Hydraulic Liner Hanger Expansion With Retrievable Solid Cone
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Existing methods for anchoring a liner hanger in a wellbore using an expansion cone face challenges such as failed seal formation by wiper darts and incomplete expansion due to leaks, leading to high risks during deployment.
Innovation Solution
A system and method utilizing a seal bushing with internal and external seals, a slick joint, and an expansion tool with a solid expansion cone, which expands the liner hanger under hydraulic pressure, ensuring secure anchoring and seal formation through metal-to-metal contact and pressure differentials.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a solid expansion cone is used to expand the liner hanger, then reliable anchoring and sealing can be achieved, but the expansion cone cannot be retrieved from the liner hanger after expansion
Solution Approach 1:
The expansion cone is divided into two separate components: a solid expansion cone for reliable anchoring and sealing, and a collapsible cage structure for retrieval. The cage contains the expansion cone during deployment, allows the expansion cone to expand the liner hanger, and then collapses to enable withdrawal of the expansion system after expansion is complete.
Solution Approach 2:
A collapsible cage acts as an intermediary structure that temporarily holds the solid expansion cone during deployment and expansion operations. After the expansion cone performs its anchoring function, the cage collapses to release the expansion cone, allowing the cage and expansion cone to be retrieved together while leaving the expanded liner hanger anchored in place.
2Productivity
If wiper darts are used to seal the liner shoe, then cement placement can be controlled, but sealing may fail due to dart failure or leaks
Solution Approach 1:
The system performs preliminary sealing actions using the expansion cone and seal bushing before cement placement is complete. The expansion cone expands the liner hanger against the base casing to create a mechanical seal, and the seal bushing provides additional sealing, ensuring that even if wiper darts fail, the liner hanger remains securely sealed and anchored.
Solution Approach 2:
The invention provides backup sealing mechanisms (expansion cone and seal bushing) that activate if the primary wiper dart sealing fails. The expansion cone creates a mechanical barrier against the base casing, cushioning against the harmful effect of dart failure or leaks by providing an alternative sealing path.
3Reliability
If the liner hanger is expanded using hydraulic pressure, then secure anchoring is achieved, but the system complexity increases due to additional sealing components
Solution Approach 1:
The invention merges multiple sealing functions into integrated components. The seal bushing combines internal and external seals in a single component that interfaces with both the expansion tool and the liner hanger. The expansion cone integrates the expansion function with sealing against the base casing, reducing the need for separate sealing components and simplifying the overall system while maintaining reliable anchoring.
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
Ensures reliable anchoring and sealing of the liner hanger to the base casing, even in cases of failed wiper dart sealing or leaks, by using hydraulic pressure to expand the liner hanger effectively, maintaining the liner at the well bottom and allowing retrieval of the expansion system.
Implementation Method 1
the expansion cone is located near the bottom of the liner hanger... Increased pressure causes the liner wiper dart to deploy... continued pumping into the sealed liner creates, in turn, a pressure increase in the liner. The pressure increase pushes a cup seal and/or the expansion cone upward
Implementation Method 2
The seal bushing may include... internal and external seals
Implementation Method 3
a plurality of dogs biased toward a center of the tubular body... The groove may be engaged by each of the plurality of dogs simultaneously
Implementation Method 4
a sleeve capable of sliding in the tubular body
Data Source
AI summary
A system includes a seal bushing that is locked into a pup joint, which is part of a liner assembly including an expandable liner hanger. The system also includes an expansion tool that is connected to a drill pipe. The expansion tool includes an expansion cone attached to the slick joint. The slick joint can slide within the bore of the seal bushing. A ball is dropped into the drill pipe and lands on a seat of the expansion tool to increase hydraulic pressure. The ball and the seal bushing can avoid pressurizing an entire liner connected below the pup joint. When the expansion cone moves through the liner hanger at least in part under the effect of pressure, the liner hanger is expanded and anchored to a base casing.