Liner hanger setting tool including a split ring cone, a well system and a method

Abstract

Provided is a liner hanger setting tool, a well system, and method. The liner hanger setting tool, in one aspect, includes a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped. The liner hanger setting tool, in accordance with this aspect, further includes a split ring cone positioned about the cone mandrel, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

Description

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 63 / 781,686, filed on Apr. 1, 2025, entitled “LINER HANGER SETTING TOOL INCLUDING A SPLIT RING CONE, A WELL SYSTEM AND A METHOD,” commonly assigned with this application and incorporated herein by reference in its entirety.BACKGROUND

[0002] During wellbore operations, it is typical to “hang” a liner onto a casing such that the liner supports an extended string of tubular below it. As used herein, “tubing string” refers to a series of connected pipe sections, casing sections, joints, screens, blanks, cross-over tools, downhole tools, and the like, inserted into a wellbore, whether used for drilling, work-over, production, injection, completion, or other processes. A tubing string may be run in and out of the casing, and similarly, the tubing string can be run in an uncased wellbore or section of wellbore. Further, in many cases a tool may be run on a wireline or coiled tubing instead of a tubing string, as those of skill in the art will recognize.

[0003] Expandable liner hangers may generally be used to secure the liner within a previously set wellbore tubular (e.g., casing or liner string). Expandable liner hangers may be “set” by expanding the liner hanger radially outward into gripping and sealing contact with the wellbore tubular. For example, expandable liner hangers may be expanded by use of hydraulic pressure to drive an expanding cone, wedge, or “pig,” through the liner hanger. Other methods may be used, such as mechanical swaging, explosive expansion, memory metal expansion, swellable material expansion, electromagnetic force-driven expansion, etc.

[0004] The expansion process may typically be performed by means of a liner hanger setting tool, which may also be used to convey the liner hanger into the wellbore. The liner hanger setting tool may be interconnected between a work string (e.g., a tubular string made up of drill pipe or other segmented or continuous tubular elements) and the liner hanger. The liner hanger setting tool may expand the liner hanger into anchoring and sealing engagement with the wellbore tubular.BRIEF DESCRIPTION

[0005] Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0006] FIGS. 1A and 1B illustrate one embodiment of a well system designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0007] FIGS. 2A through 2J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more embodiments of the disclosure at different states of deployment;

[0008] FIGS. 3A through 3H illustrate a liner hanger system designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0009] FIGS. 4A through 4J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0010] FIGS. 5A through 5H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0011] FIGS. 6A through 6Y illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0012] FIGS. 7A through 7H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0013] FIGS. 8A through 8J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0014] FIGS. 9A through 9E illustrate different cross-sectional views of various embodiments of spiral split ring cones designed, manufactured and / or operated according to one or more embodiments of the disclosure; and

[0015] FIGS. 10A through 10H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment.DETAILED DESCRIPTION

[0016] In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.

[0017] Unless otherwise specified, use of the terms “connect,”“engage,”“couple,”“attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Furthermore, unless otherwise specified, use of the terms “up,”“upper,”“upward,”“uphole,”“upstream,” or other like terms shall be construed as generally toward the surface of the subterranean formation; likewise, use of the terms “down,”“lower,”“downward,”“downhole,”“downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. Additionally, unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.

[0018] Various values and / or ranges are explicitly disclosed in certain embodiments herein. However, values / ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited. Similarly, values / ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited. In the same way, values / ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Similarly, an individual value disclosed herein may be combined with another individual value or range disclosed herein to form another range.

[0019] The term “approximately XYZ,” as used herein, means that it is within plus or minus 20percent of perfectly XYZ. The term “substantially XYZ,” as used herein, means that it is within plus or minus 10 percent of perfectly XYZ. The term “significantly XYZ,” as used herein, means that it is within plus or minus 5 percent of perfectly XYZ. The term “ideally XYZ,” as used herein, means that it is within plus or minus 1 percent of perfectly XYZ. The monicker “XYZ” could refer to parallel, perpendicular, alignment, or other relative features disclosed herein.

[0020] The present disclosure has recognized, for the first time, that certain wellheads (e.g., certain wellheads in deepwater operations) come with a standard inside diameter (ID), which prevents the run-in-hole of liner hanger systems with larger outside diameter (OD) features, such as larger outside diameter (OD) cones. Typically, the larger outside diameter (OD) of the liner hanger system is required to successfully expand the liner hanger assembly in lighter weight casings, where the inside diameter (ID) is larger. Accordingly, a liner hanger system is needed that employs a liner hanger setting tool with a cone that can move between a run-in-hole state having a lesser outside diameter (ODL) (e.g., so that it can pass through smaller inside diameter (ID) wellheads) and a deployed state having a greater outside diameter (ODG) (e.g., for engaging with the expandable liner hanger assembly).

[0021] In at least one embodiment, the liner hanger system employs a split ring cone (e.g., C-ring in one embodiment). The split ring cone, in at least one embodiment, includes a slot extending from a first end (e.g., an uphole end) of the split ring cone to a second end (e.g., second opposing end or downhole end) of the split ring cone, the slot allowing the split ring cone to expand between the run-in-hole state having the lesser outside diameter (ODL) and the deployed state having the greater outside diameter (ODG). In yet another embodiment, the liner hanger system employs a cone assembly including a first cone assembly portion (e.g., uphole cone assembly portion) and a second cone assembly portion (e.g., downhole cone assembly portion). In at least this one embodiment, the first cone assembly portion has a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and the second cone assembly portion has a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings. In one or more embodiments, ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another. In even yet another embodiment, the liner hanger system employs a spiral split ring cone (e.g., shaped similar to a spring), for the same purpose.

[0022] Turning now to FIGS. 1A and 1B, illustrated is one embodiment of a well system 100 designed, manufactured and / or operated according to one or more embodiments of the disclosure. The well system 100, in at least one embodiment, includes a wellbore 110 extending through one or more subterranean formations 115 (e.g., one or more hydrocarbon bearing subterranean formations). Further to the embodiment of FIGS. 1A and 1B, a wellbore tubular 120 (e.g., casing string in the illustrated embodiment) has been installed and cemented within the wellbore 110. The wellbore tubular 120 may comprise many different materials and minimum yield strengths and remain within the scope of the disclosure. Nevertheless, the present disclosure is particularly useful when the wellbore tubular 120 comprises a high grade steel. For instance, the wellbore tubular may have a minimum yield strength of at least 125 ksi in one embodiment, at least 140 ksi in another embodiment, at least 150 ksi in yet another embodiment, etc., and remain within the scope of the disclosure.

[0023] In the illustrated embodiment, a liner hanger system 130 (e.g., expandable liner hanger system) is positioned within the wellbore 110 and / or wellbore tubular 120. The liner hanger system 130, in at least one embodiment, includes a liner hanger setting tool (not shown), as well as an expandable liner hanger assembly 135 disposed thereabout. In at least one embodiment, the expandable liner hanger assembly 135 includes a radially expandable tubular 140. In the illustrated embodiment, the radially expandable tubular 140 defines an interior passageway and an exterior surface. In accordance with one embodiment, the expandable liner hanger assembly 135 additionally includes one or more anchoring ridges 145 (e.g., one or more continuous anchoring ridges) extending radially outward from the radially expandable tubular 140. In accordance with one embodiment of the disclosure, the radially expandable tubular 140 is configured to move between an initial state (as shown in FIG. 1A) wherein the one or more anchoring ridges 145 are not in contact with the wellbore tubular 120, and an expanded state (e.g., as shown in FIG. 1B) wherein the one or more anchoring ridges 145 are in gripping engagement with the wellbore tubular 120.

[0024] As shown, the expandable liner hanger assembly 135 may be hung, extending downhole from a lower end of wellbore tubular 120. An annulus 150 may be created between the wellbore tubular 120 and the liner hanger system 130. In embodiments, the liner hanger system 130 can support additional wellbore casing, operational tubulars or tubing strings, completion strings, downhole tools, etc., for positioning at greater depths.

[0025] As further illustrated in FIGS. 1A and 1B, the liner hanger system 130 may seal and secure an upper end of expandable liner hanger assembly 135 near a lower end of the wellbore tubular 120, for example using one or more sealing elements 160. Alternatively, the liner hanger system 130 may seal and secure the upper end of expandable liner hanger assembly 135 above a window (not shown) formed through a sidewall of the wellbore tubular 120, with the expandable liner hanger assembly 135 extending outwardly through the window into a branch or lateral wellbore. Thus, it will be appreciated that many different configurations and relative positions of the wellbore tubular 120 and the liner hanger system 130 are possible.

[0026] As used herein, the terms “tubular,”“liner,” and “casing” are used generally to describe tubular wellbore items, used for various purposes in wellbore operations. Tubulars, liners, and casings can be made from various materials (metal, plastic, composite, etc.), can be expanded or unexpanded as part of an installation procedure, and can be segmented or continuous. It is not necessary for a tubular, liner or casing to be cemented into position. Any type of tubular, liner, or casing may be used in keeping with the principles of the present invention.

[0027] Turning now to FIGS. 2A through 2J, illustrated are different views of a liner hanger setting tool 200 designed, manufactured and / or operated according to one or more embodiments of the disclosure at different states of deployment. For example, FIGS. 2A through 2E illustrate the liner hanger setting tool 200 at a run-in-hole state, wherein FIG. 2A is a perspective view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2B is a top view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2C is a side view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2D is a top cross-sectional view of the liner hanger setting tool 200 in the run-in-hole state, and FIG. 2E is a side cross-sectional view of the liner hanger setting tool 200 in the run-in-hole state. In contrast, FIGS. 2F through 2J illustrate the liner hanger setting tool 200 at a deployed state, wherein FIG. 2F is a perspective view of the liner hanger setting tool 200 in the deployed state, FIG. 2G is a top view of the liner hanger setting tool 200 in the deployed state, FIG. 2H is a side view of the liner hanger setting tool 200 in the deployed state, FIG. 2I is a top cross-sectional view of the liner hanger setting tool 200 in the deployed state, and FIG. 2J is a side cross-sectional view of the liner hanger setting tool 200 in the deployed state.

[0028] With reference to FIGS. 2A through 2J, the liner hanger setting tool 200 includes a cone mandrel 210. In the illustrated embodiment, the cone mandrel 210 includes a first flange member 220 (e.g., uphole flange member) and a second flange member 225 (e.g., downhole flange member). In at least one embodiment, as shown, at least a portion of an outer radial surface 230 of the cone mandrel 210 is outwardly sloped 240. In at least one embodiment, as shown, the outer radial surface 230 of the cone mandrel 210 is outwardly sloped 240 when moving from the second flange member 225 toward the first flange member 220. The cone mandrel 210 may comprise a variety of different materials and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the cone mandrel 210 is a metal cone mandrel.

[0029] In at least one other embodiment (e.g., not shown), the liner hanger setting tool 200 includes a downhole feature, the cone mandrel 210 positioned radially about the downhole feature. The downhole feature, in one or more embodiments, is a prop feature, for example having a first flange member and a second flange member, of which the cone mandrel 210 is placed between. The downhole feature may comprise a variety of different materials and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the downhole feature is a metal downhole feature.

[0030] The liner hanger setting tool 200, in the illustrated embodiment of FIGS. 2A through 2J, further includes a split ring cone 250 positioned about the cone mandrel 210. In one or more embodiments, the split ring cone 250 includes a slot 260 extending from a first end 255a (e.g., uphole end) of the split ring cone 250 to a second end 255b of the split ring cone 250. As discussed above, the slot 260 is configured to allow the split ring cone 250 to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E) and a split ring cone deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 2F through 2J) as the cone mandrel 210 and the split ring cone 250 axially move relative to one another. In at least one embodiment, the split ring cone 250 has a thickness (t) located proximate the slot 260, and further wherein the slot 260 extends through an entirety of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250. In another embodiment (not shown), the slot 260 does not extend through the entirety of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250, but: 1) only extends through a portion of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250, such that the remaining portion will snap when the split ring cone 250 moves from the run-in-hole state having the lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E) to the deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 2F through 2J); or 2) extends through an entirety of the thickness (t) from only a portion of the space between the first end 255a of the split ring cone 250 and the second end 255b of the split ring cone 250; or 3) any other suitable configuration.

[0031] In one or more embodiments, such as that shown, the split ring cone 250 has a split ring cone centerline (CLC) and the slot 260 has a slot centerline (CLS). In the illustrated embodiment, the split ring cone 250 is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone 250 is in the split ring cone run-in-hole state having the lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E). Accordingly, in at least this one embodiment, the slot 260 is a straight slot. In yet another embodiment (e.g., not shown), the split ring cone 250 is configured such that the slot centerline (CLS) is angled relative to the split ring cone centerline (CLS), when the split ring cone 250 is in the split ring cone run-in-hole state. Accordingly, in at least this one embodiment, the slot 260 is an angled slot. For example, in at least one embodiment, the slot centerline (CLS) may be angled (α) from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC), when the split ring cone 250 is in the split ring cone run-in-hole state. This embodiment is illustrated with the dotted line in FIG. 2A.

[0032] The liner hanger setting tool 200, in the illustrated embodiment of FIGS. 2A through 2J, may further include a second cone 270 positioned about the cone mandrel 210 (e.g., positioned about the cone mandrel 210 downhole of the split ring cone 250). In the illustrated embodiment of FIGS. 2A through 2F, the second cone 270 is a non-split ring cone. The non-split ring cone, in at least one embodiment, has the benefit of providing consistent expansion of the expandable liner hanger assembly about an entirety of the inner circumference thereof, for example prior to the split ring cone 250 engaging with the expandable liner hanger assembly. In contrast, the slot 260 in the split ring cone 250 may cause the split ring cone 250 to provide inconsistent expansion of the expandable liner hanger assembly about an entirety of the inner circumference thereof, for example after the second cone 270 has engaged with the expandable liner hanger assembly. Thus, the second cone 270 and the split ring cone 250 may be used in conjunction with one another in various embodiments.

[0033] As shown when comparing FIGS. 2A through 2E to FIGS. 2F through 2J, as the cone mandrel 210 and the split ring cone 250 axially move relative to one another, the second cone 270 pushes the split ring cone 250 up the outwardly sloped 240 portion of the outer radial surface 230 of the cone mandrel 210. Accordingly, based upon this movement, the split ring cone 250 moves to the deployed state, and thus from the lesser outside diameter (ODL) to the greater outside diameter (ODG).

[0034] Turning now to FIGS. 3A through 3H, illustrated is a liner hanger system 300 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 300, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 300, in the illustrated embodiment, may further include a liner hanger setting tool 330. The liner hanger setting tool 330 is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0035] FIGS. 3A and 3B illustrate top and side cross-sectional views, respectively, of the liner hanger system 300 in the run-in-hole state. As shown, the liner hanger setting tool 330 has yet to engage with the expandable liner hanger assembly 310.

[0036] FIGS. 3C and 3D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the split ring cone deployed state. As shown, the cone mandrel 210 and the split ring cone 250 have axially moved relative to one another, for example closing an upper gap therebetween, and moving the split ring cone 250 to the deployed state. At this stage, the slot 260 in the split ring cone is larger, and the split ring cone 250 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0037] FIGS. 3E and 3F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 330 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0038] FIGS. 3G and 3H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 330 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the split ring cone 250 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0039] Turning to FIGS. 4A through 4J, illustrated are different views of a liner hanger setting tool 400 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 4A through 4E illustrate the liner hanger setting tool 400 at a run-in-hole state, wherein FIG. 4A is a perspective view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4B is a top view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4C is a side view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4D is a top cross-sectional view of the liner hanger setting tool 400 in the run-in-hole state, and FIG. 4E is a side cross-sectional view of the liner hanger setting tool 400 in the run-in-hole state. In contrast, FIGS. 4F through 4J illustrate the liner hanger setting tool 400 at a deployed state, wherein FIG. 4F is a perspective view of the liner hanger setting tool 400 in the deployed state, FIG. 4G is a top view of the liner hanger setting tool 400 in the deployed state, FIG. 4H is a side view of the liner hanger setting tool 400 in the deployed state, FIG. 4I is a top cross-sectional view of the liner hanger setting tool 400 in the deployed state, and FIG. 4J is a side cross-sectional view of the liner hanger setting tool 400 in the deployed state.

[0040] The liner hanger setting tool 400 of FIGS. 4A through 4J is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 400 of FIGS. 4A through 4J differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that its cone mandrel 210 is positioned about a downhole feature 410. In the illustrated embodiment, the cone mandrel 210 is configured to slide relative to the downhole feature 410 to move the split ring cone 450 from the run-in-hole state to the deployed state.

[0041] The liner hanger setting tool 400 of FIGS. 4A through 4J further differs from the liner hanger setting tool 200 of FIGS. 2A through 2J in that edges of its slot 460 are not parallel with one another when the split ring cone 450 is in the split ring cone run-in-hole state. For example, in the illustrated embodiment, the slot 460 (e.g., when the split ring cone 450 is in the split ring cone run-in-hole state) is a wedge shaped slot. Nevertheless, the slot 460 may comprise a variety of different shapes (e.g., including a variety of different polygonal shapes) and remain within the purview of the disclosure. Further to the embodiment of FIGS. 4A through 4J, the liner hanger setting tool 400 may additionally include a wedge shaped key 480 positioned about the cone mandrel 210. In this embodiment, the wedge shaped key 480 is configured to fill in the slot 460 (e.g., wedge shaped slot) when the split ring cone 450 is in the split ring cone deployed state.

[0042] Further to the embodiment of FIGS. 4A through 4J, the wedge shaped key 480 is positioned about an outwardly sloped portion 485 of the downhole feature 410. In at least one embodiment, as shown, the outwardly sloped portion 485 is outwardly sloped 240 when moving from the second flange member 225 toward the first flange member 220. In this embodiment, the outwardly sloped portion 485 of the downhole feature 410 is configured to move the wedge shaped key 480 radially outward and fill in the slot 460 as the downhole feature 410, cone mandrel 210 and the split ring cone 450 axially move relative to one another.

[0043] The liner hanger setting tool 400 of FIGS. 4A through 4J further differs from the liner hanger setting tool 200 of FIGS. 2A through 2J in that the split ring cone 450 includes a plurality of segment portions 452 that come together to form the split ring cone 450. This is in contrast to the split ring cone 250 of FIGS. 2A through 2J, which is a single piece split ring cone. Any number of segment portions 452, for example from two to one hundred, may be used and remain within the scope of the disclosure. Nevertheless, in at least one embodiment from two to twenty segment portions 452 are employed, if not from four to sixteen segment portions 452, if not from six to twelve segment portions 452.

[0044] The segment portions 452, in one or more embodiments, may be held together with a retaining member 454. The retaining member 454 may comprise a variety of different styles, shapes, materials, etc. and remain within the scope of the disclosure. Nevertheless, in at least one embodiment the retaining member 454 is a snap ring (e.g., metal snap ring), or alternatively elastic material (e.g., such as an O-ring).

[0045] Turning now to FIGS. 5A through 5H, illustrated is a liner hanger system 500 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 500, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 500, in the illustrated embodiment, may further include a liner hanger setting tool 530. The liner hanger setting tool 530 is similar in many respects to the liner hanger setting tool 400 of FIGS. 2A through 4J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0046] FIGS. 5A and 5B illustrate top and side cross-sectional views, respectively, of the liner hanger system 500 in the run-in-hole state. As shown, the liner hanger setting tool 530 has yet to engage with the expandable liner hanger assembly 310.

[0047] FIGS. 5C and 5D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the split ring cone deployed state. As shown, the cone mandrel 210 and the split ring cone 450 have axially moved relative to one another, for example closing an upper gap therebetween, and moving the split ring cone 450 to the deployed state. At this stage, the slot 460 in the split ring cone 450 is larger, and the split ring cone 450 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310. Furthermore, the wedge shaped key 480 now fills in the slot 460.

[0048] FIGS. 5E and 5F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 530 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0049] FIGS. 5G and 5H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 530 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the split ring cone 450 in the expanded state (e.g., and the wedge shaped key 480) is now in contact with the expandable liner hanger assembly 310.

[0050] Turning to FIGS. 6A through 6Y, illustrated are different views of a liner hanger setting tool 600 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 6A through 6E illustrate the liner hanger setting tool 600 at a run-in-hole state, wherein FIG. 6A is a perspective view of the liner hanger setting tool 600 in the run-in-hole state, FIG. 6B is a top view of the liner hanger setting tool 600 in the run-in-hole state, and FIG. 6C is a side view of the liner hanger setting tool 600 in the run-in-hole state, FIG. 6D is a top cross-sectional view of the liner hanger setting tool 600 in the run-in-hole state, and FIG. 6E is a side cross-sectional view of the liner hanger setting tool 600 in the run-in-hole state. In contrast, FIGS. 6F through 6J illustrate the liner hanger setting tool 600 at a first partial deployed state, wherein FIG. 6F is a perspective view of the liner hanger setting tool 600 in the first partial deployed state, FIG. 6G is a top view of the liner hanger setting tool 600 in the first partial deployed state, and FIG. 6H is a side view of the liner hanger setting tool 600 in the first partial deployed state, FIG. 6I is a top cross-sectional view of the liner hanger setting tool 600 in the first partial deployed state, and FIG. 6J is a side cross-sectional view of the liner hanger setting tool 600 in the first partial deployed state. In contrast, FIGS. 6K through 6O illustrate the liner hanger setting tool 600 at a second partial deployed state, wherein FIG. 6K is a perspective view of the liner hanger setting tool 600 in the second partial deployed state, FIG. 6L is a top view of the liner hanger setting tool 600 in the second partial deployed state, and FIG. 6M is a side view of the liner hanger setting tool 600 in the second partial deployed state, FIG. 6N is a top cross-sectional view of the liner hanger setting tool 600 in the second partial deployed state, and FIG. 6O is a side cross-sectional view of the liner hanger setting tool 600 in the second partial deployed state. In contrast, FIGS. 6P through 6T illustrate the liner hanger setting tool 600 at a third partial deployed state, wherein FIG. 6P is a perspective view of the liner hanger setting tool 600 in the third partial deployed state, FIG. 6Q is a top view of the liner hanger setting tool 600 in the third partial deployed state, and FIG. 6R is a side view of the liner hanger setting tool 600 in the third partial deployed state, FIG. 6S is a top cross-sectional view of the liner hanger setting tool 600 in the third partial deployed state, and FIG. 6T is a side cross-sectional view of the liner hanger setting tool 600 in the third partial deployed state. In contrast, FIGS. 6U through 6Y illustrate the liner hanger setting tool 600 at a fully deployed state, wherein FIG. 6U is a perspective view of the liner hanger setting tool 600 in the fully deployed state, FIG. 6V is a top view of the liner hanger setting tool 600 in the fully deployed state, and FIG. 6W is a side view of the liner hanger setting tool 600 in the fully deployed state, FIG. 6X is a top cross-sectional view of the liner hanger setting tool 600 in the fully deployed state, and FIG. 6Y is a side cross-sectional view of the liner hanger setting tool 600 in the fully deployed state.

[0051] The liner hanger setting tool 600 of FIGS. 6A through 6Y is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 600 of FIGS. 6A through 6Y differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that it employs a cone assembly 610 positioned about the cone mandrel 210. The cone assembly 610, in at least one embodiment, includes a first cone assembly portion 620 (e.g., uphole cone assembly portion), the first cone assembly portion 620 having a plurality of first cone portions 630, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings 635. The cone assembly 610, in at least one embodiment, further includes a second cone assembly portion 640 (e.g., downhole cone assembly portion), the second cone assembly portion 640 having a plurality of second cone portions 650, the plurality of second cone portions 650 circumferentially spaced apart by a plurality of second spacings 655. Any number of first cone portions 630 and second cone portions 650 may be used for the first cone assembly portion 620 and second cone assembly portion 640, respectively. Nevertheless, in at least one embodiment, the plurality of first cone portions 630 are three or more first cone portions and the plurality of second cone portions 650 are three or more second cone portions. In yet another embodiment, the plurality of first cone portions 630 are four or more first cone portions and the plurality of second cone portions 650 are four or more second cone portions. In even yet another embodiment, the plurality of first cone portions 630 are six or more first cone portions and the plurality of second cone portions 650 are six or more second cone portions. In most embodiments, the plurality of first cone portions 630 are less than 50 first cone portions and the plurality of second cone portions 650 are less than 50 second cone portions.

[0052] In at least one embodiment, the cone assembly 610 is configured such that ones of the plurality of first cone portions 630 are rotationally aligned with ones of the plurality of second spacings 655 and ones of the plurality of second cone portions 650 are rotationally aligned with ones of the plurality of first spacings 635. Accordingly, in at least this one embodiment, the first cone assembly portion 620 and second cone assembly portion 640 are configured to allow the cone assembly 610 to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) (e.g., as shown in FIGS. 6A through 6E) and a cone assembly deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 6U through 6Y, for example via the different states shown in FIGS. 6F through 6T) as the cone mandrel 210 and the cone assembly 610 axially move relative to one another. Thus, in at least one embodiment the ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 engage one another like opposing interdigitated fingers when the cone assembly 610 is in the deployed state. In at least one embodiment, such as that shown, the cone assembly 610 is configured such that the first cone assembly portion 620 is radially misaligned with the second cone assembly portion 640 when the cone assembly 610 is in the cone assembly run-in-hole state (e.g., as shown in FIGS. 6A through 6E), and the first cone assembly portion 620 is at least partially radially aligned (e.g., if not totally radially aligned) with the second cone assembly portion 640 when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y).

[0053] Furthermore, in at least one embodiment, a rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 100 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 50 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 25 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 5 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y).

[0054] Further to the embodiment of FIGS. 6A through 6Y, the outer radial surface 230 of the cone mandrel 210 includes a first outwardly sloped portion 660a (e.g., an uphole outwardly sloped portion) configured to engage with the plurality of first cone portions 630 and a second outwardly sloped portion 660b (e.g., downhole outwardly sloped portion) configured to engage with the plurality of second cone portions 650. Further to the embodiment of FIGS. 6A through 6Y, the first outwardly sloped portion 660a includes ones of first axial guides 665a for the plurality of first cone portions 630.

[0055] Turning now to FIGS. 7A through 7H, illustrated is a liner hanger system 700 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 700, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 700, in the illustrated embodiment, may further include a liner hanger setting tool 730. The liner hanger setting tool 730 is similar in many respects to the liner hanger setting tool 600 of FIGS. 6A through 6Y. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0056] FIGS. 7A and 7B illustrate top and side cross-sectional views, respectively, of the liner hanger system 700 in the run-in-hole state. As shown, the liner hanger setting tool 730 has yet to engage with the expandable liner hanger assembly 310.

[0057] FIGS. 7C and 7D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the split ring cone deployed state. As shown, the cone mandrel 210 and the cone assembly 610 have axially moved relative to one another, for example closing a gap therebetween, and moving the cone assembly 610 to the deployed state. At this stage, the cone assembly 610 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0058] FIGS. 7E and 7F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 730 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0059] FIGS. 7G and 7H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 730 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the cone assembly 610 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0060] Turning to FIGS. 8A through 8J, illustrated are different views of a liner hanger setting tool 800 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 8A through 8E illustrate the liner hanger setting tool 800 at a run-in-hole state, wherein FIG. 8A is a perspective view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8B is a top view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8C is a side view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8D is a top cross-sectional view of the liner hanger setting tool 800 in the run-in-hole state, and FIG. 8E is a side cross-sectional view of the liner hanger setting tool 800 in the run-in-hole state. In contrast, FIGS. 8F through 8J illustrate the liner hanger setting tool 800 at a deployed state, wherein FIG. 8F is a perspective view of the liner hanger setting tool 800 in the deployed state, FIG. 8G is a top view of the liner hanger setting tool 800 in the deployed state, FIG. 8H is a side view of the liner hanger setting tool 800 in the deployed state, FIG. 8I is a top cross-sectional view of the liner hanger setting tool 800 in the deployed state, and FIG. 8J is a side cross-sectional view of the liner hanger setting tool 800 in the deployed state.

[0061] The liner hanger setting tool 800 of FIGS. 8A through 8J is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 800 of FIGS. 8A through 8J differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that it employs a spiral split ring cone 850 positioned about the cone mandrel 210. In one or more embodiments, the spiral split ring cone 850 includes one or more circumferential slots 860 extending from a first end 855a (e.g., an uphole end) of the spiral split ring cone 850 toward a second end 855b (e.g., second opposing end or downhole end) of the spiral split ring cone 850. In at least one embodiment, the one or more circumferential slots 860 are configured to allow the spiral split ring cone 850 to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel 210 and the spiral split ring cone 850 axially move relative to one another. In at least one embodiment, the spiral split ring cone 850 has a thickness (t) located proximate the one or more circumferential slots 860 and further wherein the one or more circumferential slots 860 extend through an entirety of the thickness (t) from the first end 855a of the spiral split ring cone 850 to the second end 855b of the spiral split ring cone 850.

[0062] In at least one embodiment, the spiral split ring cone 850 is a spring having a single circumferential slot 860, the single circumferential slot 860 configured to allow the spiral split ring cone 850 to move between the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) and the spiral split ring cone deployed state having the greater outside diameter (ODG) as the cone mandrel 210 and the spiral split ring cone 850 axially move relative to one another. For example, in at least one embodiment the spring is a flat spiral spring or a helix spring, but other types of springs may be used and remain within the scope of the disclosure. In at least one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least 1½ full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In at least one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least two full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least four full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state.

[0063] The spiral split ring cone 850, in one embodiment, is configured such that an axial spacing (s) between adjacent coils of the spring is less than 100 mm when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In yet another embodiment, the spiral split ring cone 850 is configured such that an axial spacing (s)between adjacent coils of the spring is less than 50 mm when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state, if not less than 25 mm, if not less than 10 mm, if not less than 1 mm.

[0064] In yet another embodiment, the spiral split ring cone 850 is a first spiral split ring cone, and the liner hanger setting tool 800 further includes a second spiral split ring cone positioned about the cone mandrel 210. For example, in at least one embodiment, the first spiral split ring cone is a first spring having a first single circumferential slot, and the second spiral split ring cone is a second spring having a second single circumferential slot. In at least one embodiment, the handedness of the first spring and the second spring are similar to one another. In yet another embodiment, the handedness of the first spring and the second spring are opposite to one another. In at least yet another embodiment, the first spring and the second spring are in physical contact with one another, but yet in another embodiment the first spring and the second spring are not in physical contact with one another.

[0065] Turning briefly to FIGS. 9A through 9E, illustrated are different cross-sectional views of various embodiments of spiral split ring cones 900a, 900b, 900c, 900d, 900e designed, manufactured and / or operated according to one or more embodiments of the disclosure. As shown in FIGS. 9A through 9E, various different cross-sectional shapes may be used for the spiral split ring cones. For example, FIGS. 9A and 9B illustrate the cross-section as round and oval, respectively. In yet other embodiments, the cross-section might include one or more straight lines, such as the case if the cross-section were polygonal. For example, a rectangular cross-section could be used, such as shown in FIG. 9C, or alternatively a rectangular cross-section with partially rounded edges, both of which may reduce point loading and distribute the loads better. In at least one embodiment, the rectangular cross-section split ring cone may be manufactured that stacks solid in its free-state, even with progressive diameters such as in a battery spring. Notwithstanding, unless otherwise required, the cross-section of the split ring cone should not be limited to any specific shape.

[0066] Turning now to FIGS. 10A through 10H, illustrated is a liner hanger system 1000 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 1000, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 1000, in the illustrated embodiment, may further include a liner hanger setting tool 1030. The liner hanger setting tool 1030 is similar in many respects to the liner hanger setting tool 800 of FIGS. 8A through 8J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0067] FIGS. 10A and 10B illustrate top and side cross-sectional views, respectively, of the liner hanger system 1000 in the run-in-hole state. As shown, the liner hanger setting tool 1030 has yet to engage with the expandable liner hanger assembly 310.

[0068] FIGS. 10C and 10D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the split ring cone deployed state. As shown, the cone mandrel 210 and the spiral split ring cone 850 have axially moved relative to one another, for example moving the spiral split ring cone 850 to the deployed state. At this stage, the spiral split ring cone 850 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0069] FIGS. 10E and 10F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 1030 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0070] FIGS. 10G and 10H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 1030 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the spiral split ring cone 850 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0071] Aspects disclosed herein include:

[0072] A. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and

[0073] 2) a split ring cone positioned about the cone mandrel, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

[0074] B. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another; 2) moving the split ring cone from the split ring cone run-in-hole state having the lesser outside diameter (ODL) to the split ring cone deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the split ring cone in the split ring cone deployed state having the greater outside diameter (ODG).

[0075] C. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

[0076] D. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and 2) a cone assembly positioned about the cone mandrel, the cone assembly including: a) a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings; and b) a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another.

[0077] E. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a cone assembly positioned about the cone mandrel, the cone assembly including: a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another; 2) moving the cone assembly from the cone assembly run-in-hole state having the lesser outside diameter (ODL) to the cone assembly deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the cone assembly in the cone assembly deployed state having the greater outside diameter (ODG).

[0078] F. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a cone assembly positioned about the cone mandrel, the cone assembly including: a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another.

[0079] G. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and 2) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another.

[0080] H. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another; 2) moving the spiral split ring cone from the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) to the spiral split ring cone deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the spiral split ring cone in the spiral split ring cone deployed state having the greater outside diameter (ODG).

[0081] I. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another.

[0082] Aspects A, B, C, D, E, F, G, H and I may have one or more of the following additional elements in combination: Element 1: wherein the split ring cone has a thickness (t) located proximate the slot, and further wherein the slot extends through an entirety of the thickness (t) from the first end of the split ring cone to the second end of the split ring cone. Element 2: wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state. Element 3: wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is angled from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state. Element 4: wherein the split ring cone is configured such that edges of the slot are not parallel with one another when the split ring cone is in the split ring cone run-in-hole state. Element 5: wherein the slot is a wedge shaped slot, and further including a wedge shaped key positioned about the cone mandrel, the wedge shaped key configured to fill in the slot when the split ring cone is in the split ring cone deployed state. Element 6: wherein the wedge shaped key is positioned about an outwardly sloped portion of a downhole feature, the outwardly sloped portion of the downhole feature configured to move the wedge shaped key radially outward and fill in the slot as the downhole feature and the split ring cone axially move relative to one another. Element 7: wherein the split ring cone includes a plurality of segment portions that come together to form the split ring cone. Element 8: wherein the plurality of segment portions are held together with a retaining member. Element 9: further including a non-split ring cone positioned about the cone mandrel and downhole of the split ring cone. Element 10: further including moving the split ring cone in the split ring cone deployed state back to the split ring cone run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore. Element 11: wherein the cone assembly is configured such that the first cone assembly portion is radially misaligned with the second cone assembly portion when the cone assembly is in the cone assembly run-in-hole state and the first cone assembly portion is at least partially radially aligned with the second cone assembly portion when the cone assembly is in the cone assembly deployed state. Element 12: wherein the outer radial surface of the cone mandrel includes a first outwardly sloped portion configured to engage with the plurality of first cone portions and a second outwardly sloped portion configured to engage with the plurality of second cone portions. Element 13: wherein the first outwardly sloped portion includes ones of first axial guides for the plurality of first cone portions and the second outwardly sloped portion includes ones of second axial guides for the plurality of second cone portions. Element 14: wherein the plurality of first cone portions are three or more first cone portions and the plurality of second cone portions are three or more second cone portions. Element 15: wherein the plurality of first cone portions are six or more first cone portions and the plurality of second cone portions are six or more second cone portions. Element 16: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 100 mm when the cone assembly is in the cone assembly deployed state. Element 17: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 50 mm when the cone assembly is in the cone assembly deployed state. Element 18: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 25 mm when the cone assembly is in the cone assembly deployed state. Element 19: further including a non-split ring cone positioned about the cone mandrel downhole of the second cone assembly portion. Element 20: further including moving the cone assembly in the cone assembly deployed state back to the cone assembly run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore. Element 21: wherein the spiral split ring cone has a thickness (t) located proximate the one or more circumferential slots, and further wherein the one or more circumferential slots extend through an entirety of the thickness (t) from the first end of the spiral split ring cone to the second end of the spiral split ring cone. Element 22: wherein the spiral split ring cone is a spring having a single circumferential slot, the single circumferential slot configured to allow the spiral split ring cone to move between the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) and the spiral split ring cone deployed state having the greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another. Element 23: wherein the spring is a flat spiral spring or a helix spring. Element 24: wherein the spiral split ring cone is configured such that the spring includes at least two full 360-degree coils when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 25: wherein the spiral split ring cone is configured such that the spring includes at least four full 360-degree coils when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 26: wherein the spiral split ring cone is configured such that an axial spacing (s)between adjacent coils of the spring is less than 100 mm when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 27: wherein the spiral split ring cone is configured such that an axial spacing (s)between adjacent coils of the spring is less than 50 mm when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 28: wherein the spiral split ring cone is a first spring having a first single circumferential slot and an adjacently placed second spring having a second single circumferential slot. Element 29: further including a non-split ring cone positioned about the cone mandrel downhole of the spiral split ring cone. Element 30: further including moving the spiral split ring cone in the spiral split ring cone deployed state back to the spiral split ring cone run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore.

[0083] Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Examples

Embodiment Construction

[0016]In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.

[0017]Unless otherwise specified,...

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application claims the benefit of U.S. Provisional Application Ser. No. 63 / 781,686, filed on Apr. 1, 2025, entitled “LINER HANGER SETTING TOOL INCLUDING A SPLIT RING CONE, A WELL SYSTEM AND A METHOD,” commonly assigned with this application and incorporated herein by reference in its entirety.BACKGROUND

[0002] During wellbore operations, it is typical to “hang” a liner onto a casing such that the liner supports an extended string of tubular below it. As used herein, “tubing string” refers to a series of connected pipe sections, casing sections, joints, screens, blanks, cross-over tools, downhole tools, and the like, inserted into a wellbore, whether used for drilling, work-over, production, injection, completion, or other processes. A tubing string may be run in and out of the casing, and similarly, the tubing string can be run in an uncased wellbore or section of wellbore. Further, in many cases a tool may be run on a wireline or coiled tubing instead of a tubing string, as those of skill in the art will recognize.

[0003] Expandable liner hangers may generally be used to secure the liner within a previously set wellbore tubular (e.g., casing or liner string). Expandable liner hangers may be “set” by expanding the liner hanger radially outward into gripping and sealing contact with the wellbore tubular. For example, expandable liner hangers may be expanded by use of hydraulic pressure to drive an expanding cone, wedge, or “pig,” through the liner hanger. Other methods may be used, such as mechanical swaging, explosive expansion, memory metal expansion, swellable material expansion, electromagnetic force-driven expansion, etc.

[0004] The expansion process may typically be performed by means of a liner hanger setting tool, which may also be used to convey the liner hanger into the wellbore. The liner hanger setting tool may be interconnected between a work string (e.g., a tubular string made up of drill pipe or other segmented or continuous tubular elements) and the liner hanger. The liner hanger setting tool may expand the liner hanger into anchoring and sealing engagement with the wellbore tubular.BRIEF DESCRIPTION

[0005] Reference is now made to the following descriptions taken in conjunction with the accompanying drawings, in which:

[0006] FIGS. 1A and 1B illustrate one embodiment of a well system designed, manufactured and / or operated according to one or more embodiments of the disclosure;

[0007] FIGS. 2A through 2J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more embodiments of the disclosure at different states of deployment;

[0008] FIGS. 3A through 3H illustrate a liner hanger system designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0009] FIGS. 4A through 4J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0010] FIGS. 5A through 5H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0011] FIGS. 6A through 6Y illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0012] FIGS. 7A through 7H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment;

[0013] FIGS. 8A through 8J illustrate different views of a liner hanger setting tool designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment;

[0014] FIGS. 9A through 9E illustrate different cross-sectional views of various embodiments of spiral split ring cones designed, manufactured and / or operated according to one or more embodiments of the disclosure; and

[0015] FIGS. 10A through 10H illustrate a liner hanger system designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure positioned within a wellbore tubular, at various different states of deployment.DETAILED DESCRIPTION

[0016] In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.

[0017] Unless otherwise specified, use of the terms “connect,”“engage,”“couple,”“attach,” or any other like term describing an interaction between elements is not meant to limit the interaction to direct interaction between the elements and may also include indirect interaction between the elements described. Furthermore, unless otherwise specified, use of the terms “up,”“upper,”“upward,”“uphole,”“upstream,” or other like terms shall be construed as generally toward the surface of the subterranean formation; likewise, use of the terms “down,”“lower,”“downward,”“downhole,”“downstream,” or other like terms shall be construed as generally toward the bottom, terminal end of a well, regardless of the wellbore orientation. Use of any one or more of the foregoing terms shall not be construed as denoting positions along a perfectly vertical axis. Additionally, unless otherwise specified, use of the term “subterranean formation” shall be construed as encompassing both areas below exposed earth and areas below earth covered by water such as ocean or fresh water.

[0018] Various values and / or ranges are explicitly disclosed in certain embodiments herein. However, values / ranges from any lower limit may be combined with any upper limit to recite a range not explicitly recited. Similarly, values / ranges from any lower limit may be combined with any other lower limit to recite a range not explicitly recited. In the same way, values / ranges from any upper limit may be combined with any other upper limit to recite a range not explicitly recited. Additionally, whenever a numerical range with a lower limit and an upper limit is disclosed, any number and any included range falling within the range are specifically disclosed. In particular, every range of values (of the form, “from about a to about b,” or, equivalently, “from approximately a to b,” or, equivalently, “from approximately a-b”) disclosed herein is to be understood to set forth every number and range encompassed within the broader range of values even if not explicitly recited. Thus, every point or individual value may serve as its own lower or upper limit combined with any other point or individual value or any other lower or upper limit, to recite a range not explicitly recited. Similarly, an individual value disclosed herein may be combined with another individual value or range disclosed herein to form another range.

[0019] The term “approximately XYZ,” as used herein, means that it is within plus or minus 20percent of perfectly XYZ. The term “substantially XYZ,” as used herein, means that it is within plus or minus 10 percent of perfectly XYZ. The term “significantly XYZ,” as used herein, means that it is within plus or minus 5 percent of perfectly XYZ. The term “ideally XYZ,” as used herein, means that it is within plus or minus 1 percent of perfectly XYZ. The monicker “XYZ” could refer to parallel, perpendicular, alignment, or other relative features disclosed herein.

[0020] The present disclosure has recognized, for the first time, that certain wellheads (e.g., certain wellheads in deepwater operations) come with a standard inside diameter (ID), which prevents the run-in-hole of liner hanger systems with larger outside diameter (OD) features, such as larger outside diameter (OD) cones. Typically, the larger outside diameter (OD) of the liner hanger system is required to successfully expand the liner hanger assembly in lighter weight casings, where the inside diameter (ID) is larger. Accordingly, a liner hanger system is needed that employs a liner hanger setting tool with a cone that can move between a run-in-hole state having a lesser outside diameter (ODL) (e.g., so that it can pass through smaller inside diameter (ID) wellheads) and a deployed state having a greater outside diameter (ODG) (e.g., for engaging with the expandable liner hanger assembly).

[0021] In at least one embodiment, the liner hanger system employs a split ring cone (e.g., C-ring in one embodiment). The split ring cone, in at least one embodiment, includes a slot extending from a first end (e.g., an uphole end) of the split ring cone to a second end (e.g., second opposing end or downhole end) of the split ring cone, the slot allowing the split ring cone to expand between the run-in-hole state having the lesser outside diameter (ODL) and the deployed state having the greater outside diameter (ODG). In yet another embodiment, the liner hanger system employs a cone assembly including a first cone assembly portion (e.g., uphole cone assembly portion) and a second cone assembly portion (e.g., downhole cone assembly portion). In at least this one embodiment, the first cone assembly portion has a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and the second cone assembly portion has a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings. In one or more embodiments, ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another. In even yet another embodiment, the liner hanger system employs a spiral split ring cone (e.g., shaped similar to a spring), for the same purpose.

[0022] Turning now to FIGS. 1A and 1B, illustrated is one embodiment of a well system 100 designed, manufactured and / or operated according to one or more embodiments of the disclosure. The well system 100, in at least one embodiment, includes a wellbore 110 extending through one or more subterranean formations 115 (e.g., one or more hydrocarbon bearing subterranean formations). Further to the embodiment of FIGS. 1A and 1B, a wellbore tubular 120 (e.g., casing string in the illustrated embodiment) has been installed and cemented within the wellbore 110. The wellbore tubular 120 may comprise many different materials and minimum yield strengths and remain within the scope of the disclosure. Nevertheless, the present disclosure is particularly useful when the wellbore tubular 120 comprises a high grade steel. For instance, the wellbore tubular may have a minimum yield strength of at least 125 ksi in one embodiment, at least 140 ksi in another embodiment, at least 150 ksi in yet another embodiment, etc., and remain within the scope of the disclosure.

[0023] In the illustrated embodiment, a liner hanger system 130 (e.g., expandable liner hanger system) is positioned within the wellbore 110 and / or wellbore tubular 120. The liner hanger system 130, in at least one embodiment, includes a liner hanger setting tool (not shown), as well as an expandable liner hanger assembly 135 disposed thereabout. In at least one embodiment, the expandable liner hanger assembly 135 includes a radially expandable tubular 140. In the illustrated embodiment, the radially expandable tubular 140 defines an interior passageway and an exterior surface. In accordance with one embodiment, the expandable liner hanger assembly 135 additionally includes one or more anchoring ridges 145 (e.g., one or more continuous anchoring ridges) extending radially outward from the radially expandable tubular 140. In accordance with one embodiment of the disclosure, the radially expandable tubular 140 is configured to move between an initial state (as shown in FIG. 1A) wherein the one or more anchoring ridges 145 are not in contact with the wellbore tubular 120, and an expanded state (e.g., as shown in FIG. 1B) wherein the one or more anchoring ridges 145 are in gripping engagement with the wellbore tubular 120.

[0024] As shown, the expandable liner hanger assembly 135 may be hung, extending downhole from a lower end of wellbore tubular 120. An annulus 150 may be created between the wellbore tubular 120 and the liner hanger system 130. In embodiments, the liner hanger system 130 can support additional wellbore casing, operational tubulars or tubing strings, completion strings, downhole tools, etc., for positioning at greater depths.

[0025] As further illustrated in FIGS. 1A and 1B, the liner hanger system 130 may seal and secure an upper end of expandable liner hanger assembly 135 near a lower end of the wellbore tubular 120, for example using one or more sealing elements 160. Alternatively, the liner hanger system 130 may seal and secure the upper end of expandable liner hanger assembly 135 above a window (not shown) formed through a sidewall of the wellbore tubular 120, with the expandable liner hanger assembly 135 extending outwardly through the window into a branch or lateral wellbore. Thus, it will be appreciated that many different configurations and relative positions of the wellbore tubular 120 and the liner hanger system 130 are possible.

[0026] As used herein, the terms “tubular,”“liner,” and “casing” are used generally to describe tubular wellbore items, used for various purposes in wellbore operations. Tubulars, liners, and casings can be made from various materials (metal, plastic, composite, etc.), can be expanded or unexpanded as part of an installation procedure, and can be segmented or continuous. It is not necessary for a tubular, liner or casing to be cemented into position. Any type of tubular, liner, or casing may be used in keeping with the principles of the present invention.

[0027] Turning now to FIGS. 2A through 2J, illustrated are different views of a liner hanger setting tool 200 designed, manufactured and / or operated according to one or more embodiments of the disclosure at different states of deployment. For example, FIGS. 2A through 2E illustrate the liner hanger setting tool 200 at a run-in-hole state, wherein FIG. 2A is a perspective view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2B is a top view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2C is a side view of the liner hanger setting tool 200 in the run-in-hole state, FIG. 2D is a top cross-sectional view of the liner hanger setting tool 200 in the run-in-hole state, and FIG. 2E is a side cross-sectional view of the liner hanger setting tool 200 in the run-in-hole state. In contrast, FIGS. 2F through 2J illustrate the liner hanger setting tool 200 at a deployed state, wherein FIG. 2F is a perspective view of the liner hanger setting tool 200 in the deployed state, FIG. 2G is a top view of the liner hanger setting tool 200 in the deployed state, FIG. 2H is a side view of the liner hanger setting tool 200 in the deployed state, FIG. 2I is a top cross-sectional view of the liner hanger setting tool 200 in the deployed state, and FIG. 2J is a side cross-sectional view of the liner hanger setting tool 200 in the deployed state.

[0028] With reference to FIGS. 2A through 2J, the liner hanger setting tool 200 includes a cone mandrel 210. In the illustrated embodiment, the cone mandrel 210 includes a first flange member 220 (e.g., uphole flange member) and a second flange member 225 (e.g., downhole flange member). In at least one embodiment, as shown, at least a portion of an outer radial surface 230 of the cone mandrel 210 is outwardly sloped 240. In at least one embodiment, as shown, the outer radial surface 230 of the cone mandrel 210 is outwardly sloped 240 when moving from the second flange member 225 toward the first flange member 220. The cone mandrel 210 may comprise a variety of different materials and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the cone mandrel 210 is a metal cone mandrel.

[0029] In at least one other embodiment (e.g., not shown), the liner hanger setting tool 200 includes a downhole feature, the cone mandrel 210 positioned radially about the downhole feature. The downhole feature, in one or more embodiments, is a prop feature, for example having a first flange member and a second flange member, of which the cone mandrel 210 is placed between. The downhole feature may comprise a variety of different materials and remain within the scope of the disclosure. Nevertheless, in at least one embodiment, the downhole feature is a metal downhole feature.

[0030] The liner hanger setting tool 200, in the illustrated embodiment of FIGS. 2A through 2J, further includes a split ring cone 250 positioned about the cone mandrel 210. In one or more embodiments, the split ring cone 250 includes a slot 260 extending from a first end 255a (e.g., uphole end) of the split ring cone 250 to a second end 255b of the split ring cone 250. As discussed above, the slot 260 is configured to allow the split ring cone 250 to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E) and a split ring cone deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 2F through 2J) as the cone mandrel 210 and the split ring cone 250 axially move relative to one another. In at least one embodiment, the split ring cone 250 has a thickness (t) located proximate the slot 260, and further wherein the slot 260 extends through an entirety of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250. In another embodiment (not shown), the slot 260 does not extend through the entirety of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250, but: 1) only extends through a portion of the thickness (t) from the first end 255a of the split ring cone 250 to the second end 255b of the split ring cone 250, such that the remaining portion will snap when the split ring cone 250 moves from the run-in-hole state having the lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E) to the deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 2F through 2J); or 2) extends through an entirety of the thickness (t) from only a portion of the space between the first end 255a of the split ring cone 250 and the second end 255b of the split ring cone 250; or 3) any other suitable configuration.

[0031] In one or more embodiments, such as that shown, the split ring cone 250 has a split ring cone centerline (CLC) and the slot 260 has a slot centerline (CLS). In the illustrated embodiment, the split ring cone 250 is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone 250 is in the split ring cone run-in-hole state having the lesser outside diameter (ODL) (e.g., as shown in FIGS. 2A through 2E). Accordingly, in at least this one embodiment, the slot 260 is a straight slot. In yet another embodiment (e.g., not shown), the split ring cone 250 is configured such that the slot centerline (CLS) is angled relative to the split ring cone centerline (CLS), when the split ring cone 250 is in the split ring cone run-in-hole state. Accordingly, in at least this one embodiment, the slot 260 is an angled slot. For example, in at least one embodiment, the slot centerline (CLS) may be angled (α) from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC), when the split ring cone 250 is in the split ring cone run-in-hole state. This embodiment is illustrated with the dotted line in FIG. 2A.

[0032] The liner hanger setting tool 200, in the illustrated embodiment of FIGS. 2A through 2J, may further include a second cone 270 positioned about the cone mandrel 210 (e.g., positioned about the cone mandrel 210 downhole of the split ring cone 250). In the illustrated embodiment of FIGS. 2A through 2F, the second cone 270 is a non-split ring cone. The non-split ring cone, in at least one embodiment, has the benefit of providing consistent expansion of the expandable liner hanger assembly about an entirety of the inner circumference thereof, for example prior to the split ring cone 250 engaging with the expandable liner hanger assembly. In contrast, the slot 260 in the split ring cone 250 may cause the split ring cone 250 to provide inconsistent expansion of the expandable liner hanger assembly about an entirety of the inner circumference thereof, for example after the second cone 270 has engaged with the expandable liner hanger assembly. Thus, the second cone 270 and the split ring cone 250 may be used in conjunction with one another in various embodiments.

[0033] As shown when comparing FIGS. 2A through 2E to FIGS. 2F through 2J, as the cone mandrel 210 and the split ring cone 250 axially move relative to one another, the second cone 270 pushes the split ring cone 250 up the outwardly sloped 240 portion of the outer radial surface 230 of the cone mandrel 210. Accordingly, based upon this movement, the split ring cone 250 moves to the deployed state, and thus from the lesser outside diameter (ODL) to the greater outside diameter (ODG).

[0034] Turning now to FIGS. 3A through 3H, illustrated is a liner hanger system 300 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 300, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 300, in the illustrated embodiment, may further include a liner hanger setting tool 330. The liner hanger setting tool 330 is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0035] FIGS. 3A and 3B illustrate top and side cross-sectional views, respectively, of the liner hanger system 300 in the run-in-hole state. As shown, the liner hanger setting tool 330 has yet to engage with the expandable liner hanger assembly 310.

[0036] FIGS. 3C and 3D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the split ring cone deployed state. As shown, the cone mandrel 210 and the split ring cone 250 have axially moved relative to one another, for example closing an upper gap therebetween, and moving the split ring cone 250 to the deployed state. At this stage, the slot 260 in the split ring cone is larger, and the split ring cone 250 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0037] FIGS. 3E and 3F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 330 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0038] FIGS. 3G and 3H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 330 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 330 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the split ring cone 250 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0039] Turning to FIGS. 4A through 4J, illustrated are different views of a liner hanger setting tool 400 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 4A through 4E illustrate the liner hanger setting tool 400 at a run-in-hole state, wherein FIG. 4A is a perspective view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4B is a top view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4C is a side view of the liner hanger setting tool 400 in the run-in-hole state, FIG. 4D is a top cross-sectional view of the liner hanger setting tool 400 in the run-in-hole state, and FIG. 4E is a side cross-sectional view of the liner hanger setting tool 400 in the run-in-hole state. In contrast, FIGS. 4F through 4J illustrate the liner hanger setting tool 400 at a deployed state, wherein FIG. 4F is a perspective view of the liner hanger setting tool 400 in the deployed state, FIG. 4G is a top view of the liner hanger setting tool 400 in the deployed state, FIG. 4H is a side view of the liner hanger setting tool 400 in the deployed state, FIG. 4I is a top cross-sectional view of the liner hanger setting tool 400 in the deployed state, and FIG. 4J is a side cross-sectional view of the liner hanger setting tool 400 in the deployed state.

[0040] The liner hanger setting tool 400 of FIGS. 4A through 4J is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 400 of FIGS. 4A through 4J differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that its cone mandrel 210 is positioned about a downhole feature 410. In the illustrated embodiment, the cone mandrel 210 is configured to slide relative to the downhole feature 410 to move the split ring cone 450 from the run-in-hole state to the deployed state.

[0041] The liner hanger setting tool 400 of FIGS. 4A through 4J further differs from the liner hanger setting tool 200 of FIGS. 2A through 2J in that edges of its slot 460 are not parallel with one another when the split ring cone 450 is in the split ring cone run-in-hole state. For example, in the illustrated embodiment, the slot 460 (e.g., when the split ring cone 450 is in the split ring cone run-in-hole state) is a wedge shaped slot. Nevertheless, the slot 460 may comprise a variety of different shapes (e.g., including a variety of different polygonal shapes) and remain within the purview of the disclosure. Further to the embodiment of FIGS. 4A through 4J, the liner hanger setting tool 400 may additionally include a wedge shaped key 480 positioned about the cone mandrel 210. In this embodiment, the wedge shaped key 480 is configured to fill in the slot 460 (e.g., wedge shaped slot) when the split ring cone 450 is in the split ring cone deployed state.

[0042] Further to the embodiment of FIGS. 4A through 4J, the wedge shaped key 480 is positioned about an outwardly sloped portion 485 of the downhole feature 410. In at least one embodiment, as shown, the outwardly sloped portion 485 is outwardly sloped 240 when moving from the second flange member 225 toward the first flange member 220. In this embodiment, the outwardly sloped portion 485 of the downhole feature 410 is configured to move the wedge shaped key 480 radially outward and fill in the slot 460 as the downhole feature 410, cone mandrel 210 and the split ring cone 450 axially move relative to one another.

[0043] The liner hanger setting tool 400 of FIGS. 4A through 4J further differs from the liner hanger setting tool 200 of FIGS. 2A through 2J in that the split ring cone 450 includes a plurality of segment portions 452 that come together to form the split ring cone 450. This is in contrast to the split ring cone 250 of FIGS. 2A through 2J, which is a single piece split ring cone. Any number of segment portions 452, for example from two to one hundred, may be used and remain within the scope of the disclosure. Nevertheless, in at least one embodiment from two to twenty segment portions 452 are employed, if not from four to sixteen segment portions 452, if not from six to twelve segment portions 452.

[0044] The segment portions 452, in one or more embodiments, may be held together with a retaining member 454. The retaining member 454 may comprise a variety of different styles, shapes, materials, etc. and remain within the scope of the disclosure. Nevertheless, in at least one embodiment the retaining member 454 is a snap ring (e.g., metal snap ring), or alternatively elastic material (e.g., such as an O-ring).

[0045] Turning now to FIGS. 5A through 5H, illustrated is a liner hanger system 500 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 500, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 500, in the illustrated embodiment, may further include a liner hanger setting tool 530. The liner hanger setting tool 530 is similar in many respects to the liner hanger setting tool 400 of FIGS. 2A through 4J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0046] FIGS. 5A and 5B illustrate top and side cross-sectional views, respectively, of the liner hanger system 500 in the run-in-hole state. As shown, the liner hanger setting tool 530 has yet to engage with the expandable liner hanger assembly 310.

[0047] FIGS. 5C and 5D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the split ring cone deployed state. As shown, the cone mandrel 210 and the split ring cone 450 have axially moved relative to one another, for example closing an upper gap therebetween, and moving the split ring cone 450 to the deployed state. At this stage, the slot 460 in the split ring cone 450 is larger, and the split ring cone 450 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310. Furthermore, the wedge shaped key 480 now fills in the slot 460.

[0048] FIGS. 5E and 5F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 530 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0049] FIGS. 5G and 5H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 530 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 530 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the split ring cone 450 in the expanded state (e.g., and the wedge shaped key 480) is now in contact with the expandable liner hanger assembly 310.

[0050] Turning to FIGS. 6A through 6Y, illustrated are different views of a liner hanger setting tool 600 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 6A through 6E illustrate the liner hanger setting tool 600 at a run-in-hole state, wherein FIG. 6A is a perspective view of the liner hanger setting tool 600 in the run-in-hole state, FIG. 6B is a top view of the liner hanger setting tool 600 in the run-in-hole state, and FIG. 6C is a side view of the liner hanger setting tool 600 in the run-in-hole state, FIG. 6D is a top cross-sectional view of the liner hanger setting tool 600 in the run-in-hole state, and FIG. 6E is a side cross-sectional view of the liner hanger setting tool 600 in the run-in-hole state. In contrast, FIGS. 6F through 6J illustrate the liner hanger setting tool 600 at a first partial deployed state, wherein FIG. 6F is a perspective view of the liner hanger setting tool 600 in the first partial deployed state, FIG. 6G is a top view of the liner hanger setting tool 600 in the first partial deployed state, and FIG. 6H is a side view of the liner hanger setting tool 600 in the first partial deployed state, FIG. 6I is a top cross-sectional view of the liner hanger setting tool 600 in the first partial deployed state, and FIG. 6J is a side cross-sectional view of the liner hanger setting tool 600 in the first partial deployed state. In contrast, FIGS. 6K through 6O illustrate the liner hanger setting tool 600 at a second partial deployed state, wherein FIG. 6K is a perspective view of the liner hanger setting tool 600 in the second partial deployed state, FIG. 6L is a top view of the liner hanger setting tool 600 in the second partial deployed state, and FIG. 6M is a side view of the liner hanger setting tool 600 in the second partial deployed state, FIG. 6N is a top cross-sectional view of the liner hanger setting tool 600 in the second partial deployed state, and FIG. 6O is a side cross-sectional view of the liner hanger setting tool 600 in the second partial deployed state. In contrast, FIGS. 6P through 6T illustrate the liner hanger setting tool 600 at a third partial deployed state, wherein FIG. 6P is a perspective view of the liner hanger setting tool 600 in the third partial deployed state, FIG. 6Q is a top view of the liner hanger setting tool 600 in the third partial deployed state, and FIG. 6R is a side view of the liner hanger setting tool 600 in the third partial deployed state, FIG. 6S is a top cross-sectional view of the liner hanger setting tool 600 in the third partial deployed state, and FIG. 6T is a side cross-sectional view of the liner hanger setting tool 600 in the third partial deployed state. In contrast, FIGS. 6U through 6Y illustrate the liner hanger setting tool 600 at a fully deployed state, wherein FIG. 6U is a perspective view of the liner hanger setting tool 600 in the fully deployed state, FIG. 6V is a top view of the liner hanger setting tool 600 in the fully deployed state, and FIG. 6W is a side view of the liner hanger setting tool 600 in the fully deployed state, FIG. 6X is a top cross-sectional view of the liner hanger setting tool 600 in the fully deployed state, and FIG. 6Y is a side cross-sectional view of the liner hanger setting tool 600 in the fully deployed state.

[0051] The liner hanger setting tool 600 of FIGS. 6A through 6Y is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 600 of FIGS. 6A through 6Y differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that it employs a cone assembly 610 positioned about the cone mandrel 210. The cone assembly 610, in at least one embodiment, includes a first cone assembly portion 620 (e.g., uphole cone assembly portion), the first cone assembly portion 620 having a plurality of first cone portions 630, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings 635. The cone assembly 610, in at least one embodiment, further includes a second cone assembly portion 640 (e.g., downhole cone assembly portion), the second cone assembly portion 640 having a plurality of second cone portions 650, the plurality of second cone portions 650 circumferentially spaced apart by a plurality of second spacings 655. Any number of first cone portions 630 and second cone portions 650 may be used for the first cone assembly portion 620 and second cone assembly portion 640, respectively. Nevertheless, in at least one embodiment, the plurality of first cone portions 630 are three or more first cone portions and the plurality of second cone portions 650 are three or more second cone portions. In yet another embodiment, the plurality of first cone portions 630 are four or more first cone portions and the plurality of second cone portions 650 are four or more second cone portions. In even yet another embodiment, the plurality of first cone portions 630 are six or more first cone portions and the plurality of second cone portions 650 are six or more second cone portions. In most embodiments, the plurality of first cone portions 630 are less than 50 first cone portions and the plurality of second cone portions 650 are less than 50 second cone portions.

[0052] In at least one embodiment, the cone assembly 610 is configured such that ones of the plurality of first cone portions 630 are rotationally aligned with ones of the plurality of second spacings 655 and ones of the plurality of second cone portions 650 are rotationally aligned with ones of the plurality of first spacings 635. Accordingly, in at least this one embodiment, the first cone assembly portion 620 and second cone assembly portion 640 are configured to allow the cone assembly 610 to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) (e.g., as shown in FIGS. 6A through 6E) and a cone assembly deployed state having a greater outside diameter (ODG) (e.g., as shown in FIGS. 6U through 6Y, for example via the different states shown in FIGS. 6F through 6T) as the cone mandrel 210 and the cone assembly 610 axially move relative to one another. Thus, in at least one embodiment the ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 engage one another like opposing interdigitated fingers when the cone assembly 610 is in the deployed state. In at least one embodiment, such as that shown, the cone assembly 610 is configured such that the first cone assembly portion 620 is radially misaligned with the second cone assembly portion 640 when the cone assembly 610 is in the cone assembly run-in-hole state (e.g., as shown in FIGS. 6A through 6E), and the first cone assembly portion 620 is at least partially radially aligned (e.g., if not totally radially aligned) with the second cone assembly portion 640 when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y).

[0053] Furthermore, in at least one embodiment, a rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 100 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 50 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 25 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y). In at least one other embodiment, the rotational spacing(s) between adjacent ones of the plurality of first cone portions 630 and ones of the plurality of second cone portions 650 is less than 5 mm when the cone assembly 610 is in the cone assembly deployed state (e.g., as shown in FIGS. 6U through 6Y).

[0054] Further to the embodiment of FIGS. 6A through 6Y, the outer radial surface 230 of the cone mandrel 210 includes a first outwardly sloped portion 660a (e.g., an uphole outwardly sloped portion) configured to engage with the plurality of first cone portions 630 and a second outwardly sloped portion 660b (e.g., downhole outwardly sloped portion) configured to engage with the plurality of second cone portions 650. Further to the embodiment of FIGS. 6A through 6Y, the first outwardly sloped portion 660a includes ones of first axial guides 665a for the plurality of first cone portions 630.

[0055] Turning now to FIGS. 7A through 7H, illustrated is a liner hanger system 700 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 700, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 700, in the illustrated embodiment, may further include a liner hanger setting tool 730. The liner hanger setting tool 730 is similar in many respects to the liner hanger setting tool 600 of FIGS. 6A through 6Y. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0056] FIGS. 7A and 7B illustrate top and side cross-sectional views, respectively, of the liner hanger system 700 in the run-in-hole state. As shown, the liner hanger setting tool 730 has yet to engage with the expandable liner hanger assembly 310.

[0057] FIGS. 7C and 7D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the split ring cone deployed state. As shown, the cone mandrel 210 and the cone assembly 610 have axially moved relative to one another, for example closing a gap therebetween, and moving the cone assembly 610 to the deployed state. At this stage, the cone assembly 610 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0058] FIGS. 7E and 7F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 730 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0059] FIGS. 7G and 7H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 730 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 730 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the cone assembly 610 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0060] Turning to FIGS. 8A through 8J, illustrated are different views of a liner hanger setting tool 800 designed, manufactured and / or operated according to one or more alternative embodiments of the disclosure at different states of deployment. For example, FIGS. 8A through 8E illustrate the liner hanger setting tool 800 at a run-in-hole state, wherein FIG. 8A is a perspective view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8B is a top view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8C is a side view of the liner hanger setting tool 800 in the run-in-hole state, FIG. 8D is a top cross-sectional view of the liner hanger setting tool 800 in the run-in-hole state, and FIG. 8E is a side cross-sectional view of the liner hanger setting tool 800 in the run-in-hole state. In contrast, FIGS. 8F through 8J illustrate the liner hanger setting tool 800 at a deployed state, wherein FIG. 8F is a perspective view of the liner hanger setting tool 800 in the deployed state, FIG. 8G is a top view of the liner hanger setting tool 800 in the deployed state, FIG. 8H is a side view of the liner hanger setting tool 800 in the deployed state, FIG. 8I is a top cross-sectional view of the liner hanger setting tool 800 in the deployed state, and FIG. 8J is a side cross-sectional view of the liner hanger setting tool 800 in the deployed state.

[0061] The liner hanger setting tool 800 of FIGS. 8A through 8J is similar in many respects to the liner hanger setting tool 200 of FIGS. 2A through 2J. Accordingly, like reference numbers have been used to indicate similar, if not identical features. The liner hanger setting tool 800 of FIGS. 8A through 8J differs, for the most part, from the liner hanger setting tool 200 of FIGS. 2A through 2J, in that it employs a spiral split ring cone 850 positioned about the cone mandrel 210. In one or more embodiments, the spiral split ring cone 850 includes one or more circumferential slots 860 extending from a first end 855a (e.g., an uphole end) of the spiral split ring cone 850 toward a second end 855b (e.g., second opposing end or downhole end) of the spiral split ring cone 850. In at least one embodiment, the one or more circumferential slots 860 are configured to allow the spiral split ring cone 850 to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel 210 and the spiral split ring cone 850 axially move relative to one another. In at least one embodiment, the spiral split ring cone 850 has a thickness (t) located proximate the one or more circumferential slots 860 and further wherein the one or more circumferential slots 860 extend through an entirety of the thickness (t) from the first end 855a of the spiral split ring cone 850 to the second end 855b of the spiral split ring cone 850.

[0062] In at least one embodiment, the spiral split ring cone 850 is a spring having a single circumferential slot 860, the single circumferential slot 860 configured to allow the spiral split ring cone 850 to move between the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) and the spiral split ring cone deployed state having the greater outside diameter (ODG) as the cone mandrel 210 and the spiral split ring cone 850 axially move relative to one another. For example, in at least one embodiment the spring is a flat spiral spring or a helix spring, but other types of springs may be used and remain within the scope of the disclosure. In at least one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least 1½ full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In at least one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least two full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In one other embodiment, the spiral split ring cone 850 is configured such that the spring includes at least four full 360-degree coils when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state.

[0063] The spiral split ring cone 850, in one embodiment, is configured such that an axial spacing (s) between adjacent coils of the spring is less than 100 mm when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state. In yet another embodiment, the spiral split ring cone 850 is configured such that an axial spacing (s)between adjacent coils of the spring is less than 50 mm when the spiral split ring cone 850 is in the spiral split ring cone run-in-hole state, if not less than 25 mm, if not less than 10 mm, if not less than 1 mm.

[0064] In yet another embodiment, the spiral split ring cone 850 is a first spiral split ring cone, and the liner hanger setting tool 800 further includes a second spiral split ring cone positioned about the cone mandrel 210. For example, in at least one embodiment, the first spiral split ring cone is a first spring having a first single circumferential slot, and the second spiral split ring cone is a second spring having a second single circumferential slot. In at least one embodiment, the handedness of the first spring and the second spring are similar to one another. In yet another embodiment, the handedness of the first spring and the second spring are opposite to one another. In at least yet another embodiment, the first spring and the second spring are in physical contact with one another, but yet in another embodiment the first spring and the second spring are not in physical contact with one another.

[0065] Turning briefly to FIGS. 9A through 9E, illustrated are different cross-sectional views of various embodiments of spiral split ring cones 900a, 900b, 900c, 900d, 900e designed, manufactured and / or operated according to one or more embodiments of the disclosure. As shown in FIGS. 9A through 9E, various different cross-sectional shapes may be used for the spiral split ring cones. For example, FIGS. 9A and 9B illustrate the cross-section as round and oval, respectively. In yet other embodiments, the cross-section might include one or more straight lines, such as the case if the cross-section were polygonal. For example, a rectangular cross-section could be used, such as shown in FIG. 9C, or alternatively a rectangular cross-section with partially rounded edges, both of which may reduce point loading and distribute the loads better. In at least one embodiment, the rectangular cross-section split ring cone may be manufactured that stacks solid in its free-state, even with progressive diameters such as in a battery spring. Notwithstanding, unless otherwise required, the cross-section of the split ring cone should not be limited to any specific shape.

[0066] Turning now to FIGS. 10A through 10H, illustrated is a liner hanger system 1000 designed, manufactured and / or operated according to one or more embodiments of the disclosure positioned within a wellbore tubular 390, at various different states of deployment. The liner hanger system 1000, in the illustrated embodiment, includes an expandable liner hanger assembly 310, the expandable liner hanger assembly 310 configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore tubular 390. As discussed above, the expandable liner hanger assembly 310 may include a radially expandable tubular 320, for example having one or more anchoring ridges 325 extending radially outward there from, the radially expandable tubular 320 and one or more anchoring ridges 325 configured to engage with (e.g., bite into) the wellbore tubular 390. The liner hanger system 1000, in the illustrated embodiment, may further include a liner hanger setting tool 1030. The liner hanger setting tool 1030 is similar in many respects to the liner hanger setting tool 800 of FIGS. 8A through 8J. Accordingly, like reference numbers have been used to indicate similar, if not identical, features.

[0067] FIGS. 10A and 10B illustrate top and side cross-sectional views, respectively, of the liner hanger system 1000 in the run-in-hole state. As shown, the liner hanger setting tool 1030 has yet to engage with the expandable liner hanger assembly 310.

[0068] FIGS. 10C and 10D illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the split ring cone deployed state. As shown, the cone mandrel 210 and the spiral split ring cone 850 have axially moved relative to one another, for example moving the spiral split ring cone 850 to the deployed state. At this stage, the spiral split ring cone 850 has moved from the lesser outside diameter (ODL) to the greater outside diameter (ODG) for deployment of the expandable liner hanger assembly 310.

[0069] FIGS. 10E and 10F illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the deployed state being pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 1030 has started to expand the expandable liner hanger assembly 310 outwardly and almost into contact with the wellbore tubular 390. For example, at this stage, only the second cone 270 is in contact with the expandable liner hanger assembly 310.

[0070] FIGS. 10G and 10H illustrate top and side cross-sectional views, respectively, of the liner hanger setting tool 1030 in the deployed state being further pushed through the expandable liner hanger assembly 310. As shown, the liner hanger setting tool 1030 has further expanded the expandable liner hanger assembly 310, this time outwardly and into contact with the wellbore tubular 390. For example, at this stage, the spiral split ring cone 850 in the expanded state is now in contact with the expandable liner hanger assembly 310.

[0071] Aspects disclosed herein include:

[0072] A. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and

[0073] 2) a split ring cone positioned about the cone mandrel, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

[0074] B. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another; 2) moving the split ring cone from the split ring cone run-in-hole state having the lesser outside diameter (ODL) to the split ring cone deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the split ring cone in the split ring cone deployed state having the greater outside diameter (ODG).

[0075] C. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

[0076] D. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and 2) a cone assembly positioned about the cone mandrel, the cone assembly including: a) a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings; and b) a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another.

[0077] E. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a cone assembly positioned about the cone mandrel, the cone assembly including: a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another; 2) moving the cone assembly from the cone assembly run-in-hole state having the lesser outside diameter (ODL) to the cone assembly deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the cone assembly in the cone assembly deployed state having the greater outside diameter (ODG).

[0078] F. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a cone assembly positioned about the cone mandrel, the cone assembly including: a first cone assembly portion, the first cone assembly portion having a plurality of first cone portions, the plurality of first cone portions circumferentially spaced apart by a plurality of first spacings, and a second cone assembly portion, the second cone assembly portion having a plurality of second cone portions, the plurality of second cone portions circumferentially spaced apart by a plurality of second spacings, wherein ones of the plurality of first cone portions are rotationally aligned with ones of the plurality of second spacings and ones of the plurality of second cone portions are rotationally aligned with ones of the plurality of first spacings, the first cone assembly portion and second cone assembly portion configured to allow the cone assembly to move between a cone assembly run-in-hole state having a lesser outside diameter (ODL) and a cone assembly deployed state having a greater outside diameter (ODG) as the cone mandrel and the cone assembly axially move relative to one another.

[0079] G. A liner hanger setting tool, the liner hanger setting tool including: 1) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and 2) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another.

[0080] H. A method, the method including: 1) positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another; 2) moving the spiral split ring cone from the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) to the spiral split ring cone deployed state having the greater outside diameter (ODG); and 3) expanding the expandable liner hanger assembly into contact with the wellbore using the spiral split ring cone in the spiral split ring cone deployed state having the greater outside diameter (ODG).

[0081] I. A well system, the well system including: 1) a wellbore extending through one or more subterranean formations; and 2) a liner hanger system positioned within the wellbore, the liner hanger system including: a) an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; and b) a liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including: i) a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; and ii) a spiral split ring cone positioned about the cone mandrel, the spiral split ring cone including one or more circumferential slots extending from an first end of the split ring cone toward a second end of the split ring cone, the one or more circumferential slots configured to allow the spiral split ring cone to move between a spiral split ring cone run-in-hole state having a lesser outside diameter (ODL) and a spiral split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another.

[0082] Aspects A, B, C, D, E, F, G, H and I may have one or more of the following additional elements in combination: Element 1: wherein the split ring cone has a thickness (t) located proximate the slot, and further wherein the slot extends through an entirety of the thickness (t) from the first end of the split ring cone to the second end of the split ring cone. Element 2: wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state. Element 3: wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is angled from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state. Element 4: wherein the split ring cone is configured such that edges of the slot are not parallel with one another when the split ring cone is in the split ring cone run-in-hole state. Element 5: wherein the slot is a wedge shaped slot, and further including a wedge shaped key positioned about the cone mandrel, the wedge shaped key configured to fill in the slot when the split ring cone is in the split ring cone deployed state. Element 6: wherein the wedge shaped key is positioned about an outwardly sloped portion of a downhole feature, the outwardly sloped portion of the downhole feature configured to move the wedge shaped key radially outward and fill in the slot as the downhole feature and the split ring cone axially move relative to one another. Element 7: wherein the split ring cone includes a plurality of segment portions that come together to form the split ring cone. Element 8: wherein the plurality of segment portions are held together with a retaining member. Element 9: further including a non-split ring cone positioned about the cone mandrel and downhole of the split ring cone. Element 10: further including moving the split ring cone in the split ring cone deployed state back to the split ring cone run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore. Element 11: wherein the cone assembly is configured such that the first cone assembly portion is radially misaligned with the second cone assembly portion when the cone assembly is in the cone assembly run-in-hole state and the first cone assembly portion is at least partially radially aligned with the second cone assembly portion when the cone assembly is in the cone assembly deployed state. Element 12: wherein the outer radial surface of the cone mandrel includes a first outwardly sloped portion configured to engage with the plurality of first cone portions and a second outwardly sloped portion configured to engage with the plurality of second cone portions. Element 13: wherein the first outwardly sloped portion includes ones of first axial guides for the plurality of first cone portions and the second outwardly sloped portion includes ones of second axial guides for the plurality of second cone portions. Element 14: wherein the plurality of first cone portions are three or more first cone portions and the plurality of second cone portions are three or more second cone portions. Element 15: wherein the plurality of first cone portions are six or more first cone portions and the plurality of second cone portions are six or more second cone portions. Element 16: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 100 mm when the cone assembly is in the cone assembly deployed state. Element 17: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 50 mm when the cone assembly is in the cone assembly deployed state. Element 18: wherein a rotational spacing(s) between adjacent ones of the plurality of first cone portions and ones of the plurality of second cone portions is less than 25 mm when the cone assembly is in the cone assembly deployed state. Element 19: further including a non-split ring cone positioned about the cone mandrel downhole of the second cone assembly portion. Element 20: further including moving the cone assembly in the cone assembly deployed state back to the cone assembly run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore. Element 21: wherein the spiral split ring cone has a thickness (t) located proximate the one or more circumferential slots, and further wherein the one or more circumferential slots extend through an entirety of the thickness (t) from the first end of the spiral split ring cone to the second end of the spiral split ring cone. Element 22: wherein the spiral split ring cone is a spring having a single circumferential slot, the single circumferential slot configured to allow the spiral split ring cone to move between the spiral split ring cone run-in-hole state having the lesser outside diameter (ODL) and the spiral split ring cone deployed state having the greater outside diameter (ODG) as the cone mandrel and the spiral split ring cone axially move relative to one another. Element 23: wherein the spring is a flat spiral spring or a helix spring. Element 24: wherein the spiral split ring cone is configured such that the spring includes at least two full 360-degree coils when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 25: wherein the spiral split ring cone is configured such that the spring includes at least four full 360-degree coils when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 26: wherein the spiral split ring cone is configured such that an axial spacing (s)between adjacent coils of the spring is less than 100 mm when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 27: wherein the spiral split ring cone is configured such that an axial spacing (s)between adjacent coils of the spring is less than 50 mm when the spiral split ring cone is in the spiral split ring cone run-in-hole state. Element 28: wherein the spiral split ring cone is a first spring having a first single circumferential slot and an adjacently placed second spring having a second single circumferential slot. Element 29: further including a non-split ring cone positioned about the cone mandrel downhole of the spiral split ring cone. Element 30: further including moving the spiral split ring cone in the spiral split ring cone deployed state back to the spiral split ring cone run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore.

[0083] Those skilled in the art to which this application relates will appreciate that other and further additions, deletions, substitutions and modifications may be made to the described embodiments.

Examples

Embodiment Construction

[0016]In the drawings and descriptions that follow, like parts are typically marked throughout the specification and drawings with the same reference numerals, respectively. The drawn figures are not necessarily to scale. Certain features of the disclosure may be shown exaggerated in scale or in somewhat schematic form and some details of certain elements may not be shown in the interest of clarity and conciseness. The present disclosure may be implemented in embodiments of different forms. Specific embodiments are described in detail and are shown in the drawings, with the understanding that the present disclosure is to be considered an exemplification of the principles of the disclosure, and is not intended to limit the disclosure to that illustrated and described herein. It is to be fully recognized that the different teachings of the embodiments discussed herein may be employed separately or in any suitable combination to produce desired results.

[0017]Unless otherwise specified,...

Claims

1. A liner hanger setting tool, comprising:a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; anda split ring cone positioned about the cone mandrel, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

2. The liner hanger setting tool as recited in claim 1, wherein the split ring cone has a thickness (t) located proximate the slot, and further wherein the slot extends through an entirety of the thickness (t) from the first end of the split ring cone to the second end of the split ring cone.

3. The liner hanger setting tool as recited in claim 1, wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state.

4. The liner hanger setting tool as recited in claim 1, wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is angled from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state.

5. The liner hanger setting tool as recited in claim 1, wherein the split ring cone is configured such that edges of the slot are not parallel with one another when the split ring cone is in the split ring cone run-in-hole state.

6. The liner hanger setting tool as recited in claim 5, wherein the slot is a wedge shaped slot, and further including a wedge shaped key positioned about the cone mandrel, the wedge shaped key configured to fill in the slot when the split ring cone is in the split ring cone deployed state.

7. The liner hanger setting tool as recited in claim 6, wherein the wedge shaped key is positioned about an outwardly sloped portion of a downhole feature, the outwardly sloped portion of the downhole feature configured to move the wedge shaped key radially outward and fill in the slot as the downhole feature and the split ring cone axially move relative to one another.

8. The liner hanger setting tool as recited in claim 1, wherein the split ring cone includes a plurality of segment portions that come together to form the split ring cone.

9. The liner hanger setting tool as recited in claim 8, wherein the plurality of segment portions are held together with a retaining member.

10. The liner hanger setting tool as recited in claim 1, further including a non-split ring cone positioned about the cone mandrel and downhole of the split ring cone.

11. A method, comprising:positioning a liner hanger system within a wellbore extending through one or more subterranean formations, the liner hanger system including:an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; anda liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including:a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; anda split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another;moving the split ring cone from the split ring cone run-in-hole state having the lesser outside diameter (ODL) to the split ring cone deployed state having the greater outside diameter (ODG); andexpanding the expandable liner hanger assembly into contact with the wellbore using the split ring cone in the split ring cone deployed state having the greater outside diameter (ODG).

12. The method as recited in claim 11, further including moving the split ring cone in the split ring cone deployed state back to the split ring cone run-in-hole state after the expandable liner hanger assembly is in contact with the wellbore to disengage the liner hanger setting tool from the expandable liner hanger assembly in contact with the wellbore.

13. The method as recited in claim 11, wherein the split ring cone has a thickness (t) located proximate the slot, and further wherein the slot extends through an entirety of the thickness (t) from the first end of the split ring cone to the second end of the split ring cone.

14. The method as recited in claim 11, wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is substantially parallel with the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state.

15. The method as recited in claim 11, wherein the split ring cone has a split ring cone centerline (CLC) and the slot has a slot centerline (CLS), and further wherein the split ring cone is configured such that the slot centerline (CLS) is angled from +15 degrees to +60 degrees from the split ring cone centerline (CLC) or −15 degrees to −60 degrees from the split ring cone centerline (CLC) when the split ring cone is in the split ring cone run-in-hole state.

16. The method as recited in claim 11, wherein the split ring cone is configured such that edges of the slot are not parallel with one another when the split ring cone is in the split ring cone run-in-hole state.

17. The method as recited in claim 11, wherein the split ring cone includes a plurality of segment portions that come together to form the split ring cone.

18. The method as recited in claim 17, wherein the plurality of segment portions are held together with a retaining member.

19. The method as recited in claim 11, further including a non-split ring cone positioned about the cone mandrel and downhole of the split ring cone.

20. A well system, comprising:a wellbore extending through one or more subterranean formations; anda liner hanger system positioned within the wellbore, the liner hanger system including:an expandable liner hanger assembly, the expandable liner hanger assembly configured to move between an expandable liner hanger assembly run-in-hole state and an expandable liner hanger assembly expanded state in contact with the wellbore; anda liner hanger setting tool positioned proximate the expandable liner hanger assembly, the liner hanger setting tool including:a cone mandrel, wherein at least a portion of an outer radial surface of the cone mandrel is outwardly sloped; anda split ring cone positioned about the cone mandrel and configured to engage with the expandable liner hanger assembly, the split ring cone including a slot extending from an first end of the split ring cone to a second end of the split ring cone, the slot configured to allow the split ring cone to move between a split ring cone run-in-hole state having a lesser outside diameter (ODL) and a split ring cone deployed state having a greater outside diameter (ODG) as the cone mandrel and the split ring cone axially move relative to one another.

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