FIELD OF INVENTION
This invention relates to a liner hanger setting tool and method
for use of same wherein setting tool is for.installing a prepositioned liner
string within a casing string in a subterranean wellbore. This invention relates,
5 . in general, to equipment utilized in conjunction 'with operations performed in
relation to subterranean wells.
BACKGROUND TECHNICAL INFORMATION
Without limiting the scope of the present invention, its
10 background is described with reference to constructing a subterranean well, as
an example.
In conventional practice, the drilling of an oil or gas well
involves creating a wellbore that traverses numerous subterranean formations.
For a variety reasons, each of the formations through which the well passes is
15 preferably sealed. For example, it is important to avoid an undesirable
passage of formation fluids, gases or materials from the formations into the
wellbore or for wellbore fluids to enter thc formations. In addition, it is
commonly desired to isolate producing formations from one another and from
nonproducing formations.
20 Accordingly, conventional well architecture typically includes
the installation of casing within the wellbore. In addition to providing' the
sealing function, the casing also provides wellbore stability to counteract the
geomechanics of the formation such as compaction forces, seismic.forces and
tectonic forces,. thereby preventing the collapse of the wellbore wall. The
25 casing is generally fixed within the wellbore by a cement layer that fills the
annulus between the outer surface of the casing and the wall of the wellbore.
For example, once a casing string is located in its desired position in the well,
a'cement slurry is pumped via the interior of the casing, around the lower end
of the casing and upward into the annulus. ' After the annulus around the
5 basing is sufficiently filled with the cement slurry, the cement slurry is
, .
allowed to harden, 'thereby supporting the casing and forming a substantially
. impermeable barrier.
In standard practice, the wellbore' is drilled in. intervals .with
casing installed in each interval before the next.interva1 is drilled. As such,
10 each succeeding casing string placed in the wellbore typically has an outside
diameter having a reduced size when compared to the previously installed
casing string. Specifically, a casing to be installed in a lower wellbore interval
must be passed- through the previously installed casing strings in the upper
wellbore intervals. In one approach, each casing string extends downhole from
15 the surface such that only a lower section of each casing string is adjacent to
the wellbore wall. Alternatively, the wellbore casing strings may i.n clu.d e one
or more liner strings, which do not extend to the surface of the wellbore, but
instead typically extend from near the bottom end of a previously installed
casing downward into the uncased 'portion of the wellbore: - In such
20 installations, the liner string may be set or suspended from a liner hanger
. .
positioned near the uphole end of the' liner string,
BRIEF DESCRIPTION OF THE DRAWINGS
. .
For a more complete understanding of the features and
25 advantages of the present disclosure, reference is now made to the'detailed
description along with the accompanying figures in which. corresponding
numerals in the different figures refer to corresponding parts and in which:
Figure 1 is a schematic illustration of an offshore oil and gas
-platform during installation of a liner string in a subterranean wellbore
5 according to an embodiment of the present disclosure;
Figures 2A-2Eare cross sectional. views of successive axial
sections of a liner hanger setting tool 'being run in a subterranean wellbore
prior to being stabbed into a liner string according to an embodiment of the
present disclosure;
10 Figures3A-3E are cross sectional views of successive axial
sections of a liner hanger setting tool being located on a liner top of a liner
hanger in a subterranean wellbore according to an embodiment of the present
disclosure;
Figures4A-4E are cross sectional views of successive axial
15 sections of a liner hanger setting tool after expansion of a liner hanger in a
subterranean wellbore according to 'an embodiment of the present disclosure;
Figure 5 is a cross sectional vicw of a locator cylinder for use
in a liner hanger setting tool according to an embodiment of the present
disclosure; and
2 0 Figures 6A-6B are cross sectional views of successive axial
sections of a liner hanger setting tool being run in a subterranean wellbore
prior to being stabbed into a liner string after a top squeeze cement operation
according to an embodiment of the present disclosure.
25 DESCRIPTION OF INVENTION w.r.t. DRAWINGS
DEL+,Z k g - Q 4 - 2 G L & H81Es
- 4 -
While various system, method and other embodiments are
discussed in detail below, it should be appreciated that the present disclosure - .
provides many applicable inventive concepts, which can be 'embodied in a
wide variety of specific contexts. The specific embodiments discussed herein
are merely illustrative, and do not delimit the scope of the present disclosure.
In a first aspect; the present disclosure is directed to a method for
installing a'liner string in a casing string disposed within a wellbore. The
method includes positioning the liner string in the wellbore, the liner string
. .
'including a liner hanger and a liner top; running the liner string through the
10 casing string such that at least the liner hanger is 'positioned within the
. .
wellb'ore casing; after running the liner string through the casing string,
I positioning a setting tool in the wellbore, the setting tool having an expansion
cone assembly and a locator cylinder; running the setting tool through the
casing string; contacting the liner top with the locator cylinder; axially moving
15 the expansion cone assembly through the liner string to radially expand the
liner hanger into contact with the casing'string; and retrieving the setting tool
out of the wellbore;
The method may also include anchoring the setting tool'within
the liner string before axially moving the expansion cone assembly through
20 the liner string; mech&cally actuating an anchor assembly operably
associated with the setting tool; hydraulically actuating an anchor assembly
operably associated with the setting tool; hydraulically shifting a .piston
operably associated with the expansion cone relative to the locator cylinder;
defining full travel of the expansion cone. assembly by exposing at least one
25 bypass port extending through the locator cylinder to an operating fluid that
hydraulically shifts the piston; axially moving the expansion cone assembly
through the liner string for primary expansion of the liner hanger; axially
. .
moving the expansion cone assembly through the liner string for re-expansion
of the liner hanger; cementing at least a portion of the liner string from the
5 liner top down before positioning the setting tool in the wellbore andlor
anchoring and sealing the liner hanger within the casing string.
In a second aspect, the present disclosure is directed to a liner ~ installation system for use in a wellbore having a casing string disposed
therein. The system includes a liner string having a liner hanger and a liner
10 . top and a setting tool having an expansion cone assembly and a locator
1 cylinder. After running the liner string through the casing string such that at
least the liner hanger .is positioned within the casing string, the setting tool is
m through the casing string until the locator cylinder contacts the liner top.
Thereafter, axially moving the expansion cone assembly through the liner
~ 15 string radially expands the liner hanger into contact with the casing string.
In some embodiments, the setting. tool may include an anchor
assembly operable to anchor the setting tool within the liner string before
axially moving the expansion cone assembly through the liner string. In these
embodiments, the anchor assembly may be a mechanically actuating anchor
20 assembly, a hydraulically actuating anchor assembly or the like. ' In certain
embodiments, the expansion cone assembly may include a piston operable for
axial movement relative to the locator cylinder responsive to hydraulic
pressure. In various embodiments,. the locator cylinder may include at least
one bypass port operable to define full travel of the expansion cone assembly
25 when the bypass, port is exposed to the hydraulic pressure. In one
IF-8 EELEX" LG-Q$- 2% ' l Q 5 - 6 -
embodiment, the radial expansion of the liner hanger into contact with the
casing string may be primary expansion of the liner hanger. In another
embodiment, the radial expansion of the liner hanger into contact ivith the
casing string may be re-expansion of the liner hanger. In certain
5 embodiments, cement may be positioned between the liner string and the
casing string from the liner top down prior to the setting tool being run
through the casing string. In particular embodiments, the radial expansion of
the liner hanger into contact with the casing string may result in anchoring and
sealing the liner hanger within the casing string.
10 Referring initially to figure 1, a setting tool for installing a liner
string in a subterranean wellbore is being deployed from an offshore oil or gas
platform that is schematically illustrated and generally designated 10. A semisubmersible
platform 12 is centered over a submerged oil and gas formation
14 located below sea floor 16. A subsea conduit 18 extends from deck 20 of
15 platform 12 to wellhead installation 22, including blowout preventers 24.
Platform 12 has a hoisting apparatus 26, a derrick 28, a travel block 30, a hook
32 and a swivel 34 for raising and lowering pipe strings, such as a work string
36.
A wellbore 38 has been drilled in sections through the various
20 earth strata including formation 14. A casing string 40 is secured within an
upper portion of wellbore 38 by cement 42. The term "casing" is used herein
to designate a tubular string operable to be positioned in a wellbore to provide
wellbore stability. The casing may be of the type known to those skilled in the
art as a "liner" and may be made of any material, such as steel or a composite
25 material. The casing may be a jointed tubular string or a continuous tubular
string. Extending downhole from casing string 40into a lower portion of
wellbore 38 is a liner string 44 that includes at its upper end, a liner hanger 46
and a liner top 48. In the illustrated embodiment, liner string 44 was
previously positioned in wellbore 38 but was not installed or not fully installed
5 within casing string 4.0. For example, liner string 44 may have been run
downhole on a convention running tool including a setting assembly but for
some reason, the operation or a failure in the operation bf the setting assembly
did not successfully set liner hanger 46 such that the desired anchor load
andfor seal was not established. Alternatively, liner string 44 may have been
10 run downhole on a ~ n n i n gto ol without a setting assembly such that, for
. ,
example, a top squeeze cement operation may be performed. Regardless of
the reason liner hanger 46for not fully installed, a setti.ng tool 50 has
subsequently been run downhole on work string 36. Once setting tool 50 has
suitably contacted liner top 48, axial movement of an expansion cone
15 assembly of setting tool 50 is operable to radially expand liner hanger 46 into
contact with casing string 40 preferably anchoring and sealing liner hanger 46
within casing string- 40. Thereafter, setting tool 50 may be retrieved from
wellbore 38. In the case wherein a previous setting operation failed, the
operation of setting tool 50 may be considered as a re-expansion operation of
20 liner hanger 46. In the case wherein no previous setting operation was
attempted, the operation of setting tool 50 may be considered as a primary
.
expansion operation of liner hanger 46.
Even though figure I depicts a liner string being installed in a
slanted wellbore, it should be understood by those skilled in the art .that the
25 present system is equally well suited' for use in wellbores having other
orientations including vertical wellbores, horizontal wellbores, deviated
wellbores or the like. Accordingly, it should bc undcrstood by those skilled in
the art that the use of directional terms such as above, below, upper,. lower,
upward, downward, uphole, downhole 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 tbward the bottom 'of the corresponding figure, the uphole
direction being toward the surface of the well; the downhole direction being
. .
toward the toe of the well. Also, even though figure' 1 depicts an offshore
operation, it should be understood by those skilled in the art that the present
system is equally well suited for use in onshore operations.
Referring next to figures 2A-2E, therein is depicted a well system
including a liner hanger setting tool positioned in a casing string having a liner
string disposed therein that is generally designated 100. As best seen in figures
2C-2D, a liner string 102 has been previously positioned but not set in casing
string 40. Liner string 102 may include any number of substantially tubular
sections that are preferably formed from jointed tubulars that are threadably
coupled together. ,In the illustrated section, liner string 102 includes a liner
hanger 104 having a plurality of resilient elements depicted as rubbers
20 elements 106 that are operable' to engage an inner surface of casing string 40
to establish a sealing and anchoring relationship therewith upon expansion of
liner hanger 104. Liner hanger 104 includes a cone receiver 108 and a liner
1 top 1 10. Liner hanger '104 may also include other elements such as a latch
1 profile 112 operable to engage or receive mating tools therein. i
Disposed within casing string 40 and partially within liner string 102 is
lincr hanger setting tool 120. Setting tool 120 includes a plurality of
substantially tubular members that may be referred to as a tubular mandrel
subassembly 122 that'coop.erate together to form a central bore 124 extending
5 throughout. Tubular mandrel subassembly 122 includes an upper body 126
that may be threadably and sealingly coupled to other components of the work
string at its upper end. Upper body 126 is threadably coupled to an upper
mandrel assembly 128that is threadably coupled to a cross over mandrel
assembly 130 that includes one or more fluid passageways 132 that are
10 depicted in dashed lines as they are not in illustrated .cross section. At its
lower end, cross over mandrel assembly 130is threadably coupled to an
intermediate mandrel assembly 134. A mandrel coupling 136 threadably
connects intermediate mandrel assembly 134 to lower mandrel assembly 138.
Lower mandrel assembly 138is threadably coupled to a lower body 140 that
15 may be threadably and sealingly coupled to other components of the work
string at its lower end such as anchor assembly 142.
Positioned generally between upper mandrel assembly 128and cross
over mandrel assembly 130 is a hydraulic communication assembly 144 that
includes a ball seat 146 and a fluid pathway 148 that is in fluid communication
20 with fluid passageways 132 of cross over mandrel .assembly 130. Setting tool
120 includes a .plurality of .substantially tubular members that may be referred
to as a tubular housing subassembly 150. Housing subassembly 150 includes
an upper housing assembly 152 that is threadably coupled'to an intermediate
housing assembly 154 that in turn is .threadably coupled to a lower housing '
25 assembly 156. Lower housing assembly 156 is threadably coupled to a locator
cylinder 158. As best seen in figure 5, locator cylinder 158 includes a
plurality of bypass ports 160 disposed about a radially reduced section 162 of
locator cylinder 158. In addition, locator cylinder 158includes a tapered nose
164 that aids in passage of setting tool 120 through wellbore restrictions such
5 as liner top' 110 through rotation of setting tool 120 upon reaching such
restrictions. Locator cylinder 158 also includes a shoulder 166 that may
operate as a no-go on liner top 110.
Setting tool 120 has an expansion cone assembly 1'80 that includes a
piston 182 that is slidably and sealingly received between, intennediate-
10 mandrel assembly 134 and locator cylinder 158. Expansion cone assembly
180 also includes a drive sleeve 184, a support ring 1.86, a support sleeve 188,
an expansion cone 190 and a shoe 192. Expansion cone 190 has a
frustoconical shape having a smallest outer diameter that is smaller than the
inner diameter of liner hanger 104. and a largest outer diameter that is larger
15 than the inner diameter of liner hanger 104. Expansion cone 190may be
received in cone receiver 108 of liner hanger 104, where the inner diameter of
liner hanger 104 is large enough to acccpt expansion cone 190 without having
been radially expanded, as best seen in figure 3C. ~rive'sleeve1 84 is initially
secured to mandrel coupling 136 by one or more frangible members depicted ''
20 as shear screws 192.
In operation and additionally referencing figures 3A-3E and 4A-4E,
setting tool 120 is used to install liner string 102 in casing string 40. In the
illustrated embodiment, liner string 102 has .been prepositioned in casing
string 40 on a previous run into. the wellbore such that liner hanger 106 is
25 disposed within a lower portion of casing string 40. For example, it may be
desirable to prepositioned liner string 102 in casing string 40 to allow a top
squeeze cement operation to place cement 194 between liner string 102 and
casing 40, as best seen in figures 6A-6B. Alternatively, liner string 102'maybe
prepositioned in casing string 40 due to a failure in a convention running
5 and setting operation associated with liner string 102. In any event, setting
tool 120 may be run in the wellbore on a work string 36 or other conveyance
, .
following the prepositioned liner string 102 in ,casing string 40. While
tripping into the wellbore, tapered nose 164 of locator cylinder 158 aids in
passage of setting tool 120 through wellbore restrictions including liner top
10 1 10 by rotating setting tool 120 upon reaching such restrictions. As best seen
in comparing figures 2C and 3C, as setting tool 120 enters liner string ,102, a
tight clearance exists between liner top 1 10 and locator cylinder 158. Tapered
nose 164 enables proper alignment and locating of setting tool 120 within liner
string 102 enabling insertion of setting tool 120 within liner string 102 until
15 shoulder 166 contacts liner'top 1 10, as best seen in figure 3C. : . .
Once setting tool 120 is suitable located within liner string 102,
anchor assembly 142 may be set hydraulically by pressurizing the fluid within
interior passageway 124, mechanically by, for example, rotation of work
string 36, or by other means to secure setting tool 120 within liner. string 102,
20 . as 'best seen in figure SE. A plug element depicted as .ball 196 may be
deployed into the wellbore to enable hydraulic operation of setting tool 120
and particularly expansion cone assembly 180; As best seen. in figure.'3A,
once ball 196 engages ball seat 146, fluid communication is established
between interior passageway 124 and fluid passageways 1'32 of cross over .
25 mandrel assembly 130 via fluid pathway 148 of hydraulic communication
assembly 144. In this configuration, fluid pressure from the surface may be
I applied to interior passageway 124 of setting tool 120 via work string 36.
With ball 196 blocking interior passageway 124, the fluid pressure enters fluid
pathway 148 of hydraulic communication assembly 144 and is directed to
5 fluid passageways 132 of cross over mandrel, assembly '130. The fluid
pressure then enters chamber 198 between mandrel subassembly .l22 and
housing subassembly 150 before acting on an upper surface of piston 182.
.Initially, the downhole force generated by the fluid pressure acting on piston
I 198 is counteracted by shear screws 192 that secure driye sleeve' 184 to '
10 mandrel coupling 136. When sufficient force is generated by the fluid
pressure acting on piston' 198, however, shear screws 192 are broken, allowing
relative movement between expansion cone assembly 180 and mandrel
subassembly 122.
To expand liner hanger 104, expansion cone assembly 180 is
15 driven downhole by the , fluid pressure acting on piston 198 such that
expansion cone 190 travels through liner hanger 104 to radially expand and
plastically deform lincr hang& 104. In certain instances, expansion cone 190
may be sized to radially expand and plastically deform. liner hanger 104 such ~ that the outer diameter of liner hanger 104 is .pressed into gripping and sealing . .
20 engagement with casing string 40, as best seen in figures 4C-4D. In the
illustrated embodiment, liner hanger 104 includes a plurality of
circumferential seals 106, that facilitate the gripping and sealing engagement
with casing string 40. Downhole travel of expansion cone assembly 180 and
expansion cone 190 ceases when piston 1.82 sufficiently enters radialljr
25 reduced section 162 of locator cylinder. 158 such that bypass ports' 160 are
exposed to the pressure within interior passageway '124. In this configuration,
the pressure enters the annulus between setting tool 120 and casing string 40
and travels'to the surface to provide a signal that the setting of liner hatiger
104 was successful. Once expansion cone 190 completes it travel through
5 liner. hanger 104 and radially expands liner hanger 104' into the desired
gripping and sealing engagement with casing string 40, setting tool. 120 may
' be disengaged from liner string 102 by. applying load andfor torque ,via work
string36 to release anchor assembly 142. Thereafter, setting tool 120 may be
retrieved to the surface with work string 36.
10 It should be understood by those skilled in the art that'the
illustrative embodiments described herein are not intended to be construed in a
limiting sense. Various modifications and combinations of the illustrative
embodiments as well as other embodiments will be apparent to persons skilled
in the art upon reference to this disclosure. It is, therefore, intended that the
15 appended claims encompass any such modifications or embodiments.

WE CLAIM:
1. A method for installing a liner string in a casing string disposed
within a wellbore, the method comprising:
positioning the liner string in the wellbore, the liner string including a
5 liner hanger and a liner top;
running the liner string through the casing string such that at least the
liner hanger is positioned within the wellbore casing;
after running the liner string through the casing string, positioning a
setting .tool in the wellbore, the setting tool having an expansion .cone
10 assembly and a locator cylinder;
running the setting tool through the casing string;
contacting the liner top with the locator cylinder;
axially moving the expansion cone assembly through the liner string to
radially expand the liner hanger into contact with the casing string; and
retrieving the setting tool out of the wellbore.
2. A method as claimed in claim 1 further comprising anchoring
the setting tool within the liner string before axially moving the expansion
cone assembly through the liner string.
3. A method as claimed in claim 2 wherein anchoring the setting.
tool within the liner string further comprises mechanically actuating an anchor
assembly operably associated with the setting tool.
. .
4. A method as claimed in claim 2 wherein anchoring the setting
tool within the liner string further comprises hydraulically actuating an anchor
assembly operably associated with the setting tool.
5 5. A method as claimed in claim 1 wherein axially. moving the
expansion cone assembly through the liner string further comprises
hydraulically shifting a piston operably associated with the expansion cone
' .
relative to the locator cylinder. . .
I 10 6. A method as claimed in claim 5 further comprising defining
I I full travel of the kxpansion cone assembly by exposing at least one bypass port
extending through the locator cylinder. to an operating fluid that hydraulically
shifts the piston.
7. A method as claimed in claim 1 wherein axially moving the
expansion cone assembly through the liner string'to radially expand the liner
hanger into contact with the casing string further comprises primary expansion
of the liner hanger.
. .
2 0 8. A method as claimed in claim 1 wherein axially moving the.
expansion cone assembly through the liner string to radially expand the liner
hanger into contact with the casing string further comprises re-expansion of
the liner hanger.
- 9. A method as claimed in claim 1 @her comprising cementing
at least a portion of the liner string from the liner top down bcfore positioning
the setting tool in the'wellbore.
5 10. A method as claimed in claim 1 wherein axially moving the
expansion cone assembly through the liner string to radially expand the liner
hanger into contact, with the casing string further c'omprises anchoring. and
sealing the liner hanger within the casing string.
10 1 1. A liner installation system for use in a wellbore having.a casing
. .
string disposed therein, the system comprising:
a liner string having.a liner hanger and a liner top; and
a setting tool having an expansion cone assembly and a locator
cylinder;
15 wherein, after running the liner string through the casing string such
. .
that at least the liner hangeris positioned within the casing s'tring, the setting
tool is run through the casing string until the locator cylinder contacts the liner
top; and
wherein, axially moving the expansion cone assembly through the liner
20 string radially expands the liner hanger into contact with the casing string.
12. A system as claimed in claim 11. wherein the' setting tool
further comprising an anchor assembly operable to anchor the setting tool
within the liner string before axially moving the expansion cone assembly
. .
25 through the liner string.
13. A system as claimed in claim 12 wherein the anchor assembly
further comprises a mechanically actuating anchor assembly.
5 14. - A system as claimed in claim 12 wherein the anchor assembly. . ,
further comprises a hydraulic~llya ctuating anchor assembly.
15. A system as claimed in ,claim 11 wherein the expansion cone
assembly further comprises a piston operable for axial movement relative to
10 the locator cylinder responsive to hydraulic pressure.
16. A system as claimed in claim 15 wherein the locator cylinder
further comprise sat least one bypass port operable to define full travel of the
expansion cone assembly when the bypass port is exposed to the hydraulic
15 pressure. .
17. A system as claimed in claim 1 wherein the radial cxpansion of
the liner hanger into contact with the. casing string further comprises primary
expansion.of the liner hanger.
20'
18. A system as chimed in claim 1 wherein the radial expansion of
the liner hanger into contact with the casing string further comprises reexpansion
of the liner hanger.
. '
- 19. A system as claimed in claim 1 further comprising cement
positioncd bcbvccn thc liner string and the casing string from the liner top
down prior to the setting tool being run through the casing string.
5 20. A system as claimed in claim 1 wherein the radial expansion of
the liner hanger into contact with the casing string further comprises anchoring
and sealing the liner hanger within the casing string.