DUAL TUBULAR EXPANDABLE LINER HANGER

Abstract

Some implementations include a liner hanger system to be positioned within a wellbore, the liner hanger system comprising a first tubular including one or more setting features positioned along at least a portion of its outer diameter and a second tubular configured to be positioned within an inner diameter of the first tubular. The liner hanger system further includes a first expansion tool coupled with a mandrel, the first expansion tool and mandrel configured to be positioned within an inner diameter of the second tubular, wherein the first expansion tool is configured to move in a first direction during a first stage expansion, wherein the first expansion tool is configured to outwardly expand the first tubular during the first stage expansion, wherein the first expansion tool is configured to move in a second, opposing direction during a second stage expansion, and wherein the first expansion tool is configured to outwardly expand the second tubular and the first tubular during the second stage expansion.

Description

TECHNICAL FIELD

The disclosure generally relates to wellbores formed in subsurface formations, and in particular, to liner hanger systems for use in a wellbore.

BACKGROUND

Deepwater offshore wells may utilize smaller diameter wellheads than shallower offshore or land-based wells. For this reason, deepwater operations may propose unique challenges for running and setting existing liner hanger systems through wellheads with restricted inner diameters (ID). In some deepwater applications, wellhead IDs may limit the size of liner hanger system to be used. This challenge may be especially prominent when installing a hanger in a lighter weight parent casing, where a larger cone and/or hanger outer diameter (OD) may be required to reach the walls of the casing during expansion. A lighter weight parent casing may refer to a casing of equal outer diameter but a lighter pound per length (feet) weight. For example, a twenty inch OD casing with a nominal weight of 94 lbs/ft may have a larger ID than a twenty inch OD casing with a nominal weight of 133 lbs/ft. The lighter casing may therefore have a larger drift ID because of its smaller wall thickness. Hence, a larger OD cone and hanger may be utilized to reach the casing ID wall of lighter weight casings. Using larger-OD cones and/or hangers may increase the risk that the tools may become stuck in the wellhead during running-in operations. Another challenge in setting liner hanger systems in slim-hole, deepwater, etc. wells is meeting high pressure conditions. High pressure, high temperature (HPHT) operations may be performed in HPHT wells configured to withstand at least 15,000 psi of pressure and temperatures of at least 350° F. For such pressures and temperatures, a hanger system with a more robust burst and collapse rating may be required.

BRIEF DESCRIPTION OF THE DRAWINGS

Implementations of the disclosure may be better understood by referencing the accompanying drawings.

FIG. 1 is an illustration depicting an example dual tubular liner hanger system configured for use in a wellbore, according to some implementations.

FIG. 2 is an illustration depicting a midpoint of a first stage expansion process, according to some implementations.

FIG. 3 is an illustration depicting the end of the first stage expansion process, according to some implementations.

FIG. 4 is an illustration depicting a portion of the second stage expansion process of the liner hanger system, according to some implementations.

FIG. 5 is an illustration depicting a raised portion of the secondary sleeve for use during the first stage expansion, according to some implementations.

FIGS. 6A-6B are illustrations depicting at least a portion of the first stage expansion of the liner hanger system of FIG. 5, according to some implementations.

FIGS. 7A-7B are illustrations depicting an end of the first stage expansion and the completed second stage expansion of FIG. 5's liner hanger system, according to some implementations.

FIG. 8 is an illustration depicting a liner hanger system including a secondary sleeve with one or more setting features, according to some implementations.

FIGS. 9A-9B are illustrations depicting at least a portion of the first stage expansion of the liner hanger system of FIG. 8, according to some implementations.

FIGS. 10A-10B are illustrations depicting an end of the first stage expansion and the completed second stage expansion of FIG. 8's liner hanger system, according to some implementations.

FIG. 11 is an illustration depicting a pressure balanced hanger system, according to some implementations.

FIGS. 12A-12B are illustrations depicting the first stage expansion of the pressure balanced hanger system of FIG. 11 with additional detail, according to some implementations.

FIG. 13 is an illustration depicting the second stage expansion of the pressure balanced hanger system of FIG. 11 with additional detail, according to some implementations.

FIG. 14 is an illustration depicting a liner hanger system including a failsafe, according to some implementations.

FIGS. 15A-15C are illustrations depicting a dual-cone configuration configured for unidirectional expansion of the liner hanger system, according to some implementations.

FIG. 16 is a first illustration depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations.

FIG. 17 is a second illustration depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations.

FIG. 18 is a third illustration depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations.

FIG. 19 is a flowchart depicting an example method of operations, according to some implementations.

FIGS. 1-19 and the operations described herein are examples meant to aid in understanding example implementations and should not be used to limit the potential implementations or limit the scope of the claims. Some implementations may perform additional operations, fewer operations, operations in parallel or in a different order, and some operations differently.

The description that follows includes example systems, methods, techniques, and program flows that embody implementations of the disclosure. However, it is understood that this disclosure may be practiced without these specific details. In other instances, well-known instruction instances, protocols, structures, and techniques have not been shown in detail in order not to obfuscate the description.

DESCRIPTION

Example implementations described herein may include a dual tubular expandable liner hanger which employs a two-stage expansion. Some conventional liner hanger systems may expand an expander sleeve and main hanger body simultaneously to an OD suitable for successful expansion of the main body hanger. However, the use of a two-stage process to expand the dual tubular liner hanger system may allow the system for use in narrower ID environments compared to more traditional systems. The first stage of the expansion may involve the expansion of a main body portion, followed by the second stage which involves the expansion of a secondary sleeve underneath the main body. This two stage expansion process may allow for a thicker body post-expansion while reducing the OD of the system during run-in, solving the above challenges.

The example dual tubular expandable liner hanger system may be suitable for smaller casing drift and larger liner drift without sacrificing performance (i.e., a thicker hanger body). Hence, using two tubulars may allow dual tubular liner hanger systems to be used in lighter casings than traditional liner hanger systems. Some implementations may be configured to expand the main body and secondary sleeve using a single solid cone. Some implementations of the two-stage expansion may include a bi-directional expansion which may eliminate the use of a workover rig to pull the cone out from the wellbore. Instead, the cone may be pulled out hydraulically, which may be a more reliable technique than conventional means. This may also reduce quality issues related to insufficient pull-out forces, which may reduce non-productive time during operations. Some implementations may include a retainer system to hold the secondary sleeve in place during the secondary stage expansion (i.e., the expansion of the secondary sleeve underneath the main hanger body). This retainer system may include a locking mechanism to couple the main hanger body and secondary sleeve. The use of the dual-tubular configuration may reduce the expansion force necessary to expand the system compared to the use of an expander sleeve due to a significantly smaller contact area. For example, traditional liner hangers may use an expander sleeve with a tapered exterior rather than one or more cones to expand the main hanger body. This tapered expander sleeve may include a greater contact surface area with the main hanger body than the expansion cone described herein, resulting in a larger frictional force, and therefore, a larger force to expand the liner hanger.

Example implementations of the dual tubular liner hanger system may be configured for use in HPHT wells. The dual tubular liner hanger configuration may allow for additional tailoring in designs with reduced time dedicated for customization. For example, the dual tubular liner hanger system, when compared to traditional liner hanger systems, may enable the creation of a calculator (operating on input parameters, formulas, limitations, a user/input interface, etc.) without necessitating the use of finite element analysis (FEA) or other more complex modeling techniques.

Example Illustrations

FIG. 1 is an illustration depicting an example dual tubular liner hanger system 100 configured for use in a wellbore, according to some implementations. The dual tubular liner hanger system 100 may include a main hanger body 102 having one or more setting features 116 positioned along its exterior, an expandable secondary sleeve 104, a solid cone 106, a collet 108, a shoulder 110, a cone mandrel 112, a casing 114, and a relief 118. In some implementations, the main hanger body 102, expandable secondary sleeve 104, solid cone 106, collet 108, shoulder 110, cone mandrel 112, and casing 114 may be comprised of one or more grades of steel. The one or more setting features 116 may include one or more slips, spikes, serrated surfaces, teeth, etc. These implementations of the setting features 116 may be comprised hardened steel and may be configured to bite into the casing 114, providing a strong mechanical hold. In some implementations, the one or more setting features 116 may include one or more gripping elements, elastomeric sections, etc. to grip the inner diameter (ID) of the casing 114.

The dual tubular liner hanger system 100 may be configured for use within one or more wellbores drilled through a land-based subterranean environment, a subsea environment, a multilateral well having multiple boreholes, vertical wells, horizontal wells, etc. In some implementations, any one or more components or elements described may be used with subterranean operations and/or equipment located on offshore platforms, drill ships, semi-submersibles, drilling barges, land-based rigs, etc. As shown, the dual tubular liner hanger system 100 may be portrayed as assembled with all primary components prior to expansion.

The process of expanding the dual tubular liner hanger system 100 may begin with the expansion of the main hanger body 102. The solid cone 106, coupled with the cone mandrel 112, may move downward (with reference to FIG. 1, the solid cone 106 may move to the right) during the expansion of the main hanger body 102. Simultaneously, the secondary sleeve 104 may be drawn into the expanded region of the main hanger body 102 by the shoulder 110 at the top of the cone mandrel 112. A straight bore may be created on the main hanger body 102 after the first stage expansion. FIGS. 2 and 3 may depict different phases of the first stage expansion.

FIG. 2 is an illustration depicting a midpoint of the first stage expansion process, according to some implementations. A dual tubular liner hanger system 200, which may be similar to the dual tubular liner hanger system 100, includes a main hanger body 202 having a one or more setting features 216 positioned along its exterior, an expandable secondary sleeve 204, a solid cone 206, a collet 208, a shoulder 210, a cone mandrel 212, a casing 214, and a relief 218. Both FIGS. 2-3 may be half section diagrams where only a portion of the example dual tubular liner hanger system is shown. In FIG. 2, the cone mandrel 212, solid cone 206, and expandable secondary sleeve 204 may be conveyed in a first direction to expand the main hanger body 202. The solid cone 206 may push the main hanger body 202 outward to create a straight bore without engaging the setting features 216 with the wall of the casing 214. Some implementations of the setting features 216 may include one or more spikes, teeth, slips, etc.

FIG. 3 is an illustration depicting the end of the first stage expansion process, according to some implementations. A dual tubular liner hanger system 300, which may be similar to the dual tubular liner hanger systems 100 and 200, includes a main hanger body 302 having one or more setting features 316 positioned along its exterior, an expandable secondary sleeve 304, a solid cone 306, a collet 308, a shoulder 310, a cone mandrel 312, a casing 314, and a relief 318. Some implementations of the setting features 316 may include one or more spikes, teeth, slips, etc. Other implementations of the setting features may utilize elastomeric sections to grip the ID of the casing 314.

In FIG. 3, the solid cone 306 and expandable secondary sleeve 304 may be moved further in the first direction (which may typically be downward) to complete the expansion of the main hanger body 302. Once the first stage expansion is completed, the collet 308, which may be assembled at the top end of the expandable secondary sleeve 304, may latch into a slot at the tie back receptacle (TBR) of the main hanger body 302. The relief 318 may be designed on the cone mandrel 312 underneath where the collet 308 is located to allow the collet 308 to flex inward during the latching process. Latching the collet 308 into the TBR of the main hanger body 302 may lock the secondary sleeve 304 in preparation for the second stage expansion. Locking the secondary sleeve 304 with the main hanger body 302 may limit movement of the secondary sleeve 304 along an axis of the casing (i.e., up/down in a typical well, or left/right as shown in FIG. 3) during the second stage expansion. Thus, the cone mandrel 312 and solid cone 306 may move while the main hanger body 302 and expandable secondary sleeve 304, once latched to one another, may remain stationary. The main hanger body 302 may remain fixed in place by a running tool. The running tool may hold the bottom of the main hanger body 302 in place while expanding the main hanger body 302 with the solid cone 306, beginning at the other end (i.e., the top) of the liner hanger.

The second stage expansion may be described with additional detail in FIG. 4. During the first stage expansion, the main hanger body 302 may be latched into place via a latching mechanism lower in the well (not shown). The main hanger body 302 may remain stationary as the solid cone 306 moves to expand the main hanger body 302 outward.

FIG. 4 is an illustration depicting a portion of the second stage expansion process of the liner hanger system 100, according to some implementations. A dual tubular liner hanger system 400, which may be similar to the dual tubular liner hanger systems 100-300, includes a main hanger body 402 having one or more setting features 416 positioned along its exterior, an expandable secondary sleeve 404, a solid cone 406, a collet 408, a cone mandrel 412, and a casing 414. During the secondary stage expansion of the dual tubular liner hanger system 400, the secondary sleeve 404 may be expanded together with the main hanger body 402. In some implementations, the collets 108, 208, 308, and 408 may instead use other locking mechanisms such as one or more lugs, one or more locking dogs, one or more latching mechanisms (e.g., a toothed latching mechanism), one or more setting features, one or more anchors, one or more retainers, etc. Other locking mechanisms of varying geometries may also be used.

Prior to this expansion, the cone mandrel 412 may be pulled in a second, opposite direction compared to FIGS. 2-3. In some implementations, the cone mandrel 412 may be moved upward. Moving the cone mandrel 412 upward may prop or otherwise secure the collet 408 with the cone mandrel surface, preventing it from the disengaging from the main hanger body 402. The cone mandrel 412 may be pulled further upward (to the left, as depicted in FIG. 4) until it shoulders and draws the solid cone 406 upward. The drawing of the solid cone 406 upward may expand the secondary sleeve 404 which may be locked in place by the propped collet 408. During the secondary stage expansion, the collet 408, main hanger body 402, and secondary sleeve 404 may remain stationary as the solid cone 406 and cone mandrel 412 are moved. The solid cone 406 may expand both the secondary sleeve 404 and main hanger body 402 to engage the setting features 416 with the casing 414. In some implementations, engaging the setting features 416 with the casing may form an interference fit with the casing 414. Some implementations of the setting features 416 may include one or more teeth, spikes, slips, elastomeric sections, serrated sections, etc. Once the solid cone 406 is drawn out of the hanger, the second stage expansion is complete. At this point, the dual tubular liner hanger system 400 may be fully installed in the casing 414. Some implementations of the first and second stage expansions may be performed hydraulically. For example, the solid cone 406 may be pulled out of the casing 414 hydraulically to complete the second stage expansion.

A narrow clearance may exist between the secondary sleeve 404 and the post-expanded ID of the main hanger body 402 after completing the second stage expansion. This may maximize the amount of thickness of the post-expansion hanger and secondary sleeve for better performance. This thickness may refer to the combined radial thickness between the outer diameter of the main hanger body 102 and the inner diameter of the expandable secondary sleeve 104 after the two-stage expansion has concluded.

Alternate Implementations

Alternative example implementations are now described. The figures described below may detail various alternate implementations pertaining to the locking mechanism of the secondary sleeve and the solid cone(s).

FIG. 5 is an illustration 500 depicting a raised portion of the secondary sleeve for use during the first stage expansion, according to some implementations. FIG. 5 includes a main hanger body 502, an expandable secondary sleeve 504 including a raised portion 514, a first solid cone 506, a second solid cone 508, a cone mandrel 510, and a casing 512. In particular, FIG. 5 depicts the end of the first stage expansion prior to beginning the second stage expansion, where the main hanger body 502 has been expanded outward via the first solid cone 506 but has not yet made contact with the casing 512.

Rather than using a collet or similar locking mechanism, the expandable secondary sleeve 504 may include the raised portion 514 to couple the expandable secondary sleeve 504 and the main hanger body 502 prior to the second stage expansion. The expandable secondary sleeve 504 may be moved into the main hanger body 502 via the cone mandrel 510 during the first stage expansion of the main hanger body 502. In some implementations, the expandable secondary sleeve 504 may include a shoulder similar to the shoulders 210 and 310. However, this shoulder may be configured to latch into or otherwise couple with the top (left hand side, as shown) of the main hanger body 502. After a certain point in the first stage expansion, the shoulder may contact the main hanger body 502. Some implementations of the shoulder may latch into the main hanger body 502, while some implementations may only contact the top of the main hanger body 502. The main hanger body 502, once contacted/latched by the shoulder, may function as a stop, which may prevent the movement of expandable secondary sleeve 504. The second solid cone 508 may follow the first solid cone 506 during the first stage expansion. Once the first stage expansion is nearing its end, the second solid cone 508 may contact the raised portion 514.

The second solid cone 508 may push against the raised portion 514 of the expandable secondary sleeve 504 as it passes underneath, and the second solid cone 508 may deflect the expandable secondary sleeve 504 into the main hanger body 502 at that location. This deflection may expand the secondary sleeve 504 onto the main hanger body 502 during the first stage expansion. A frictional fit may be formed between the expandable secondary sleeve 504 and main hanger body 502 at the raised portion 514. The frictional fit via the raised portion 514 (and the shoulder) may couple the two tubulars and anchor the expandable secondary sleeve 504 in place prior to the second stage expansion, preventing it from pushing out together with the first solid cone 506. In some implementations, the raised portion 514 may be a raised bum, bump, convex section, or similar component with a larger width than the remainder of the expandable secondary sleeve 504. The shoulder at the top of the expandable secondary sleeve 504 may limit movement of the expandable secondary sleeve 504 further into the main hanger body 502, and movement out of the top of the main hanger body 502 may be limited by the raised portion 514 after expanding outward via the second solid cone 508. The two-stage expansion of the liner hanger system depicted in FIG. 5 is shown with additional detail in FIGS. 6-7.

FIGS. 6A-6B are illustration depicting at least a portion of the first stage expansion of the liner hanger system of FIG. 5, according to some implementations. The illustrations 600 and 625 include a main hanger body 602, an expandable secondary sleeve 604 having a raised portion 614, a first solid cone 606, a second solid cone 608, a cone mandrel 610, a casing 612, one or more elastomeric sections 616, and a shoulder 618. FIG. 6A depicts the beginning of the first stage expansion of the dual tubular liner hanger system, and FIG. 6B depicts a point during the first stage expansion when the second solid cone 608 contacts the raised portion 614. In some implementations, the shoulder 618 may be similar to the shoulder 518 of FIG. 5. The main hanger body 802 may include the one or more elastomeric sections 616. The expandable secondary sleeve 604 may include the shoulder 618. In some implementations, the shoulder 618 may be configured to latch into, be positioned against, contact, or otherwise couple with the top of the main hanger body 602.

FIGS. 7A-7B are illustrations depicting an end of the first stage expansion and the completed second stage expansion of FIG. 5's liner hanger system, according to some implementations. The illustrations 700 and 725 include a main hanger body 702, an expandable secondary sleeve 704 having a raised portion 714, a first solid cone 706, a second solid cone 708, a cone mandrel 710, a casing 712, one or more elastomeric sections 716, and a shoulder 718. FIG. 7A depicts the end of the first stage expansion of the dual tubular liner hanger system when the second solid cone 708 expands the raised portion 714 into the main hanger body 702. FIG. 7B depicts the completed second stage expansion after both the expandable secondary sleeve 704 and main hanger body 702 have been expanded to engage the casing 712.

As shown, the expandable secondary sleeve 704 may include the shoulder 718. In some implementations, the shoulder 718 may be configured to latch into, be positioned against, contact, or otherwise couple with the top of the main hanger body 702. The main hanger body 702, once engaged by the shoulder 718, may function as a stop, which may prevent the expandable secondary sleeve 704 from further sliding into the main hanger body 702. The expandable secondary sleeve 704 may be coupled to the main hanger body 702 by the raised portion 714 as it is pressed into the main hanger body 702 by the second solid cone 708.

In some implementations, the expandable secondary sleeve 704 may include a latch or latching mechanism rather than the shoulder 718. The latch and/or latching mechanism may latch into a receptacle on the main hanger body 702 to prevent the expandable secondary sleeve 704 from sliding further into the main hanger body 702. During the second stage expansion, the frictional fit between the expanded raised portion 714 and the main hanger body 702 may prevent the movement of the expandable secondary sleeve 704 and the main hanger body 702.

Similar to the raised portion of FIGS. 5, 6A, 6B, 7A, and 7B, other techniques may be used to lock the expandable secondary sleeve in place prior to the second stage expansion. FIG. 8 is an illustration 800 depicting a liner hanger system including a secondary sleeve with one or more setting features, according to some implementations. FIG. 8 includes a main hanger body 802, an expandable secondary sleeve 804 having one or more setting features 814, a first solid cone 806, a second solid cone 808, a cone mandrel 810, a casing 812, and one or more elastomeric sections 816. The main hanger body 802 may include one or more elastomeric sections 816. Instead of using the raised portion 514 of FIG. 5, the expandable secondary sleeve 804 may be coupled with the main hanger body 802 via the one or more setting features 814. In some implementations, the one or more setting features 814 may include one or more ribbed sections, one or more elastomeric sections, one or more spiked sections, one or more slips, etc. Some implementations of the one or more setting features 814 may include a combination of spikes, ribbed sections, elastomeric sections, slips, etc. Other configurations may also be possible. Some implementations of the expandable secondary sleeve 804 may not include the one or more setting features 814. Instead, these implementations may use an expandable secondary sleeve 804 with a smooth outer diameter configured to form an interference fit with the ID of the casing 812.

In some implementations, the expandable secondary sleeve 804 may include a shoulder similar to the shoulders 210 and 310. However, this shoulder may be configured to latch into or otherwise couple with the top (left hand side, as shown) of the main hanger body 802. After a certain point in the first stage expansion, the shoulder may contact the main hanger body 802 and prevent the movement of expandable secondary sleeve 804. In some implementations, this may prevent movement of the expandable secondary sleeve 804 further into or out of the main hanger body 802. While the first solid cone 806 is moving to expand the main hanger body 802, the second solid cone 808 may follow behind it. Once the expandable secondary sleeve 804 is stopped via the shoulder contacting the top of the main hanger body 802, the second solid cone 808 may contact the inner diameter of the one or more setting features 814. The second solid cone 808 may outwardly expand the one or more setting features 814 into at least a portion of the inner diameter of the main hanger body 802 while the expandable secondary sleeve 804 is stationary. The one or more setting features 814 may be configured to form a frictional fit with the main hanger body 802 after the first stage expansion. The one or more setting features 814, once the expandable secondary sleeve 804 has expanded, may anchor the expandable secondary sleeve 804 to the main hanger body 802 in preparation for the second stage expansion.

Rather than using slips, teeth, or spikes, some implementations of the main hanger body 802 may use the one or more elastomeric sections 816 to form an interference fit with an inner surface of the casing 812. In some implementations, the one or more elastomeric sections 816 may be comprised of a rubber (e.g., fluorine rubber, nitrile rubber, hydrogenated nitrile rubber (HNBR), etc.) or one or more polymers and/or polymeric seals to form the seal with the main hanger body 802. The expansion of the liner hanger system of FIG. 8 is shown with additional detail in FIGS. 9-10.

FIGS. 9A-9B are illustrations depicting at least a portion of the first stage expansion of the liner hanger system of FIG. 8, according to some implementations. The illustrations 900 and 925 include a main hanger body 902, an expandable secondary sleeve 904 having one or more setting features 914, a first solid cone 906, a second solid cone 908, a cone mandrel 910, a casing 912, one or more elastomeric sections 916, and a shoulder 918. FIG. 9A depicts the beginning of the first stage expansion of the dual tubular liner hanger system, and FIG. 9B depicts a point during the first stage expansion when the second solid cone 908 contacts the one or more setting features 914. The main hanger body 802 may include the one or more elastomeric sections 916. The expandable secondary sleeve 904 may follow the first solid cone 906 during the first stage expansion of the main hanger body 902.

FIGS. 10-10B are illustrations depicting an end of the first stage expansion and the completed second stage expansion of FIG. 8's liner hanger system, according to some implementations. The illustrations 1000 and 1025 include a main hanger body 1002, an expandable secondary sleeve 1004 having one or more setting features 1014, a first solid cone 1006, a second solid cone 1008, a cone mandrel 1010, a casing 1012, one or more elastomeric sections 1016, and a shoulder 1018. FIG. 10A depicts the end of the first stage expansion of the dual tubular liner hanger system when the second solid cone 1008 expands the one or more setting features 1014 into the main hanger body 1002. FIG. 10B depicts the completed second stage expansion after both the expandable secondary sleeve 1004 and main hanger body 1002 have been expanded to engage the casing 1012.

As shown, the expandable secondary sleeve 1004 may include the shoulder 1018. In some implementations, the shoulder 1018 may be configured to latch into, be positioned against, contact, or otherwise couple with the top of the main hanger body 1002. The second solid cone 1008 may be configured to expand the one or more setting features 1014 into the main hanger body 1002 to couple the main hanger body 1002 and expandable secondary sleeve 1004.

Some implementations of the dual tubular liner hanger system may be configured as a pressure balanced liner hanger system. FIG. 11 is an illustration 1100 depicting a pressure balanced hanger system, according to some implementations. FIG. 11 includes a main hanger body 1102 having one or more setting features 1114, a secondary sleeve 1104, a solid cone 1106, an O-ring 1108, a cone mandrel 1110, a casing 1112, and a hydraulic chamber 1116. FIG. 11 may be similar to FIG. 1, but the secondary sleeve 1104, having the O-ring 1108, may be configured to hold pressure within the hydraulic chamber 1116. Therefore, some implementations of the dual tubular liner hanger system may be pressure-containing, while some implementations may not. The secondary sleeve 1104 may function as a dynamic piston cylinder. The secondary sleeve 1104 may include a tie back receptacle (TBR) which may follow the solid cone 1106 during the first stage expansion. The secondary sleeve 1104 may also be expanded during the second stage expansion.

The liner hanger systems of FIGS. 1-10A and 10B may use hydraulic force to move the cones and/or cone mandrel, depending on the configuration. The hydraulic force may be applied in various locations to actuate movement of liner hanger components downhole. In FIG. 11, this hydraulic force may be concentrated within the hydraulic chamber 1116. In some implementations, a running tool may include the cone mandrel 1110. The running tool may apply a hydraulic force to the solid cone 1106. The liner hanger system of FIG. 11 may use the solid cone 1106 as a piston to expand the main hanger body 1102 during the first stage expansion.

The hydraulic chamber 1116 may be formed behind the solid cone 1106 between the cone mandrel 1110, solid cone 1106, and the secondary sleeve 1104. The hydraulic chamber 1116 may be pressurized by a fluid, as the fluid may be bound within the hydraulic chamber 1116 via the solid cone 1106 and the O-ring 1108. The solid cone 1106 and main hanger body 1102 may form a metal to metal seal. When the hydraulic chamber 1116 is pressurized, the solid cone 1106 may be pushed downward (as shown, to the right) similar to a piston. The solid cone 1106 and the cone mandrel 1110 may move downward with additional pressurization and/or fluid into the hydraulic chamber 1116. In some implementations, the hydraulic fluid may be supplied to the hydraulic chamber 1116 via an annulus between an outer diameter of the cone mandrel 1110 and an inner diameter of the secondary sleeve 1104.

Similar to FIGS. 1-10A and 10B, FIG. 11 also details a two-stage expansion process. The first stage expansion may be completed by expanding the main hanger body 1102 via the solid cone 1106, the solid cone 1106 propelled by a fluid pressurizing the hydraulic chamber 1116. The secondary sleeve 1104 may follow the solid cone 1106 during the first stage expansion. Similar to FIG. 1, a collet or similar locking mechanism, latching mechanism, etc. may couple the secondary sleeve 1104 to the main hanger body 1102 after the first stage expansion. During the second stage expansion, the cone mandrel 1110 and solid cone 1106 may be pulled out of the main hanger body 1102, expanding both the secondary sleeve 1104 and main hanger body 1102 to engage the one or more setting features 1114 of the main hanger body 1102 with the ID of the casing 1112. The solid cone 1106 may be pulled out from the main hanger body 1102 via the hydraulic force.

FIGS. 12A-12B are illustrations depicting the first stage expansion of the pressure balanced hanger system of FIG. 11 with additional detail, according to some implementations. The illustrations 1200 and 1225 include a main hanger body 1202 having one or more setting features 1214, a secondary sleeve 1204, a solid cone 1206, a primary O-ring 1208, a cone mandrel 1210, a casing 1212, a hydraulic chamber 1216, a cylinder restriction 1218, secondary O-rings 1220, a piston cylinder 1222, a secondary chamber 1224, and a bypass 1226. FIG. 12A depicts the beginning of the first stage expansion of the dual tubular liner hanger system, and FIG. 12B depicts a point during the first stage expansion when the secondary sleeve 1204 passes through the cylinder restriction 1218.

The secondary sleeve 1204 may be housed within the piston cylinder 1222 for at least a portion of the expansion of the main hanger body 1202. The piston cylinder 1222 may be stationary throughout the expansion process. The secondary sleeve 1204 may be pushed by the pressurized hydraulic fluid within the hydraulic chamber 1216 in tandem with the movement of the solid cone 1206 (e.g., downward in the well, or to the right as shown in FIG. 12). The solid cone 1206 may also be pushed by the hydraulic fluid. Once the secondary sleeve 1204 snaps out of the cylinder restriction 1218, a bypass 1226 may be created to dump hydraulic fluid from the hydraulic chamber 1216.

FIG. 13 is an illustration depicting the second stage expansion of the pressure balanced hanger system of FIG. 11 with additional detail, according to some implementations. FIG. 13 includes components similar to FIGS. 11, 12A, and 12B, such as a main hanger body 1302 having one or more setting features 1314, a secondary sleeve 1304, a solid cone 1306, a primary O-ring 1308, a cone mandrel 1310, a casing 1312, a hydraulic chamber 1316, a cylinder restriction 1318, secondary O-rings 1320, a piston cylinder 1322, a secondary chamber 1324, a bypass 1326.

During the second stage expansion, the movement of the solid cone 1306 may be reversed to expand the secondary sleeve 1304 together with the main hanger body 1302. The bottom end of the piston cylinder 1322 (i.e., the portion including the cylinder restriction 1318) may shoulder the secondary sleeve 1304 during the second stage expansion. The cylinder restriction 1318 may prevent the secondary sleeve 1304 from shifting upwards (as shown, to the left) during the second stage expansion as the solid cone 1306 moves in the reverse direction. In some implementations, the secondary chamber 1324 may fill with hydraulic fluid during the second stage expansion.

FIG. 14 is an illustration 1400 depicting a liner hanger system including a failsafe, according to some implementations. FIG. 14 includes a main hanger body 1402 having one or more setting features 1414, an expandable secondary sleeve 1404, a primary cone 1406, a secondary cone 1408, a cone mandrel 1410, and a casing 1412. Both the primary cone 1406 and secondary cone 1408 may be coupled with the cone mandrel 1410. FIGS. 1-14 may utilize a two-stage expansion which may involving moving a cone in a first direction, followed by moving the cone in an opposite direction during the second stage expansion. However, FIGS. 14, 15A, 15B, and 15C may utilize a unidirectional expansion using two cones.

The unidirectional expansion of FIG. 14 may involve moving the primary cone 1406 downward (as shown, to the right) to expand the main hanger body 1402 and expandable secondary sleeve 1404 in a single stroke. In some implementations, the primary cone 1406 may be used to perform the expansion of the main hanger body 1402 and expandable secondary sleeve 1404. In some implementations, the secondary cone 1408 may be used as a failsafe. For example, a problem may arise during the expansion of the main hanger body 1402 and expandable secondary sleeve 1404. This may stop the primary cone 1406 in place before the expansion is complete. The secondary cone 1408 may be used as a contingency to complete the remainder of the expansion process. The secondary cone 1408 may be located at the bottom of the hanger and travel upwards, opposite of the primary cone 1406, to expand the remaining region of the main hanger body 1402 and expandable secondary sleeve 1404. In some implementations, the primary cone 1406 and secondary cone 1408 may be actuated to move via a hydraulic force.

FIGS. 15A-15C are illustrations depicting a dual-cone configuration configured for unidirectional expansion of the liner hanger system, according to some implementations. The illustrations 1500, 1525, and 1550 include a main hanger body 1502 having one or more setting features 1514, an expandable secondary sleeve 1504, a first cone 1506, a second cone 1508, a cone mandrel 1510, and a casing 1512. FIG. 15A depicts the unexpanded liner hanger system, FIG. 15B depicts a first stage expansion performed by the first cone 1506, and FIG. 15C depicts a second stage expansion performed by the second cone 1508. The first cone 1506 may be configured to expand the main hanger body 1502 outward in a single stroke during the first stage expansion. The expandable secondary sleeve 1504 may be expanded together with the main hanger body 1502 by the second cone 1508 during the second stage expansion. In some implementations, the first cone 1506 may complete the first stage expansion before the second cone 1508 begins the second stage expansion. However, some implementations of the first stage expansion and second stage expansion may occur simultaneously (i.e., the second cone 1508 may follow behind the first cone 1506). The first cone 1506 and second cone 1508 may be configured to travel in the same direction during both the first and second stages of expansion. When the main hanger body 1502 and expandable secondary sleeve 1504 have been expanded outward via the second cone 1508, the one or more setting features 1514 may engage with the ID of the casing 1512, anchoring the liner hanger system onto the parent casing. Some implementations of the second cone 1508 may be positioned along a wider OD portion of the cone mandrel 1510. This may enable the second cone 1508 to fully expand both the secondary sleeve 1504 and main hanger body 1502 until the one or more setting features 1514 engage the ID of the casing 1512.

FIGS. 16-18 may describe an alternate implementation of FIG. 1's locking mechanism. Rather than using a collet, a secondary cone may be used to expand a raised portion of the secondary sleeve into the relief to couple the main hanger body and secondary sleeve. This dual-cone configuration may be used for a bidirectional two-stage expansion to engage the liner hanger system with the casing.

FIG. 16 is a first illustration 1600 depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations. The illustration 1600 includes a main hanger body 1602 having one or more setting features 1614, an expandable secondary sleeve 1604, a primary cone 1606, a cone mandrel 1610, a casing 1612, and a relief 1618. FIG. 16 portrays an early point in the first stage expansion, where the cone mandrel is moved into the main hanger body 1602, and the primary cone 1606 is used to expand the main hanger body 1602 outwards. Similar to the relief 118 of FIG. 1, the relief 1618 may be a region in which a locking mechanism is engaged to couple the main hanger body 1602 and secondary sleeve 1604.

FIG. 17 is a second illustration 1700 depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations. The illustration 1700 includes a main hanger body 1702 having one or more setting features 1714, an expandable secondary sleeve 1704, a primary cone 1706, a secondary cone 1708, a cone mandrel 1710, a casing 1712, a shoulder 1716, a relief 1718, and a locking mechanism 1720. FIG. 17 portrays the end of the first stage expansion. To lock the expandable secondary sleeve 1704 to the main hanger body 1702 in preparation for the second stage expansion, the secondary cone 1708 may expand the locking mechanism 1720 into the relief 1718. In some implementations, the locking mechanism 1720 may be a raised portion of the expandable secondary sleeve 1704. Once expanded into the relief 1718, the locking mechanism 1720 may couple the main hanger body 1702 and expandable secondary sleeve 1704.

FIG. 18 is a third illustration 1800 depicting dual-cone configuration configured to engage a locking mechanism, according to some implementations. The illustration 1800 includes a main hanger body 1802 having one or more setting features 1814, an expandable secondary sleeve 1804, a primary cone 1806, a cone mandrel 1810, a casing 1812, a shoulder 1816, a relief 1818, and a locking mechanism 1820. FIG. 18 portrays the liner hanger system near the end of the second stage expansion, where the primary cone 1806 is moved in an opposing direction (e.g., out of the liner hanger) to expand the expandable secondary sleeve 1804 and main hanger body 1802. Upon completion of the second stage expansion, the setting features 1814 of the main hanger body 1802 may engage with the inner wall of the casing 1812.

Example Method of Operations

FIG. 19 is a flowchart depicting an example method of operations, according to some implementations. Operations of a method 1900 may be performed by software, firmware, hardware, or a combination thereof. Such operations are described with reference to FIGS. 1-18. However, such operations may be performed by other systems or components. The operations of the method 1900 begin at block 1902.

At block 1902, the method 1900 includes moving, during a first stage expansion, a first expansion tool in a first direction, wherein the first expansion tool is configured to outwardly expand a first tubular during the first stage expansion. For example, an expansion tool, such as the solid cone 106 of FIG. 1's dual tubular liner hanger system 100, may be configured to move in a first direction to expand the main hanger body 102 outward during a first stage of expansion. However, expansion tools of other geometries may also be possible (e.g., domed expansion tools, semicircular expansion tools, etc.). Some implementations may include a second expansion tool, such as FIG. 15's second cone 1508, which may also be configured to move in the first direction. In some implementations, the second cone 1508 may be configured to expand both the main hanger body 902 and the expandable secondary sleeve 1504. Flow progresses to block 1904.

At block 1904, the method 1900 includes moving, during a second stage expansion, the first expansion tool in a second direction, wherein the second direction is opposite the first direction, and wherein the first expansion tool is configured to outwardly expand a second tubular and the first tubular during the second stage expansion. For example, the solid cone 106 may be moved in a second direction, (i.e., out of the hanger body) to expand both the expandable secondary sleeve 104 and the main hanger body 102. Expanding the main hanger body 102 during the second stage expansion may engage the one or more setting features 116 with an ID of the casing 114, thereby setting the dual tubular liner hanger system 100 in the wellbore. Some implementations which utilize a second cone may also be configured to move in this second direction. For example, FIG. 14's secondary cone 1408 may be configured to move in an opposing direction of the primary cone 1406 should the primary cone 1406 fail to complete the expansion of the main hanger body 1402 and expandable secondary sleeve 1404. In some implementations, the first cone and second cone may be movable via a hydraulic force provided by a fluid. Flow of the method 1900 ceases.

Various modifications to the implementations described in this disclosure may be readily apparent to those skilled in the art, and the generic principles defined herein may be applied to other implementations without departing from the spirit or scope of this disclosure. Thus, the claims are not intended to be limited to the implementations shown herein but are to be accorded the widest scope consistent with this disclosure, the principles and the novel features disclosed herein.

Certain features that are described in this specification in the context of separate implementations also may be implemented in combination in a single implementation. Conversely, various features that are described in the context of a single implementation also may be implemented in multiple implementations separately or in any suitable sub-combination. Moreover, although features may be described as acting in certain combinations and even initially claimed as such, one or more features from a claimed combination may in some cases be excised from the combination, and the claimed combination may be directed to a sub-combination or variation of a sub-combination.

While operations are depicted in the drawings in a particular order, this should not be understood as requiring that such operations be performed in the particular order shown or in sequential order, or that all illustrated operations be performed, to achieve desirable results. Further, the drawings may schematically depict one more example process in the form of a flow diagram. However, some operations may be omitted and/or other operations that are not depicted may be incorporated in the example processes that are schematically illustrated. For example, one or more additional operations may be performed before, after, simultaneously, or between any of the illustrated operations. In certain circumstances, multitasking and parallel processing may be advantageous. Moreover, the separation of various system components in the implementations described should not be understood as requiring such separation in all implementations, and the described program components and systems may generally be integrated together in a single software product or packaged into multiple software products. Additionally, other implementations are within the scope of the following claims. In some cases, the actions recited in the claims may be performed in a different order and still achieve desirable results.

Plural instances may be provided for components, operations or structures described herein as a single instance. Finally, boundaries between various components, operations and data stores are somewhat arbitrary, and particular operations are illustrated in the context of specific illustrative configurations. Other allocations of functionality are envisioned and may fall within the scope of the disclosure. In general, structures and functionality presented as separate components in the example configurations may be implemented as a combined structure or component. Similarly, structures and functionality presented as a single component may be implemented as separate components. These and other variations, modifications, additions, and improvements may fall within the scope of the disclosure.

Use of the phrase “at least one of” preceding a list with the conjunction “and” should not be treated as an exclusive list and should not be construed as a list of categories with one item from each category, unless specifically stated otherwise. A clause that recites “at least one of A, B, and C” may be infringed with only one of the listed items, multiple of the listed items, and one or more of the items in the list and another item not listed. Similarly, “at least one of: a, b, or c” is intended to cover: a, b, c, a-b, a-c, b-c, and a-b-c.

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; likewise, use of the terms “down,” “lower,” “downward,” “downhole,” or other like terms shall be construed as generally toward the bottom, terminal end of the 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 axis. In some instances, a part near the end of the well may be horizontal or even slightly directed upwards. Unless otherwise specified, use of the terms “subsurface formation” or “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.

Example Implementations

Implementation #1: A liner hanger system to be positioned in a wellbore, the liner hanger system comprising: a first tubular including one or more setting features positioned along at least a portion of its outer diameter; a second tubular configured to be positioned within an inner diameter of the first tubular; and a first expansion tool coupled with a mandrel, the first expansion tool and mandrel configured to be positioned within an inner diameter of the second tubular, wherein the first expansion tool is configured to move in a first direction during a first stage expansion, wherein the first expansion tool is configured to outwardly expand the first tubular during the first stage expansion, and wherein the first expansion tool is configured to move in a second, opposing direction during a second stage expansion, wherein the first expansion tool is configured to outwardly expand the second tubular and the first tubular during the second stage expansion.

Implementation #2: The liner hanger system of Implementation 1, wherein the first tubular is configured to couple with an inner diameter of a casing via the one or more setting features, and wherein the first tubular is configured to contact the casing during the second stage expansion.

Implementation #3: The liner hanger system of any one or more of Implementations 1-2, further comprising: a locking mechanism, wherein the locking mechanism is configured to couple the second tubular to the first tubular prior to the second stage expansion, and wherein the first tubular and second tubular are stationary during the second stage expansion.

Implementation #4: The liner hanger system of any one or more of Implementations 1-3, wherein the second tubular includes the locking mechanism, wherein the locking mechanism is configured to engage with the inner diameter of the first tubular, and wherein the locking mechanism includes at least one of a collet, a latch, a raised portion, an elastomeric section, or one or more slips.

Implementation #5: The liner hanger system of any one or more of Implementations 1-4, wherein the second tubular includes an O-ring, wherein a pressurized chamber is formed between the first expansion tool, the first tubular, and the O-ring, and wherein the pressurized chamber is configured, at least in part, to move the first expansion tool.

Implementation #6: The liner hanger system of any one or more of Implementations 1-5, further comprising: a second expansion tool coupled with the mandrel, wherein the second expansion tool is configured to move in the first direction, wherein the second expansion tool is configured to outwardly expand the second tubular and the first tubular.

Implementation #7: The liner hanger system of any one or more of Implementations 1-6, wherein the second expansion tool is configured to move in the second, opposing direction to outwardly expand the second tubular and the first tubular.

Implementation #8: An apparatus to be positioned in a wellbore, the apparatus comprising: a first tubular including one or more setting features positioned along at least a portion of its outer diameter; a second tubular configured to be positioned within an inner diameter of the first tubular; and a mandrel configured to be positioned within an inner diameter of the second tubular, wherein the mandrel includes a first expansion tool, wherein the first expansion tool is configured to outwardly expand the first tubular during a first stage expansion, and wherein the first expansion tool is configured to outwardly expand the second tubular and the first tubular during a second stage expansion.

Implementation #9: The apparatus of Implementation 8, wherein the first expansion tool is configured to move in a first direction during the first stage expansion, and wherein the first expansion tool is configured to move in a second direction during the second stage expansion, wherein the second direction is opposite of the first direction.

Implementation #10: The apparatus of any one or more of Implementations 8-9, wherein the first tubular is configured to couple with an inner diameter of a casing via the one or more setting features, and wherein the first tubular is configured to contact the casing during the second stage expansion.

Implementation #11: The apparatus of any one or more of Implementations 8-10, wherein the second tubular includes an O-ring, wherein a pressurized chamber is formed between the first expansion tool, the first tubular, and the O-ring, and wherein the pressurized chamber is configured, at least in part, to move the first expansion tool.

Implementation #12: The apparatus of any one or more of Implementations 8-11, further comprising: a locking mechanism, wherein the locking mechanism is configured to couple the second tubular to the first tubular prior to the second stage expansion, wherein the first tubular and second tubular are stationary during the second stage expansion, wherein the second tubular includes the locking mechanism, wherein the locking mechanism is configured to engage with the inner diameter of the first tubular, and wherein the locking mechanism includes at least one of a collet, a raised portion, a latch, an elastomeric section, or one or more slips.

Implementation #13: The apparatus of any one or more of Implementations 8-12, wherein the mandrel includes a second expansion tool, wherein the second expansion tool is configured to move in a first direction, wherein the second expansion tool is configured to outwardly expand the second tubular and the first tubular.

Implementation #14: The apparatus of any one or more of Implementations 8-13, wherein the second expansion tool is configured to move in a second direction to outwardly expand the second tubular and the first tubular, wherein the second direction is opposite of the first direction.

Implementation #15: A method comprising: operating a liner hanger system to engage with a casing in a wellbore, wherein operating the liner hanger system includes, moving, during a first stage expansion, a first expansion tool in a first direction, wherein the first expansion tool is configured to outwardly expand a first tubular during the first stage expansion; and moving, during a second stage expansion, the first expansion tool in a second direction, wherein the second direction is opposite the first direction, and wherein the first expansion tool is configured to outwardly expand a second tubular and the first tubular during the second stage expansion.

Implementation #16: The method of Implementation 15, further comprising: completing the first stage expansion of the first tubular; and coupling, via a locking mechanism, the second tubular to the first tubular prior to the second stage expansion, wherein the first tubular and second tubular are stationary during the second stage expansion, wherein the second tubular includes the locking mechanism, wherein the locking mechanism is configured to engage with an inner diameter of the first tubular, and wherein the locking mechanism includes at least one of a collet, a latch, raised portion, an elastomeric section, or one or more slips.

Implementation #17: The method of any one or more of Implementations 15-16, further comprising: forming a pressurized chamber between the first expansion tool, the first tubular, and an O-ring of the second tubular; and moving the first expansion tool, at least in part, via the pressurized chamber.

Implementation #18: The method of any one or more of Implementations 15-17, wherein the first expansion tool is coupled with a mandrel, wherein the second tubular is configured to be positioned within an inner diameter of the first tubular, and wherein the first tubular is configured to be positioned within an inner diameter of the casing.

Implementation #19: The method of any one or more of Implementations 15-18, further comprising: moving, in the first direction, a second expansion tool, wherein the second expansion tool is configured to outwardly expand the second tubular and the first tubular, and wherein the second expansion tool is coupled with the mandrel.

Implementation #20: The method of any one or more of Implementations 15-19, further comprising: moving the second expansion tool in the second direction to outwardly expand the second tubular and the first tubular.

Claims

1. A liner hanger system to be positioned within a wellbore, the liner hanger system comprising:

a first tubular including one or more setting features positioned along at least a portion of its outer diameter;

a second tubular configured to be positioned within an inner diameter of the first tubular; and

a first expansion tool coupled with a mandrel, the first expansion tool and mandrel configured to be positioned within an inner diameter of the second tubular,

wherein the first expansion tool is configured to move in a first direction during a first stage expansion, wherein the first expansion tool is configured to outwardly expand the first tubular during the first stage expansion, wherein the first expansion tool is configured to move in a second, opposing direction during a second stage expansion, and wherein the first expansion tool is configured to outwardly expand the second tubular and the first tubular during the second stage expansion.

2. The liner hanger system of claim 1, wherein the first tubular is configured to couple with an inner diameter of a casing via the one or more setting features, and wherein the first tubular is configured to contact the casing during the second stage expansion.

3. The liner hanger system of claim 1, further comprising:

a locking mechanism, wherein the locking mechanism is configured to couple the second tubular to the first tubular prior to the second stage expansion, and wherein the first tubular and second tubular are stationary during the second stage expansion.

4-7. (canceled)

8. An apparatus to be positioned in a wellbore, the apparatus comprising:

a first tubular including one or more setting features positioned along at least a portion of its outer diameter;

a second tubular configured to be positioned within an inner diameter of the first tubular; and

a mandrel configured to be positioned within an inner diameter of the second tubular, wherein the mandrel includes a first expansion tool, wherein the first expansion tool is configured to outwardly expand the first tubular during a first stage expansion, and wherein the first expansion tool is configured to outwardly expand the second tubular and the first tubular during a second stage expansion.

9. The apparatus of claim 8, wherein the first expansion tool is configured to move in a first direction during the first stage expansion, and wherein the first expansion tool is configured to move in a second direction during the second stage expansion, wherein the second direction is opposite of the first direction.

10. The apparatus of claim 8, wherein the first tubular is configured to couple with an inner diameter of a casing via the one or more setting features, and wherein the first tubular is configured to contact the casing during the second stage expansion.

11-20. (canceled)