Patent Grant
12134956
The present disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, more particularly, to an improved liner hanger system.
During wellbore operations, it is typical to “hang” a liner onto another section of casing above such that the liner is supported by the casing from which the liner is hung. Expandable liner hangers may generally be used to secure the liner within a previously set wellbore tubular (e.g., casing or liner string). Expandable liner hangers may be “set” by expanding the liner hanger radially outward into gripping and sealing contact with the wellbore tubular. For example, expandable liner hangers may be expanded by use of hydraulic pressure to drive an expanding cone, wedge, or “pig,” through the liner hanger. Other methods may be used, such as mechanical swaging, explosive expansion, memory metal expansion, swellable material expansion, electromagnetic force-driven expansion, etc.
The expansion process may typically be performed by means of a setting tool used to convey the liner hanger into the wellbore. The setting tool may be interconnected between a work string (e.g., a tubular string made up of drill pipe or other segmented or continuous tubular elements) and the liner hanger. The setting tool may expand the liner hanger into anchoring and sealing engagement with the casing. In certain instances, when the liner hanger is expanded, a proper seal may not form between the liner hanger and the casing when high pressure and/or large temperature swings are present in the well.
Embodiments of the Liner Hanger System are described with reference to the following figures. The same or sequentially similar numbers are used throughout the figures to reference like features and components. The features depicted in the figures are not necessarily shown to scale. Certain features of the embodiments may be shown exaggerated in scale or in somewhat schematic form, and some details of elements may not be shown in the interest of clarity and conciseness.
The present disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, more particularly, to an improved expandable liner hanger system over existing designs.
Illustrative embodiments of the present disclosure are described in detail below. In the interest of clarity, not all features of an actual implementation are described in this specification. It will of course be appreciated that in the development of any such actual embodiment, numerous implementation-specific decisions must be made to achieve the developers' specific goals, such as compliance with system-related and business-related constraints, which will vary from one implementation to another. Moreover, it will be appreciated that such a development effort might be complex and time-consuming, but would nevertheless be a routine undertaking for those of ordinary skill in the art having the benefit of the present disclosure.
To facilitate a better understanding of the present disclosure, the following examples of certain embodiments are given. In no way should the following examples be read to limit, or define, the scope of the disclosure. Embodiments of the present disclosure may be applicable to horizontal, vertical, deviated, or otherwise nonlinear wellbores in any type of subterranean formation. Embodiments may be applicable to injection wells as well as production wells, including hydrocarbon wells. Devices and methods in accordance with certain embodiments may be used in one or more of wireline, measurement-while-drilling (MWD) and logging-while-drilling (LWD) operations. Certain embodiments according to the present disclosure may provide for a single trip liner setting and drilling assembly.
The terms “couple” or “couples” as used herein are intended to mean either an indirect or a direct connection. Thus, if a first device couples to a second device, that connection may be through a direct connection, or through an indirect electrical or mechanical connection via other devices and connections. The term “wellbore” as used herein refers to any hole drilled into a formation for the purpose of exploration or extraction of natural resources such as, for example, hydrocarbons. The term “uphole” as used herein means along the drillstring or the hole from the distal end towards the surface, and “downhole” as used herein means along the drillstring or the hole from the surface towards the distal end.
It will be understood that the term “oil well drilling equipment” or “oil well drilling system” is not intended to limit the use of the equipment and processes described with those terms to drilling an oil well. The terms also encompass drilling natural gas wells or hydrocarbon wells in general. Further, such wells can be used for production, monitoring, or injection in relation to the recovery of hydrocarbons or other materials from the subsurface. This could also include geothermal wells intended to provide a source of heat energy instead of hydrocarbons. Embodiments may be applicable to injection wells as well as production wells, including hydrocarbon wells.
Below casing 14, a lower portion 20 of the wellbore 10 may be drilled through casing 14. The lower portion 20 may have a smaller diameter than the upper portion 16. A length of liner 22 is shown positioned within the lower portion 20. The liner 22 may be used to line or case the lower portion 20 and/or to drill the lower portion 20. If desired, cement may be placed between the liner 22 and lower portion 20 of wellbore 10. The liner 22 may be installed in the wellbore 10 by means of a work string 24. The work string 24 may include a releasable collet, not shown, by which the work string 24 can support and rotate the liner 22 as the liner 22 is placed in the wellbore 10.
Attached to the upper end of, or formed as an integral part of, liner 22 is the liner hanger 26. A polished bore receptacle, or tie back receptacle, 30 may be coupled to the upper end of the liner hanger 26. In one embodiment, the polished bore receptacle 30 may be coupled to the liner hanger 26 by a threaded joint 32, but in other embodiments a different coupling mechanism may be employed. The inner bore of the polished bore receptacle 30 may be smooth and machined to close tolerance to permit work strings, production tubing, etc. to be connected to the liner 22 in a fluid-tight and pressure-tight manner. For instance, a work string may be connected by means of the polished bore receptacle 30 and used to pump fracturing fluid at high pressure down to the lower portion 20 of the wellbore 10 without exposing the casing 14 to the fracturing pressure. It may be desirable for the outer diameter of liner 22 to be as large as possible while being able to lower the liner 22 through the casing 14. It also may be desirable to have the outer diameter of the polished bore receptacle 30 and the liner hanger 26 to be about the same as the diameter of liner 22.
In various embodiments, first and second expansion cones 36 and 38 may be carried on the work string 24 just above the reduced diameter body 34 of the liner hanger 26. Fluid pressure applied between the work string 24 and the liner hanger 26 may be used to drive the cones 36, 38 downward through the liner hanger 26 to expand the hanger body 34 to an outer diameter at which a portion, or portions, of the liner hanger 26 is forced into sealing and supporting contact with the casing 14, as further described herein. The first expansion cone 36 may be a solid, or fixed diameter, cone having an outer diameter smaller than the inner diameter 33 of the threaded joint 32. In the run in condition, second expansion cone 38 may have an outer diameter greater than first cone 36 and also greater than the inner diameter 33 of the threaded joint 32. In an embodiment, the second expansion cone 38 may be collapsible, that is, may be reduced in diameter smaller than the inner diameter 33 of the threaded joint 32 when the second expansion cone 38 needs to be withdrawn from the liner hanger 26. In some contexts, the second expansion cone 38 may be referred to as a collapsible expansion cone. After the liner hanger 26 is expanded, expansion cones 36, 38 may be withdrawn from the liner hanger 26, through the polished bore receptacle 30 and out of the wellbore 10 with the work string 24. In the illustrated embodiment, expansion cones 36, 38 are utilized to expand the liner hanger 26 from an initial state to an expanded state. Further, expandable liner hangers, such as liner hanger 26 may be expanded by use of hydraulic pressure to drive an expanding cone, wedge, or “pig,” through the liner hanger. Other embodiments are envisioned which utilize any number of techniques, or combinations thereof, to expand the liner hanger 26 such as mechanical swaging, explosive expansion, memory metal expansion, swellable material expansion, electromagnetic force-driven expansion, etc.
Referring primarily to
Referring primarily to
The system illustrated in
In at least one embodiment, the seal 500 comprises an elastomer such as Hydrogenated Nitrile Butadiene Rubber, i.e., HNBR or VITON®, and/or combinations thereof. Other embodiments are envisioned where the seal comprises rubber, plastic, TEFLON®, i.e., PTFE (Polytetrafluoroethylene), etc., and combinations thereof. In at least one embodiment, the seal 500 comprises a composite or metamaterial. In such instance, the metamaterial may have a negative thermal expansion coefficient or the thermal expansion coefficient can be zero. In at least one embodiment, the seal 500 comprises a metamaterial having a thermal expansion coefficient that is the same or substantially the same as the thermal expansion coefficient of the spike 402. In at least one embodiment, the seal 500 may be constructed from molding for rubber or injection molding for plastics, and combinations thereof (Inventors to provide materials from U.S. Patent Application Publication No. 2021/0020263). In at least one embodiment, the seal 500 comprises a metamaterial having a lattice structure. For example, the seal 500 may be constructed from metals and rubber or thermoplastics and rubber. In such instances, a metal and/or plastic lattice structure is produced from additive manufacturing, and the rubber is used to encapsulate the lattice structure to form the seal. In at least one embodiment, the lattice structure is constructed of 4140 Steel, type 316 steel, PTFE, PEEK (Polyetheretherketone), etc, and combinations thereof. In at least one embodiment, the lattice structure is constructed of an aluminum alloy, or a titanium aluminum alloy, or a titanium-aluminum-vanadium alloy, etc., and combinations thereof. In at least one embodiment, the lattice is constructed of the same type of material but different portions of the structure have different coefficients of thermal expansion due to the shape of the lattice structure. In at least one embodiment, the seal 500 comprises a single naturally occurring material, i.e., a non-metamaterial. Further, the seal 500 may be constructed of rubber, thermoplastics, and combinations thereof. In at least one embodiment, the seal 500 comprises rubber having fillers with different material properties.
In at least one embodiment, the seal 500 comprises a squeeze (i.e., the percentage of deformation to the seal from its initial shape to its deformed shape) of 20% to 50%. However, other embodiments are envisioned where the squeeze of the seal 500 is any suitable percentage. In at least one embodiment, the seal 500 comprises a metamaterial having a squeeze of 5% to 10% for example. In at least one embodiment, the seal 500 comprises substantially the same cross-sectional area as the cross-sectional area of the annular groove 404. In at least one embodiment, the cross-sectional area of the annular seal 500 is slightly smaller than the cross-sectional area of the annular groove 404 by 1% to 5%, for example. Other embodiments are envisioned where the cross-sectional area of the annular seal 500 is slightly larger than the cross-sectional area of the annular groove 404, for example.
In the illustrated embodiment, two annular spikes 402 and two annular seals 500 are shown spaced apart axially within the casing 14. It should be readily understood that any number of spikes 402 and seals 500 may be incorporated into the system and the illustrated embodiments should not be considered limiting.
Further to the above, the liner hanger 26 is configured to transition between an initial run in state, where one or more spikes 402 are not in contact with the casing 14 and an expanded state where the outer diameter of the liner hanger 26 has been expanded such that one or more spikes 402 are in gripping and sealing contact with the casing 14.
Further to the above, the annular seal 500 and the spike 402 are configured to seal an uphole well portion from a downhole well portion when the liner hanger 26 is in its expanded state. In various embodiments, the spike 402 may deform a portion of the well casing 14 when the liner hanger 26 is in the expanded state to connect the liner hanger 26 to the casing 14. In various embodiments, the seal 500 is compressed by the inner wall 15 of the casing 14 and fills a portion of the annular groove 404 of the spike 402 to aid in sealing the uphole well portion from the downhole well portion. After the liner hanger 26 is expanded, the system may be pressurized such that there is a pressure differential between the uphole side and downhole side of a given spike 402, for example. In such instances, the pressure differential may further deform and/or compress the seal 500 within the annular groove 404, for example. In at least one embodiment, when the liner hanger 26 is expanded and the system is under pressure, the seal 500 is compressed and fills an undercut region 408 of the annular groove 404 as illustrated in
Further to the above, the liner hanger 26′ comprises another annular seal 29 positioned intermediate the upper spike 402 and the lower spike 402. In the illustrated embodiment, the annular seal 29 fills the region between the spikes 402 and is flush with the outer surface 406 of each spike 402. However, other embodiments are envisioned where the seal 29 has an outer diameter that is smaller than the outer diameter of the spikes 402, for example. Further still, other embodiments are envisioned where the seal 29 has an outer diameter that is larger than the outer diameter of the spikes 402, i.e., the seal 29 extends beyond the outer surface 406 of the spikes 402. Further, other embodiments are envisioned where the seal 29 does not extend entirely between the upper spike 402 and the lower spike 402. In the illustrated embodiment, the seal 29 comprises a trapezoid cross-section. However other embodiments are envisioned where the seal 29 comprises a different cross-section shape such as a square, a rectangle, a hexagon, a polygon, and/or any other geometric shape, for example. In at least one embodiment, the cross-sectional shape of the seal 29 includes arcuate portions and/or flat portions. In any event, when the liner hanger 26′ is expanded, the seal 29 is forced into sealing and supporting contact with the casing 14.
Typically, seals 28, 29 are made of elastomeric elements (e.g., rubber) however other embodiments are envisioned where the seals 28, 29 are comprised of other materials such as metamaterials, materials having a negative or zero coefficient of thermal expansion, etc. In various embodiments the seals 28, 29 may comprises the same material as the annular seal 500, for example. Other embodiments are envisioned where the seals 28, 29 comprise a different material than the seal 500, for example.
Further to the above, the annular spike 202 comprises a flat outer surface which, similar to the spike 402, is configured to provide gripping and sealing contact with the casing 14 when the liner hanger 26″ is expanded. In the illustrated embodiment, the spike 202 comprises a trapezoid cross-section. However, other embodiments are envisioned where the spike 202 comprises a different cross-section such as a square, a triangular, a rectangle, a hexagon, a polygon, and/or any other geometric shape, for example. In at least one embodiment, the cross-sectional shape of the spike 202 includes arcuate portions and/or flat portions.
Further to the above, the spike 202 may be metal. The spike 202 may be made of any suitable steel grade, alloy steel, aluminum, any other ductile material, and a combination thereof. In certain implementations, the spike 202 may be made from a combination of one or more of the recited materials. In certain embodiments, the spike 202 is integral to the liner hanger 26″, however other embodiments are envisioned where the spike 202 is attached to the outer perimeter of the liner hanger 26″ via welding or any other suitable method. In certain embodiments, the spike 202 may be made from AISI4140 steel or AISI4340 steel. In certain implementations, the spike 202 may be an annular or circular ring that extends along an outer perimeter of the liner hanger 26″ at a desired axial location. However, the present disclosure is not limited to this particular configuration of spike 202. For instance, in certain embodiments, one or more spikes 202 may be positioned axially around an outer perimeter of the liner hanger 26″. Moreover, in certain implementations, different spikes 202 may have different surface geometries without departing from the scope of the present disclosure.
Further to the above, it should be understood that any number of the spikes 402 including seals 500, the spikes 202, and the seals 28, 29 may be incorporated into the system and the illustrated embodiments should not be considered limiting. In at least one embodiment, one of the spikes 402 including the seal 500 is positioned above one or more spikes 202, similar to
Although the figures depict embodiments of the present disclosure in a particular orientation, it should be understood by those skilled in the art that embodiments of the present disclosure are well suited for use in a variety of orientations. Further, it should be understood by those skilled in the art that the use of directional terms such as above, below, upper, lower, upward, downward and the like are used in relation to the illustrative embodiments as they are depicted in the figures, the upward direction being toward the top of the corresponding figure and the downward direction being toward the bottom of the corresponding figure.
Therefore, the present disclosure is well adapted to attain the ends and advantages mentioned as well as those that are inherent therein. The particular embodiments disclosed above are illustrative only, as the present disclosure may be modified and practiced in different but equivalent manners apparent to those skilled in the art having the benefit of the teachings herein. Furthermore, no limitations are intended to the details of construction or design herein shown, other than as described in the claims below. It is therefore evident that the particular illustrative embodiments disclosed above may be altered or modified and all such variations are considered within the scope and spirit of the present disclosure. Also, the terms in the claims have their plain, ordinary meaning unless otherwise explicitly and clearly defined by the patentee. The indefinite articles “a” or “an,” as used in the claims, are defined herein to mean one or more than one of the element that the particular article introduces; and subsequent use of the definite article “the” is not intended to negate that meaning.
Examples of the above embodiments include:
In Example 2, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a polygonal cross-section
In Example 3, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a substantially circular cross-section.
In Example 4, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a metamaterial.
In Example 5, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a encapsulated lattice structure.
In Example 6, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a material having a negative or zero coefficient of thermal expansion.
In Example 7, the embodiments of any preceding paragraph or combination thereof further include the annular seal is at least partially compressed by an inner wall of the well casing when the liner hanger is in the expanded state.
In Example 8, the embodiments of any preceding paragraph or combination thereof further include the annular seal extends beyond an outer surface of the spike when the liner hanger is in the initial state.
In Example 9, the embodiments of any preceding paragraph or combination thereof further include the annular groove comprises a dovetail shape.
In Example 10, the embodiments of any preceding paragraph or combination thereof further include the liner hanger comprises another annular seal extending in an annular ring around the outer perimeter of the liner hanger adjacent to the spike.
In Example 11, the embodiments of any preceding paragraph or combination thereof further include the spike comprises a first spike. The liner hanger further comprises a second spike adjacent the first spike. The second spike comprises a continuously flat outer surface configured to contact the well casing when the liner hanger is in the expanded state.
In Example 12, the embodiments of any preceding paragraph or combination thereof further include the annular seal is compressed and fills a portion of the annular groove when a pressure differential is present across the uphole well portion and the downhole well portion.
Example 13 is an expandable liner hanger for use with a well casing in a subterranean well. The expandable liner hanger comprises a spike extending in an annular ring along an outer perimeter of the expandable liner hanger. The spike comprises an annular groove defined therein. The liner hanger further comprises an annular seal positioned within at least a portion of the annular groove of the spike. The spike is configured to grippingly engage an inner wall of the well casing when the expandable liner hanger is in an expanded state. The annular seal is configured to be compressed to fill a portion of the annular groove when a pressure differential is present across an uphole well side and a downhole well side of the spike.
In Example 14, the embodiments of any preceding paragraph or combination thereof further include the annular seal is positioned intermediate the annular grove and the well casing.
In Example 15, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a polygon cross-section.
In Example 16, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a substantially circular cross-section.
In Example 17, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a metamaterial.
In Example 18, the embodiments of any preceding paragraph or combination thereof further include the annular seal comprises a material having a negative or zero coefficient of thermal expansion.
In Example 19, the embodiments of any preceding paragraph or combination thereof further include the annular seal is at least partially compressed by an inner wall of the well casing when the expandable liner hanger is in the expanded state.
In Example 20, the embodiments of any preceding paragraph or combination thereof further include the annular seal extends beyond an outer surface of the spike when the expandable liner hanger is in an initial state prior to being expanded.
In Example 21, the embodiments of any preceding paragraph or combination thereof further include the annular groove comprises a dovetail shape.
In Example 22, the embodiments of any preceding paragraph or combination thereof further include another annular seal extending in an annular ring along the outer perimeter of the expandable liner hanger adjacent to the spike.
Example 23 is a method of performing operations in a subterranean well. The method comprises positioning a liner hanger system within a well casing. The liner hanger system comprises a liner hanger and a spike extending in an annular ring along an outer perimeter of the liner hanger. The spike comprises an annular groove defined therein. The liner hanger system further comprises an annular seal positioned in at least a portion of the annular groove. The method further comprises expanding the liner hanger system from an initial state where the spike is not in contact with the well casing to an expanded state where the spike is in contact with the well casing. The spike and the annular seal are configured to seal an uphole well portion from a downhole well portion when the liner hanger system is in the expanded state.
In Example 24, the embodiments of any preceding paragraph or combination thereof further include the annular groove comprises a dovetail shape and the annular seal comprises a polygon cross-section.
Certain terms are used throughout the description and claims to refer to particular features or components. As one skilled in the art will appreciate, different persons may refer to the same feature or component by different names. This document does not intend to distinguish between components or features that differ in name but not function.
While descriptions herein may relate to “comprising” various components or steps, the descriptions can also “consist essentially of” or “consist of” the various components and steps.
Unless otherwise indicated, all numbers expressing quantities are to be understood as being modified in all instances by the term “about” or “approximately”. Accordingly, unless indicated to the contrary, the numerical parameters are approximations that may vary depending upon the desired properties of the present disclosure. As used herein, “about”, “approximately”, “substantially”, and “significantly” will be understood by persons of ordinary skill in the art and will vary to some extent on the context in which they are used. If there are uses of the term which are not clear to persons of ordinary skill in the art given the context in which it is used, “about” and “approximately” will mean plus or minus 10% of the particular term and “substantially” and “significantly” will mean plus or minus 5% of the particular term.
The embodiments disclosed should not be interpreted, or otherwise used, as limiting the scope of the disclosure, including the claims. It is to be fully recognized that the different teachings of the embodiments discussed may be employed separately or in any suitable combination to produce desired results. In addition, one skilled in the art will understand that the description has broad application, and the discussion of any embodiment is meant only to be exemplary of that embodiment, and not intended to suggest that the scope of the disclosure, including the claims, is limited to that embodiment.
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