Expandable wellbore liner system

A setting tool has an expansion cone drive sub-assembly operable to axially move an expansion cone of the setting tool through the liner to radially, plastically expand the liner. With the wellbore liner residing outside of a wellbore, the setting tool is changed to enable decoupling the wellbore liner from the setting tool while leaving at least the expansion cone drive sub-assembly substantially assembled.

BACKGROUND

The present disclosure relates to wellbore liner systems incorporating expandable wellbore liners and to setting tools therefore.

An expandable wellbore liner is a type of wellbore liner that is intended to be radially, plastically deformed while in a wellbore. Such liners are often set in another tubular or against the interior wall of the wellbore by radially, plastically deforming the expandable liner into gripping and/or sealing engagement with the other tubular or the wall of the wellbore. For example, an expandable liner can be set near the foot of a casing and extend downhole into a wellbore, or hang other liners that extend downhole into the wellbore, to line an additional portion of the wellbore below the casing. In another example, an expandable liner can be set proximate a rupture, leak or otherwise weakened portion of a casing or liner as a repair measure to reinforce and/or seal the casing or liner.

Wellbore liners incorporating expandable liners are typically assembled to and carried into the wellbore on a setting tool. Thereafter, the setting tool is operated to radially, plastically expand the expandable liner. Due to the complexity of the setting tool, assembling the setting tool and assembling the expandable liner to the setting tool is a complex procedure involving many steps that must typically be performed in a certain sequence. If after assembly, a change is desired to be made to the setting tool or to the liner, the setting tool and liner must be disassembled in sequence (typically the reverse of the assembly sequence) to gain access to the aspect being changed. Because the assembly/disassembly must be performed in sequence, many aspects that are not affected by the change must still be disassembled to gain access to the aspect being changed and then reassembled.

SUMMARY

The present disclosure relates to wellbore liner systems incorporating expandable wellbore liners and to setting tools therefore.

An aspect encompasses a method of decoupling a wellbore liner from a setting tool. The setting tool has an expansion cone drive sub-assembly operable to axially move an expansion cone of the setting tool through the liner to radially, plastically expand the liner. In the method, with the wellbore liner residing outside of a wellbore, the setting tool is changed to enable decoupling the wellbore liner from the setting tool while leaving at least the expansion cone drive sub-assembly substantially assembled. The setting tool is then decoupled from the wellbore liner.

An aspect encompasses a method of assembling a wellbore liner to a setting tool. The setting tool being of the type for radially, plastically expanding the liner. In the method, with an expansion cone of the setting tool, expansion cone drive sub-assembly of the setting tool and liner latching member of the setting tool assembled, the wellbore liner is assembled to the setting tool. Then the liner latching member is engaged to the wellbore liner to couple the wellbore liner to the setting tool.

An aspect encompasses a setting tool for coupling to a wellbore liner and radially; plastically expanding the wellbore liner in a wellbore. The setting tool includes a tubular mandrel. A wellbore liner expander cone is carried on the tubular mandrel and operable to radially, plastically expand the liner when moved axially through in interior of the wellbore liner. An expander cone driving sub-assembly is carried on the tubular mandrel and operable to axially move the expander cone to expand the wellbore liner. A liner latching member is carried on the tubular mandrel and changeable, with the setting tool residing outside of the wellbore, from latched to unlatched from the wellbore liner without disassembling or operating the expander cone driving sub-assembly or disassembling the wellbore liner.

The aspects can include one, more than one or none of the following features. In certain instances, the setting tool can be changed to enable decoupling the wellbore liner from the setting tool while leaving a hydraulic chamber assembly, that is responsive hydraulic pressure to drive the expansion cone, substantially in tact to the setting tool. In certain instances, changing the setting tool to enable decoupling the setting tool from the liner includes changing the setting tool to allow a liner latching member of the setting tool to move radially inward. In certain instances, this can be accomplished by moving and/or removing a propping member that supports the latching member in engagement with the liner. In certain instances, the propping member can be removed from the setting tool comprises removing the propping member through a downhole end of the liner. In its substantially in tact or assembled state, the expansion cone driving sub-assembly of the setting tool is operable to axially move the expansion cone over its full axial travel. The wellbore liner can include a liner hanger and the setting tool can be operable to radially, plastically expand at least a portion of the liner hanger. The wellbore liner can be a single, unitary tubular member extending from end to end thereof.

DETAILED DESCRIPTION

Referring first toFIG. 1, an example wellbore liner system10is shown residing in wellbore12. The example liner system10includes an expandable wellbore liner called an expandable liner hanger14and a sub-assembly18of other liner components depending from the downhole end thereof.FIG. 1shows the expandable liner hanger14having been radially, plastically deformed by a setting tool20so that its outer diameter continuously engages the interior diameter of the casing16. InFIG. 1, the setting tool20is depicted as having been operated to deform the expandable liner hanger14.

The wellbore12extends substantially vertically from a terranean surface22into the Earth. Although the wellbore12is depicted as being substantially vertical, in other instances, the entire wellbore or portions thereof may deviate to be slanted, curved substantially horizontal or otherwise non-vertical. Similarly, although the wellbore12is depicted as being a single wellbore, in other instances the wellbore can be a multilateral configuration having one or more lateral wellbores branching therefrom. The wellbore12provides access for injecting fluids into or withdrawing fluids from one or more subterranean zones of interest, where a subterranean zone of interest can correspond to a particular geological formation, can be a portion of a geological formation, or can include two or more geological formations. The casing16extends from a wellhead26at the surface22and through a portion of the wellbore12. In certain instances, the casing16is cemented and/or otherwise affixed to the walls of the wellbore12. In certain instances, the casing16is unapertured wall tubing.

The liner sub-assembly18can include one or more lengths of tubular liner, including unapertured wall tubing, slotted and/or apertured tubing, sand screen and/or other liner. If the liner sub-assembly18includes multiple lengths, the multiple lengths can be coupled together end to end (threadingly and/or otherwise) to define the liner sub-assembly18. The liner sub-assembly18can also include other components, such as valves, seals, centralizers, and/or other components. In certain instances, the downhole end of the liner sub-assembly18can include provisions to attach to additional components (threadingly and/or otherwise). The downhole end of the expandable liner hanger14includes provisions to couple to the liner sub-assembly18(threadingly and/or otherwise).

The expandable liner hanger14is shown engaging the downhole end of the casing16, such that the expandable liner hanger14and the liner sub-assembly18extend from the downhole end of the casing16further into the wellbore12. In other instances, the expandable liner hanger14and liner sub-assembly18can be positioned elsewhere within the wellbore12and/or in other associated wellbores. For example, in the context of a casing repair, the expandable liner hanger14can be positioned uphole from a rupture, leakage, or otherwise weakened point in the casing16. In another example, in the context of a multilateral, the expandable liner hanger14can be positioned proximate a lateral branch with the liner hanger extending into the lateral branch. Still further examples exist, and more than one liner hanger14and liner sub-assembly18can be provided in the wellbore12.

InFIG. 1, the expandable liner hanger14includes one or more seals24(three shown) circumscribing the outer diameter of the expandable liner hanger14. The seals24facilitate sealing between the expandable liner hanger14and the casing16when the outer diameter of the expandable liner hanger14engages the inner diameter of the casing16. In certain instances, the seals24form a gas-tight seal between the expandable liner hanger14and the casing16. In other instances, the seals24can be omitted.

The setting tool20is a component of a working string36that extends from the surface22into the wellbore12. In addition to the setting tool20, the working string36includes tubing (e.g., jointed tubing, continuous tubing without joints (e.g., coiled tubing), and/or other types of tubing) and/or other components. The setting tool20carries the expandable liner hanger14and liner sub-assembly18into the wellbore12, and operates to radially, plastically deform the expandable liner hanger14into engagement with the casing16. The setting tool20includes radially extendable and retractable latching lugs28used in coupling the setting tool20to the expandable liner hanger14.FIG. 1shows the setting tool20coupled to the expandable liner hanger14, with lugs28radially extended into engagement with a profile30of the expandable liner hanger14. When coupled to the expandable liner hanger14, the lugs28can axially support the expandable liner hanger14, the liner sub-assembly18and any additional components associated there with. In certain instances, the lugs28can additionally transmit torque between the setting tool20and the expandable liner hanger14, for example, to enable the expandable liner hanger14and liner sub-assembly18to be rotated while in the wellbore12. The setting tool20can be decoupled from the expandable liner hanger14by allowing the lugs28to radially retract out of engagement with the profile30. Notably, setting tool20can be changed from having the lugs28extended to allowing the lugs to radially retract without having to operate the setting tool20radially, plastically expand the liner hanger10.

The setting tool20includes an expansion cone32that when driven through the expandable liner hanger14radially, plastically deforms the expandable liner hanger14from a first, smaller outer diameter to a second, larger outer diameter. The setting tool20has an expansion cone driving sub-assembly34that drives the expansion cone32towards the lugs28in expanding the expandable liner hanger14. In certain instances, the cone driving sub-assembly34can include hydraulic aspects having one or more pistons and cylinders that move the expansion cone32in response to hydraulic pressure, such as hydraulic pressure applied through the interior bore of the setting tool20and/or otherwise. In certain instances, the cone driving sub-assembly34move the expansion cone32in response to hydraulic pressure without use of pistons and cylinders. Some examples of hydraulic expansion cone driving sub-assemblies suitable for use herein can be seen in a U.S. patent application entitled “Setting tool for Expandable Liner Hanger and Associated Methods,” Ser. No. 12/342,718, filed Dec. 23, 2008 and/orFIGS. 2A-Jdiscussed below. In certain instances, the cone driving sub-assembly34can include mechanical aspects, for example, a power screw that moves the expansion cone when the power screw is rotated via the working string36. Still further examples of expansion cone driving sub-assembly34exist.

In the configuration ofFIG. 1, the setting tool20drives the expansion cone32from a location about an uphole end of the expandable liner hanger14, and distal from the lugs28, axially toward a location about the downhole end of the expandable liner hanger14, and proximate the lugs28. In other instances, the setting tool20can be configured to operate in other manners, for example, to drive the expansion cone32from location about a downhole end of the expandable liner hanger14axially toward a location about the uphole end of the expandable liner hanger14and toward or away from the lugs28.

In operation, the expandable liner hanger14and liner sub-assembly18are coupled to the setting tool20. The expandable liner hanger14and liner sub-assembly18are then run into the wellbore on the setting tool20as part of the working string36. The working string36is manipulated to locate the expandable liner hanger14to place the expandable liner hanger14at the location in which the expandable liner hanger14will be radially, plastically expanded (e.g., where the expandable liner hanger14will be expanded into engagement with the casing16). The expansion cone driving sub-assembly34is then hydraulically actuated to drive the expansion cone32through the expandable liner hanger14and radially, plastically expand the expandable liner hanger14into engagement with the interior of the casing16. When expansion of the expandable liner hanger14is complete, the lugs28are released to radially retract out of engagement with the profile30and the working string36, including setting tool20, is withdrawn from the wellbore12.

Turning now toFIGS. 2A-2JandFIGS. 3A-3J, an exemplary setting tool200and liner hanger210are shown. The exemplary setting tool200and liner hanger210can be used in liner system10(discussed above), as setting tool20and liner hanger14, respectively.FIGS. 2A-2Jare successive detail side cross-sectional views of the exemplary setting tool200coupled to the liner hanger210as the setting tool200would be configured when carrying the liner hanger210(and liner sub-assembly18) into the wellbore.FIGS. 3A-3Jare successive detail side cross-sectional views of the exemplary setting tool200after having operated to radially, plastically expand the liner hanger210.

The liner hanger210is tubular, and as with liner hanger14, can have provisions at its downhole end to couple (threadingly and/or otherwise) to the liner sub-assembly18. Also, in certain instances, the liner hanger210can be constructed as a single, unitary tubular member extending from end to end.

Although made up of a number of different subcomponents, the exemplary setting tool200is substantially tubular having a central bore212extending throughout. Similar to the setting tool20and liner hanger14, discussed above, setting tool200includes latching lugs220(FIG. 2J) that engage a mating profile222(FIG. 2J) of the liner hanger210to couple and decouple the setting tool200with the liner hanger210. The setting tool200also includes an expansion cone250(FIGS. 2H and 3I) that, when driven through the liner hanger210, radially, plastically expands the liner hanger210, and an expansion cone drive sub-assembly270(FIGS. 2B-2HandFIGS. 3C-3I) that operates to drive the expansion cone250through the liner hanger210.

Referring first toFIG. 2A, the setting tool200includes a tubular upper body214at its uphole end. The upper body214has provisions at its uphole end to couple to other components (threadingly and/or otherwise), for example, other components of a working string used to carry the setting tool200into a wellbore and to manipulate the setting tool200. The upper body214is coupled to an inner mandrel assembly216that extends substantially the remaining length of the tool200to a lower latch prop body224, shown inFIG. 2J. The upper body214, inner mandrel assembly216and latch prop body224define the central bore212, and can be threadingly and/or otherwise coupled together. The lower latch prop body224has provisions at its downhole end to couple to other components (threadingly and/or otherwise), for example, other components of the working string. The latch prop body224is readily removable from the downhole end of the inner mandrel assembly216. For example, if threadingly coupled, the latch prop body224can be unscrewed from the inner mandrel assembly216.

The lugs220and their operation are best understood with reference toFIG. 2J. The inner mandrel assembly216carries a latch assembly218having the plurality of circumferentially spaced lugs220residing at the ends of an equal number of radially flexible fingers226extending from a base ring228. The lugs220, when radially extended, engage corresponding female receptacles of mating profile222in the liner hanger210. The lugs220, when allowed to radially retract, disengage from the corresponding mating profile222in the liner hanger210. The flexible fingers226bias the lugs220into the corresponding mating profile222. The female receptacles in the mating profile220correspond in number to the number of lugs220. In the present example, there are twelve lugs220, but fewer or more can be provided.

The lugs220are radially supported extended into engagement with the mating profile222via a latch prop230. As shown inFIG. 6, the latch prop230has a plurality of U-shaped latch prop receptacles232into which the lugs220are received. The latch prop receptacles232correspond in number to the number of lugs220. The receptacles232both radially support the lugs220in the extended state, as well as prevent circumferential movement between the lugs220and the latch prop230. The latch prop230is keyed to the inner mandrel assembly216to prevent circumferential movement between the latch prop230and the inner mandrel assembly216. Thus, torque applied through the setting tool200is transmitted to the liner hanger210.

The latch prop230and lugs220abut a shoulder on the latch prop body224, such that force on the liner hanger210towards the downhole end of the setting tool200(e.g., from the weight of the liner and the reaction force against the expansion cone250being driven downhole through the liner hanger210) is supported by the latch prop body224.

The lugs220are released to be able to radially retract out of engagement with the mating profile222of the liner hanger210by moving the latch prop230out of engagement with the lugs220. The base ring228of the latch assembly216rests against a shoulder ring234that is coupled to the inner mandrel assembly216by a shear pin238. When sufficient force is applied to the inner mandrel assembly216, forcing the inner mandrel assembly216downhole relative to the liner hanger210, the shear pin238shears and allows the inner mandrel assembly216, the lower latch prop body224and latch prop230to shift downhole relative the latch assembly218and shoulder ring234. In doing so, the latch prop230moves out of engagement with the lugs220, and leaves the lugs220radially unsupported. The lugs220have a sloped uphole surface configured to radially retract the lugs220out of engagement with the mating profile222of the liner hanger210when the lugs are radially unsupported and moved uphole relative to the liner hanger210. The lugs220have a square downhole surface configured to engage the mating profile222and supports load when loaded in a downhole direction relative to the liner hanger210. Downhole movement of the inner mandrel assembly216is limited when the shoulder ring234abuts a shoulder242on the inner mandrel assembly216. The downhole directed load on the inner mandrel assembly216is thus supported between the lugs220engaging the mating profile222and the shoulder242. Thereafter, the lugs220are released from the mating profile222, by withdrawing the setting tool200uphole.

The lugs220are prevented from shifting back downhole and re-engaging the latch prop230as the shifting tool200is withdrawn from the wellbore by a garter spring236that is stretched around the inner mandrel assembly216. The garter spring236is captured between the shoulder ring234and a garter spring guide244that is coupled to the shoulder ring234. Thus, as the inner mandrel assembly216moves downhole and the lugs220are desupported, a circumferential recess240on the inner mandrel assembly216moves under the garter spring236to receive the garter spring236. The garter spring236thereafter engages the recess240, and holds the shoulder ring234and latch assembly218to the inner mandrel assembly216with the lugs220out of engagement with the latch prop230. With the garter spring236engaged in the recess240, the latch assembly218does not slide downward to reengage the latch prop230. Subsequently, the setting tool200can be withdrawn from the liner hanger210, and the uphole movement of the inner mandrel assembly216does not reengage the lugs220with the latch prop230. As will be described in more detail below, the setting tool200can release from the liner hanger210(i.e., the lugs220be desupported) with or with out operating the tool200to expand the liner hanger210.

The expansion cone250, shown inFIGS. 2H and 3I, is a frustoconical shaped element having a smallest outer diameter smaller than the inner diameter of the liner hanger210, and a largest outer diameter larger than the inner diameter of the liner hanger210. The expansion cone250is initially received in a cone launcher portion260of the liner hanger210(FIG. 2H), where the inner diameter of the liner hanger210is large enough to accept the expansion cone250without having been radially expanded. In this initial state, the liner hanger210is retained to the setting tool200, pinched between the expansion cone250and the latching lugs220. To expand the liner hanger210, the expansion cone250is driven from the cone launcher portion260to a downhole position (FIG. 3I), through the liner hanger210, by the expansion cone drive sub-assembly270shown overFIGS. 2B-2Hand3C-3I. As the expansion cone250passes through the liner hanger210it plastically, radially expands the liner hanger210. In certain instances, the expansion cone250is sized to plastically, radially expand the liner hanger210such that the outer diameter of the liner hanger210is pressed into gripping and/or sealing engagement with the wall290of a wellbore (e.g. casing292or other). In certain instances, the liner hanger210can include one or more circumferential seals212(three shown) to facilitate achieving a liquid and/or gas tight seal with the wall290of the wellbore.

The expansion cone drive sub-assembly270includes an expansion cone driving sleeve assembly272that is coupled, about its downhole end, to the expansion cone250to drive the expansion cone253through the liner hanger210. The uphole end of the driving sleeve assembly272abuts a support sleeve256that supports the driving sleeve assembly272against moving uphole relative to the inner mandrel assembly216. The support sleeve256is affixed to the inner mandrel assembly216by dogs258that engage both the inner mandrel assembly216and the support sleeve256.

The driving sleeve assembly272, which may be made of multiple lengths of tubing, carries a plurality of axially spaced pistons274that seal against the inner mandrel assembly216. In the configuration shown, the pistons274couple multiple lengths of tubing of the driving sleeve assembly272together. The expansion cone drive sub-assembly270further includes a plurality of axially spaced bulkheads276affixed to the inner mandrel assembly216and that seal against the interior of the driving sleeve assembly272. The pistons274, bulkheads276, inner mandrel assembly216and driving sleeve assembly272cooperate to define a number of sealed hydraulic chambers278corresponding to the number of pistons274and bulkheads276. Pressure applied in the hydraulic chambers278moves the driving sleeve assembly272, and thus expansion cone250, toward the lugs220. The passages280, at least one per hydraulic chamber278, between the hydraulic chamber278and central bore212of the inner mandrel assembly216communicate pressure from the bore212of the inner mandrel assembly216. The space between the driving sleeve assembly272and the inner mandrel assembly216, opposite the hydraulic chambers278, is ported to the outside of the driving sleeve assembly272. InFIGS. 2B-2H, driving sleeve assembly272carries four pistons274and the inner mandrel assembly216carries four bulkheads276. Thus, inFIGS. 2B-2Hthere are four hydraulic chambers278. In other instances, fewer or more pistons274and bulkheads276can be provided to decrease or increase, respectively, the amount of force applied to the expansion cone250.

Normally, fluid can flow freely through the bore212. As shown inFIG. 3J, the bore212has a constricted portion284of reduced interior diameter that can sealingly receive a plug282, such as a spherical ball and/or other plug, to seal against passage of fluid flow downhole through the bore212. To apply pressure to the hydraulic chambers278, and thus actuate the expansion cone driving sub-assembly270, the plug282is placed in the constricted portion284, for example by being dropped and/or pumped from the terranean surface into the constricted portion284. Thereafter, pressure applied through the bore212is communicated through the passages280into the hydraulic chambers278. Enough fluid is provided to expand the hydraulic chambers278, move the pistons274and driving sleeve assembly272downhole, to drive the expansion cone250through its full axial stroke. For example, compare the position of the pistons274inFIGS. 2C-2Hto the position the same pistons274inFIGS. 3D-3I.

At the bottom of its stroke, the expansion cone driving sub-assembly270opens a bypass that allows flow in the bore212to bypass the hydraulic chambers278, and thus cease operating the expansion cone driving sub-assembly270in moving the expansion cone250. More specifically, referring toFIGS. 2J and 3J, as the expansion cone driving sub-assembly270reaches the bottom of its stroke, the expansion cone250impacts and shifts a bypass sleeve286, carried on the inner mandrel assembly216uphole from the constricted portion284. As seen inFIG. 2J, prior to being shifted by the expansion cone250, the bypass sleeve286sealingly covers a plurality of bypass ports294of inner mandrel assembly216and seals against passage of fluids from the bore212out of the inner mandrel assembly216. The bypass sleeve286is retained in this position sealingly covering the bypass ports294by shear pins288. When the expansion cone250impacts the bypass sleeve286, the shear pins288shear and the bypass sleeve286shifts downhole into contact with the lug242. Thereafter, as shown inFIG. 3J, corresponding ports296on the bypass sleeve286align with the bypass ports294in the inner mandrel assembly216and allow flow from the bore212to flow of the inner mandrel assembly216.

After expanding the liner hanger210(FIGS. 3H-3J), the setting tool200can be decoupled from the liner hanger210by applying a downward force to the inner mandrel assembly216, shift the inner mandrel assembly216downhole relative to the liner hanger210, and desupport the lugs220as described above. When desupported, the lugs220can retract inward and release from the mating profile222(thus releasing the setting tool200from the liner hanger210) as the setting tool200is withdrawn, uphole, from the liner hanger and out of the wellbore.

The setting tool200can also release from the liner hanger210(i.e., the lugs220be desupported) without having operated the tool200to expand the liner hanger210. For example, in the operation described above, the inner mandrel assembly216is discussed as fixed relative to an expansion cone drive sub-assembly270. However, the setting tool200is changeable to partially release the inner mandrel assembly216from the expansion cone drive sub-assembly270, so that the inner mandrel assembly216can be shifted downhole to desupport lugs228without operating the expansion cone drive sub-assembly270.

To this end, referring toFIGS. 2A and 2B, the upper body214has an interior facing slot246that receives an outwardly protruding lug248of the inner mandrel assembly216. The slot profile246is generally configured as an upside down “J,” i.e. with hook portion of the J near the uphole end of the upper body214and the long portion of the J extending axially downhole therefrom. The J-slot246defines an upper receptacle246atowards an uphole end and a lower receptacle246btowards a downhole end. In normal operation of the setting tool200, for example when the setting tool200is run into a wellbore, the lug248of the inner mandrel assembly216is received in the upper receptacle246a. With the lug248in the upper receptacle246a, the upper body214and the inner mandrel assembly216are retained so that the upper body214cannot move downhole relative to the inner mandrel assembly216. However, rotating the upper body214counterclockwise dislodges the lug248from the upper receptacle246aand allows the upper body214to move downhole relative to the inner mandrel assembly216and the lug248to traverse the remainder of the J-slot246and be received in the lower receptacle246b.

When the upper body214moves downhole relative to the inner mandrel assembly216, it releases the inner mandrel assembly216from the expansion cone drive sub-assembly270. A support sleeve256supports the expansion cone drive sub-assembly270relative to the inner mandrel assembly216. As the upper body214moves downhole, it contacts a release sleeve252and shears shear pins254retaining the release sleeve252to the support sleeve256. The release sleeve252supports dogs258that engage the inner mandrel assembly216and affix the support sleeve256relative to the inner mandrel assembly216. Thus, when desupported, the dogs258release from the inner mandrel assembly216and allow the support sleeve256to move relative to the inner mandrel assembly216.

After the inner mandrel assembly216is released from the expansion cone drive sub-assembly270, the upper body214acts upon the inner mandrel assembly216to drive the inner mandrel assembly216downhole relative to the liner hanger210. Driving the inner mandrel assembly216downhole relative to the liner hanger210moves the latch prop230out of engagement with the lugs220, and desupports the lugs220as described above. When desupported, the lugs220can retract inward and release from the mating profile222(thus releasing the setting tool200from the liner hanger210) as the setting tool200is withdrawn, uphole, from the liner hanger and out of the wellbore.

Prior to operation, the setting tool200is substantially assembled before assembly with the liner hanger210and the liner sub-assembly. Such assembly of the setting tool200and assembly of the liner hanger210to the setting tool200is performed outside of the wellbore, and typically in an assembly shop remote from the well. In certain instances, however, some or all of the assembly can be performed at the well site. To this end, the inner mandrel assembly216, the expansion cone250, expansion cone driving sub-assembly270, the bypass sleeve286, the support sleeve256, the release sleeve252, the upper lug body214, and the latch assembly218are all assembled to the setting tool200. The latch prop body224and the latch prop230are not assembled to the inner mandrel assembly216, as shown inFIG. 5. In this state, the expansion cone250and expansion cone driving sub-assembly270are fully assembled, and can even be operated over a portion or the entirety of its stroke (e.g., for testing purposes) by plugging the bore212and applying pressure to the hydraulic chambers278. Because the latch prop230is not assembled to the inner mandrel assembly216, the lugs224can retract from the radially extended state. The liner hanger210, thus, can be received over the setting tool200such that the expansion cone250is received in the cone launcher260of the liner hanger210, and the lugs220of the latch assembly218are aligned axially with and loosely received in their mating profile222. The latch prop230is then fitted to the inner mandrel assembly216to support the lugs220radially extended into locking engagement with the mating profile222, and the latch prop body224is coupled to the inner mandrel assembly216to support the latch prop230. Thereafter, any remaining small number of steps are performed to complete assembly of the setting tool200.

Notably, in certain instances, the latch prop body224and latch prop230are able to be fitted to the inner mandrel assembly216through the bottom end of the liner hanger210. Thus, the liner hanger210can be constructed as a single, unitary tubular member extending from end to end, and need not have provisions to be separated intermediate its ends (e.g., a threaded connection) to facilitate access to the latch assembly218or fitting the latch prop230. In certain instances, a single piece, unitary liner hanger210is stronger and less expensive to manufacture than a liner hanger with provisions to be separated intermediate its ends.

Subsequently, if it is desired to access a portion of the setting tool200or otherwise decouple the expandable liner hanger210from the setting tool200, the expandable liner hanger210can be easily decoupled from the setting tool200, because the setting tool200was substantially assembled prior to coupling with the expandable liner hanger210. Thus, the step of coupling the setting tool200with the expandable liner hanger210was the last or one of the last steps to have been performed, and the setting tool200need not be substantially disassembled. Such ease of removal and installation of the liner hanger210to the setting tool200enables the liner hanger210to be easily changed (e.g., for a liner hanger210of a different material, different configuration and/or different dimension) and/or enables easy access to the setting tool200to change or verify aspects of the setting tool200. Because the expansion cone driving sub-assembly270and the remainder of the tool200remain in-tact and assembled, it is unnecessary to re-perform any testing or quality checks performed on the setting tool200before or when the liner hanger210was initially assembled to the setting tool200.

To this end, to decouple the liner hanger210from the setting tool200, the latch prop body224is decoupled from the inner mandrel assembly216and the latch prop230removed from the inner mandrel assembly216. In certain instances, the latch prop body224and latch prop230are removed through the bottom end of the liner hanger210to desupport the lugs220while the expansion cone driving sub-assembly270and the remainder of the tool200remains substantially in-tact and assembled. Any frangible parts, such as the shear pins238,254and288, can remain in place and remain in-tact and not sheared. In certain instances, some minor additional operations can be performed. In certain instances, the only operations whatsoever needed to enable removal of the liner hanger210from the setting tool200are removal of the latch prop body224from the inner mandrel assembly and moving or removing the latch prop230to desupport the lugs220.

With the lugs220desupported, the liner hanger210can be removed from the setting tool200, by pulling the setting tool200axially out through the uphole end of the liner hanger210or by pulling the liner hanger210off the downhole end of the setting tool200. Any changes, adjustments, or inspections can be made to the setting tool200and/or liner hanger210, and the liner hanger210or another liner hanger210reinstalled as described above.

Notably, although described herein as involving removal of the latch prop230and latch prop body224to release the liner hanger210from the setting tool200, the same effect can be achieved in a number of different manners consistent with the concepts described herein. For example, in certain instances, the setting tool can be configured such that the latch prop230is moveable to desupport the lugs220without removal of the latch prop body224or latch prop230from the inner mandrel216.