment, the expansion cone is adapted to be displaced in the second axial direction and relative to the hanger body after the hanger body is radially expanded and the tapered internal annular surface is disengaged from the tapered external annular surface; and, when the expansion cone is displaced in the second axial direction and relative to the hanger body, the frusto-conical member is adapted to bell radially inward at the cone crest to permit extrication of the expansion cone from the hanger body. In an exemplary embodiment, when the hanger body is radially expanded by the expansion cone, the cone crest is adapted to be sealingly engaged with the hanger body; and the sealing engagement of the cone crest with the hanger body causes the displacement of the expansion cone in the first axial direction, and relative to the hanger body, to be effectuated by a fluid pressure within the hanger body.
The present disclosure also introduces a method of installing an expandable liner hanger system within a casing string, the method including positioning the expandable liner hanger system within the casing string, the expandable liner hanger system including a hanger body and a setting tool disposed within the hanger body, the setting tool including a cone mandrel defining a tapered external annular surface and an expansion cone defining a tapered internal annular surface; engaging the tapered external annular surface of the cone mandrel with the tapered internal annular surface of the expansion cone; radially expanding the hanger body to engage the casing string by displacing the cone mandrel and the expansion cone in a first axial direction and relative to the hanger body; displacing the cone mandrel in a second axial direction and relative to the expansion cone to disengage the tapered internal annular surface from the tapered external annular surface, thus permitting the expansion cone to bell radially inward from the hanger body; and extricating the expansion cone from the expanded hanger body. In an exemplary embodiment, the expandable liner hanger system further includes a liner string connected to the hanger body; and, when the hanger body is expanded by the expansion cone to engage the casing string, the liner string extends into the wellbore beyond the casing string. In an exemplary embodiment, the setting tool further includes a cone retainer extending from the cone mandrel; and extricating the expansion cone from the expanded hanger body includes engaging the expansion cone with the cone retainer and displacing the expansion cone in the second axial direction and relative to the hanger body. In an exemplary embodiment, the cone mandrel further defines an external annular groove and an annular contact surface extending between the external annular groove and the tapered external annular surface; and the external annular groove accommodates the cone retainer, thus trapping the expansion cone axially between the cone retainer and the tapered external annular surface. In an exemplary embodiment, when the cone mandrel is displaced in the second axial direction and relative to the expansion cone to disengage the tapered internal annular surface from the tapered external annular surface, the annular contact surface of the cone mandrel slidably engages the contact ring. In an exemplary embodiment, the expansion cone includes a contact ring and a frusto-conical member connected to the contact ring, the frusto-conical member defining a cone crest; and radially expanding the hanger body to engage the casing string includes slidably engaging the frusto-conical member, including at least the cone crest, with a reduced diameter portion of the hanger body, thus imparting radially outward force to the hanger body. In an exemplary embodiment, radially expanding the hanger body to engage the casing string further includes sealingly engaging the cone crest with the hanger body and effecting the displacement of the expansion cone in the first axial direction using a fluid pressure within the hanger body. In an exemplary embodiment, the tapered external annular surface of the cone mandrel defines first and second end portions; the cone mandrel defines a first wall thickness at the first end portion and a second wall thickness at the second end portion; and the first wall thickness of the cone mandrel is greater than the second wall thickness of the cone mandrel. In an exemplary embodiment, when the hanger body is radially expanded by the expansion cone, the first wall thickness of the cone mandrel is adapted to support a portion of the frusto-conical member, including at least the cone crest. In an exemplary embodiment, extricating the expansion cone includes displacing the expansion cone in the second axial direction and relative to the hanger body after the hanger body is radially expanded and the tapered internal annular surface is disengaged from the tapered external annular surface; and, when the expansion cone is displaced in the second axial direction and relative to the hanger body, the frusto-conical member is adapted to bell radially inward at the cone crest to permit extrication of the expansion cone from the hanger body.
It is understood that variations may be made in the foregoing without departing from the scope of the present disclosure.
In several exemplary embodiments, the elements and teachings of the various illustrative exemplary embodiments may be combined in whole or in part in some or all of the illustrative exemplary embodiments. In addition, one or more of the elements and teachings of the various illustrative exemplary embodiments may be omitted, at least in part, and/or combined, at least in part, with one or more of the other elements and teachings of the various illustrative embodiments.
Any spatial references, such as, for example, “upper,” “lower,” “above,” “below,” “between,” “bottom,” “vertical,” “horizontal,” “angular,” “upwards,” “downwards,” “side-to-side,” “left-to-right,” “right-to-left,” “top-to-bottom,” “bottom-to-top,” “top,” “bottom,” “bottom-up,” “top-down,” etc., are for the purpose of illustration only and do not limit the specific orientation or location of the structure described above.
In several exemplary embodiments, while different steps, processes, and procedures are described as appearing as distinct acts, one or more of the steps, one or more of the processes, and/or one or more of the procedures may also be performed in different orders, simultaneously and/or sequentially. In several exemplary embodiments, the steps, processes, and/or procedures may be merged into one or more steps, processes and/or procedures.
In several exemplary embodiments, one or more of the operational steps in each embodiment may be omitted. Moreover, in some instances, some features of the present disclosure may be employed without a corresponding use of the other features. Moreover, one or more of the above-described embodiments and/or variations may be combined in whole or in part with any one or more of the other above-described embodiments and/or variations.
Although several exemplary embodiments have been described in detail above, the embodiments described are exemplary only and are not limiting, and those skilled in the art will readily appreciate that many other modifications, changes and/or substitutions are possible in the exemplary embodiments without materially departing from the novel teachings and advantages of the present disclosure. Accordingly, all such modifications, changes, and/or substitutions are intended to be included within the scope of this disclosure as defined in the following claims. In the claims, any means-plus-function clauses are intended to cover the structures described herein as performing the recited function and not only structural equivalents, but also equivalent structures. Moreover, it is the express intention of the applicant not to invoke 35 U.S.C. § 112, paragraph 6 for any limitations of any of the claims herein, except for those in which the claim expressly uses the word “means” together with an associated function.
Filing Document | Filing Date | Country | Kind |
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PCT/US2016/020042 | 2/29/2016 | WO | 00 |