Stepped Liner Hanger Expander Using Segmented Piston Assemblies
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Solution Overview
Problem
Current methods for expanding liner hangers in subterranean wells require high pressures and multiple pistons, leading to increased complexity, length, and weight of the setting tool, which can be ineffective for heavier casings and higher pressures.
Innovation Solution
The use of a series of successive pressure applications with stackable piston/slip/spring assemblies to radially expand the liner against the well casing, reducing the necessary expansion pressure and overall tool length, and providing more accurate control over the expansion force.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Length of moving object
If multiple pistons with long stroke lengths are used to expand the liner hanger, then the expansion distance is achieved, but the tool length, weight, and complexity increase
Solution Approach 1:
The expansion tool is divided into multiple stackable piston assemblies that can be independently actuated. Each piston assembly contributes a portion of the total expansion stroke, allowing the liner hanger to be expanded over a long distance L through multiple shorter strokes S without requiring a single excessively long piston or increasing overall tool length.
Solution Approach 2:
The expansion process uses periodic pressure applications to actuate the piston assemblies in successive steps. Each pressure application produces a short piston stroke S, and multiple periodic applications accumulate to achieve the total expansion distance L, allowing controlled progressive expansion rather than requiring a single long stroke.
2Stress or pressure
If higher pressures are applied to expand heavier casing and liners, then expansion effectiveness improves, but the required expansion pressure increases beyond pump capabilities
Solution Approach 1:
The total expansion force is segmented across multiple piston assemblies acting in parallel. Each piston assembly requires only a portion of the total expansion pressure to contribute its share of the force, reducing the pressure requirement on individual components and allowing standard pump capabilities to achieve the total expansion of heavier liners.
Solution Approach 2:
Multiple piston assemblies continue to actuate in sequence through periodic pressure applications, maintaining continuous useful action on the liner hanger. This continuous progressive expansion allows the system to overcome high friction and resistance from heavier casing without requiring single extreme pressure spikes, improving reliability.
3Device complexity
If a single pressure application strokes the entire expansion distance, then the expansion is completed in one action, but the required pressure and tool complexity increase
Solution Approach 1:
The single expansion action is segmented into multiple discrete piston strokes. Each piston assembly performs a short stroke S under controlled pressure, and the cumulative effect of these segmented actions achieves the total expansion distance L. This segmentation reduces the complexity of individual piston designs and allows for more manageable tool construction.
Solution Approach 2:
The system transitions from a static single-action expansion mechanism to a dynamic multi-step process. The piston assemblies can be selectively actuated and deactivated during the expansion process, allowing adaptive control of the expansion sequence. This dynamic capability enables optimization of expansion efficiency while keeping individual component complexity low.
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
This approach reduces expansion pressure, shortens the tool length, eliminates the need for a break-apart mechanism, and enhances control over expansion, allowing for more efficient and effective liner expansion in subterranean wells.
Implementation Method 1
stackable piston/slip/spring assemblies
Data Source
AI summary
Disclosed is a tubular expansion tool which includes a plurality of stackable piston/slip/spring assemblies that are used to radially expand a liner against well casing along a longitudinal distance “L.” The pistons are repeatedly stroked a short distance “S” with the application of hydraulic pressure. As the pistons are stroked, they move a mandrel-expansion die sub assembly in successive steps a distance “S” to perform the tubular expansion over a longer distance “L.”