Biased lug cartridge, wear bushing with biased lug cartridge, and system and method using the same

A wear bushing includes: a wear bushing body having one or more cavities formed therein; and one or more lug cartridges each disposed within a corresponding one of the cavities in the wear bushing body. Each lug cartridge includes: a biased lug configured to be transitioned between a first position in which the lug protrudes in a radially inward direction from an inner diameter of the wear bushing body and a second position in which the lug is retracted into the corresponding cavity of the wear bushing body; and a retainer configured to retain the biased lug in the second position.

TECHNICAL FIELD

The present disclosure relates generally to wear bushings for use in oil and gas wells, and more particularly, to a selectively-retrievable wear bushing equipped with a spring-loaded lug cartridge.

BACKGROUND

Wear bushings (sometimes referred to as “wear sleeves” or “bore protectors”) are used while drilling to protect the bore of surface or subsea well equipment from damage or wear. The bore of the wellhead must be protected so that metal-to-metal seal assemblies can later be installed when a casing hanger is landed and the annulus between the wellhead bore and the casing run is “packed-off” with the metal seal assembly. Scratches in the wellhead bore could prevent the metal seal from passing pressure tests.

Certain designs of wear bushings were introduced to enable installation and retrieval of the wear bushings while the drill bit and bottom hole assembly were being run and retrieved. These were called “bit runable wear bushings” and later shortened to “wear sleeves.” A drawback of these designs is that every time the bit is retrieved, the wear sleeve is also retrieved. There is risk involved with this process, because the drill bit passes through the exposed wellhead before the wear sleeve is installed and, on the trip out, the wear sleeve is retrieved first, and later the drill bit will pass through the exposed wellhead. In the case of smaller, deeper drilling intervals, the drilled hole may require multiple trips because worn drill bits would have to be replaced before the desired depth of penetration is reached.

Selectively retrievable wear bushings (or wear sleeves) were introduced, allowing the wear bushings to remain installed both as the drill bit and bottom hole assembly are being run and retrieved. This prevents the risk associated with exposure of the wellhead to wear during drilling processes. There is room for improvement in the conventional selectively retrievable wear bushings. For example, these selectively retrievable wear bushings and their associated running tool(s) can be difficult and costly to manufacture. In addition, conventional designs for selectively retrievable wear bushings require the use of a specially constructed adapter coupled to the drill string, regardless of whether the wear bushing is going to be left in the wellhead or retrieved. Finally, conventional designs of selectively retrievable wear bushings and their associated running tools lack flexibility, since each wear bushing size has its own uniquely sized dedicated adapter.

It is now recognized that a need exists for selectively retrievable wear bushings that have a more flexible and/or modular design with improved manufacturability.

SUMMARY

Embodiments of the present disclosure are generally directed to wear bushings (also known as “wear sleeves” or “bore protectors”), and more particularly, to wear bushings for use in oil and gas wells, and more particularly, to a selectively-retrievable wear bushing equipped with a spring-loaded (or otherwise biased) lug cartridge. The systems and methods disclosed herein may be used to allow for efficient replacement of lugs (also referred to as “dogs” or “dog segments”) from a wear bushing. In particular, a modular-style lug cartridge may be assembled prior to installation on a wear bushing. The lug cartridge may be capable of being reset on the surface or replaced with a new lug cartridge.

In order to leave the wear bushing in the wellbore, the lug cartridge may be actuated by a running tool. The actuation may collapse one or more spring-loaded lugs and allow the one or more lugs to be retained by a retainer (e.g., spring-loaded or otherwise biased retainer). Thus, the bore of the wear bushing may be exposed so that objects will not catch on the lugs. In order to return the wear bushing to the rig floor, a split lock ring attached to an adapter coupled to the running tool may engage into a mating profile of the wear bushing. In case the lug cartridge needs to be run downhole a second time, the lug cartridge may be equipped with a quick reset. The desired configuration of the selectively retrievable wear bushing may be determined and implemented at the rig floor via minor adjustments.

The present disclosure embodies several advantages. For example, the disclosed wear bushings, adapters, and associated running tools allow for improved manufacturability, since the design uses a reduced length running tool compared to existing systems, no weld-on fins extending from the adapter, and modular lug cartridges that can be used on any size wear bushing. Furthermore, many embodiments of the present disclosure eliminate the need for an adapter when leaving the wear bushing in the wellhead. Additionally, embodiments of the present disclosure eliminate the need for an adapter whenever it is desired for the wear bushing to remain in the wellhead. Moreover, all wear bushings and their associated adapters may have the same top interface, regardless of the size of the wellhead in which the wear bushing is being positioned, making the wear bushing retrievable via a multi-purpose tool (MPT) as opposed to a dedicated retrieval tool. These and other advantages of the systems and methods of the present disclosure may be used to improve bushing-related wellbore processes.

DETAILED DESCRIPTION

For purposes of the description hereinafter, it is to be understood that the disclosure may assume alternative variations and step sequences, except where expressly specified to the contrary. It is also to be understood that the specific devices and processes illustrated in the attached drawings and described in the following specification are simply exemplary aspects of the disclosure. Hence, specific dimensions and other physical characteristics related to the aspects disclosed herein are not to be considered as limiting.

As used herein, the term “coupled” should be understood to include any direct or indirect connection between two things, including, and without limitation, a physical connection (including, and without limitation, a wired or mechanical connection), a non-physical connection (including, and without limitation, a wireless connection), or any combination thereof. Furthermore, the words “comprising” (and any form of comprising, such as “comprise” and “comprises”), “having” (and any form of having, such as “has” and “have”), “including” (and any form of including, such as “includes” and “include”) or “containing” (and any form of containing, such as “contains” and “contain”) are to be understood as inclusive and open-ended and do not exclude additional, unrecited elements or method steps.

As used herein, the term “at least one of” is synonymous with “one or more of.” For example, the phrase “at least one of A, B, and C” means any one of A, B, and C, or any combination of any two or more of A, B, and C. For example, “at least one of A, B, and C” includes one or more of A alone; or one or more of B alone; or one or more of C alone; or one or more of A and one or more of B; or one or more of A and one or more of C; or one or more of B and one or more of C; or one or more of all of A, B, and C. Similarly, as used herein, the term “at least two of” is synonymous with “two or more of.” For example, the phrase “at least two of D, E, and F” means any combination of any two or more of D, E, and F. For example, “at least two of D, E, and F” includes one or more of D and one or more of E; or one or more of D and one or more of F; or one or more of E and one or more of F; or one or more of all of D, E, and F.

Turning now to the drawings,FIGS.1A and1Billustrate a wear bushing100, in accordance with one or more embodiments of the present disclosure. The wear bushing100may be a selectively retrievable wear bushing. The phrase “selectively retrievable” means that the wear bushing100may be positioned in a well component (e.g., wellhead) and selectively maintained within the well component during subsequent trips of the drilling string (and running tool) through the well component or selectively retrieved to the surface by the running tool.

The wear bushing100includes a wear bushing body102having one or more cavities104, as shown. In the illustrated embodiment, the wear bushing body102includes four such cavities104. However, in other embodiments, the wear bushing body102may include a different number (e.g., 1, 2, 3, 5, 6, 7, 8, 9, 10, or more) cavities104formed therein. The wear bushing body102may be formed of metal and generally cylindrical in shape. The wear bushing body102has a bore extending therethrough, and an inner circumferential surface112of the bore of the wear bushing body102is generally smooth. Indeed, the wear bushing body102may be similar in construction to conventional wear bushings used to protect the bores of surface and subsea wellheads. Seals105may be disposed around an upper portion of the wear bushing body102, as shown.

The wear bushing100also includes one or more lug cartridges106. When the wear bushing100is fully assembled, each lug cartridge106is disposed within a corresponding one of the cavities104in the wear bushing body102. As illustrated, the wear bushing100may include multiple lug cartridges106disposed in cavities104located substantially equidistant from each other about a circumference of the wear bushing body102.

As shown, the lug cartridges106may have generally the same size, shape, and construction as each other, but are each located in a different cavity104in the wear bushing body102.FIG.1Ashows an exploded version of one lug cartridge106, whileFIG.1Bshows cross sections of two lug cartridges106. Each lug cartridge106includes at least a spring-loaded (or otherwise biased) lug108and a retainer110. Although the term “spring-loaded” is used throughout the application, and springs are shown in the drawings, it should be noted that other types of biasing mechanisms may be used to bias the lug(s)108and/or the retainer110in given directions. For example, instead of spring(s), one or more hydraulic cylinders or other such features may be used to bias the lug108(or the retainer110) in a given direction. The spring-loaded lug108is configured to be transitioned between a first position in which the lug108protrudes in a radially inward direction from the inner circumferential surface112of the bore of the wear bushing body102(as shown inFIG.1B) and a second position in which the lug108is retracted into the corresponding cavity104of the wear bushing body102. The retainer110is configured to retain the spring-loaded lug108in the second (i.e., retracted) position.

Each lug cartridge106may further include a housing114holding the spring-loaded lug108and the retainer110. The housing114has an opening116formed therein such that the spring-loaded lug108, in its first (protruding) position extends outward from the opening116of the housing114. As shown, each lug cartridge106may have an elongated shape (e.g., having a length that is greater than a width of the housing114). The lug cartridges106may each be positioned such that a long side of the lug cartridge106is substantially (e.g., less than 5 degrees from) parallel to a longitudinal axis118of the wear bushing body102. In addition, the lug cartridge106may include a plate120(or plate surface of the housing) on a side of the housing114opposite the opening116. The plate120may be separate from and coupled to the housing114, or integral with the rest of the housing114. The plate120may secure the lug cartridge106to the wear bushing body102. In particular, the plate120may be used to form a connection between the lug cartridge106and the wear bushing body102. For example, as shown, the plate120may be disposed over and coupled to an outer surface (e.g., a recess formed in the outer surface)122of the wear bushing body102via one or more fastening mechanisms124(e.g., bolts (as shown), screws, welds, or others) to secure the lug cartridge106to the wear bushing body102. In other embodiments, the lug cartridge106may be secured to the wear bushing body102by other mechanisms such as, for example, a snap fit, an interference fit, and/or fastening mechanisms extending laterally from the lug cartridge106to engage the wear bushing body102. The lug cartridges106may each be easily removed from the wear bushing body102at a desired time and replaced with a new component, for example, if the lug has experienced significant wear during its prior use.

Each lug cartridge106may include a reset opening126therein that enables access to an inside of the lug cartridge106(e.g., inside of the housing114). As shown, the reset opening126may be formed in the plate120. In other embodiments, the reset opening126may be formed in other parts of the lug cartridge106. The reset opening126may be accessible from outside an outer circumferential surface128of the wear bushing body102. This enables for simple resetting of the lug cartridge106upon the wear bushing100being retrieved to a surface location. Resetting the lug cartridge106involves resetting the spring-loaded lug108from the second (retracted) position back to the first (extended) position. As described in more detail below, the retainer110of each lug cartridge106may include an engagement feature configured to interface with a tool received through the reset opening126to release the spring-loaded lug108from the second position back to the first position. As such, the wear bushing102may be retrieved to a surface location, and the spring-loaded lug108reset without removing the lug cartridge106from the wear bushing body102.

Further details regarding the possible structure and function of individual lug cartridges106are provided below with reference toFIGS.2A-2E.

In addition to the lug cartridge(s)106, the wear bushing100may include one or more spring-loaded pins130, which may be spring-loaded shear pin assemblies. The wear bushing body102may include a number (e.g., eight) of threaded pockets132spaced around the outer circumferential surface128of the wear bushing body102that are designed to accommodate the spring-loaded pins130. The spring-loaded pins130are designed to interface with an inner circumferential surface of a well component. For example, the spring-loaded pins130may be designed to lock into corresponding recesses formed in a casing hanger or a landing shoulder within a wellhead, as will be understood by a person of ordinary skill in the art.

The wear bushing body102may include a number (e.g., eight) shear pin holes134formed therethrough. The shear pin holes134may be designed to accommodate shear components136(e.g., shear pins). As illustrated, the shear pin holes134may be arranged in pairs, the shear pin holes134in each pair being separated in a direction parallel to the longitudinal axis118. The different pairs of shear pin holes134may be spaced around the outer circumferential surface128of the wear bushing body102. However, it should be noted that other arrangements of one or more shear pin holes134through the wear bushing body102may be used in other embodiments.

The wear bushing body102may include a groove138formed along the inner circumferential surface112of the wear bushing body102. As described in more detail below, the groove138may be configured to receive an expending lock ring from a retrieval adapter used to retrieve the wear bushing100from the well component in which it is landed to the surface. As illustrated, the wear bushing body102may include a number of pin holes140extending through the wear bushing body102at circumferentially spaced positions aligned with the groove138. These pin holes140may facilitate the disconnection of the wear bushing100from a retrieval adapter. For example, pins or other components may be inserted into these pin holes140to radially collapse the lock ring of the retrieval adapter so that the lock ring disengages from the groove138of the wear bushing100.

Although not shown, in some embodiments the multiple lugs108positioned circumferentially along the wear bushing body102may be connected to each other to enable consistent, uniform, and/or controlled transitioning of the lugs108between their first (expanded) positions and their second (retracted) positions. For example, a split ring may be coupled to each of the lugs108, either along a radially inner surface of the wear bushing body102or on a radially outer surface of the wear bushing body102. If the lugs108are connected to a split ring on the outside of the wear bushing body102, the plates120may have openings formed therein to enable a connection point between the lugs108and a split ring. In certain embodiments, the multiple lugs108may be integral with such a split ring. For example, the lugs108may constitute a split ring having multiple, thicker dog segments of the ring with thinner ring segments interspersed between the dog segments.

FIGS.2A-2Eillustrate a single lug cartridge106in more detail. The lug cartridge106may be a modular component that can be assembled prior to installation on the wear bushing body (e.g.,102ofFIGS.1A and1B), or any other equipment where lugs can be used to run but then are retracted to avoid drifting obstructions. As illustrated, the lug cartridge106includes the housing114with the opening116formed therein. The lug cartridge106also includes the spring-loaded lug108disposed in the housing114. The spring-loaded lug108is configured to be transitioned between a first position (shown inFIG.2D) in which the lug108extends outward from the opening116in the housing114and a second position (shown inFIG.2E) in which the lug108is retained substantially within the housing114. As illustrated, the spring-loaded lug108may be biased toward the first (extended) position (e.g., via one or more springs200). The lug cartridge106also includes the retainer110disposed in the housing114. As shown inFIG.2E, the retainer110is configured to retain the lug108in the second position. The retainer110is configured to be automatically actuated into position to retain the spring-loaded lug108in response to movement of the lug108from the first position (FIG.2D) to the second position (FIG.2E). The disclosed lug cartridge106utilizes a spring-loaded lug108that, when actuated by a running tool stem, will collapse, and which will automatically be retained by the retainer110. This exposes the bore of the wear bushing so that objects will not catch on the lugs108.

In the illustrated embodiment, the retainer110is a spring-loaded retainer110. However, other types of retainers may be used in other embodiments. The spring-loaded retainer110may be biased in a direction toward the spring-loaded lug108. As shown, the spring-loaded lug108may be biased in a direction perpendicular to the direction in which the spring-loaded retainer110is biased.

As illustrated, the housing114may have a generally rectangular prism shape with a large opening202on a side opposite the opening116for the lug108. The housing114may reduce the likelihood of rotation of the lug108during wear bushing setting operations. The larger opening202may facilitate easy construction of the lug cartridge106. As illustrated, the housing114may have an elongated shape, with the spring(s)200biasing the spring-loaded lug108oriented substantially perpendicular to a long side of the housing114and the spring(s)214biasing the spring-loaded retainer110oriented substantially parallel to the long side of the housing114. The housing114may include one or more guide features204(e.g., protrusions (as shown), grooves, etc.) formed therein to guide movement of the spring-loaded lug108in a desired direction (e.g., aligned with the springs200). The spring-loaded lug108may have complementary shaped features206(e.g., grooves (as shown), protrusions, etc.) formed therein to move along the guide features204of the housing114.

The spring-loaded lug108may be a solid piece of machined metal (or other material) coupled to the spring(s)200. As shown, the spring-loaded lug108may include a base portion108A and a lug portion108B, the lug portion108B being the part of the spring-loaded lug108that can be extended from the opening116to engage component(s) outside of the housing114. The base portion108A may be sized larger than the lug portion108B (and the opening116) so as to maintain the spring-loaded lug108at least partially inside the housing114at all times. The spring(s)200used to bias the lug108may extend partially into the base portion108A of the lug108. The base portion108A may have the complementary shaped features206formed therein. The base portion108A may have a cutout207formed therein on a side facing the retainer110so as to guide and/or receive the retainer110into engagement with the base portion108A when the spring-loaded lug108is in the second position. The lug portion108B may have generally straight walls208extending in a direction of movement of the lug portion108B in and out of the housing114. The lug portion108B may have a chamfer210formed between at least one of the straight walls208and a furthest extending end212of the lug portion108B.

The spring-loaded retainer110may be a solid piece of machined metal (or other material) coupled to one or more springs214. The spring-loaded retainer110may include a lip216protruding in a direction toward the lug108and on a side of the retainer110corresponding to a side of the lug portion108B of the lug108. As shown inFIG.2A, this lip216may directly engage a side of the base portion108A of the lug108when the lug is in the extended first position. As the lug108is collapsed toward the second position, the spring(s)214bias the retainer110in a direction toward the lug108such that the lip216slides beneath the base portion108A and a shoulder218of the retainer110abuts the base portion108A. The spring force on the retainer110is then able to retain the shoulder218against the lug108, thereby retaining the lug108in the retracted position. When the lug108is in the first position, the lip216of the retainer110may be held within the cutout207of the base portion108A of the lug108. When the lug108is in the second position, the shoulder218of the retainer110may be held within the cutout207of the base portion108A of the lug108.

The lug cartridge106may also include a retainer receiver body220located in the housing114. The retainer receiver body220may support and guide the spring-loaded retainer110within the larger housing114. As illustrated, the retainer receiver body220may be a solid piece of metal (or other material) sized to fit snugly within the housing114and having a smaller guide cutout222formed therein to hold the spring(s)214and guide movement of the spring-loaded retainer110toward or away from the spring-loaded lug108. As shown inFIGS.2D and2E, the guide cutout222may also receive a complementary shaped extension224of the plate120extending into the housing114. When the lug cartridge106is fully assembled and the spring-loaded lug108is in the first (extended) position, which may be used during run in of the wear bushing ofFIGS.1A and1B, there is secure contact between the housing114, the lug108, the retainer110, and the retainer receiver body220. This secure connection between all the components of the lug cartridge106help to effectively distribute forces on the lug portion108B through the lug cartridge106and into the rest of the wear bushing as needed during operations of running in and setting the wear bushing.

As discussed above, the lug cartridge106may have a plate120disposed over the housing114on a side of the housing114opposite the opening116. The plate120may be coupled to the housing114and may include attachment features (e.g., bolt holes230) for attaching the lug cartridge106to a surface (e.g., recessed surface of the wear bushing body102ofFIG.1A). As illustrated, the plate120may be coupled to the housing114via screws232. The screws232coupling the plate120to the housing114may be oriented substantially parallel to the one or more springs200biasing the spring-loaded lug108. The screws232may provide the ability to relieve potential energy in the lug springs200for safe disassembly of the lug cartridge106.

As discussed above, the lug cartridge106may include a reset opening126that enables access to an inside of the housing114. As shown, the reset opening126may be formed through the plate120. In addition to the reset opening126, the lug cartridge106may include an engagement feature234on the spring-loaded retainer110. The engagement feature234is configured to interface with a tool received through the reset opening126to release the spring-loaded lug108from the second position back to the first position. The engagement feature234may include a groove (as shown), bump, detent, protrusion, ridge, textured surface, lever, or any other mechanical feature that can be engaged by a tool inserted through the reset opening126. For example, a screw driver or similar tool may be inserted through the reset opening126, positioned in the grooved engagement feature234on the retainer110, and used to pull the retainer110in a direction away from the lug108so that the spring(s)200can return the lug108to its extended position. This allows for quick resetting of the lug cartridge106so that it can be run again with the wear bushing and to remove potential energy in the spring(s)200. The design of the lug cartridge106enables the lug108to be reset quickly at the surface without remove the lug cartridge106from the wear bushing.

Having described the general structure of the wear bushing100(with reference toFIGS.1A and1B) and its lug cartridge(s)106(with reference toFIGS.2A-2E), the processes of running, setting and selectively retrieving the wear bushing100will not be described.FIGS.3A-3Fillustrate a system300including a running tool302and the wear bushing100. The wear bushing100is configured to be set in a well component (e.g., wellhead, casing hanger, etc.) via the running tool302. Although the well component is not shown in the figures, the relative locations and interactions of the wear bushing100with respect to the well component will be described. The well component may be any desired well component having a bore that needs to be protected by a wear bushing. The wear bushing100ofFIGS.3A-3Fmay be the same or a similar wear bushing as described above with reference toFIGS.1A-2E.FIGS.3A-3Fillustrate the process for running and setting the wear bushing100when the wear bushing100is intended to be left in the well component.

FIG.3Aillustrates the system300in a running configuration. The running tool302is installed within the wear bushing100such that the extended lug(s)108of the lug cartridge(s)106are located within corresponding J-slot(s)304on an outer surface of the running tool302.FIG.3Dshows a more detailed view of the J-slots304of the running tool302. To install the running tool302within the wear bushing100in the running configuration (ofFIG.3A), the running tool302may first be lowered down through the wear bushing100with elongated slots306of the running tool302vertically aligned with the extended lug(s)108. Once the extended lug(s)108are captured in the elongated slots306, the running tool302may be lowered further and then rotated to the right to move the lug(s)108into the J-slot(s)304. With the lug(s)108in the J-slot(s)304, the running tool302may then be lowered slowly until shear pin holes308on a radially outer surface of the running tool302are aligned with the shear pin holes134of the wear bushing100. At this point, shear components136(e.g., rolled shear pins) are inserted through the aligned shear pin holes134and308. The shear component(s)136are therefore disposed between and coupling the wear bushing100to the running tool302to secure the wear bushing100to the running tool302in the running configuration. Once installed in the running configuration ofFIG.3A, the entire system300may be picked up and slowly lowered downhole. As such, the process for setting the wear bushing100includes lowering the wear bushing toward and/or through a well component via the running tool302.

The process for setting the wear bushing100may then include landing the wear bushing100in the well component. As the assembly lands, a shoulder on the wear bushing100may land out on a landing profile in the well component. Upon landing on the well component, or in order to land on the well component, the spring-loaded pins130may lock into corresponding recesses formed in a casing hanger or a landing shoulder within a wellhead. As such, the process may include connecting the wear bushing100to a radially inner portion of the well component upon landing the wear bushing100. After landing the wear bushing100, the process includes disengaging the running tool302from the wear bushing body102. For example, upon landing the wear bushing100and/or connecting the wear bushing100to the well component, the process may include setting weight down on the running tool302to shear out the shear components136(shown inFIG.3B), causing the running tool302to drop (e.g., about 2 inches) relative to the wear bushing100.

After disengaging the running tool302from the wear bushing body102, the process may include lifting the running tool302relative to the wear bushing100to apply an overpull to the wear bushing100via interaction between a surface310on the running tool302and the spring-loaded lug108. This overpull step is shown inFIG.3C. The surface310on the running tool may include a lower surface of the J-slot304in which the lug108is located. Applying the overpull to the wear bushing100allows the system to verify proper engagement of the wear bushing100with the well component before releasing the wear bushing entirely from the running tool302. If a predetermined amount of overpull (e.g., 20,000 lbs) is applied by the running tool302and the wear bushing100does not move from the well component, this verifies the connection. Upon completion of the overpull, the running tool302may be lowered again so that the spring-loaded lug108is at a desired location within the J-slot304for rotation.

The process for setting the wear bushing100may then include rotating the running tool302(e.g., to the left) relative to the wear bushing100to build minor torque and move the lug108back into the elongated slot306, as shown inFIG.3D. With the lug108in the elongated slot306, the spring-loaded lug108is in line with a ramped outer surface312of the running tool302at an upper end of the elongated slot306. The ramped outer surface312is configured to interface with the spring-loaded lug108to move the spring-loaded lug from its first (extended) position to its second (retracted) position.

The process may then include dropping weight on the running tool302again to begin to collapse the lug(s)108. Each lug108may be aligned with a ramped outer surface312at the top of the corresponding elongated slot306. Moving the running tool302downward relative to the wear bushing100, as shown inFIG.3E, moves the ramped outer surface(s)312of the running tool302against the lug(s)108to collapse the spring-loaded lug(s)108into their retracted position in the lug cartridge(s)106. As the lug(s)108are collapsed and the running tool302continues to move downward, this releases the running tool302from the wear bushing100.

After collapsing the lug(s)108, the process may include lowering the running tool302through the wear bushing100while the spring-loaded lug(s)108are retracted, as shown inFIG.3F. The retainer(s)110in the lug cartridge(s)106may maintain the spring-loaded lug(s)108in the retracted position, as described above. With the lug(s)108retracted, a minimum inner diameter of the wear bushing100(including the retracted lug(s)108) may be larger than an outer diameter of the running tool302, thus enabling the running tool302to continue its descent as the drilling string on which the running tool302is positioned continues to drill ahead. At a later time, it may be desirable to remove the drilling string (including the running tool302) from the well system. As such, the running tool302and drill string may be removed upward through the wear bushing100without removing the wear bushing100and while the spring-loaded lug(s)108remain retracted.

FIG.4illustrates a wear bushing retrieval adapter400that may be used to retrieve the wear bushing (e.g.,100ofFIGS.1A-3F) to the rig floor. The retrieval adapter400is configured to be removably coupled to a running tool (e.g.,302ofFIGS.3A-3F) and used to selectively retrieve the wear bushing100. The retrieval adapter400may be generally cylindrical and sized to be positioned around an upper portion of the running tool and to fill an annular space between the upper portion of the running tool and the wear bushing, as shown inFIG.5. The retrieval adapter400may include a lock ring402(e.g., a split lock ring) on a radially external surface404thereof. The lock ring402is biased in a radially outward direction to be received into the groove (e.g.,138ofFIGS.1A and1B) of the wear bushing. The lock ring402is configured to directly engage the wear bushing to facilitate retrieval of the wear bushing. The retrieval adapter400may include shear pin holes406and J-slots408for attaching the retrieval adapter400to the running tool.

FIG.5shows a system500including the wear bushing100and the running tool302with the retrieval adapter400installed thereon. The running tool302and retrieval adapter400ofFIG.5may be used to selectively disengage the wear bushing100from a well component and retrieve the wear bushing100to a surface location (e.g., for reuse).

First the retrieval adapter400may be installed on the running tool302. This may involve engaging lugs (not shown) on the running tool302with the retrieval adapter J-slots (e.g.,408ofFIG.4). In addition, multiple shear components502may be positioned in the shear pin holes406and upper shear pin holes503of the running tool302to connect the retrieval adapter400to the running tool302. The running tool302and adapter400together are picked up from the connection at the top of the running tool302and slowly landed in the well component. As the assembly lands, a shoulder504on the retrieval adapter400will land out on a landing profile506of the wear bushing100in the well component. The lock ring402on the retrieval adapter400may then snap and engage into the groove138of the wear bushing100, thereby connecting the retrieval adapter400to the wear bushing100(as shown inFIG.5). The process may include setting weight down on the running tool302to shear the shear components502between the retrieval adapter400and the running tool302. Then, rotating the running tool302(e.g., to the left) may release the running tool302from the retrieval adapter400/wear bushing100.

The process may include further lowering the running tool302through the retrieval adapter400and the wear bushing100. This enables the running tool302to continue its descent as the drilling string on which the running tool302is positioned continues to drill ahead. At a later time, it may be desirable to remove the drilling string (including the running tool302) and the wear bushing100from the well system. As such, the running tool302and drill string may be pulled straight upward through the wear bushing100and the retrieval adapter400until the running tool302tags the retrieval adapter400. While applying tension in an overhead crane, the running tool302may be rotated (e.g., to the right) until the running tool302can be pulled into the J-slots (e.g.,408ofFIG.4) of the retrieval adapter400and then locked to the retrieval adapter400once again. At this point, the running tool302may be carefully lifted, carrying with it the retrieval adapter400and the wear bushing100, to retrieve the wear bushing100from the well component.

While the above description discusses using a retrieval adapter400to remove the wear bushing100from its downhole position, it should be noted that other methods may be used for removal of the wear bushing100. For example, in some embodiments, the lug cartridge(s)106may be configured with a mechanism by which the lug(s)108can be selectively moved from their second (retracted) position back to their first (expanded) position. This may enable the running tool302alone (without a retrieval adapter) to be used to retrieve the wear bushing100to the surface. To that end, the running tool302may include some type of actuator used to selectively actuate the lug(s)108to release them from their retracted position(s) back to their expanded position(s). In embodiments where the lug(s)108are connected via a split ring, the actuator on the running tool302may be configured to interface with the split ring to move the lug(s)108back to their expanded positions.

With reference to all figures contained herein, in certain embodiments, the process of inserting a wear bushing100equipped with a lug cartridge106into a wellhead housing may comprise one or more of the following steps: (1) insert a running tool302and wear bushing100into a wellhead housing; (2) land the wear bushing100on the wellhead housing, set the weight, and apply about 20,000 to 60,000 pounds of weight, thereby moving the assembly downward roughly one to three inches; (3) pickup and apply about 20,000 pounds of tensile force via a pull in the opposite direction, and verify proper engagement to the wellhead; (4) rotate the wear bushing100and build torque; (5) drop the weight and begin to collapse one or more lugs108; (6) continue to collapse the one or more lugs108; and (7) drill ahead. Any one or more of these steps may be used alone or in combination with any other steps, including steps not explicitly recited above. Though several wear bushing configurations may be practiced with several methods of insertion without departing from the scope of the present disclosure, in certain embodiments, one or more figures presented herein may correspond to one or more steps of the process listed above. The example embodiments listed above are purely exemplary and non-limiting. Moreover, it is within the ability of one skilled in the art and with the benefit of the present disclosure to select an appropriate insertion process and appropriate corresponding wear bushing configurations.

In certain embodiments, a lug cartridge106as disclosed herein may be used on a casing hanger seal assembly running tool (not shown), tubing hanger running tool (not shown), lockdown sleeve running tool (not shown), seal assembly running tool (not shown), other running tool, BOP test tool (not shown), other test tool, emergency retrieval tool (not shown), other retrieval tool, cam-activated drilling ahead tool (not shown), other tool, or any combination thereof. A lug cartridge106may be equipped on the internal or external diameters of tools or equipment in a well. A lug cartridge106may be used to apply torque for adjustment, setting, and/or releasing of tools and/or equipment.

In certain embodiments, the lug cartridge106may be assembled as a standalone assembly that can be assembled into another assembly, such as a wear bushing100. In certain embodiments, the modular nature and removability of the lug cartridge106may increase efficiency at a wellsite. In certain embodiments, damaged lugs108may be removed and replaced, either in the same lug cartridge106or a new lug cartridge106.

Certain Illustrative Embodiments (“Embodiments”) of the present disclosure are listed below.

Embodiment 1: A wear bushing, including: a wear bushing body having one or more cavities formed therein; and one or more lug cartridges each disposed within a corresponding one of the cavities in the wear bushing body, each lug cartridge including: a biased lug configured to be transitioned between a first position in which the lug protrudes in a radially inward direction from an inner diameter of the wear bushing body and a second position in which the lug is retracted into the corresponding cavity of the wear bushing body; and a retainer configured to retain the biased lug in the second position.

Embodiment 1A: The assembly of Embodiment 1, wherein the biased lug is a spring-loaded lug.

Embodiment 2: The assembly of Embodiment 1, wherein the retainer is a biased retainer.

Embodiment 2A: The assembly of Embodiment 2, wherein the biased retainer is a spring-loaded retainer.

Embodiment 3: The assembly of Embodiment 1, wherein the wear bushing body is substantially cylindrical.

Embodiment 4: The assembly of Embodiment 1, wherein each lug cartridge further includes a housing holding the biased lug and the retainer, the housing having an opening formed therein, wherein the biased lug in the first position extends outward from the opening of the housing.

Embodiment 5: The assembly of Embodiment 1, wherein: each lug cartridge further includes a reset opening therein that enables access to an inside of the lug cartridge; and the retainer of each lug cartridge has an engagement feature configured to interface with a tool received through the reset opening to release the biased lug from the second position back to the first position.

Embodiment 6: The assembly of Embodiment 5, wherein the reset opening is accessible from outside an outer circumferential surface of the wear bushing body.

Embodiment 7: The assembly of Embodiment 1, further including one or more biased pins disposed along an outer circumferential surface of the wear bushing body.

Embodiment 7A: The assembly of Embodiment 7, wherein the one or more biased pins are one or more spring-loaded pins.

Embodiment 8: The assembly of Embodiment 1, wherein the wear bushing body includes a groove formed along an inner circumferential surface thereof.

Embodiment 9: The assembly of Embodiment 1, wherein the wear bushing body includes one or more shear pin holes formed therethrough.

Embodiment 10: The assembly of Embodiment 1, wherein the one or more lug cartridges include a plurality of lug cartridges disposed in cavities located substantially equidistant from each other about a circumference of the wear bushing body.

Embodiment 11: The assembly of Embodiment 1, wherein each lug cartridge has an elongated shape, and wherein each lug cartridge is positioned such that a long side of the lug cartridge is substantially parallel to a longitudinal axis of the wear bushing body.

Embodiment 11A: The assembly of Embodiment 1, wherein each lug cartridge is removable from the wear bushing body and replaceable with another lug cartridge.

Embodiment 12: A lug cartridge, including: a housing with an opening formed therein; a biased lug disposed in the housing and configured to be transitioned between a first position in which the lug extends outward from the opening in the housing and a second position in which the lug is retained substantially within the housing, the biased lug being biased toward the first position; and a biased retainer disposed in the housing and configured to retain the lug in the second position, wherein the retainer is biased in a direction toward the biased lug.

Embodiment 13: The lug cartridge of Embodiment 12, wherein the retainer is configured to be automatically actuated into position to retain the biased lug in response to movement of the lug from the first position to the second position.

Embodiment 14: The lug cartridge of Embodiment 12, wherein the biased lug is biased in a direction perpendicular to a direction in which the biased retainer is biased.

Embodiment 15: The lug cartridge of Embodiment 12, further including: a reset opening that enables access to an inside of the housing; and an engagement feature on the biased retainer configured to interface with a tool received through the reset opening to release the biased lug from the second position back to the first position.

Embodiment 16: The lug cartridge of Embodiment 12, further including a plate disposed over the housing on a side of the housing opposite the opening, the plate being coupled to the housing, wherein the plate includes attachment features for attaching the lug cartridge assembly to a surface.

Embodiment 17: The lug cartridge of Embodiment 16, further including screws coupling the plate to the housing, the screws being oriented substantially parallel to one or more springs biasing the biased lug.

Embodiment 18: The lug cartridge of Embodiment 12, wherein: the housing has an elongated shape, one or more springs biasing the biased lug are oriented substantially perpendicular to a long side of the housing, and one or more springs biasing the biased retainer are oriented substantially parallel to the long side of the housing.

Embodiment 19: A system, including: a running tool; and a wear bushing configured to be positioned and set in a well component via the running tool, wherein the wear bushing includes: a wear bushing body having one or more cavities formed therein; and one or more lug cartridges each disposed within a corresponding one of the cavities in the wear bushing body, each lug cartridge including: a biased lug configured to be transitioned between a first position in which the lug protrudes in a radially inward direction from an inner diameter of the wear bushing body and a second position in which the lug is retracted into the corresponding cavity of the wear bushing body; and a retainer configured to retain the biased lug in the second position.

Embodiment 20: The system of Embodiment 19, wherein the running tool includes a ramped outer surface configured to interface with the biased lug to move the biased lug from the first position to the second position.

Embodiment 21: The system of Embodiment 19, further including one or more shear components disposed between and coupling the wear bushing to the running tool.

Embodiment 22: The system of Embodiment 19, wherein an inner diameter of the wear bushing with the one or more biased lugs in the second position is larger than an outer circumferential surface of the running tool.

Embodiment 23: The system of Embodiment 19, further including a retrieval adapter configured to be removably coupled to the running tool and used to selectively retrieve the wear bushing.

Embodiment 24: The system of Embodiment 23, wherein the retrieval adapter is configured to be coupled to the running tool via one or more shear components.

Embodiment 25: The system of Embodiment 23, wherein the retrieval adapter includes a lock ring biased in a radially outward direction, and the wear bushing body includes a groove formed in its inner circumferential surface to receive the lock ring.

Embodiment 25A: The system of Embodiment 19, wherein each lug cartridge is configured to be selectively actuated to transition the biased lug from the second position back to the first position while the wear bushing is disposed in the well component.

Embodiment 26: A method, including: lowering, via a running tool, a wear bushing and landing the wear bushing in a well component, the wear bushing including: a cylindrical body having a cavity formed therein; and a lug cartridge disposed within the cavity, the lug cartridge having a biased lug and a retainer; disengaging the running tool from the body of the wear bushing; collapsing the biased lug into a retracted position within the lug cartridge via movement of a ramped outer surface of the running tool against the lug; and maintaining the biased lug in the retracted position via the retainer.

Embodiment 27: The method of Embodiment 26, further including connecting the wear bushing to a radially inner portion of the well component upon landing the wear bushing.

Embodiment 28: The method of Embodiment 27, further including, after disengaging the running tool from the body of the wear bushing: lifting the running tool relative to the wear bushing to apply an overpull to the wear bushing via interaction between a surface on the running tool and the biased lug; and rotating the running tool relative to the wear bushing to move the ramped outer surface in line with the biased lug.

Embodiment 29: The method of Embodiment 26, further including lowering the running tool through the wear bushing while the biased lug is retracted.

Embodiment 30: The method of Embodiment 26, further including coupling a retrieval adapter to the running tool and retrieving the wear bushing from the well component via the retrieval adapter.

Embodiment 31: The method of Embodiment 30, further including expanding a lock ring on the retrieval adapter in a radially outward direction into a groove formed along an inner circumferential surface of the wear bushing body to couple the wear bushing to the retrieval adapter.

Embodiment 32: The method of Embodiment 26, further including retrieving the wear bushing to a surface location, and resetting the biased lug from the second position to the first position without removing the lug cartridge from the wear bushing body.

Embodiments illustrated under any heading or in any portion of the disclosure may be combined with embodiments illustrated under the same or any other heading or other portion of the disclosure unless otherwise indicated herein or otherwise clearly contradicted by context.

Numerous modifications, alterations, and changes to the described embodiments are possible without departing from the scope of the present invention defined in the claims. It is intended that the present invention not be limited to the described embodiments, but that it has the full scope defined by the language of the following claims, and equivalents thereof.

While various embodiments of wear bushings, lug cartridges, systems, and methods were provided in the foregoing description, those skilled in the art may make modifications and alterations to these aspects without departing from the scope and spirit of the invention. For example, it is to be understood that this disclosure contemplates that, to the extent possible, one or more features of any aspect can be combined with one or more features of any other aspect. Accordingly, the foregoing description is intended to be illustrative rather than restrictive. The invention described hereinabove is defined by the appended claims, and all changes to the invention that fall within the meaning and the range of equivalency of the claims are to be embraced within their scope.