Liner Hanger Expansion Cone to Prevent Premature Slip Actuation
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Solution Overview
Problem
Existing liner hanger deployment methods face issues with premature actuation of extendable slips and deformable packers due to pressure differentials, excessive loads, and failure to release from run-in tools, leading to unreliable deployment operations with multiple moving parts, activation ports, and pressure cycles.
Innovation Solution
A liner hanger with an expandable pipe and launcher chamber, utilizing an adjustable cone that expands to securely suspend and deploy the liner, reducing the need for multiple activations and pressure cycles by using a torque transfer nut and seal members for reliable anchoring and sealing.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If extendable slips and deformable packer are provided on the tubular body for anchoring and sealing, then the liner hanger can be anchored and sealed in the base casing, but the extendable slips and deformable packer may prematurely be actuated when a pressure differential develops across the tubular body
Solution Approach 1:
The liner hanger is divided into separate functional components: the tubular body for suspension, extendable slips for anchoring, and a deformable packer for sealing. Each component can be independently actuated and controlled, allowing premature actuation issues to be addressed by isolating control mechanisms for each segment.
Solution Approach 2:
A valve body with a ball seat and flow passage is introduced as an intermediary component between the work string and the liner hanger. This valve body controls the actuation of slips and packer by managing fluid pressure distribution, preventing premature actuation caused by uncontrolled pressure differentials while maintaining reliable deployment.
2Reliability
If multiple activation ports and pressure cycles are used to complete deployment, then the liner hanger can be reliably deployed, but the deployment operations require more complex procedures and longer time
Solution Approach 1:
The liner hanger is pre-assembled with extendable slips and deformable packer already positioned on the tubular body before deployment. The valve body is pre-configured with ball seats and flow passages. This preliminary preparation eliminates the need for multiple field activations and reduces deployment time while maintaining reliability.
Solution Approach 2:
The functions of suspension, anchoring, and sealing are combined into a single integrated liner hanger assembly that can be deployed in one continuous operation. The valve body integrates multiple control functions (ball seat, flow passage, actuation control) into a single component, reducing the number of separate activation steps required.
3Reliability
If the liner hanger uses retractable dogs and a sleeve retaining mechanism for release from the run-in tool, then the liner hanger can be securely held during tripping in, but the dogs may release under excessive loads or fail to release after a ball is dropped
Solution Approach 1:
The complex retractable dogs and sleeve retaining mechanism are removed from the design. Instead, a simplified release mechanism using a ball seat and flow passage control is implemented. The ball drops through the flow passage to trigger release, eliminating the need for mechanical dogs and sleeves while improving reliability under excessive loads.
Solution Approach 2:
The mechanical dog-and-sleeve release system is replaced with a fluid-pressure-controlled release mechanism. A ball dropped through the flow passage uses fluid pressure to actuate the release, substituting a simple mechanical action for a complex multi-component mechanical system.
4Adaptability or versatility
If the expandable pipe has a first inner diameter and the launcher chamber has a larger second inner diameter, then the adjustable cone can be inserted through the expandable pipe into the launcher chamber, but the expandable pipe must be radially expanded to accommodate the launcher chamber dimensions
Solution Approach 1:
The expandable pipe transitions from a contracted state with a first inner diameter to an expanded state with a second inner diameter that matches the launcher chamber dimensions. This dynamic size change allows the pipe to accommodate the larger launcher chamber while minimizing pressure requirements by only expanding when needed during deployment.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The solution enhances the reliability of liner deployment by minimizing moving parts and pressure cycles, ensuring secure anchoring and sealing, and allowing for efficient expansion and contraction of the expandable pipe for effective wellbore operations.
Implementation Method 1
the adjustable cone is in an expanded configuration in which the outer diameter of the adjustable cone is more than the first inner diameter of the expandable pipe
Implementation Method 2
radially expanding at least a portion of the expandable pipe to the second inner diameter of the launcher chamber
Implementation Method 3
compressing at least one seal member disposed around the expandable pipe against a base casing
Data Source
AI summary
A liner hanger is used for deploying a liner into a wellbore. The liner hanger includes a tubular body having a first end and a second end. The first end can include a connection to a liner. The second end can include a sealed connection to an operational pipe. The sealed connection can be releasable. An expansion tool attached to a work string can be used for suspending the liner hanger into the wellbore. At least a portion of the expandable pipe is radially expanded using the expansion tool. The radial expansion of the expandable pipe can cause compression of at least one seal member against a base casing.