Tools for well completion with a separable, partially retrievable, expansion cone

Abstract

A running tool utilizes bottom-up expansion to expand a dog-bone-shaped liner hanger (also referred to as an anchor) connected at the top of a liner. The running tool includes a multi-portion cone comprising an outer portion, which can be a slim solid conical piece, a base portion, which supports the outer portion, and a mechanism to selectively couple or decouple the outer and base portions. The multi-portion cone allows most of the running tool to be retrieved along with the drill pipe onto which it is suspended while leaving the liner and liner hanger unexpanded in the well.

Description

TOOLS FOR WELL COMPLETION WITHA SEPARABLE, PARTIALLY RETRIEVABLE, EXPANSION CONEBACKGROUND

[0001] The disclosure relates generally to systems and methods for deploying a tubular in a well and expanding the tubular downhole in the bottom-up direction. The disclosure relates more particularly to an expandable cone and / or a mechanism that is partially retrievable without requiring the full expansion of the tubular.

[0002] In a known running tool used in bottom-up liner expansion, there is often a solid cone or another expansion cone that is part of the running tool. Because the expansion is performed using a bottom-up direction, the solid cone is located below a steel shoulder of the portion of the liner to be expanded. As such, the running tool can carry the weight of the liner applied by the steel shoulder on the face of the solid cone before its expansion. However, in order to retrieve the drill pipe suspending the running tool and the running tool, the portion of the liner above the steel shoulder must be expanded. If that expansion cannot be initiated or completed and the liner is stuck in-hole due to environmental conditions or tool / liner failure modes, there is no longer a possibility to retrieve the running tool along with the drill pipe from the well. This impossibility is considered to be a limitation.

[0003] There is a need in the art for being able to retrieve the running tool along with the drill pipe even when the liner cannot be expanded.SUMMARY

[0004] The disclosure describes a running tool that utilizes bottom-up expansion to expand a dog-bone-shaped liner hanger (also referred to as an anchor) connected at the top of a liner. However, the running tool may be used in any bottom-up expandable application where there is value in being able to retrieve the expansion assembly. This running tool includes a multi-portion cone comprising an outer portion, which can be a slim solid conical piece, a base portion, which supports the outer portion, and a mechanism to selectively couple or decouple the outer and base portions. The multi-portion cone allows most of the running tool to be retrieved along with thedrill pipe onto which it is suspended while leaving the liner and liner hanger unexpanded in the well.

[0005] The running tool is suitable for use in the bottom-up expansion market, especially in the expandable liner hanger market. The running tool provides a contingency retrieval process to the cases when the expansion of the liner hanger is not hindered.

[0006] The running tool carries the weight of the liner on the face of the multi-portion cone similarly to other known technologies of tubular expansion. The running tool is located in the liner hanger connected at the top of the liner. Expansion of the liner hanger is used to set the liner into the base casing. However, the entirety of the liner is not expanded. The expansion of the liner hanger provides both the functionalities of anchoring the liner and sealing the space between the liner hanger and the base casing. Thus, an expandable liner hanger can replace both a conventional liner anchor and a packer.

[0007] If the retrieval of the running tool is desired, the multi-portion cone comes apart and leaves only the outer portion of the cone behind the lower steel shoulder of the dog-bone-shaped liner hanger. The outer portion of the cone has a pass-through diameter that is comparable to the inner diameter or drift diameter of the liner below. The preferred embodiment uses a collet that is integral to the base portion to provide the mechanism to selectively couple or decouple the outer and base portions. A seal, preferably of elastomeric or thermoplastic material, is provided between the base and outer portions of the multi-portion cone.

[0008] A hydraulic piston, which is preferably pinned in place by a shearable retainer, is used to prevent the deflection of the collet in the base portion of the cone. As such, the hydraulic piston prevents the decoupling of the outer portion of the cone from the base portion of the cone. The hydraulic piston is normally pressure-balanced in the run-in-hole configuration and cannot shift under normal operating conditions. If the retrieval of the running tool is desired, a ball or other obstruction can be dropped from the surface to enable the multi-portion cone to come apart. The ball lands on a seat within the running tool at the approximate location of the hydraulic piston, creating a seal within the running tool. Increasing pressure above the ball to a certain predetermined threshold that depends on the shearable retainer will shift the hydraulic piston and allow the collet to deflect. As such, the outer portion of the cone can decouple from the base portion. Once the hydraulic piston has shifted, the running tool may be retrieved through the innerdiameter of the outer portion of the cone. Thus, the running tool may be retrieved, with the exception of the outer portion of the cone.

[0009] Optionally, some pieces (e.g., wiper darts) part of, or connected to the running tool, that are attached to the bottom of the running tool by a shearable device, and have a large diameter that does not fit through the inner diameter of the outer portion of the cone may disconnect from the running tool by applying overpull on the drill pipe. These pieces, as well as the outer portion of the cone, may be milled or fished out-of-hole in subsequent operations.

[0010] It is to be understood that the following descriptions disclose several exemplary embodiments for implementing different features, structures, or functions of the invention. Exemplary embodiments of components, arrangements, and configurations are described below to simplify the disclosure; however, these exemplary embodiments are provided merely as examples and are not intended to limit the scope of the invention.BRIEF DESCRIPTION OF THE DRAWINGS

[0011] For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein:

[0012] FIG. 1 is a sectional view of a tool for expanding a liner hanger connected on top of a liner in a well in accordance with a preferred embodiment, wherein the tool and the liner hanger are illustrated in a run-in-hole configuration in which an outer portion and a base portion of an expansion cone are linked, and a hydraulic actuator is in a position preventing the separation of the outer portion from the base portion;

[0013] FIG. 2 is a sectional view of the tool shown in FIG. 1, wherein the tool and the liner hanger are illustrated in a contingency configuration in which a ball has been dropped, hydraulic pressure upstream of the ball was raised, and the hydraulic actuator has shifted to a position allowing the separation of the outer portion from the base portion of the expansion cone; and

[0014] FIG. 3 is a sectional view of the tool shown in FIG. 1, wherein the tool and the liner hanger are illustrated in a retrieval configuration in which the tool is being retrieved from the liner hanger without expanding it, leaving only the outer portion of the expansion cone in the liner hanger.

[0015] As is customary, the drawings may not be drawn to scale for the sake of clarity.DETAILED DESCRIPTION OF EMBODIMENTS

[0016] In reference to FIG. 1, a liner hanger 10 is connected on top of a liner 12. A running tool includes an elongated mandrel 30, which may be suspended to a pipe string and connected to an expansion cone, as further described below. The elongated mandrel is used to apply mechanical pull through it and into the cone to aid in expansion, as well as to carry the liner weight. In this example, the elongated mandrel 30 may also be connected to an optional liner release mechanism (not shown) and wiper darts (no shown). In other examples, the elongated mandrel may also be connected to a jack (not shown). The outer diameter of the elongated mandrel is preferably sufficiently small to mount the expansion cone and other provided components, such as the liner release mechanism.

[0017] The expansion cone comprises a base portion, which includes a first section 14 that may be threaded on the elongated mandrel 30 and a second section 16 (e.g., in the form of a collet) that is connected to the first section 14. The expansion cone also includes an outer portion 20, which has an expansion face 22 for expanding the liner hanger 10 and / or carry the weight of the liner 12.

[0018] Seals 26 and 28 are provided to isolate a fluid volume below the expansion cone from a fluid volume above the expansion cone.

[0019] In the configuration shown in FIG. 1, the base portion is linked to the outer portion 20 by extending a protrusion 18 provided on the second section 16 of the base portion into a groove 24 provided on a surface of an inner cavity of the outer portion 20. The protrusion 18 is prevented from deflecting inward because of a hydraulic actuator, as further described below.

[0020] In reference to FIG. 2, a hydraulic actuator includes a fixed portion 40, which is connected to the elongated mandrel 30, and a movable piston 42. A piston chamber 44 is located between the movable piston 42 and the elongated mandrel 30. The piston chamber 44 is in fluid communication with a longitudinal bore 32 provided in the elongated mandrel 30 via passageways 36. The longitudinal bore 32 preferably has a diameter sufficiently large to pass obstructions such as balls and / or darts and flow cement / drilling fluid at elevated circulation rates.

[0021] In the configuration shown in FIG. 1, the movable piston 42 was attached in a first position to the elongated mandrel 30 by a retainer, such as a shearable pin 46. In the first position, the movable piston 42 was preventing the protrusion 18 from deflecting inward and the outerportion 20 of the expansion cone from separating from the base portion. However, in the configuration shown in FIG. 2, an obstruction, such as a ball 38, is landed on a seat 34, preventing fluid pumped into the longitudinal bore 32 from flowing downward. The fluid under pressure has flown into the piston chamber 44, causing a downward force on the movable piston 42 to fail the shearable pin 46 and then shift the movable piston 42 to a second position in which the protrusion 18 is free to deflect inward.

[0022] In reference to FIG. 3, the elongated mandrel 30, the first section 14 and the second section 16 of the base portion of the expansion cone, and the hydraulic actuator can be retrieved through the outer portion 20 of the expansion cone without expanding the liner hanger 10. However, the outer portion 20 of the expansion cone is left in the liner hanger 10.

[0023] While the preferred embodiment uses a collet, another part, which may be a snap ring, set of dogs, or other mechanisms that are separate from a solid piece, can alternatively be used to provide the mechanism that couples / decouples the base portion to / from the outer portion. Movement (i.e., inward contraction) of the snap ring, set of dogs, or other mechanisms would release the outer portion of the cone.

[0024] Additionally, the disclosure also contemplates at least the following embodiments 1 to 13. It should be noted that any element of these embodiments may further include details related to this element that are disclosed in a paragraph or Figure describing the preferred embodiment without necessarily including details of other elements that are disclosed in the same or other paragraph or Figure.Embodiment 1

[0025] Embodiment l is a tool for expanding a tubular, such as a liner hanger connected on top of a liner, in a well.

[0026] The tool comprises an elongated mandrel and a cone. Generally, the elongated mandrel is used to move the cone relative to the mandrel in a down-up direction, typically in order to expand at least a portion of the tubular. More particularly, the elongated mandrel may be connected to a liner release mechanism. Optionally, the elongated mandrel may also be connected to wiper darts, a jack assembly that can provide the upward force to move the cone through the tubular, and / or other components known in the art.

[0027] The cone includes a base portion and an outer portion. The base portion is coupled to the elongated mandrel. The outer portion has an outer flared surface configured the expand a tubular. Generally, the base portion and the outer portion can selectively be linked or separable. Also, the base portion has an outermost diameter that is smaller than an outermost diameter of the outer portion. As such, when the base portion is separated from the outer portion, the base portion is capable of moving through the tubular without expanding the tubular. More particularly, the base portion may have a first section that is coupled to the elongated mandrel and a second section that is connected to the first section but at least partially movable relative to the elongated mandrel and the outer portion. The outer portion may have a cavity sized to receive the second section of the base portion at least partially. A part of the second section of the base portion may selectively engage a surface of the cavity in the outer portion so that the base portion and the outer portion are linked. The part of the second section of the base portion may also deflect so that the base portion and the outer portion separate.

[0028] The tool comprises a hydraulic actuator. A fixed portion of the hydraulic actuator is connected to the elongated mandrel. Generally, a movable portion of the hydraulic actuator (e.g., a piston) is capable of moving relative to the elongated mandrel using force generated by hydraulic pressure. More particularly, the movable portion may shift from a first position to a second position after the hydraulic pressure reaches a threshold.

[0029] Generally, in the first position, the movable portion of the hydraulic actuator prevents the outer portion from separating from the base portion. In the second position, the movable portion of the hydraulic actuator no longer prevents the outer portion from separating from the base portion. More particularly, the second section of the base portion of the cone and the elongated mandrel may cooperate to form an opening therebetween. The opening may be sized to receive the movable portion of the hydraulic actuator, at least partially. In the first position, the movable portion of the hydraulic actuator may be at least partially in the cavity. As such, the movable portion of the hydraulic actuator may prevent the part of the second section of the cone from deflecting. In the second position, the movable portion of the hydraulic actuator may be displaced out of the cavity, leaving a free space for the part of the second section of the cone to deflect. As such, the second section of the base portion may disengage from the surface of the cavity, and the outer portion can separate from the base portion.

[0030] Preferably, seals are provided between the base portion and the outer portion of the cone and between the elongated mandrel and the base portion so that hydraulic pressure can be applied to the cone. However, these seals may not be required if, for expanding the tubular, only a pulling force is exerted on the cone by the drill pipe.Embodiment 2

[0031] Embodiment 2 is a tool as described in embodiment 1 wherein the elongated mandrel has a longitudinal bore and a seat capable of sealing against an obstruction flowing in the longitudinal bore. The elongated mandrel further has a flow passageway between the longitudinal bore and an outer surface of the elongated mandrel. The flow passageway is provided upstream of the seat. The hydraulic actuator is in fluid communication with the flow passageway. As such, the longitudinal bore can be sealed by an obstruction, and the hydraulic pressure upstream of the obstruction can rise above the threshold. The hydraulic pressure can be communicated to the hydraulic actuator via the flow passageway.Embodiment 3

[0032] Embodiment 3 is a tool as described in embodiment 2 wherein the movable portion of the hydraulic actuator includes a piston. The piston has a through bore for receiving and sliding along the elongated mandrel. The piston and the elongated mandrel cooperate to form a chamber therebetween, which is in fluid communication with the flow passageway.

[0033] In the first position of the hydraulic actuator, the piston is attached to the elongated mandrel by a retainer, and the chamber is collapsed. The hydraulic pressure upstream of the obstruction may be communicated to the chamber, push against the piston, and exert a force on the retainer. When the hydraulic pressure reaches the threshold, the retainer may fail. As such, the piston may be released from the elongated mandrel, the chamber may expand, and the movable portion of the hydraulic actuator may shift to the second position.Embodiment 4

[0034] Embodiment 4 is a tool as described in any of embodiments 1 to 3 wherein the cavity of the outer portion includes a recess having a first shoulder. The second section of the base portion includes a protrusion having a second shoulder. The protrusion is sized to extend into the recessat least partially so that the first shoulder abuts the second shoulder and the base portion and the outer portion are linked.

[0035] In the first position, the movable portion of the hydraulic actuator prevents the protrusion from leaving the recess entirely and the first shoulder from disconnecting from the second shoulder. In the second position, the movable portion of the hydraulic actuator allows the protrusion to leave the recess entirely and the first shoulder to disconnect from the second shoulder.Embodiment 5

[0036] Embodiment 5 is a tool as described in embodiment 4 wherein the recess includes a circumferential groove formed in the cavity of the outer portion.Embodiment 6

[0037] Embodiment 6 is a tool as described in embodiments 4 or 5 wherein the protrusion includes a collet finger, a snap ring, a dog, or a combination thereof.Embodiment 7

[0038] Embodiment 7 is a tool as described in any of embodiments 4 to 6 wherein the protrusion is elastically flexible and urged to extend into the recess at least partially.Embodiment 8

[0039] Embodiment 8 is a method of using the tool as described in any of embodiments 1 to 7.

[0040] The method may comprise the step of placing the hydraulic actuator in the first position so as to link the base portion and the outer portion of the cone.

[0041] The method may comprise the step of resting the tubular on the outer portion.

[0042] The method may comprise the step of lowering the tool and the tubular in a well.Embodiment 9

[0043] Embodiment 9 is a method as described in embodiment 8, further comprising the steps of moving the base portion and the outer portion together through the tubular and expanding the tubular in the well. For example, the expansion of the tubular may be performed by just using hydraulic pressure below the cone, driving the cone upward. In other examples, the expansion of the tubular may be performed by using a jack assembly.Embodiment 10

[0044] Embodiment 10 is a method as described in embodiment 8, further comprising the steps of increasing hydraulic pressure inside the tool beyond the threshold to cause the movable portion of the hydraulic actuator to shift from the first position to the second position, separating the base portion and the outer portion after the hydraulic actuator is in the second position, and moving the base portion through the tubular without expanding the tubular.

[0045] For example, embodiment 10 may be performed as a contingency when the expansion of the tubular is not possible.Embodiment 11

[0046] Embodiment 11 is a method as described in embodiment 10 wherein increasing the hydraulic pressure inside the tool beyond the threshold causes the retainer of the tool, as described in any of embodiments 3 to 7, to fail.Embodiment 12

[0047] Embodiment 12 is a method as described in embodiments 10 or 11 wherein moving the movable portion of the hydraulic actuator to the second position frees a space adjacent to the protrusion of the tool as described in any of claims 4 to 7, so as to allow the protrusion to leave the recess.Embodiment 13

[0048] Embodiment 13 is a method as described in any of embodiments 8 to 12 wherein the tubular is a liner hanger connected on top of a liner.

Claims

What is claimed is:

1. A tool for expanding a tubular in a well, the tool comprising: an elongated mandrel; a hydraulic actuator, the hydraulic actuator being capable of moving from a first position to a second position; and a cone, the cone including a base portion and an outer portion, the base portion having a first section affixed to the elongated mandrel, the base portion having a second section coupled to the first section and deformable, the second section and the elongated mandrel cooperating to form an opening therebetween, the opening being sized to receive the hydraulic actuator, the outer portion having a cavity sized to receive the base portion at least partially, the outer portion having an outer flared surface configured the expand a tubular; wherein the base portion has an outermost diameter that is smaller than an outermost diameter of the outer portion, whereby the base portion is capable of moving through the tubular without expanding the tubular; wherein the base portion and the outer portion are linked when the hydraulic actuator is in the first position; wherein the base portion and the outer portion are capable of being separated when the hydraulic actuator is in the second position.

2. The tool of claim 1, wherein: the elongated mandrel has a longitudinal bore, the longitudinal bore has a seat capable of sealing against an obstruction flowing in the longitudinal bore, the elongated mandrel further has a flow passageway between the longitudinal bore and an outer surface of the elongated mandrel; and the hydraulic actuator is in fluid communication with the flow passageway.

3. The tool of claim 2, wherein: the hydraulic actuator includes a piston, the piston having a through bore for receiving and sliding along the elongated mandrel, the piston and the elongated mandrel cooperating to form a chamber therebetween, the chamber being in fluid communication with the flow passageway, the piston is attached to the elongated mandrel by a retainer and the chamber is collapsed in the first position of the hydraulic actuator; the retainer has failed, the piston is released from the elongated mandrel, and the chamber is expanded in the second position of the hydraulic actuator;4. The tool of any of claims 1 to 3, wherein: the cavity of the outer portion includes a recess having a first shoulder; the second section of the base portion includes a protrusion having a second shoulder, the protrusion being sized to extend into the recess at least partially so that the first shoulder abuts the second shoulder, and the base portion and the outer portion are linked; the hydraulic actuator prevents the protrusion from leaving the recess entirely and the first shoulder from disconnecting from the second shoulder when the hydraulic actuator is in the first position; and the hydraulic actuator allows the protrusion to leave the recess and the first shoulder to disconnect from the second shoulder when the hydraulic actuator is in the second position;5. The tool of claim 4, wherein the recess includes a circumferential groove.

6. The tool of claim 4, wherein the protrusion includes a collet finger, a snap ring, a dog, or a combination thereof.

7. The tool of claim 4, wherein the protrusion is elastically flexible and is urged to extend into the recess at least partially.

8. A method for expanding a tubular in a well, the method comprising: providing the tool of any of claims 1 to 7 in a tubular; placing the hydraulic actuator in the first position so as to link the base portion and the outer portion of the cone; resting the tubular on the outer portion; and lowering the tool and the tubular in a well.

9. The method of claim 8, further comprising: moving the base portion and the outer portion together through the tubular; and expanding the tubular;10. The method of claim 8, further comprising: increasing a hydraulic pressure inside the tool beyond a threshold to cause the hydraulic actuator to move from the first position to the second position; separating the base portion and the outer portion after the hydraulic actuator is in the second position; and moving the base portion through the tubular without expanding the tubular.

11. The method of claim 10, wherein: increasing the hydraulic pressure inside the tool beyond the threshold causes the retainer of the tool of claim 3 to fail.

12. The method of claim 10 or 11, wherein: moving the piston of the hydraulic actuator of the tool of claim 3 to the second position frees a space adjacent the protrusion of the tool of any of claims 4 to 7 so as to allow the protrusion to leave the recess of the tool of any of claims 4 to 7.

13. The method of any of claims 8 to 12 wherein the tubular is a liner hanger connected on top of a liner.

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