Expandable drilling liner hanger assembly with anchor keys in dovetail grooves on hanger body

Abstract

An expandable liner hanger assembly is disclosed that may include a liner hanger body having a radially expandable tubing. The expandable liner hanger assembly may also include a groove formed in a radially outer surface of the liner hanger body, the groove configured to extend circumferentially around the liner hanger body. In addition, the expandable liner hanger assembly may include at least one anchor key having a base portion disposed within the groove. Further, an engagement end of the at least one anchor key may extend radially outward from the groove. The engagement end is configured to engage a casing string to anchor into the casing string in response to expansion of the drilling liner hanger body.

Description

Background Technology

[0001] During wellbore operations, the liner is typically "suspended" over the casing, supporting the extended tubing string below. As used herein, a "tubing string" refers to a series of connected sections of tubing, casing, fittings, screens, blind flanges, conversion tools, downhole tools, etc., inserted into the wellbore, whether for drilling, workover, production, injection, completion, or other processes. Tubing strings can penetrate and exit the casing, and similarly, they can penetrate uncased wellbore or wellbore sections. Furthermore, in many cases, as those skilled in the art will recognize, tools can run on wirelines or coiled tubing, rather than on a tubing string.

[0002] Expandable liner hangers are typically used to secure the liner within a previously installed wellbore fitting (e.g., casing or liner string). An expandable liner hanger is "placed" by radially expanding the hanger to clamp and seal against the wellbore fitting. For example, an expandable liner hanger can be expanded by using hydraulic pressure to drive an expansion cone, expansion wedge, or "pig" through the hanger. Other methods can be used, such as mechanical forging, explosive expansion, shape memory metal expansion, expandable material expansion, and electromagnetically driven expansion.

[0003] The expansion process is typically performed using a placement tool to deliver the liner hanger into the wellbore. The placement tool can be interconnected between the working string (e.g., a string consisting of drill pipe or other segmented or continuous tubular elements) and the liner hanger. The placement tool allows the liner hanger to expand to anchor and seal against the casing. Attached Figure Description

[0004] These accompanying drawings illustrate certain aspects of some embodiments of the present disclosure and are not intended to limit or restrict the method.

[0005] Figure 1 An elevation view of a well completion system according to some embodiments of the present disclosure is shown.

[0006] Figure 2 A cross-sectional view of an expandable liner hanger assembly of a well completion system according to some embodiments of the present disclosure is shown.

[0007] Figure 3 A cross-sectional view of a tailpipe suspension body having at least one anchoring key and at least one spike ridge according to some embodiments of the present disclosure is shown.

[0008] Figure 4 A cross-sectional view showing at least one anchor key engaging with a sleeve post according to some embodiments of the present disclosure is shown.

[0009] Figure 5A cross-sectional view of a tailpipe suspension body having grooves and corresponding anchoring keys of various shapes, according to some embodiments of the present disclosure, is shown.

[0010] Figure 6 A cross-sectional view is shown of a plurality of anchoring keys disposed in corresponding grooves in the tailpipe suspension body according to some embodiments of the present disclosure.

[0011] Figure 7 A cross-sectional view of an inlet groove formed in a tailpipe hanger body according to some embodiments of the present disclosure is shown.

[0012] Figure 8 A cross-sectional view of a retainer system according to some embodiments of the present disclosure is shown. Detailed Implementation

[0013] This document discloses an expandable tailpipe suspension assembly, and more particularly, an expandable tailpipe suspension assembly in which an anchoring key (e.g., an anchoring key) is mounted into a dovetail groove formed in the radially outer surface of the tailpipe suspension body of the expandable tailpipe suspension assembly. The anchoring key can be used in conjunction with spiked ridges projecting from the radially outer surface of the tailpipe suspension body to anchor the expandable tailpipe suspension assembly to the sleeve post. That is, the anchoring key and / or spiked ridges can be configured to engage the sleeve post in response to the expansion of the tailpipe suspension body to anchor the expandable tailpipe suspension assembly to the sleeve post.

[0014] Figure 1 An elevation view of a wellbore completion system according to some embodiments of the present disclosure is shown. As shown, the wellbore completion system 100 may include a casing 102 (e.g., a casing string) disposed within a wellbore (e.g., wellbore 104). Specifically, the casing 102 may be run into the well to a desired location during completion operations. Once in place, the casing 102 may be consolidated or otherwise secured in place. The casing 102 may support the surrounding downhole formation 118 during production operations. Further, the casing 102 may provide a flow path for produced fluids (e.g., hydrocarbons) along the wellbore 104.

[0015] Furthermore, as shown in the figure, the liner 106 can be secured to the downhole end 108 of the casing 102 via an expandable liner hanger assembly (e.g., liner hanger 110). Specifically, the liner 106 can be secured to the liner hanger 110, and the liner hanger 110 can be anchored to the downhole end 108 of the casing 102. During installation, the liner hanger 110 can be lowered into the well to the downhole end 108 of the casing 102. Once in place, at least one downhole tool 112 can be configured to actuate the expansion of the liner hanger 110. As described in more detail below, such expansion can drive at least one anchoring key 114 and / or at least one spike ridge 116 of the liner hanger 110 into the casing 102, thereby anchoring the liner hanger 110 to the casing 102.

[0016] Tailpipe 106 can be suspended from casing 102 via tailpipe hanger 110, such that tailpipe 106 extends downhole from the downhole end 108 of casing 102. Tailpipe 106 can extend along wellbore 104 for the flow path of produced fluids (e.g., hydrocarbons). During well completion operations, produced fluids can flow upward through tailpipe 106, tailpipe hanger 110, casing 102, and / or additional fittings to reach the surface. The terms “tailpipe,” “casing,” and “fittings” are generally used to describe tubular wellbore articles used for various purposes in wellbore operations. Tailpipe 106, casing 102, and fittings can be made of various materials (metals, plastics, composites, etc.), which may or may not expand as part of the installation procedure, and can be segmented or continuous. Tailpipe 106 or casing 102 does not require consolidation in place. Furthermore, any type of tailpipe, casing, or fitting can be used according to the principles of the invention.

[0017] Figure 2 A cross-sectional view of an expandable liner hanger assembly of a wellbore completion system according to some embodiments of the present disclosure is shown. As described above, the expandable liner hanger assembly (e.g., liner hanger 110) can be configured to expand to anchor into the casing 102 (e.g., Figure 1(As shown). The tailpipe hanger 110 may include a tailpipe hanger body 200 (e.g., a radially expandable tube). As shown, the tailpipe hanger body 200 may include a central bore 202 that forms an internal channel for the flow of output fluid through the tailpipe hanger 110. Further, the tailpipe hanger 110 may include at least one spiked ridge 116 that projects radially outward from the tailpipe hanger body 200 to engage the sleeve 102 in response to expansion of the tailpipe hanger 110. As described in more detail below, the at least one spiked ridge 116 may extend around the tailpipe hanger body 200. Alternatively, the at least one spiked ridge 116 may extend partially around the tailpipe hanger body 200. Further, the tailpipe hanger 110 may include any suitable number of spiked ridges 116. For example, as shown, the tailpipe hanger 110 may include a plurality of spiked ridges 116. The spikes 116 of the plurality of spikes may be offset axially and / or circumferentially relative to the tailpipe hanger body 200. Having additional spikes 116 can improve the anchoring of the tailpipe hanger 110 to the casing 102. Therefore, the number of spikes 116 formed along the axial direction of the tailpipe hanger body 200 can depend on several factors, such as, for example, the desired anchoring load. As described above, the at least one spike 116 may be configured to engage the casing 102 in response to the expansion of the tailpipe hanger body 200. In practice, when the tailpipe hanger 110 is lowered into the well, the at least one spike 116 may not contact the wellbore fittings (e.g., the casing 102). However, in response to the expansion of the tailpipe hanger 110 into an expanded state (e.g., ...), the spikes 116 may engage the casing 102. Figure 1 As shown), the at least one spike ridge 116 can be moved to engage with the sleeve 102.

[0018] The at least one spike ridge 116 may be made of any suitable steel, aluminum, any other ductile material, or combinations thereof. Additionally, the at least one spike ridge 116 may be made of one or more of the listed materials. For example, the at least one spike ridge 116 may be made of AISI 4140 steel or AISI 4340 steel. Furthermore, each at least one spike ridge 116 may have an annular shape extending around the tailpipe suspension body 200 at a specific axial position. For example, a first anchoring ridge 204 may extend along the outer periphery of the tailpipe suspension body 200 at a first axial position 206, and a second anchoring ridge 208 may extend along the outer periphery of the tailpipe suspension body 200 at a second axial position 210. Alternatively, at least one spike ridge 116 may extend axially along the tailpipe suspension body 200. Further, each at least one spike ridge 116 may have a different surface geometry without departing from the scope of this disclosure.

[0019] At least one spiked ridge 116 may be formed using any suitable method known to those skilled in the art. For example, in some embodiments, at least one spiked ridge 116 may be formed by machining the outer surface of the tailpipe hanger body 200. However, this disclosure is not limited to machining the ridge. In fact, the at least one spiked ridge 116 may be formed using any suitable method known to those skilled in the art. For example, in some embodiments, the at least one spiked ridge 116 may be formed as a separate structure that may be coupled to the tailpipe hanger body 200 using any suitable coupling mechanism known to those skilled in the art.

[0020] Therefore, each of the spiked ridges 116 can provide a metal-to-metal seal between the tailpipe hanger 110 and the sleeve 102. In some embodiments, the at least one spiked ridge 116 may have a flat-top portion 212. Using at least one spiked ridge 116 with a flat-top portion 212 instead of spikes or threads can be advantageous because a ridge 116 with a flat-top portion 212 may be less sensitive to sleeve variations and has a higher load capacity than a spiked ridge. The at least one spiked ridge 116 may be symmetrically aligned such that the angle θ is the same on both sides of each at least one spiked ridge 116. However, in some embodiments, the angle θ may differ on opposite sides of the at least one spiked ridge 116 without departing from the scope of this disclosure. The angle θ is referred to herein as the ridge angle (θ). In one embodiment, the ridge angle (θ) is selected such that, after expansion, the at least one spiked ridge 116 remains substantially normal to the tailpipe hanger body 200. For example, in some embodiments, the ridge angle (θ) may be selected in the range of approximately 30° to approximately 70°.

[0021] As used herein, the terms “fittings,” “tailpipes,” and “casings” are commonly used to describe tubular wellbore articles used for various purposes in wellbore operations. Fittings, tailpipes, and casings can be made of a variety of materials (metals, plastics, composites, etc.), which may or may not expand as part of the installation procedure, and can be segmented or continuous. Fittings, tailpipes, or casings do not require consolidation in place. Any type of fitting, tailpipe, or casing can be used in accordance with the principles of this disclosure.

[0022] It is understood that the tailpipe suspension 110 can be configured to support a significant amount of weight (e.g., the tailpipe 106 to which the tailpipe suspension 110 is attached) of the tailpipe 106. Figure 1(As shown). For deep and ultra-deep wells, subsea wells, etc., the liner 106 can apply significant axial loads to the suspension mechanism (e.g., the at least one spiked ridge 116) that engages the liner hanger 110 to the casing 102. Additionally, in many high-pressure / high-temperature applications, the industry is currently using high-grade steel (e.g., with minimum yield strengths of 860 MPa, 965 MPa, 1035 MPa, etc.) and increased wall thicknesses for the casing 102, which can lead to various problems with conventional suspension mechanisms. For example, conventional spiked ridges (e.g., with a minimum yield strength of 760 MPa or less) may not be able to engage with casing 102 having such yield strengths and / or wall thicknesses, and may not be able to deform such casing 102. Therefore, conventional spiked ridges, especially when used with high-grade steel wellbore fittings, may rely solely on metal-to-metal friction between the spiked ridge and the casing 102 to anchor the liner hanger 110 to the casing 102. Unfortunately, in some applications, metal-to-metal friction may not provide the required anchoring capability.

[0023] The number of spiked ridges 116 formed on the tailpipe hanger body 200 can be increased to increase the anchoring capability of the tailpipe hanger 110. However, the spiked ridges 116 may need to be sufficiently spaced. Therefore, in order to increase the number of at least one spiked ridge 116 formed on the tailpipe hanger body 200, the length of the tailpipe hanger body 200 may also need to be increased. Unfortunately, increasing the length of the tailpipe hanger body 200 may pose challenges for field installation and may also increase the cost of the tailpipe hanger 110 and the lowering tools used to expand the tailpipe hanger 110.

[0024] Therefore, as shown, the tailpipe hanger 110 may further include the at least one anchor key 114, which is configured to improve the axial load performance of the tailpipe hanger 110 without increasing the length of the tailpipe hanger 110. For example, the at least one anchor key 114 may be configured to replace at least one spike ridge 116. The anchor key 114 may have a higher yield strength than the sleeve 102, the tailpipe hanger body 200, and / or the at least one spike ridge 116. For example, the anchor key 114 may have a minimum yield strength of at least 1210 MPa (or at least 1380 MPa if not, at least 1720 MPa if not, or up to 2070 MPa or more). Having a higher yield strength than the sleeve 102 allows the at least one anchor key 114 to engage with the sleeve 102, which improves the axial load performance of the tailpipe hanger 110.

[0025] As shown in the figure, the liner hanger 110 may include a combination of spiked ridges 116 and at least one anchoring key 114. Compared to a liner hanger with only spiked ridges, this combination provides improved axial load retention performance while still retaining the sealing characteristics of the spiked ridges. As mentioned above, the at least one anchoring key 114 provides improved axial load performance than the at least one spiked ridge 116. However, the at least one spiked ridge 116 provides improved sealing than the at least one anchoring key 114. Therefore, the liner hanger 110 may be based on a wellbore completion system 100 (such as...). Figure 1 The combination of spiked ridge 116 and anchor key 114 is included to meet the anchoring load requirements and sealing requirements (as shown).

[0026] Furthermore, as described in more detail below, a groove 216 (e.g., a first groove 218) may be formed in the radially outer surface 220 of the tailpipe hanger body 200 to receive the at least one anchoring key 114. Specifically, the tailpipe hanger body 200 may include a circumferential groove ridge 222 projecting radially outward from the radially outer surface 220 of the tailpipe hanger body 200. The groove 216 may be formed in the circumferential groove ridge 222. Further, the groove 216 may be configured to extend circumferentially around the tailpipe hanger body 200. The at least one anchoring key 114 may be received within the groove 216 such that at least a portion of the at least one anchoring key 114 projects radially outward from the groove 216 to engage the sleeve 102 in response to expansion of the tailpipe hanger body 200.

[0027] Additionally, as described in more detail below, the at least one anchoring key 114 may include a plurality of anchoring keys 114 disposed within each groove 216 formed in the tailpipe hanger body 200. For example, the tailpipe hanger 110 may include a second groove 224 formed in a second circumferential groove ridge 226 projecting radially outward from the radially outer surface 220 of the tailpipe hanger body 200. The second groove 224 may also extend circumferentially around the tailpipe hanger body 200. Further, the at least one anchoring key 114 may include a first set of anchoring keys 228 disposed with the first groove 218 and a second set of anchoring keys 230 disposed within the second groove 224.

[0028] Figure 3A cross-sectional view of a tailpipe hanger body having at least one anchoring key and at least one spiked ridge according to some embodiments of the present disclosure is shown. As described above, a groove 216 may be formed in the radially outer surface 220 of the tailpipe hanger body 200. In particular, the groove 216 may be formed in a circumferential groove ridge 222 projecting radially outward from the radially outer surface 220 of the tailpipe hanger body 200. The circumferential groove ridge 222 may include an upper sidewall 300 and a lower sidewall 302, each sidewall extending at least partially from the tailpipe hanger body 200 in a radially outward direction. An outer ridge surface 304 of the circumferential groove ridge 222 may extend between the respective radially outer edges of the upper sidewall 300 and the lower sidewall 302. The outer ridge surface 304 may be substantially flat. For example, as shown, the circumferential groove ridge 222 may include a trapezoidal cross-section. However, the circumferential groove ridge 222 may include any suitable shape for receiving the groove 216.

[0029] Furthermore, similar to the at least one spiked ridge 116, the circumferential groove ridge 222 can be made of any suitable steel grade, aluminum, any other ductile material, or combinations thereof. Additionally, the circumferential groove ridge 222 can be made of one or more of the listed materials. For example, the circumferential groove ridge 222 can be made of AISI 4140 steel or AISI 4340 steel. Furthermore, each circumferential groove ridge 222 can have an annular shape extending around the tailpipe suspension body 200 at a specific axial location. Alternatively, the circumferential groove ridge 222 can extend axially along the tailpipe suspension body 200. Further, each circumferential groove ridge 222 can have a different surface geometry without departing from the scope of this disclosure.

[0030] The circumferential groove ridge 222 can be formed using any suitable method known to those skilled in the art. For example, in some embodiments, the circumferential groove ridge 222 can be formed by machining the outer surface of the tailpipe hanger body 200. However, this disclosure is not limited to machining the ridge. In fact, the circumferential groove ridge 222 can be formed using any suitable method known to those skilled in the art. For example, in some embodiments, the circumferential groove ridge 222 can be formed as a separate structure that can be coupled to the tailpipe hanger body 200 using any suitable coupling mechanism known to those skilled in the art.

[0031] Furthermore, as described above, the groove 216 may be formed in the circumferential groove ridge 222. Specifically, the groove 216 may extend along the circumferential groove ridge 222 such that the groove 216 extends around the tailpipe hanger 110. The groove 216 may include any suitable cross-sectional shape configured to retain the at least one anchoring key 114 within the groove 216. For example, as shown, the groove 216 may be a dovetail groove having a trapezoidal cross-section. The groove 216 may include an inner base surface 306, an upper surface 308, and a lower surface 310. The upper surface 308 and the lower surface 310 may extend radially outward from the inner base surface 306. As shown, an upper groove edge 312 may be formed at the radially outer end of the upper surface 308, and a lower groove edge 314 may be formed at the radially outer end of the lower surface 310. Furthermore, at least one of the upper surface 308 and the lower surface 310 may form an acute angle with the inner base surface 306, such that the inner base surface 306 has an axial width greater than the key gap 316 formed between the upper groove edge 312 and the lower groove edge 314. Typically, in order to retain the at least one anchoring key 114, the groove may be shaped such that at least a portion of the axial width between the upper surface 308 and the lower surface 310 is greater than the axial width of the key gap 316.

[0032] As described above, at least a portion of the at least one anchoring key 114 may be disposed within the groove 216. Specifically, the at least one anchoring key 114 may include a base portion 318 disposed within the groove 216. At least a portion of the base portion 318 may have an axial width greater than the key gap 316, such that the upper groove edge 312 and the lower groove edge 314 may interface with the base portion 318 to constrain radial movement of the base portion 318 and retain the at least one anchoring key 114 within the groove 216. Further, the base portion 318 may be configured to interface with the upper side surface 308 and the lower side surface 310 to constrain lateral movement and / or rotation of the at least one anchoring key 114 relative to the groove 216.

[0033] Further, the at least one anchoring key 114 may include an engagement portion 320 configured to extend radially outward from the key gap 316 of the groove 216 relative to the tailpipe hanger body 200. The engagement portion 320 is configured to engage the sleeve 102 in response to expansion of the tailpipe hanger body 200 to anchor the tailpipe hanger 110 to the sleeve 102 (e.g., Figure 1 (As shown). The engagement portion 320 may taper in a radially outward direction, such that the engagement portion 320 narrows near the radially outer end of the at least one anchoring key 114. The engagement portion 320 may be configured to narrow to a sharp tip, a rounded tip, or any suitable tip. As shown, the engagement portion 320 narrows to a flat tip configured to engage the sleeve 102.

[0034] Furthermore, the tailpipe hanger 110 may include the at least one spiked ridge 116, which is configured to be adjacent to but axially offset from the at least one anchoring key 114 and the corresponding circumferential grooved ridge 222. As described above, the at least one spiked ridge 116 projects radially outward from the radially outer surface 220 of the tailpipe hanger body 200 and is configured to engage the sleeve 102 in response to expansion of the tailpipe hanger body 200. In particular, the at least one spiked ridge 116 may taper in the radially outward direction 322 to form a tip 324 at the radially outer end of the at least one spiked ridge 116. The tip 324 of the at least one spiked ridge 116 may be configured to engage the sleeve 102.

[0035] As shown in the figure, relative to the tailpipe hanger body 200, the at least one spiked ridge 116 extends radially outward beyond the outer ridge surface 304 of the circumferential grooved ridge 222. That is, the at least one spiked ridge 116 may have a greater radial height than the circumferential grooved ridge 222. Furthermore, the at least one anchoring key 114 may extend radially outward from the circumferential grooved ridge 222, such that the at least one anchoring key 114 also has a greater radial height than the circumferential grooved ridge 222. In practice, the radial height of the circumferential grooved ridge 222 may be configured based on the corresponding heights of the at least one spiked ridge 116 and the at least one anchoring key 114, such that the circumferential grooved ridge 222 has minimal contact with the sleeve 102 during engagement of the tailpipe hanger 110 and the sleeve 102. If the circumferential grooved ridge 222 contacts the sleeve 102, the performance of the at least one anchoring key 114 may be adversely affected. Furthermore, the at least one anchoring key 114 may extend radially outward beyond the at least one spiked ridge 116. Alternatively, the at least one anchor key 114 and the at least one spike ridge 116 may have the same radial height, or the at least one spike ridge 116 may have a greater radial height than the at least one anchor key 114.

[0036] Figure 4 A cross-sectional view is shown of at least one anchor key engaged with a sleeve post according to some embodiments of the present disclosure. The anchor key 114 may be formed of any of a variety of suitable materials. For example, the anchor key 114 may be formed of any metal, plastic, or composite material having sufficient yield strength. As mentioned above, the at least one anchor key 114 may have a minimum yield strength of at least 1,210 MPa. For example, the at least one anchor key 114 may have a yield strength between 1,210 MPa and 1,380 MPa. Alternatively, the at least one anchor key 114 may have a yield strength between 1,380 MPa and 1,720 MPa, between 1,720 MPa and 2,070 MPa, or higher than 2,070 MPa.

[0037] Having a higher yield strength than sleeve 102 allows the at least one anchoring key 114 to more effectively bite into (e.g., pierce, retract, etc.) sleeve 102, which improves the axial load performance of tailpipe hanger 110. In practice, the at least one anchoring key 114 may be made of material having a higher yield strength than the at least one spiked ridge 116 (e.g., Figure 3 The material is formed with a higher yield strength (e.g., higher hardness) to enable the anchor key 114 to achieve a larger indentation in the casing 102 than the at least one spike ridge 116. The anchor key 114 improves the anchoring force of the liner hanger 110, for example, by having a higher contact force than the at least one spike ridge 116 and by creating a localized indentation in the wellbore fitting (e.g., casing 102). As shown, the at least one anchor key 114 can be configured to retract the casing 102 in response to the engagement of the at least one anchor key 114 to form a recess 400 corresponding to the at least one anchor key 114. The axial interface between the at least one anchor key 114 and the recess 400 formed in the casing 102 can be configured to anchor the liner hanger 110 to the casing 102 by retaining at least a portion of the axial load required for the liner hanger 110.

[0038] Additionally, the at least one anchor key 114 may comprise a material with sufficient ductility to withstand the compressive force applied to the at least one anchor key 114 as the expansion of the tailpipe suspension body 200 drives the at least one anchor key 114 into the sleeve 102.

[0039] Figure 5 A cross-sectional view of a tailpipe hanger body having a groove and corresponding anchor keys of various shapes according to some embodiments of the present disclosure is shown. As shown, the tailpipe hanger 110 may include a first groove 218 having a hexagonal cross-section and a corresponding first anchor key 500 disposed within the first groove 218. A first base portion 502 of the first anchor key 500 may include a shape corresponding to the first groove 218. Further, the first anchor key 500 may include a first engagement portion 510 extending radially outward from a first key gap 514. The first engagement portion 510 may include any suitable anchor key tip 504. As shown, the first engagement portion 510 may include a flat anchor key tip 504.

[0040] Furthermore, the tailpipe hanger 110 may include a second groove 224 and a corresponding second anchoring key 506 disposed within the second groove 224. As shown, the second anchoring key 506 may have a circular cross-section, wherein a second base portion 508 is disposed within the second groove 224, and a second engagement portion 512 extends radially outward from the second key gap 516. The tailpipe hanger 110 may include a groove 216 having any suitable shape and a corresponding anchoring key 114, such that the groove 216 holds the corresponding anchoring key 114.

[0041] Figure 6 A cross-sectional view is shown of a plurality of anchoring keys disposed in corresponding grooves of the tailpipe suspension body according to some embodiments of the present disclosure. As described above, the at least one anchoring key 114 may include a plurality of anchoring keys 114 configured to be disposed in corresponding grooves 216. That is, the at least one anchoring key 114 may include a first set of anchoring keys 228, and each anchoring key 114 of the first set of anchoring keys 228 may be disposed in a first groove 218.

[0042] As shown, the first set of anchor keys 228 may include twenty separate anchor keys 114. However, the first set of anchor keys 228 may include any suitable number of anchor keys 114. For example, the first set of anchor keys 228 may alternatively include four separate anchor keys 114, eighteen separate anchor keys 114, twenty-four separate anchor keys 114, or any suitable number of separate anchor keys 114. The circumferential dimension of each separate anchor key 114 may be based at least in part on the number of separate anchor keys 114 disposed within the groove 216. For example, each separate anchor key 114 in a set of eighteen anchor keys 114 may be configured to extend circumferentially around the tailpipe suspension body 200 at a key angle 600 between five and twenty degrees. Each of the separate anchor keys 114 may have the same dimensions. Alternatively, the separate anchor keys 114 may have various dimensions. Furthermore, the anchor keys 114 may be equidistant from each other in the first groove 218. Alternatively, the anchor keys 114 may be unevenly spaced within the first groove 218.

[0043] Furthermore, the anchor key 114 may be manufactured from a ring, such as a metal ring. The ring can then be cut into individual segments to form separate anchor keys 114. Suitable techniques for cutting the ring may include, for example, electrical discharge machining (EDM), such as wire EDM. However, the manufacture of the anchor key 114 is not limited to wire EDM of the ring. Any suitable technique for forming the anchor key 114 may be used according to this embodiment. For example, alternative techniques may include manufacturing each of the anchor keys 114 separately from raw materials.

[0044] Further, as shown in the figure, the radially inner surface 602 of each of the plurality of anchor keys 114 may include a curvature corresponding to the radially outer surface 604 of the tailpipe hanger body 200. That is, the radius of curvature of the radially inner surface 602 of each anchor key 114 may be substantially the same as the radius of curvature of the radially outer surface 604 of the tailpipe hanger body 200, which can improve the force transmission between the plurality of anchor keys 114 and the tailpipe hanger body 200. Further, the anchor keys 114 have a curved radially inner surface 602, which can improve the ease of movement of the plurality of anchor keys 114 along the groove 216 during insertion of the anchor keys 114 into the groove 216.

[0045] Figure 7 A cross-sectional view of an inlet groove formed in a tailpipe hanger body according to some embodiments of the present disclosure is shown. As described above, a circumferential groove ridge 222 may be formed in the radially outer surface 220 of the tailpipe hanger body 200. The circumferential groove ridge 222 may include a groove 216 (e.g., a dovetail groove) formed therein. As shown, the tailpipe hanger 110 may further include an inlet groove 700 formed along the groove 216 to allow the insertion of anchor keys 114 into the groove 216. During installation, each anchor key 114 may be inserted into the groove 216 one after another at the inlet groove 700. That is, a first anchor key 500 may be inserted into the groove 216 via the inlet groove 700. After the first anchor key 500 is inserted, a second anchor key 506 may be inserted into the groove 216 via the inlet groove 700. Contact between the second anchor key 506 and the first anchor key 500 may drive the first anchor key 500 further into the groove. Each anchor key 114 can be similarly inserted into the groove 216 via the inlet slot 700.

[0046] Furthermore, the inlet groove 700 may include a groove formed in the radially outer surface 220 of the tailpipe hanger body 200, which is circumferentially aligned with the recess 216. The axial inlet groove width 702 of the inlet groove 700 may be greater than the axial key gap width 704 of the key gap 316. Further, the axial inlet groove width 702 of the inlet groove 700 may be greater than the base portion 318 of the at least one anchoring key 114 (e.g., Figure 3 The axial width (as shown) allows the at least one anchor key 114 to be radially inserted into the inlet groove 700. With the at least one anchor key 114 disposed in the inlet groove 700, the base portion 318 of the anchor key 114 can be radially inwardly disposed from the key gap 316 of the groove 216, allowing the at least one anchor key 114 to slide circumferentially from the inlet groove 700 into the groove 216.

[0047] Figure 8A cross-sectional view of a retainer system according to some embodiments of the present disclosure is shown. As described above, the anchor key 114 can be inserted into the recess 216 via an inlet groove 700. The retainer system 800 can retain the anchor key 114 within the recess 216 after insertion. In particular, the retainer system 800 can be configured to block at least a portion of the inlet groove 700 to restrain movement of the at least one anchor key 114 through the inlet groove 700. That is, the retainer system 800 can prevent the anchor key 114 from leaving the recess 216 via the inlet groove 700.

[0048] The retainer system 800 may include a retaining feature 802 that may be fixed above at least a portion of the inlet groove 700 to restrain the movement of the at least one anchoring key 114 through the inlet groove 700. For example, as described above, the groove 216 may include a dovetail groove 216 formed within a circumferential groove ridge 222 between an upper sidewall 300 and a lower sidewall 302 of the circumferential groove ridge 222. The inlet groove 700 may be formed in the upper sidewall 300, the lower sidewall 302, or some combination thereof. As shown, the inlet groove 700 is formed in the upper sidewall 300. In particular, the upper sidewall 300 at the inlet groove 700 may extend less radially outward than the upper sidewall 300 along the groove 216, such that the keyway gap 804 at the inlet groove 700 has a larger axial width than the axial keyway gap width 704 along the keyway gap 316 of the groove 216. However, the retaining feature 802 may include a retaining block 806 positioned at the inlet groove 700. For example, as shown, the retaining block 806 may be secured to the upper sidewall 300. The retaining block 806 may extend radially outward from the upper sidewall 300. Additionally, the retaining block 806 may include an angled surface 808 that further reduces the axial width between the retaining block 806 and the lower sidewall 302 and prevents the anchoring key 114 from passing through the inlet groove 700 and exiting the recess 216.

[0049] Furthermore, as shown, fasteners (e.g., set screws 810) can be used to secure the retaining block 806 to the tailpipe hanger body 200. Specifically, the set screws 810 can be used to secure the retaining block 806 to the upper sidewall 300, the lower sidewall 302, or some combination thereof. However, the retaining block 806 can be secured to the tailpipe hanger body 200 via any suitable fastener. Further, the retaining block 806 may include a channel 812 configured to receive the upper sidewall 300 and / or the lower sidewall 302 formed on the tailpipe hanger body 200 to aid in securing the retaining block 806 in the inlet groove 700. Additionally or alternatively, the retainer system 800 may include a T-clamp (not shown) that can expand and permanently lock into the inlet groove 700, which can be closed by welding and / or by 3D printing. For example, metal or alloy can be applied via welding and / or 3D printing to partially fill the inlet groove 700.

[0050] Therefore, this disclosure provides an expandable stern tube hanger assembly having at least one anchoring key to improve the anchoring of the stern tube hanger to the sleeve. Systems and methods may include any of the various features disclosed herein, including one or more of the following statements.

[0051] Statement 1. An expandable tailpipe suspension assembly comprising: a tailpipe suspension body, wherein the tailpipe suspension body includes a radially expandable tube; a groove formed in a radially outer surface of the tailpipe suspension body, wherein the groove is configured to extend circumferentially around the tailpipe suspension body; and at least one anchoring key having a base portion disposed within the groove, wherein an engaging end of the at least one anchoring key extends radially outward from the groove, wherein the engaging end is configured to engage a sleeve post in response to expansion of the tailpipe suspension body for anchoring to the sleeve post.

[0052] Statement 2. The expandable tailpipe suspension assembly according to Statement 1, wherein the engaging end of the at least one anchoring key extends radially outward from the groove via a key gap formed between the upper groove edge and the lower groove edge, and wherein at least a portion of the base portion of the at least one anchoring key has a width greater than the key gap to retain the at least one anchoring key together with the groove.

[0053] Statement 3. The expandable tailpipe suspension assembly according to Statement 1 or Statement 2, wherein the groove includes a dovetail groove.

[0054] Statement 4. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the tailpipe suspension body includes a circumferential groove ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, and wherein the groove is formed in the circumferential groove ridge.

[0055] Statement 5. The expandable tailpipe suspension assembly according to any of the foregoing statements further includes a spiked ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, wherein the spiked ridge extends circumferentially around the tailpipe suspension body, wherein the spiked ridge is axially offset from the circumferential grooved ridge, and wherein the spiked ridge is configured to engage the sleeve post in response to expansion of the tailpipe suspension body to help anchor the tailpipe suspension body to the sleeve post.

[0056] Statement 6. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the cross-section of the spike ridge tapers in a radially outward direction to form a tip at the radially outer end of the spike ridge, and wherein the tip is configured to engage the sleeve post.

[0057] Statement 7. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the spike ridge extends radially outward beyond the radially outer end of the circumferential groove ridge relative to the tailpipe suspension body.

[0058] Statement 8. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the at least one anchoring key extends radially outward beyond the spike ridge.

[0059] Statement 9. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the at least one anchoring key comprises a plurality of anchoring keys, wherein each anchoring key is disposed within a groove, and wherein the anchoring keys are equidistantly positioned from each other within the groove.

[0060] Statement 10. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein each of the plurality of anchor keys is configured to extend circumferentially around the tailpipe suspension body between five and twenty degrees.

[0061] Statement 11. The expandable tailpipe suspension assembly according to any of the foregoing statements further includes a second groove formed in the radially outer surface of the tailpipe suspension body, wherein the second groove is configured to extend circumferentially around the tailpipe suspension body, and wherein the at least one anchoring key includes a first set of separate anchoring keys disposed together with the groove and a second set of separate anchoring keys disposed within the second groove.

[0062] Statement 12. The expandable tailpipe suspension assembly according to any of the preceding statements further includes an inlet groove formed along a recess, wherein the inlet groove has a wider width than the base portion of the at least one anchoring key, wherein the inlet groove is configured to provide a channel for inserting the at least one anchoring key into the recess.

[0063] Statement 13. The expandable tailpipe suspension assembly according to any of the foregoing statements further includes a retainer system configured to block at least a portion of the inlet slot to restrain movement of the at least one anchoring key through the inlet slot.

[0064] Statement 14. The expandable tailpipe suspension assembly according to any of the preceding statements, wherein the at least one anchoring key has a minimum yield strength of at least 1,210 MPa.

[0065] Statement 15. The expandable tailpipe hanger assembly according to any of the preceding statements, wherein the at least one anchoring key is configured to retract the sleeve post to form a recess corresponding to the at least one anchoring key, and wherein the interface between the at least one anchoring key and the recess formed in the sleeve post is configured to anchor the tailpipe hanger to the sleeve post.

[0066] Statement 16. An expandable tailpipe hanger assembly comprising: a tailpipe hanger body, wherein the tailpipe hanger body includes a radially expandable tube; a circumferential groove ridge extending radially outward from a radially outer surface of the tailpipe hanger body; a dovetail groove formed in the circumferential groove ridge, wherein the dovetail groove is configured to extend circumferentially around the tailpipe hanger body; at least one anchoring key having a base portion disposed within the dovetail groove, wherein an engaging end of the at least one anchoring key extends radially outward from the dovetail groove, wherein the engaging end is configured to engage a sleeve post in response to expansion of the tailpipe hanger body to anchor to the sleeve post; an inlet groove formed along the dovetail groove, wherein the inlet groove has a width greater than the base portion of the at least one anchoring key, wherein the inlet groove is configured to provide a channel for inserting the at least one anchoring key into the dovetail groove; and a retainer system having a retaining feature fixable above at least a portion of the inlet groove to restrain movement of the at least one anchoring key through the inlet groove.

[0067] Statement 17. The expandable tailpipe suspension assembly of Statement 16 further includes a spiked ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, wherein the spiked ridge extends circumferentially around the tailpipe suspension body, wherein the spiked ridge is axially offset from the circumferential grooved ridge, wherein the spiked ridge is configured to engage a sleeve post in response to expansion of the tailpipe suspension body to aid in anchoring the tailpipe suspension body to the sleeve post, and wherein the spiked ridge extends radially outward further than the radially outer end of the circumferential grooved ridge relative to the tailpipe suspension body.

[0068] Statement 18. The expandable tailpipe suspension assembly according to Statement 16 or Statement 17, wherein the retaining feature includes a retaining block that can be secured within at least a portion of the inlet slot via fasteners.

[0069] Statement 19. The expandable tailpipe suspension assembly according to any one of Statements 16 to 18, wherein the at least one anchoring key comprises a plurality of anchoring keys, wherein each anchoring key is disposed within a dovetail groove, and wherein the anchoring keys are equidistantly positioned relative to each other within the dovetail groove.

[0070] Statement 20. A method comprising: inserting an expandable liner hanger assembly into a wellbore, wherein the expandable liner hanger assembly includes a liner hanger body, wherein the liner hanger body includes a groove formed in a radially outer surface of the liner hanger body and said at least one anchoring key disposed within the groove, wherein the groove is configured to extend circumferentially around the liner hanger body, wherein a base portion of said at least one anchoring key is disposed within the groove, and wherein an engaging end of said at least one anchoring key extends radially outward from the groove; and expanding the liner hanger body to drive said at least one anchoring key to engage a casing string disposed within the wellbore and anchor the expandable liner hanger assembly to the casing string.

[0071] For the sake of brevity, only certain ranges are explicitly disclosed herein. However, a range beginning with any lower limit can be combined with any upper limit to enumerate ranges not explicitly listed, and a range beginning with any lower limit can be combined with any other lower limit to enumerate ranges not explicitly listed, and in the same way, a range beginning with any upper limit can be combined with any other upper limit to enumerate ranges not explicitly listed. Furthermore, whenever a range of values ​​with lower and upper limits is disclosed, any quantity falling within that range and any range included therein is specifically disclosed. In particular, even if not explicitly listed, each range of values ​​disclosed herein (in the form of “about a to about b,” or equivalently “approximately a to b,” or equivalently “approximately ab”) should be understood as describing every number and range covered within a broader range of values. Therefore, each point or individual value can serve as its own lower or upper limit, or any other lower or upper limit, combined with any other point or individual value, to enumerate ranges not explicitly listed.

[0072] Therefore, this embodiment is well suited to achieve the stated objects and advantages, as well as those inherent therein. The specific embodiments disclosed above are merely illustrative, as these embodiments can be modified and practiced in different but equivalent ways that will be apparent to those skilled in the art who benefit from the teachings herein. While individual embodiments are discussed, this disclosure contemplates and covers all combinations of each embodiment. Furthermore, the details of the constructions or designs shown herein are not intended to be limited beyond what is described in the following claims. Additionally, the terms in the claims have their ordinary, general meaning unless otherwise expressly and clearly defined by the patentee. Therefore, it is apparent that the specific illustrative embodiments disclosed above can be changed or modified, and all such changes are considered to be within the scope and spirit of this disclosure.

Claims

1. An expandable tailpipe suspension assembly, comprising: Tailpipe hanger body, wherein the tailpipe hanger body includes a radially expandable tube; A groove is formed in the radial outer surface of the tailpipe suspension body, wherein the groove is configured to extend circumferentially around the tailpipe suspension body. as well as At least one anchoring key having a base portion disposed within the groove, wherein an engaging end of the at least one anchoring key extends radially outward from the groove, wherein the engaging end is configured to engage a sleeve post in response to expansion of the tailpipe suspension body to anchor into the sleeve post.

2. The expandable tailpipe suspension assembly of claim 1, wherein the engaging end of the at least one anchoring key extends radially outward from the groove via a key gap formed between the upper groove edge and the lower groove edge, and wherein at least a portion of the base portion of the at least one anchoring key has a width greater than the key gap to retain the at least one anchoring key together with the groove.

3. The expandable tailpipe hanger assembly of claim 1, wherein the groove includes a dovetail groove.

4. The expandable tailpipe suspension assembly of claim 1, wherein the tailpipe suspension body includes a circumferential groove ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, and wherein the groove is formed in the circumferential groove ridge.

5. The expandable tailpipe suspension assembly of claim 4, further comprising a spiked ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, wherein the spiked ridge extends circumferentially around the tailpipe suspension body, wherein the spiked ridge is axially offset from the circumferential grooved ridge, and wherein the spiked ridge is configured to engage the sleeve post in response to expansion of the tailpipe suspension body to aid in anchoring the tailpipe suspension body to the sleeve post.

6. The expandable tailpipe suspension assembly of claim 5, wherein the cross-section of the spike ridge tapers in a radially outward direction to form a tip at the radially outer end of the spike ridge, and wherein the tip is configured to engage the sleeve post.

7. The expandable tailpipe suspension assembly of claim 5, wherein the spiked ridge extends radially outward beyond the radially outer end of the circumferential grooved ridge relative to the tailpipe suspension body.

8. The expandable tailpipe suspension assembly of claim 5, wherein the at least one anchoring key extends radially outward beyond the spike ridge.

9. The expandable tailpipe suspension assembly of claim 1, wherein the at least one anchoring key comprises a plurality of anchoring keys, wherein each anchoring key is disposed within the groove, and wherein the anchoring keys are equidistantly positioned relative to each other within the groove.

10. The expandable tailpipe suspension assembly of claim 9, wherein each of the plurality of anchoring keys is configured to extend circumferentially around the tailpipe suspension body at an angle between five and twenty degrees.

11. The expandable tailpipe suspension assembly of claim 1, further comprising a second groove formed in the radially outer surface of the tailpipe suspension body, wherein the second groove is configured to extend circumferentially around the tailpipe suspension body, and wherein the at least one anchoring key comprises a first set of separate anchoring keys disposed together with the groove and a second set of separate anchoring keys disposed within the second groove.

12. The expandable tailpipe suspension assembly of claim 1, further comprising an inlet groove formed along the recess, wherein the inlet groove has a wider width than the base portion of the at least one anchor key, wherein the inlet groove is configured to provide a channel for inserting the at least one anchor key into the recess.

13. The expandable tailpipe suspension assembly of claim 12, further comprising a retainer system configured to block at least a portion of the inlet slot to restrain movement of the at least one anchoring key through the inlet slot.

14. The expandable tailpipe suspension assembly of claim 1, wherein the at least one anchoring key has a minimum yield strength of at least 1,210 MPa.

15. The expandable tailpipe hanger assembly of claim 1, wherein the at least one anchoring key is configured to retract the sleeve post to form a recess corresponding to the at least one anchoring key, and wherein the interface between the at least one anchoring key and the recess formed in the sleeve post is configured to anchor the tailpipe hanger to the sleeve post.

16. An expandable tailpipe suspension assembly, comprising: Tailpipe hanger body, wherein the tailpipe hanger body includes a radially expandable tube; A circumferential groove ridge extends radially outward from the radially outer surface of the tailpipe hanger body; A dovetail groove is formed in the circumferential groove ridge, wherein the dovetail groove is configured to extend circumferentially around the tailpipe suspension body; At least one anchoring key having a base portion disposed within the dovetail groove, wherein the engaging end of the at least one anchoring key extends radially outward from the dovetail groove, wherein the engaging end is configured to engage a sleeve post in response to expansion of the tailpipe hanger body to anchor to the sleeve post. An inlet groove is formed along the dovetail groove, wherein the inlet groove has a wider width than the base portion of the at least one anchor key, and wherein the inlet groove is configured to provide a channel for inserting the at least one anchor key into the dovetail groove; as well as A retainer system having a retaining feature that can be fixed above at least a portion of the inlet groove to restrain the movement of the at least one anchoring key through the inlet groove.

17. The expandable tailpipe suspension assembly of claim 16, further comprising a spiked ridge projecting radially outward from the radially outer surface of the tailpipe suspension body, wherein the spiked ridge extends circumferentially around the tailpipe suspension body, wherein the spiked ridge is axially offset from the circumferential grooved ridge, wherein the spiked ridge is configured to engage the sleeve post in response to expansion of the tailpipe suspension body to aid in anchoring the tailpipe suspension body to the sleeve post, and wherein the spiked ridge extends radially outward beyond the radially outer end of the circumferential grooved ridge relative to the tailpipe suspension body.

18. The expandable tailpipe suspension assembly of claim 16, wherein the retaining feature comprises a retaining block that can be secured within at least a portion of the inlet slot via fasteners.

19. The expandable tailpipe suspension assembly of claim 16, wherein the at least one anchoring key comprises a plurality of anchoring keys, wherein each anchoring key is disposed within the dovetail groove, and wherein the anchoring keys are equidistantly positioned relative to each other within the dovetail groove.

20. A method comprising: An expandable liner hanger assembly is inserted into the wellbore, wherein the expandable liner hanger assembly includes a liner hanger body, wherein the liner hanger body includes a groove formed in the radially outer surface of the liner hanger body and at least one anchoring key disposed in the groove, wherein the groove is configured to extend circumferentially around the liner hanger body, wherein a base portion of the at least one anchoring key is disposed in the groove, and wherein an engaging end of the at least one anchoring key extends radially outward from the groove. as well as The liner hanger body expands to drive the at least one anchoring key to engage the casing string disposed within the wellbore and to anchor the expandable liner hanger assembly to the casing string.

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