Liner Hanger with Mechanically Locked Hydraulic Actuator

This application claims the benefit of the filing date of U.S. provisional application No. 63/635,739 filed on 18 Apr. 2024. The entire disclosure of the prior application is incorporated herein by this reference for all purposes.

This disclosure relates generally to equipment utilized and operations performed in conjunction with a subterranean well and, in examples described below, more particularly provides a liner hanger.

A liner is a protective lining used in a wellbore. A liner hanger is used to anchor the liner in a previously installed liner or casing.

Unfortunately, in some circumstances a liner hanger can be inadvertently set before it has been appropriately positioned in the previous liner or casing. Such an improperly set liner hanger can result in expensive and time-consuming operations to mitigate this problem.

It will, therefore, be appreciated that improvements are continually needed in the art of designing, constructing and operating liner hangers for use in subterranean wells. The present disclosure provides such improvements, which may be used in a variety of different types of well environments and well configurations.

Representatively illustrated inis a systemfor use with a subterranean well, and an associated method, which can embody principles of this disclosure. However, it should be clearly understood that the systemand method are merely one example of an application of the principles of this disclosure in practice, and a wide variety of other examples are possible. Therefore, the scope of this disclosure is not limited at all to the details of the systemand method described herein and/or depicted in the drawings.

As depicted in, a liner stringis installed in a wellboreand is secured to a previously installed liner or casingwith a liner hanger. A work stringwith a running toolis used to convey the liner stringin the wellbore, and then to set the liner hangerwhen it is appropriately positioned in the previous liner or casing.

In theexample, the liner hangeris set by applying increased pressure in the work stringafter deploying a ball, dart or other plug(see) into the work string. The applied pressure causes slipsto extend outward from the liner hangerand grip an interior surface of the previous liner or casing. A packer sectionof the liner hangerincludes additional slipsand an annular sealthat extend outwardly to grip the interior surface and seal against the interior surface, respectively, after the initial slipsare set.

It is important that the liner hangernot be set until it is positioned at a desired location in the previous liner or casing. As described more fully below, the liner hangerincludes features that prevent it from being set until it is appropriately positioned in the previous liner or casing.

Referring additionally now to& B, more detailed cross-sectional views of a portion of examples of the liner hangerand running toolare representatively illustrated. The liner hangerand running toolmay be used in thesystemand method, or they may be used in other systems and methods. For convenience, setting of the liner hangerwith the running toolis described below as used with thesystemand method.

As depicted in& B, the liner hangerhas been positioned at a desired location in the previous liner or casingfor setting the liner hanger. The plughas been deployed into a flow passageextending through the running tooland the work string(see). As viewed in& B, the plughas engaged an expandable seatof the running tool.

Sufficient increased pressure applied to the flow passageuphole of the plugwill cause the increased to be applied to an interior of the liner hangervia portsformed in a tubular mandrelof the running tool. The increased pressure enters at least one portformed through an inner tubular mandrelof the liner hanger.

The liner hangeris set in response to the increased pressure applied via the port. More specifically, the liner hangeris set in response to a predetermined differential pressure created between an interior of the liner hanger (communicated via the port) and an exterior of the liner hanger (such as, an annulusformed radially between the liner hanger and the interior surface of the previous liner or casing).

Note that the& B running toolis merely one example of a running tool that may be used to set the liner hanger. Other types of running tools (with or without an expandable seat) may be used in other examples. The scope of this disclosure is not limited to use of any particular type or configuration of running tool used to set the liner hanger.

Referring additionally now to, cross-sectional views of another example of the liner hangerare representatively illustrated in a succession of stages of setting the liner hanger. The upper packer section(see) and the running tool(see& B) are not shown infor clarity of illustration and description. Instead, only the setting of the initial set of slipsis described below, for an understanding of how inadvertent premature setting of the liner hangercan be prevented using the principles of this disclosure.

As depicted in& B, the liner hangeris in a run-in configuration in which the liner hanger is conveyed into the previous liner or casing(see& B). The slipsare in radially retracted positions in which they will not grip the previous liner or casing(or any other structure surrounding the liner hanger). A gauge ringsecured to the mandrelmaintains radial spacing between the slipsand the previous liner or casingas the liner hangeris conveyed into a well.

A tubular outer housingoutwardly surrounds the mandrel. An actuation sleeveis secured at an upper end of the outer housing. A support surfaceformed in the actuation sleeveoutwardly supports multiple engagement membersin engagement with an annular profileformed on the mandrel. In this example, the engagement membersare in the form of dogs or lugs, but in other examples other types of engagement members may be used (such as collets, etc.).

The engagement membersextend through a slip connectorthat is secured to the slips. While the engagement membersare radially inwardly maintained in engagement with the profileby the actuation sleeve, the slipscannot be displaced longitudinally relative to the mandrel. When the engagement membersare not maintained in engagement with the profileby the actuation sleeve(as described more fully below), the slipscan be set by displacing them upward relative to the mandrel, so that the slips are deflected radially outward by conical wedgesinto gripping engagement with the previous liner or casing.

Annular seals,seal between an inner surface of the outer housingand an outer surface of the mandrel. An annular chamberis formed longitudinally between the seals,and radially between the outer housingand the mandrel. The chamberis in fluid communication with an interior of the mandrelvia the ports.

A retainer ringprevents upward displacement of the sealrelative to the mandrel. A retainer sleeveis positioned in an annulusformed radially between the outer housingand the mandrel. The chamberis a portion of the annulus.

A support surfaceformed on the retainer sleeveradially outwardly supports engagement members(only one of which is visible in) in engagement with respective recesses(only one of which is visible in) formed in the outer housing. In this example, the engagement membersare in the form of dogs or lugs, but in other examples other types of engagement members may be used (such as collets, etc.).

The engagement membersextend through a sleeveportion of the gauge ring. The gauge ring sleeveis received in an annular space radially between the outer housingand the retainer sleeve. The gauge ringis secured against longitudinal displacement relative to the mandrel.

While the engagement membersare maintained in engagement with the recessesby the retainer sleevesupport surface, the outer housingis prevented from displacing longitudinally upward relative to the mandrel. In this manner, inadvertent premature setting of the liner hangeris prevented. When the engagement membersare not longer supported in engagement with the recesses, increased pressure applied to the chambervia the portscan be used to displace the outer housingupward to thereby set the slips(as described more fully below).

Shear members(such as, shear pins, shear screws, etc., only one of which is visible in) extend through the gauge ring sleeveand into openingsformed through the retainer sleeve. The sealacts as a piston to apply a downwardly biasing force against the retainer sleevein response to an increased pressure applied to the chamber. When a sufficient differential pressure has been applied from the chamberto the annulus(that is, from an interior to an exterior of the liner hanger), the shear memberswill shear and allow the retainer sleeveto displace downward relative to the mandrel.

Referring additionally now to, a side view of an example of the gauge ringis representatively illustrated. In this view, it may be seen that the gauge ringhas multiple circumferentially distributed sets of openings,formed radially through the sleeve.

In this example, the openingsare internally threaded for securement of the shear memberstherein (which are externally threaded). The openingsreceive the engagement memberstherein (see).

A longitudinally extending slotformed through the upper sleevereceives a torque pin(see) therein. The torque pinis secured to the outer housing. Thus, the outer housingcan displace longitudinally relative to the mandrel(when the liner hangeris set), but relative rotation between the outer housing and the mandrel is prevented by engagement of the torque pinwith the slot.

Referring additionally now to, the liner hangeris representatively illustrated in a partially set configuration. In this configuration, sufficient increased pressure has been applied to the chambervia the ports(for example, using the& B running tool) to cause the shear membersto shear.

The increased differential pressure across the sealhas caused the seal to displace downward relative to the mandrel, thereby also displacing the retainer sleevedownward. The level of differential pressure required to shear the shear membersand allow the retainer sleeveto be displaced downward can be adjusted by varying the number of shear members, or by varying a shear strength of the shear members.

Downward displacement of the retainer sleeveis limited by an internal shoulderformed in the gauge ring. In its downwardly displaced position, the openingsare aligned with the engagement members.

The support surfaceon the retainer sleeveno longer outwardly supports the engagement membersin engagement with the recesses. However, the engagement membersdo not necessarily retract radially inward, until the outer housingdisplaces upward relative to the mandrel, as described more fully below. Shear membersextending through the outer housingand into the gauge ringreleasably secure the outer housing against upward displacement relative to the mandrel.

Referring additionally now to, a cross-sectional view of the liner hangerin a set configuration is representatively illustrated. Theview is rotated somewhat relative to theview, so that the engagement of the torque pinin the slotis visible in.

In theset configuration, sufficient increased pressure has been applied to the chamberto cause the shear membersto shear and thereby allow the outer housingto displace upward relative to the mandrel. The increased differential pressure applied across the sealcauses an upwardly directed biasing force to be applied to the outer housingand the actuation sleeve, with this biasing force being sufficient to shear the shear members.

The level of differential pressure required to shear the shear membersand allow the outer housingto be displaced upward can be adjusted by varying the number of shear members, or by varying a shear strength of the shear members. The differential pressure required to shear the shear membersis preferably greater than the differential pressure required to shear the shear members, but in some examples the differential pressure required to shear the shear memberscould be equal to or less than the differential pressure required to shear the shear members.

When the outer housingdisplaces upward, the actuation sleevealso displaces upward, so that the support surfaceno longer outwardly supports the engagement members. Thus, the engagement membersare allowed to displace radially outward and out of engagement with the profile. Inclined surfaces on the engagement membersand the profilecause the engagement members to displace radially outward as the actuation sleevedisplaces upward due to the differential pressure across the seal.

An abutment surfaceformed in the actuation sleeveeventually contacts a lower end of the slip connector. The slip connectorand the slipsare thereby displaced upward relative to the mandrelby the biasing force due to the differential pressure across the seal. The slipsare deflected outward by the wedges(see& B) into gripping engagement with the interior surface of the previous liner or casingas described above. Referring additionally now to, another cross-sectional view of a lower portion of the liner hangeris representatively illustrated in the set configuration. In this view, the liner hangeris rotated somewhat relative to theview, so that one of the engagement membersis visible in theview.

As the outer housingis displaced upward relative to the mandrel, inclined surfaces on the engagement membersand the recessescause the engagement members to be displaced radially inward and into the openingsin the retainer sleeve. Thus, the engagement membersno longer prevent upward displacement of the outer housingrelative to the mandrel. The outer housingcan displace upward due to the differential pressure across the sealto the set configuration as described above.

Note that theliner hangerexample can be functionally tested prior to actual use in a well, and after testing the liner hanger can be conveniently prepared for use. Specifically, the liner hangercan be assembled as described above, but without installing the shear members.

Pressure applied to the portswill cause the retainer sleeveto displace downward relative to the mandrel, so that the support surfaceno longer outwardly supports the engagement membersin engagement with the recesses. When the applied pressure is sufficient to shear the shear members, the outer housingwill displace upward relative to the mandreland the engagement memberswill retract radially inward. The upward displacement of the outer housingwill cause the slipsto displace upward and radially outward as described above (with the actuation sleevesupport surfaceno longer outwardly supporting the engagement members), thereby verifying proper operation of the liner hanger.

After the functional testing, the slips, engagement membersand outer housingcan be downwardly displaced to their initial run-in positions. The retainer sleevecan be upwardly displaced to its initial run-in position, with an inclined surfaceof the openingsdeflecting the engagement membersoutward through the openingsand back into engagement with the recesses. Shear members,can then be installed in preparation for use of the liner hanger.

It may now be fully appreciated that the above disclosure provides significant advancements to the art of designing, constructing and operating liner hangers for use in subterranean wells. In one example described above, the liner hangercannot be set, until a sufficient differential pressure has been applied from an interior to an exterior of the liner hanger (e.g., from the portto the annulus), thereby preventing inadvertent premature setting of the liner hanger.

The above disclosure provides to the art a liner hangerfor use in a subterranean well. In one example, the liner hangercomprises: slipsconfigured to anchor the liner hangerin the well; a tubular mandrel; a tubular outer housingoutwardly surrounding the mandrel; a first engagement memberthat releasably secures the slipsagainst longitudinal displacement relative to the mandrel; and a second engagement memberthat releasably secures the outer housingagainst longitudinal displacement relative to the mandrel.

The first engagement membermay be supported in engagement with a profileformed on the mandrelby a first support surface. The first support surfacemay be configured to permit disengagement of the first engagement memberfrom the profilein response to longitudinal displacement of the outer housingrelative to the mandrel.

The liner hangermay include a shear memberthat releasably secures the outer housingagainst displacement relative to the mandrel.

A retainer sleevemay be disposed in an annulusformed between the outer housingand the mandrel, the retainer sleeveincluding a second support surfacethat supports the second engagement memberin engagement with a recessformed in the outer housing. The second support surfacemay be configured to permit disengagement of the second engagement memberfrom the recessin response to longitudinal displacement of the retainer sleeve.

The liner hangermay include a first shear memberthat releasably secures the retainer sleeveagainst displacement relative to the mandrel. The first shear membermay be received in a first openingformed in a gauge ring sleevesecured to the mandrel, and the second engagement membermay be received in a second openingformed in the gauge ring sleeve.

A second shear membermay be received in the gauge ring sleeve. The second shear membermay releasably secure the outer housingagainst displacement relative to the mandrel.

The liner hangermay include first and second seals,disposed in an annulusformed between the outer housingand the mandrel. An annular chambermay be formed longitudinally between the first and second seals,. Increased fluid pressure applied to the chambermay be operative to displace the outer housingand slipsrelative to the mandrel.

Also provided to the art by the above disclosure is a method of setting a liner hangerin a subterranean well. In one example, the method can comprise: applying a first differential pressure from an interior to an exterior of the liner hanger, thereby displacing a retainer sleeverelative to a mandrelof the liner hanger; and applying a second differential pressure from the interior to the exterior of the liner hanger, thereby displacing an outer housingof the liner hangerrelative to the mandrel. The outer housingis prevented from displacing relative to the mandreluntil after the retainer sleeveis displaced relative to the mandrel.

The method may include positioning the retainer sleevein an annulusformed between the outer housingand the mandrel.