Running tool and tubular coupled with a clutch that is impact resistant and / or reduces flow erosion
Patent Information
- Authority / Receiving Office
- US · United States
- Patent Type
- Applications(United States)
- Current Assignee / Owner
- Filing Date
- 2024-03-28
- Publication Date
- 2026-08-13
AI Technical Summary
Providing a conventional castellated clutch, including upward-facing fingers machined at the top of the liner using conventional turning or milling methods, may not be ideal for transmitting the torque.
[0007]In operations where a liner needs to be rotated in a well, torque must be transmitted from the drill pipe to the liner. Providing a conventional castellated clutch, including upward-facing fingers machined at the top of the liner using conventional turning or milling methods, may not be ideal for transmitting the torque. The disclosure describes an alternative clutch design. This clutch design may reduce or eliminate the risk of excessive fluid erosion of the base casing. This clutch design may also eliminate the risk of impacting the castellations during subsequent operations, such as when passing a milling assembly through the liner, and of bending the castellations inward.
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Figure US20260235017A1-D00000_ABST
Abstract
Description
CROSS-REFERENCE TO RELATED APPLICATIONS
[0001] This application claims the benefit of priority to U.S. provisional application Ser. No. 63 / 455,511 filed on Mar. 29, 2023, which is incorporated herein by reference in its entirety for all and any purposes.BACKGROUND
[0002] The disclosure relates generally to systems and methods for deploying a liner assembly in a well with the ability to apply torque from a drill pipe through a running tool and to the liner assembly while the liner assembly is downhole. The disclosure relates more particularly to a clutch coupling the running tool and a tubular of the liner assembly and capable of transmitting torque between the running tool and the tubular. The design of the portion of the clutch on the tubular is preferably resistant to potential impacts by equipment. Also, the design of the portion of the clutch on the tubular preferably reduces flow erosion that potentially occurs when a fluid is pumped at a high rate through a bore in the tubular.
[0003] FIGS. 1 and 2 show a known method for transmitting torque to a liner assembly, which may be conventional or expandable. Torque is transmitted from a drill pipe to the top of the liner assembly through a running tool 14. Typically, a liner hanger, packer, or other joint 10, which is connected to, and near the top of the liner being deployed, has castellations 12 protruding from the top of the liner and facing upward. These castellations 12 mate together with fingers 16 on the running tool 14. The fingers 16 extend downward. Once the liner hanger and / or packer 10 is set in a base casing 18, the running tool 14 is released and retrieved to the surface along with the drill pipe. The liner, which remains in-hole, has the castellations 12 at or near the top of the liner assembly and facing upward.
[0004] The castellations 12 present risks to future operations within the wellbore. For example, when running equipment, such as a milling assembly, the castellations 12 could be impacted by the equipment and bend inward. Additionally, if fracking operations are to be conducted by pumping fracking fluid at a high rate after the liner assembly is installed, the castellations 12 could generate flow turbulence and cause erosion of the base casing. Thus, the castellations 12 or other upward-facing similar features that could be bent upon impact or could generate turbulence during hydraulic fracturing may not be ideal.
[0005] Therefore, there is a need to design an improved clutch to transfer torque between the running tool and the top of the liner. Preferably, the clutch design does not cause the issues discussed above during wellbore operations following the setting of the liner and the retrieval of the running tool and drill pipe.SUMMARY
[0006] It is to be understood that the following disclosure describes 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.
[0007] In operations where a liner needs to be rotated in a well, torque must be transmitted from the drill pipe to the liner. Providing a conventional castellated clutch, including upward-facing fingers machined at the top of the liner using conventional turning or milling methods, may not be ideal for transmitting the torque. The disclosure describes an alternative clutch design. This clutch design may reduce or eliminate the risk of excessive fluid erosion of the base casing. This clutch design may also eliminate the risk of impacting the castellations during subsequent operations, such as when passing a milling assembly through the liner, and of bending the castellations inward.
[0008] In a preferred embodiment, one side of the clutch is manufactured inside the uppermost tubular in the liner assembly, leaving a solid, cylindrical wall of steel (i.e., a shroud) at the top of the uppermost tubular surrounding fingers. For example, the fingers may protrude inwardly from and be integral to the shroud. The shroud may be thin (e.g., its thickness may be less than twenty-five percent of the thickness of the uppermost tubular). The shroud may provide support to the fingers and limit their bending in the inward direction in cases where they are accidentally impacted. Also, the shroud may at least partially shield the base casing from the flow of fracking fluid and limit its erosion.
[0009] Furthermore, the surfaces delimiting the top of the fingers and the bottom of the spaces between the fingers may be oriented at forty-five degrees or less with respect to the axis of the uppermost tubular at the top of the liner so as to smoothly direct fluid flow toward the inner bore of the liner without generating significant turbulence. The upper surface of the shroud (i.e., the nose) may also be profiled to limit the generation of turbulence. Thus, the configuration of these surfaces may limit flow turbulence and thus reduce erosion that would otherwise be caused by stronger flow turbulence. Also, the configuration of these surfaces can limit the force generated upon accidental impact with other well equipment, such as a milling assembly.
[0010] The top of the uppermost tubular in the liner assembly is preferably machined out of the inner diameter of a pipe using plunge or die-sink Electrical Discharge Machining (EDM). Alternative methods could be using wire EDM, horizontal milling, or broaching.
[0011] The clutch described herein can be used to rotate liners. It may have applications in both the expandable and conventional liner hanger markets.BRIEF DESCRIPTION OF THE DRAWINGS
[0012] For a more detailed description of the embodiments of the present disclosure, reference will now be made to the accompanying drawings, wherein:
[0013] FIG. 1 is a perspective view of a setting tool and a liner hanger coupled through a clutch during the conveyance of a liner, illustrating a known method for transmitting torque;
[0014] FIG. 2 is a sectional view of the liner hanger shown in FIG. 1 set in place in a base casing, illustrating the flow of fracking fluid and the possible resulting erosion of the base casing by turbulence;
[0015] FIG. 3 is a partially transparent perspective view of a setting tool and a liner hanger coupled through a clutch illustrating a preferred embodiment;
[0016] FIG. 4 is a perspective view of the liner hanger shown in FIG. 3; and
[0017] FIG. 5 is a sectional view of the liner hanger shown in FIG. 3 set in place in a base casing, illustrating the flow of fracking fluid.
[0018] As is customary, the drawings may not be drawn to scale for the sake of clarity.DETAILED DESCRIPTION
[0019] In reference to FIGS. 3 and 4, a tubular 110 (e.g., a liner hanger, packer, or other joints) is connected to and near the top of a liner being deployed. One side of an example clutch is formed on the tubular 110 by fingers 112 that protrude inwardly from and are integral to a shroud 120. The other side of the example clutch is formed on the running tool 14, for example, in a way similar to the way illustrated in FIGS. 1 and 2.
[0020] Surfaces 123 delimit the top of the fingers 112. In the example shown, each surface 123 consists of a first cone portion located adjacent to a nose 127 of the shroud 120 and a second cone portion located between the first cone portion and a lateral surface (a cylindrical portion) of a corresponding finger 112. Alternatively, each surface 123 may consist of one or more planar or nearly planar surfaces. Optionally, angles between adjacent surfaces may be rounded. The angle of inclination (e.g., thirty degrees) of the first cone portion relative to the axis of the tubular 110 is larger than the angle of inclination (e.g., fifteen degrees) of the second cone portion relative to the axis of the tubular 110.
[0021] Surfaces 125 delimit the bottom of the spaces between the fingers 112. In the example shown, each surface 125 consists of a cone portion. Alternatively, each surface 125 may consist of one or more planar or nearly planar surfaces. Optionally, angles between adjacent surfaces may be rounded. The angle of inclination of each surface relative to the axis of the tubular 110 is less than forty-five degrees.
[0022] Nose 127 is located at the top of the shroud 120 and the top of the fingers 112. In the example shown, the nose 127 is partially rounded.
[0023] In reference to FIG. 5, the flow of fracking fluid is schematically illustrated by red arrows. The shroud 120 may provide a barrier between the fluid flowing inside the tubular 110 and the base casing 18, thus limiting erosion of the tubular 110 and / or base casing 18. Alternatively or additionally, the configuration of the surfaces 123, 125, and / or 127, and in particular the orientation of the surfaces 123 and / or 125, can limit the generation of flow turbulence, thus also limiting erosion of the tubular 110 and / or base casing 18.
[0024] Additionally, the disclosure also contemplates at least the following embodiments 1 to 11. 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 embodiments without necessarily including details of other elements that are disclosed in the same or other paragraph or Figure.Embodiment 1
[0025] Embodiment 1 is a liner assembly comprising a liner and a tubular connected on top of the liner. For example, the tubular may include a liner hanger or packer, and the liner may be expandable or not expandable.
[0026] The tubular has a bottom end that may provide a connection to the liner and a top end that is free. The top end comprises fingers extending upward and a solid, cylindrical wall extending upward. The solid, cylindrical wall surrounds and is attached to the fingers.
[0027] Preferably, the top of the fingers is flush with the top of the solid, cylindrical wall. However, the top of the fingers may be higher or lower than the top of the solid, cylindrical wall.Embodiment 2
[0028] Embodiment 2 is a liner assembly as described in embodiment 1, wherein the fingers protrude inwardly from and are integral to the solid, cylindrical wall.Embodiment 3
[0029] Embodiment 3 is a liner assembly as described in embodiments 1 or 2 wherein at least some surfaces delimiting the top of the fingers or the bottom of spaces between the fingers face inwardly and upwardly.Embodiment 4
[0030] Embodiment 4 is a liner assembly as described in embodiment 3 wherein the at least some surfaces are portions or cones or portions of planes.Embodiment 5
[0031] Embodiment 5 is a liner assembly as described in embodiment 4 wherein the at least some surfaces are oriented at forty-five degrees or less with respect to a longitudinal axis of the tubular.Embodiment 6
[0032] Embodiment 6 is a method of deploying a liner assembly in a well. The method comprises the step of providing a liner assembly as described in any of embodiments 1 to 5 and a running tool connected to a drill string. The running tool includes an outer surface having fingers thereon. The method comprises the step of coupling the liner assembly to the running tool by mating the fingers of the running tool with the fingers of the liner assembly. The method comprises the steps of lowering the liner assembly and the running tool in the well and then applying torque to the drill string to rotate the liner. The method comprises the step of transmitting the torque through the fingers of the running tool and the fingers of the liner assembly to the liner.Embodiment 7
[0033] Embodiment 7 is a method of deploying a liner assembly in a well as described in embodiment 6, further comprising the steps of releasing and retrieving the running tool, lowering equipment through a bore in the liner assembly, and supporting one or more fingers and limiting their bending in the inward direction upon impact with the equipment using the solid, cylindrical wall.Embodiment 8
[0034] Embodiment 8 is a method of deploying a liner assembly in a well as described in embodiments 6 or 7, further comprising the steps of setting the liner in a base casing, releasing and retrieving the running tool, flowing fluid into a bore in the liner assembly, and shielding the base casing from turbulence generated by the fluid flow with the solid, cylindrical wall.Embodiment 9
[0035] Embodiment 9 is a method of making a liner assembly. The method comprises the step of machining out the inner diameter of a pipe to produce a tubular as described in any of embodiments 1 to 5 and connecting the tubular on top of a liner.Embodiment 10
[0036] Embodiment 10 is a method of making a liner assembly as described in embodiment 9, wherein the machining out is performed using plunge or die-sink Electrical Discharge Machining (EDM), wire EDM, horizontal milling, or broaching.Embodiment 11
[0037] Embodiment 11 is a method of making a liner assembly as described in embodiment 9, wherein the machining out is performed using plunge or die-sink Electrical Discharge Machining (EDM).
Examples
embodiment 1
[0025]Embodiment 1 is a liner assembly comprising a liner and a tubular connected on top of the liner. For example, the tubular may include a liner hanger or packer, and the liner may be expandable or not expandable.
[0026]The tubular has a bottom end that may provide a connection to the liner and a top end that is free. The top end comprises fingers extending upward and a solid, cylindrical wall extending upward. The solid, cylindrical wall surrounds and is attached to the fingers.
[0027]Preferably, the top of the fingers is flush with the top of the solid, cylindrical wall. However, the top of the fingers may be higher or lower than the top of the solid, cylindrical wall.
embodiment 2
[0028]Embodiment 2 is a liner assembly as described in embodiment 1, wherein the fingers protrude inwardly from and are integral to the solid, cylindrical wall.
embodiment 3
[0029]Embodiment 3 is a liner assembly as described in embodiments 1 or 2 wherein at least some surfaces delimiting the top of the fingers or the bottom of spaces between the fingers face inwardly and upwardly.
Claims
1. A liner assembly comprising:a liner anda tubular connected on top of the liner,the tubular having a bottom end that provides a connection and a top end that is free,the top end of the tubular including fingers extending upward and a solid, cylindrical wall extending upward,wherein the solid, cylindrical wall surrounds the fingers and is attached to the fingers.
2. The liner assembly of claim 1 wherein a top of each of the fingers is flush with a top of the solid, cylindrical wall.
3. The liner assembly of claim 1 or 2 wherein the fingers protrude inwardly from and are integral to the solid, cylindrical wall.
4. The liner assembly of claim 1 or 2 wherein at least some surfaces delimiting a top of each of the fingers or a bottom of spaces between the fingers face inwardly and upwardly.
5. The liner assembly of claim 4 wherein the at least some surfaces are portions or cones or portions of planes.
6. The liner assembly of claim 5 wherein the at least some surfaces are oriented at forty-five degrees or less with respect to a longitudinal axis of the tubular.
7. A method of deploying a liner assembly in a well, comprising:providing a liner assembly, the liner assembly including a liner and a tubular connected on top of the liner, the tubular having a bottom end that provides a connection and a top end that is free, the top end of the tubular including fingers extending upward and a solid, cylindrical wall extending upward, wherein the solid, cylindrical wall surrounds the fingers and is attached to the fingers;providing a running tool connected to a drill string, the running tool including an outer surface having fingers;coupling the liner assembly to the running tool by mating the fingers of the running tool with the fingers of the liner assembly;lowering the liner assembly and the running tool in the well;applying torque to the drill string to rotate the liner; andtransmitting the torque through the fingers of the running tool and the fingers of the liner assembly to the liner.
8. The method of claim 7 wherein a top of each of the fingers is flush with a top of the solid, cylindrical wall.
9. The method of claim 7 or 8 wherein the fingers protrude inwardly from and are integral to the solid, cylindrical wall.
10. The method of claim 7 or 8 wherein at least some surfaces delimiting a top of each of the fingers or a bottom of spaces between the fingers face inwardly and upwardly.
11. The method of claim 7 or 8 further comprising:releasing and retrieving the running tool,lowering equipment through a bore in the liner assembly, andsupporting one or more fingers and limiting their bending in the inward direction upon impact with the equipment using the solid, cylindrical wall.
12. The method of claim 7 or 8 further comprising:setting the liner in a base casing,releasing and retrieving the running tool, flowing fluid into a bore in the liner assembly, andshielding the base casing from turbulence generated by the fluid flow with the solid, cylindrical wall.
13. A method of making a liner assembly, comprisingmachining out an inner diameter of a pipe to produce a tubular having a bottom end that provides a connection and a top end that is free, the top end of the tubular including fingers extending upward and a solid, cylindrical wall extending upward, wherein the solid, cylindrical wall surrounds the fingers and is attached to the fingers, andconnecting the tubular on top of a liner.
14. The method of claim 12 wherein a top of each of the fingers is flush with a top of the solid, cylindrical wall.
15. The method of claim 12 or 13 wherein the fingers protrude inwardly from and are integral to the solid, cylindrical wall.
16. The method of claim 12 or 13 wherein at least some surfaces delimiting a top of each of the fingers or a bottom of spaces between the fingers face inwardly and upwardly.
17. The method of claim 12 or 13 wherein the machining out is performed using plunge or die-sink Electrical Discharge Machining (EDM).