RETRIEVABLE ADAPTER FOR LINER HANGER SYSTEMS

CROSS-REFERENCE TO RELATED APPLICATION

[0001] This application is based on and claims priority to U.S. Provisional Application Serial No. 62/876, 111, filed July 19, 2019, which is incorporated herein by reference in its entirety.

BACKGROUND

[0002] In many well applications, liners or casing may be deployed downhole into a wellbore and cemented in place within the wellbore. A liner may be hung either adjacent the lower end of a previously suspended and cemented casing, or from a previously suspended and cemented liner. A liner hanger is used to suspend the liner within the lower end of the previously set casing or liner. A running or setting tool disposed on the lower end of a work string is releasably connected to the liner hanger that is coupled with the top of the liner. Additionally, the liner hanger may be combined with a liner top packer to provide a seal between the liner and the surrounding casing.

[0003] In conventional liner hanger systems, the setting tool can only accommodate a single liner size, a slick joint supported by the running tool may measure up to 10-15 feet, and a seal bore is required in the liner top packer and a packoff is required below the liner top packer to transmit pump out forces to a mandrel of the liner top packer.

SUMMARY

[0004] An assembly according to one or more embodiments of the present disclosure includes a retrievable adapter including a body including an internal longitudinal passage extending therethrough, at least one internal seal mounted in the body along the internal longitudinal passage, the at least one internal seal configured to seal between the retrievable adapter and an internal slick joint slidably received along the internal passage, and at least one outer seal that is configured to seal with a tieback receptacle, and a running tool that latches into the retrievable adapter, the slick joint being supported on the running tool, wherein the retrievable adapter connects the running tool to a downhole tool such that the running tool latches into the retrievable adapter, and the retrievable adapter latches into the downhole tool, and wherein the retrievable adapter transmits pump out forces to a mandrel of the downhole tool.

[0005] A method according to one or more embodiments of the present disclosure includes running a downhole tool including a mandrel downhole into a wellbore, coupling a tieback receptacle including a bore to a top end of the downhole tool, running an assembly into the bore of the tieback receptacle and the mandrel of the downhole tool, the assembly including a retrievable adapter that includes a body including an internal longitudinal passage extending therethrough, at least one internal seal mounted in the body along the internal longitudinal passage, the at least one internal seal configured to seal between the retrievable adapter and an internal slick joint slidably received along the internal passage, and at least one outer seal that is configured to seal with the tieback receptacle, and a running tool that latches into the retrievable adapter, the slick joint being supported on the running tool, wherein the retrievable adapter connects the running tool to the downhole tool such that the running tool latches into the retrievable adapter, and the retrievable adapter latches into the downhole tool, releasing the running tool from the assembly, performing a downhole operation, pulling the slick joint from the internal longitudinal passage of the retrievable adapter, causing the retrievable adapter to detach from the downhole tool, and retrieving the retrievable adapter from the wellbore.

[0006] However, many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims. BRIEF DESCRIPTION OF THE DRAWINGS

[0007] Certain embodiments of the disclosure will hereafter be described with reference to the accompanying drawings, wherein like reference numerals denote like elements. It should be understood, however, that the accompanying figures illustrate the various implementations described herein and are not meant to limit the scope of various technologies described herein, and:

[0008] FIG. l is a liner hanger assembly including a retrievable adapter, according to one or more embodiments of the present disclosure;

[0009] FIG. 2 is an illustration of various components of the retrievable adapter, according to one or more embodiments of the present disclosure; and

[0010] FIGS. 3-7 illustrate a method of operating the liner hanger assembly including the retrievable adapter, according to one or more embodiments of the present disclosure.

DETATTED DESCRIPTION

[0011] In the following description, numerous details are set forth to provide an understanding of some embodiments of the present disclosure. However, it will be understood by those of ordinary skill in the art that the apparatus and/or method may be practiced without these details and that numerous variations or modifications from the described embodiments may be possible.

[0012] In the specification and appended claims: the terms“up” and“down,”“upper” and “lower,” “upwardly” and “downwardly,” “upstream” and “downstream,” “uphole” and “downhole,”“above” and“below,” and other like terms indicating relative positions above or below a given point or element are used in this description to more clearly describe some embodiments of the disclosure.

[0013] The present disclosure generally relates to an apparatus and method for running and setting a liner hanger system. Specifically, one or more embodiments of the present disclosure includes using a retrievable adapter to connect a running tool to a liner top packer or other downhole tool in a liner hanger assembly. This configuration allows the retrievable adapter to play the role of a retrievable cement bushing during cementing operations. U.S. Patent No. 9,540,902, entitled“RETRIEVABLE CEMENTING BUSHING SYSTEM,” which issued January 10, 2017; U.S. Patent No. 9,062,520, entitled“RETRIEVABLE CEMENTING BUSHING SYSTEM,” which issued June 23, 2015; and U.S. Patent No. 10, 145,201, entitled “RETRIEVABLE CEMENT BUSHING SYSTEM AND METHODOLOGY,” which issued December 4, 2018, are incorporated herein by reference in their entirety. Once the cementing operations are completed, the retrievable adapter may be retrieved when a slick joint supported on the running tool is pulled out of the wellbore.

[0014] Advantageously, using the retrievable adapter increases the asset utilization of the running tools, facilitates a tapered entry into the liner without the use of a castellation, shortens the overall length of the liner hanger assembly by eliminating the need for a long slick joint, and eliminates the seal bore in the liner top packer (or other downhole tool) and the packoff below the liner top packer while still being able to transmit pump out forces to the packer mandrel.

[0015] Referring generally to FIG. 1, a liner hanger assembly 10 including a retrievable adapter 12, according to one or more embodiments of the present disclosure is shown. As specifically shown in FIG. 1, in addition to the retrievable adapter 12, which is further described below, the liner hanger assembly 10 may also include a running tool 14, a tieback receptacle (“TBR”) 16, and a liner top packer 18 having a mandrel 20, according to one or more embodiments of the present disclosure. While a liner top packer 18 is shown in FIG. 1, the liner hanger assembly 10 may include another downhole tool having a mandrel such as a unibody system or a setting adapter, for example, instead of the liner top packer 18. For example, a setting adapter may be used in the liner hanger assembly 10 when a liner top packer 18 is not required or where no liner hanger is used. Advantageously, when a setting adapter is implemented in the liner hanger assembly 10 as the downhole tool having the mandrel according to one or more embodiments of the present disclosure, a significant cost savings may be realized when used in conjunction with the retrievable adapter 12. [0016] Still referring to FIG. 1, the running tool 14 may latch into the retrievable adapter 12. According to one or more embodiments of the present disclosure, the retrievable adapter connects the running tool 14 to the liner top packer 18 (or other downhole tool) such that the running tool 14 latches into the retrievable adapter 12, and the retrievable adapter 12 latches into the liner top packer 18 (or other downhole tool). With this latching arrangement, the hang weight of the liner (not shown) is transmitted through the retrievable adapter 12 to the running tool 14. Moreover, the retrievable adapter 12 may include a profile 13 that is configured to latch onto a plurality of running tools 14 according to one or more embodiments of the present disclosure. The profile 13 of the retrievable adapter 12 is configured to latch onto at least two of a collet running tool, a right-hand-release running tool, a simple mechanical running tool, or any other type of running tool in accordance with one or more embodiments of the present disclosure. In this way, the retrievable adapter 12 increases the asset utilization of a multitude of running tools according to one or more embodiments of the present disclosure. Moreover, by only changing the retrievable adapter 12 of the liner hanger assembly 10, liner hanger equipment of different sizes may be run using only one set of running tools 14. This advantage can save a service company from developing a specific running tool 14 for each liner size, or from having to use a crossover below the liner equipment, whereby the maximum ratings that are achievable is reduced. Moreover, the retrievable adapter 12 according to one or more embodiments of the present disclosure may advantageously be configured to latch into a plurality of liner top packers 18 (or other downhole tools) of different sizes using a single running tool 14 size. As further shown in FIG. 1, the running tool 14 may support a slick joint 22 according to one or more embodiments of the present disclosure.

[0017] Still referring to FIG. 1, the liner top packer 18 (or other downhole tool) may be set down on top of a liner hanger (not shown), and the liner top packer 18 may be set by the running tool 14 to seal an annulus between the liner (not shown) and the previously set casing or liner. According to one or more embodiments of the present disclosure, the liner top packer 18 or other downhole tool may be run with the liner hanger (not shown) downhole into the wellbore. As further shown in FIG. 1, a TBR 16 having a bore 17 may be coupled with a top end of the liner top packer 18 (or other downhole tool). According to one or more embodiments of the present disclosure, the running tool 14 latched into the retrievable adapter 12, as previously described, may be run into the bore 17 of the TBR 16 and the mandrel 20 of the liner top packer 18 (or other downhole tool) for latching of the retrievable adapter 12 into the liner top packer 18 (or other downhole tool).

[0018] Still referring to FIG. 1, several components of the retrievable adapter 12 of the liner hanger assembly 10 are shown including a body 24, a longitudinal passage 26, at least one slick joint seal 28, at least one TBR seal 30, at least one latch collet 32, at least one engagement lug 34, and at least one torque dog 36. These components of the retrievable adapter 12 are more specifically described below with respect to FIG. 2.

[0019] Referring now to FIG. 2, an illustration of components of the retrievable adapter 12 according to one or more embodiments of the present disclosure is shown. As shown in FIG. 2, the retrievable adapter 12 according to one or more embodiments of the present disclosure may include a body 24 having an internal longitudinal passage 26 extending therethrough. As further shown in FIG. 2, the internal longitudinal passage 26 of the retrievable adapter 12 may slidably receive the internal slick joint 22 according to one or more embodiments of the present disclosure. The retrievable adapter 12 may also include at least one internal slick joint seal 28 mounted in the body 24 along the internal longitudinal passage 26, according to one or more embodiments of the present disclosure. The at least one internal slick joint seal 28 seals between the retrievable adapter 12 and the internal slick joint 22 that is slidably received along the internal longitudinal passage 26 of the retrievable adapter 12 in accordance with one or more embodiments of the present disclosure.

[0020] Still referring to FIG. 2, the retrievable adapter 12 may also include at least one outer TBR seal 30 that seals with the TBR 16. That is, the retrievable adapter 12 according to one or more embodiments of the present disclosure may include at least one internal slick joint seal 28 and at least one outer TBR seal 30, without having a seal bore in the inner diameter of the liner top packer 18 (or other downhole tool), and without having a packoff, or elastomeric sealing element, below the liner top packer 18 (or other downhole tool). Advantageously, the dynamic outer TBR seal 30 and the internal slick joint seal 28 enable the retrievable adapter 12 to transmit pump out forces to the mandrel 20 of the liner top packer 18 (or other downhole tool) during a downhole operation, such as a cementing operation, for example, without the need for a seal bore in the liner top packer 18 (or other downhole tool) or a packoff below the liner top packer 18 (or other downhole tool). Moreover, placement of the at least one outer TBR seal 30 of the retrievable adapter 12 in the TBR 16 permits reducing the length of the slick joint 22 from 10-15 feet to 3-4 feet, for example, as the retrievable adapter 12 can move up when setting the liner top packer 18 and still allow for a packer pressure test, according to one or more embodiments of the present disclosure. That is, the retrievable adapter 12 no longer needs to be attached to the liner top packer 18, in embodiments of the present disclosure where the downhole tool is the liner top packer 18, when the liner top packer 18 is being set. Advantageously, the significantly shorter slick joint 22 reduces the overall length of the liner hanger assembly 10 that is shipped to the rig site and run in the wellbore. Moreover, the liner top packer 18 can still be pressure tested against the retrievable adapter 12.

[0021] Still referring to FIG. 2, the retrievable adapter 12 may also include at least one engagement lug 34 mounted on the body 24 and supported by the slick joint 22 in a run-in- hole position. As shown in FIG. 2, the at least one engagement lug 34 facilitates latching the retrievable adapter 12 into the liner top packer 18 (or other downhole tool) via at least one latch collet 32. In one or more embodiments of the present disclosure, the at least one latch collet 32 may be threaded. However, a non-threaded latch collet 32 or other type of fastener is within the scope of the present disclosure. Indeed, as further described below, the latch collet 32 may float to allow the retrievable adapter 12 to relatch downhole when pushing down after detachment, according to one or more embodiments of the present disclosure.

[0022] Still referring to FIG. 2, the retrievable adapter 12 may also include at least one torque dog 36 that engages a torque profile 38 in the liner top packer 18 (or other downhole tool), thereby transferring torque to the liner top packer 18 (or other downhole tool) and further connecting the retrievable adapter 12 to the liner top packer 18 (or other downhole tool). As shown in FIG. 2, the torque dog 36 may include a torque spring 40 that biases the torque dog 36 into engagement with the torque profile 38 in the liner top packer 18 (or other downhole tool). However, the torque spring 40 may bias the torque dog 36 in an opposite direction according to one or more embodiments of the present disclosure. [0023] In one or more embodiments of the present disclosure, the retrievable adapter 12 may also include a fluid bypass therethrough for removal of debris, which may occur during cementing operations, for example.

[0024] Referring now to FIGS. 3-7, a method of operating the liner hanger assembly 10 including the retrievable adapter 12, according to one or more embodiments of the present disclosure is shown. With respect to FIG. 3, for example, in the method of operating the liner hanger assembly 10, a downhole tool, such as a liner top packer 18, including a mandrel 20 may be run downhole into a wellbore. While a liner top packer 18 is shown in FIG. 3, the liner hanger assembly 10 may include another downhole tool having a mandrel such as a unibody system or a setting adapter, for example, instead of the liner top packer 18, as previously described. Further, the method according to one or more embodiments of the present disclosure may include coupling a TBR 16 including a bore 17 to a top end of the liner top packer 18 (or other downhole tool). The method may further include running an assembly including the retrievable adapter 12 and the running tool 14, as previously described, into the bore 17 of the TBR 16 and the mandrel 20 of the of the liner top packer 18 (or other downhole tool), according to one or more embodiments of the present disclosure. The method may also include releasing the running tool 14 from the assembly, as shown in FIG. 4. Further, the method may include performing a downhole operation as shown in FIG. 5. Although FIG. 5 shows that the downhole operation is a cementing treatment, other downhole operations, such as pressure testing the liner top packer 18 against the retrievable adapter 12, are within the scope of the present disclosure. The method may also include bypassing fluid through the retrievable adapter 12 to remove debris in accordance with one or more embodiments of the present disclosure.

[0025] Now referring to FIGS. 6 and 7, the method may also include pulling the slick joint 22 from the internal longitudinal passage 26 of the retrievable adapter 12, causing the retrievable adapter 12 to detach from the liner top packer 18 (or other downhole tool), according to one or more embodiments of the present disclosure. In one or more embodiments of the present disclosure, the slick joint 22 may include an undercut 42. As the slick joint 22 is pulled, the slick joint 22 slides upward through the longitudinal passage 26 of the retrievable adapter 12. During pulling, the at least one engagement lug 34 continues to be supported by the slick joint 22 until the undercut 42 of the slick joint 22 causes the at least one engagement lug 34 to break contact with the slick joint 22. Once the at least one engagement lug 34 is no longer supported by the slick joint 22, the at least one latch collet 32 and the at least one torque dog 36 on the retrievable adapter 12 are free to unlatch from the liner top packer 18 (or other downhole tool). In this way, the undercut 42 of the slick joint 22 facilitates the unlatching of the retrievable adapter 12, according to one or more embodiments of the present disclosure. Once the retrievable adapter 12 is unlatched, the retrievable adapter 12 may be retrieved from the wellbore. After retrieval of the retrievable adapter 12, the method according to one or more embodiments of the present disclosure may include reattaching the retrievable adapter 12 to the liner top packer 18 (or other downhole tool) for additional downhole operations. For example, the retrievable adapter 12 may be retrieved to wash excess cement resulting from a downhole cementing operation, and then reattached to the liner top packer 18 to test or set more weight on the liner top packer 18, according to one or more embodiments of the present disclosure. In some embodiments of the present disclosure, the latch collet 32 is floating so that the latch collet 32 can allow the retrievable adapter 12 to relatch downhole when pushing down. On the contrary, upward pull on the slick joint 22 loads up on the at least one engagement lug 34 and prevents unlatching of the retrievable adapter 12 until the running tool 14 is released, according to one or more embodiments of the present disclosure.

[0026] Advantageously, the retrievable adapter 12 according to one or more embodiments of the present disclosure may provide for a shorter liner top packer 18 architecture and lower product cost. Further, one or more embodiments of the present disclosure allows the assembly of liner top packer 18 components from above, which may be particularly useful for unibody designs. The retrievable adapter 12 according to one or more embodiments of the present disclosure may also include an integrated box connection. As another advantage, the retrievable adapter 12 may facilitate the retrieval of dropped liners with a multitude of different running tools 14. Moreover, in embodiments of the present disclosure where the liner hanger assembly 10 includes a rotating dog assembly above the running tool 14, the retrievable adapter 12 allows the rotating dog assembly to be made up close to the running tool 14, which allows increased pick-up before the rotating dog assembly exits the TBR 16 during retrieval. [0027] Although a few embodiments of the disclosure have been described in detail above, those of ordinary skill in the art will readily appreciate that many modifications are possible without materially departing from the teachings of this disclosure. Accordingly, such modifications are intended to be included within the scope of this disclosure as defined in the claims.