Abstract:
Hangers and related tools which actuate without fluid or mechanical communication between the interior of the tool and its exterior are disclosed. Devices as disclosed herein may include a piston for applying actuating force based on the fluid pressure outside of the tool. The piston may be fixed to a tubing wall or other body of the tool with a shear element to prevent the tool from actuating until a certain pressure is applied to piston, such as by the static pressure of wellbore fluid at a certain depth, by pressure applied to the annulus from surface, or a combination thereof. Actuation of the tool may cause latches to expand outwardly to engage a latch receptacle fixed in or along the host tubing or such actuation may lead to other hanging members, such as slips, to engage the host tubing wall in order to suspend the hanging string therein.

Description:
CROSS REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims the benefit of U.S. Provisional Patent Application Ser. No. 62/343,470 titled “Tubular Connector Device and Methods”, filed on May 31, 2016, the entirety of which is incorporated herein by reference. 
     
    
     STATEMENT REGARDING FEDERALLY SPONSORED RESEARCH OR DEVELOPMENT 
       [0002]    Not applicable. 
       BACKGROUND 
       [0003]    The present disclosure relates to apparatuses, systems and methods for suspending tubing in a well or wellbore. Certain embodiments according to the present disclosure may permit actuation of the apparatus without applying fluid pressure or fluid flow, may permit systems or apparatuses to operate without teeth or other elements that bite into the casing wall, may set automatically upon reaching the desired location, combinations of certain or all of the foregoing, and/or provide other benefits. 
         [0004]    Devices for suspending tubing, such as a tubing string, within sections of a well or wellbore are known in the art. Such devices utilize slips with teeth, buttons, or other features to penetrate the wall of the wellbore, which may be larger diameter tubing (host tubing), surrounding the device. Longitudinal force may be applied in order to move the slips up a cone or other angular surface to force the slips radially outward and create such penetration. Such devices may be identified as liner hangers, liner top packers, permanent packers, or other nomenclature, and are intended to be part of a sealed fluid flowpath from the surface, or other selected location, down to lower regions of the well. 
         [0005]    Actuation of many such prior art devices requires communication of force, such as fluid pressure, from the interior of the device in order to generate longitudinal movement of the slips, or of the cone in relation to the slips, on the outside of the device. In other words, the walls of such devices have ports, slots, or other penetrations to allow communication of setting forces. The penetrations are typically in fluid isolation from the device&#39;s interior flowpath and/or exterior through the use of o-rings or other sealing elements. Seals may fail, however, compromising the fluid integrity of the interior flowpath and in some cases preventing the proper function of the devices. Prior art devices also comprise slips that penetrate into, causing at least some damage to, the wall of tubing into which the device is suspended. 
         [0006]    Further, prior art devices require a separate running tool so that the slips and other components may be reliably set at the desired time and in the desired order. The need for such running tools requires a trip out to remove the setting tool and an additional run into the well to connect treating or production tubing with the hanger string. Eliminating the need for such running tools, may be simplify and speed up installation, thereby reducing costs. 
       BRIEF SUMMARY 
       [0007]    Embodiments of the present disclosure include hanger devices which do not have penetrations through the device wall because such devices do not require communication of force, such as fluid pressure or mechanical force, through the wall of the device in order to actuate. Embodiments according to the disclosure herein may actuate and set based in part on the distance below surface and/or location of the hanger within the host tubing. Still further embodiments may eliminate the use of teeth or other devices that penetrate the wall of the tubing into which the device is set. 
         [0008]    Certain embodiments of the present disclosure may comprise a collet with latches that, in the actuated or set state, engage both a hanging shoulder fixed to the hanger string (the string to be placed and hung off within the host string) and a receiving or engagement shoulder fixed to or along the host string. In some embodiments, the hanging shoulder may have a diameter that will pass through the receiving shoulder in the absence of the latches. 
         [0009]    Embodiments of the present disclosure may be installed in the host tubing without the use of a running tool which must be removed from the well. Conventional tubing connections at the top of the hangers may be used to connect the hanger in a string extending to the surface. Such connections may be threaded or other types of connections. 
         [0010]    Embodiment devices may further comprise an actuating assembly to provide force for moving the hanging elements outward, such as over the angular shoulder of cone and into engagement with the host tubing at, or after, a selected point in the well. Some actuating assemblies may include a piston to push the hanging elements up a cone based on the pressure of the fluid surrounding the piston. Shear pins may be used to hold the piston in its initial position until the surrounding fluid pressure applies sufficient force to the piston to overcome the shear value of the pins. Shear values may be selected with consideration for wellbore fluid density and piston surface area so that the piston will not apply force to actuate the tool until the tool reaches a certain depth or until external pressure is added to the annulus between the host string and the hanging string. 
         [0011]    Embodiments according to the present disclosure may further a coupling for placement along the host tubing string. Such coupling may have a latch receptacle section coordinated with embodiment hangers according to the disclosure herein such that positioning of the latches adjacent to the coupling allows the hanger to fully set and the latches to engage with the coupling, suspending the hanger string in the host string. 
     
    
     
       BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS 
         [0012]      FIGS. 1A and 1B  are a sectional elevation of an embodiment hanger according to the present disclosure. 
           [0013]      FIGS. 2A and 2B  are a sectional elevation of an embodiment hanger according to the present disclosure in a set position. 
           [0014]      FIG. 3  is a partial sectional elevation of the hanger in  FIGS. 1A and 1B  more fully disclosing the region adjacent the latch section of the collet, the top sub, and the cone. 
           [0015]      FIG. 4  is a partial sectional elevation of the hanger in  FIGS. 2A and 2B  more fully disclosing the region adjacent the latch section of the collet, the top sub, and the cone with the hanger in a set position. 
           [0016]      FIG. 5  is a partial sectional elevation of an embodiment hanger showing the latch section of the collet inside a section of a host string. 
           [0017]      FIG. 6  is a partial sectional elevation of an embodiment hanger showing the latch section of the collet inside the engagement portion along a host string. 
           [0018]      FIG. 7  is a sectional elevation of one embodiment coupling for connecting adjacent tubing of a host string. 
       
    
    
     DETAILED DESCRIPTION 
       [0019]      FIGS. 1A and 1B  illustrate one embodiment according to the present disclosure in the unactuated or run in position. The illustrated embodiment comprises tubing  180  with a hanging section and an actuation section arranged on its outer surface. The hanging section comprises a top sub  110 , the top sub  110  having a hanging shoulder  112 , cone  120  with angular surface  122  and collet  130  having a plurality of latches  132  positioned adjacent to angular surface  122 . 
         [0020]    The actuation section may comprise a spring element  140 , a piston  160  and a lock such as lock ring  152  in lock housing  150 . Spring assembly  140  may be adjacent to and engage collet  130 . Spring assembly  140  may comprise a spring element  144  and end rings  142 ,  146 . End rings  142 ,  146  may be attached to the ends of spring element  144  and may engage a groove  182 , such as in tubing  180 , such that spring assembly  140  resists rotation. 
         [0021]    Piston  160  slidably engages tubing  180 . Seal stacks  166 ,  168  prevent fluid communication between the piston  160  and the tubing  180  and define chamber  164 . Chamber  164  has a fluid pressure therein which may be determined during assembly of the tool. Certain embodiment tools may have a valve or other device to permit adjustment of the fluid content or fluid pressure of chamber  164  after assembly. Lock housing  150  slidably engages tubing  180  and contacts piston  160  adjacent to seal stack  166 . Lock housing  150  may be connected to tubing  180  by shear pins  154  to prevent premature movement of lock housing  150  and piston  160 . Lock ring  152  is in a groove in lock housing  150  such that movement of lock housing  150  moves lock ring  152  therewith. 
         [0022]    Gauge ring  170  is connected to tubing  180  adjacent to piston  160 . The outer diameter of gauge ring  170  is greater than the outer diameter of collet  130 , end rings  142 ,  146 , spring  144 , lock housing  150  and piston  160 . Top sub  110  has outer diameter  111  similar to the outer diameter of gauge ring  170 . Configured as described, top sub  110  and gauge ring  170  may reduce the contact between the moveable components—collet  130 , spring assembly  140 , lock housing  150  and piston  160 —and the inner wall of tubing, including the host tubing, through which the tool is being conveyed. 
         [0023]      FIGS. 2A and 2B  show an embodiment tool in the actuated state. In the embodiment of  FIGS. 2A and 2B , piston  160  has moved such that seals  166  have moved towards stop  162 , reducing the size of chamber  164 . Such movement may occur in response to hydrostatic pressure against the end of piston  160  near seal stack  166  creating a pressure differential in comparison to the fluid in chamber  164 . When the force from the pressure differential becomes sufficiently high, shear pins  154  break, permitting movement of piston  160  and lock housing  150 . 
         [0024]    As will be appreciated, movement of the lock housing  150  will compress spring  144  of spring assembly  140 , applying longitudinal force to collet  130  through end ring  142 . Collet  130  may then slide along the outer surface of tubing  180 , forcing latches  132  outward along the angular surface  122  of cone  120 . Lock ring  152  engages teeth  184  along the outer surface of tubing  180 , holding the lock housing  150  in its actuated position and maintaining the actuation force on spring  144 . 
         [0025]    In this arrangement, it will be appreciated that spring  144  may act as a load dampener, compressing and thereby absorbing some of the force otherwise applied to collet  130  from piston  160 . The actuation section may have additional features to dampen or otherwise limit the load applied to the collet  130 . For example, the actuation section may have a stop, such as ring  162 , which in the illustrated embodiment also serves to hold seal stack  166  in place. Further, tubing  180  may have a depression  186  such that movement of seal stack  168  over depression  186  establishes fluid communication from the exterior into chamber  164 , thereby eliminating he pressure differential across piston  160 . This alleviates the hydraulic force driving piston  160 . Force to set, and hold, latches  132  onto cone  120  and top sub  110  may be maintained by the lock housing  150 —retained by engagement of lock ring  152  on teeth  184 —holding spring  144  in compression between collet  130  and lock housing  150 . 
         [0026]    Tubing  180 , may be threaded at either end for connection of the hanger to the hanger string. Other connections to tubing  180  may also be used. The hanging string, which extends to the surface, may remain in place after the latches are set against the hanging shoulder because there is no requirement to trip out of the well to remove a setting tool. In other words, for tripping purposes, tubing  180  acts like any other joint of tubing in the hanging string. 
         [0027]      FIGS. 3 and 4  are enlarged views of a portion of the latching section as indicated in  FIGS. 1A and 2A  respectively and showing the relationship of the latches  132 , cone  120 , top sub  110 , and tubing  180  of certain embodiments according to the disclosure herein. In the run-in or non-actuated position, as can be seen in  FIG. 3 , the outer surface  134  of latches  132  is radially inward of the largest diameter surface  111  of top sub  110 . Following actuation, as can be seen in  FIG. 4 , the force from the spring  144  forces latches  132  upward across angular surface  122  of cone  120  and onto the outer surface  121  of cone  120  and receiving surface  113  of top sub  110 . It will be appreciated that, in the embodiment of  FIG. 4 , top sub  110  functions as a hanging sub for transferring the weight of the hanging string through the latch and into the host string. The hanging sub may be the topmost element around tubing  180 , but locating a hanging sub as the topmost element is not required. Such movement of latches  132  causes a portion of upper face  138  of latches  132  to engage shoulder  112  of top sub  110 . Further, in the actuated position, outer surface  134  of latches  132  has a greater radius (is a greater distance) from the center of tubing  180  than the outer diameter  111  of top sub  110 . 
         [0028]    Latches  132  may have a groove  133  engageable by a shear ring, such as shear ring  123  of cone  120 . Such shear ring  123  may help maintain latch  132  in the set position while having a shear value that permits removal of the hanging device, including tubing  180 , in response to force that exceeds the capacity of the shear ring  123 . 
         [0029]      FIG. 5  shows an embodiment tool in an actuated and unset position. Piston  160  has moved to the actuated position, such as described with respect to  FIG. 2B  for example, compressing spring  144 , applying longitudinal force to collet  130  and causing latches  132  to move radially outward along angular surface  122 . The ability of latches  132  move outward may be limited, such as by contact between outer surface  134  of latch  132  and the inner surface  214  of host tubing  210 . It will be appreciated that host tubing  210  may be casing, liner or any other tubing. Outer surface  134  of latch  132  may be hardened to reduce the wear to latch  132  as it moves along the inner surface  214  of host tubing  210 . 
         [0030]    As the collet  130  moves down the tubing  210 , latches  132  may be brought adjacent to a latch receptacle having an engagement portion  220 . The engagement portion  220  is configured, both in depth and length, to permit latches  132  to complete its movement radially outward along angular surface  122  and to engage bottom sub  110  at hanging shoulder  112 . Thus, in the illustrated embodiment, moving the latches  132  adjacent to the engagement portion  220  permits the latches  132  to move to the fully set position, such as is shown in  FIG. 2A . In this way, latches  132  may function as a locator to identify the designated location for setting the hanger in the well. 
         [0031]    After the collet  130 , and therefore latches  132 , move to the set position, the latches  132  may be brought into contact with the engagement shoulder  224  adjacent to engagement portion  220  of the latch receptacle such as is shown in  FIG. 6 . Latches  132  are positioned between and engaging each of the hanging shoulder  112  and engagement shoulder  224 . In this way, the weight of the hanging string is transferred to latch  132  through hanging shoulder  112  and from latch  132  to the host tubing  210  through engagement shoulder  224 . It will be appreciated that the diameter of engagement portion&#39;s inner surface  222  may be configured to engage the outer surface  134  of latches  132 , preventing latch  132  from disengaging hanging shoulder  112 . Further, the outer surface of cone  120 , and the outer surface of top sub between cone  120  and hanging shoulder  112  prevent latches  132  from disengaging with engagement shoulder  224 . Latch  132  may thereby be mechanically trapped between four or more surfaces. In some embodiments, leading edge  136  may be configured such that the weight of tubing  180  pulls latch  132  radially inward as leading edge  136  of latches  132  seats on engagement shoulder  224 . 
         [0032]    It will be appreciated that the latch  132  and top sub  110  are the only portions of the hanger assembly that bear any substantial portion of the load from the hanger string. Thus, top sub  110  is configured such that its connection to the tubing  180 , e.g. a threaded connection, and the hanging shoulder  112  are sufficient to bear the weight of the hanger string along which the hanger is placed. The weight of such hanger string imposes shear and bearing forces on latches  132  and collet  130  may be designed and manufactured to withstand such shear and bearing forces. However, the fingers of collet  130  generally do not bear any such load. In some embodiments, it may be possible to include latches  132  of one material and attach them to a collet of another, weaker material because in such embodiments the fingers may only function to connect the piston  160  to latches  132  and to push the latches  132  up the angular surface  122  cone  120  when the piston  160  is actuated. 
         [0033]    The embodiment of  FIG. 1A  is shown as having a collet  130  with latches  132  having a smaller outer radius in the relaxed state than in the set state illustrated in  FIG. 2A . Embodiments having a collet with latches  132  at a larger radius in the relaxed state than in the set state are also within the scope of the present disclosure. In some wells, host tubing  210  may extend from the well surface in a single diameter to the engagement section  220 . In such wells, retracting the collet  130  for insertion into the well may permit the inner surface  214  of the host tubing  210  to hold the latches in an actuated but unset position until the latches  132  are positioned adjacent to the engagement portion  220 . A retracting ring, for example, may be placed around the collet fingers and/or latches  132  to hold the latches in a retracted position. Such ring may be configured to be removable from around the latches  132  as the latches  132  are moving inside the host tubing  210 . Such embodiments would not require an actuation section but may still require a spring or other mechanism applying force to move the latches  132  up angular surface  122  and into engagement with top sub  110 . 
         [0034]    The latches may be configured such that the length of upper surface  134  prevents presetting of the latches. In some embodiments, the latches may be about 1.5 inches to about 1.75 inches, though other sizes are within the scope of the present disclosure. Casing strings, which serves as host tubing  210  in some embodiments, may have incompletely made up connections or other irregularities along the inner surface  214 . If outer surface  134  is of sufficient length, latch  132  cannot expand out into such irregularities. Further, a leading profile  136  of latch  132  having an obtuse angle relative to the hanging strings line of travel may assist in guiding latch  132  out of such irregularities and prevent presets or other failures. 
         [0035]    It will be appreciated that alternative embodiments may include hanging sections with slips or other load bearing element in place of the latch. In such a case, collet fingers may function as the locator, preventing setting of the load bearing element until the desired location is reached. Further, the collet of the present disclosure may be combined with alternative actuation mechanisms. For example, radio frequency identification (RFID) or magnetic induction may be used to release a compressed spring engaging the collet to push latch onto the top sub. Alternatively, RFID or magnetic induction could be used to release the piston to move in response to the wellbore hydraulic pressure or to release fluid and create a pressure differential across the piston. 
         [0036]      FIG. 7  shows an embodiment tubing coupling  310  which may be used as a latch receptacle with certain embodiment hangers according to the disclosure herein. The illustrated embodiment of  FIG. 7  is a box to pin coupling, and other coupling arrangements, including without limitation box-to-box, pin-to-box, and pin-to-pin couplings are within the scope of the present disclosure. The embodiment coupling  310  has a box end  330 , a box shoulder  332 , a pin end  340 , an inner surface  314 , an engagement portion  322  and an engagement shoulder  324 . Box end  330  and pin end  340  may be threaded to connect with tubing on either end of the coupling  310 , thereby incorporating couple  310  into a tubing string. Box end  330  will connect to a pin end of adjacent tubing, bringing the inner wall of such tubing adjacent to inner surface  314 . Such inner wall may have a diameter similar or substantially identical to inner surface  314  and the end of such pin may engage or otherwise shield box shoulder  332  to prevent collet latches  132  from engaging the connection and hanging up in the tubing string. 
         [0037]    Engagement portion  320  is configured similarly to engagement portion  220  in  FIGS. 5 and 6  to permit collet latches  132  to expand along cone  120  to engage the shoulder  112  of top sub  110 . Further movement of the hanger toward the pin end  340  of coupling  310  brings latches  132  against engagement shoulder  324 , setting the hanger in place against and preventing further movement toward the pin end  340 . It will be appreciated that the embodiment of  FIG. 7  may be placed in the host string with pin end  340  down relative to the box end  330  such that gravity applies force pulling collet latches  132  onto engagement shoulder  324  and pulling shoulder  112  of top sub  110  onto the upper ends of collet latches  132 . In this way, gravity fixes top sub  110 , and attached hanging string, to coupling  310 , thereby securing the hanging string in the host string. 
         [0038]    Other Devices according to the present disclosure are described with reference to one or more specific embodiments. For example, “dogs” or “lugs” may be used in place of the collet fingers and serve as the latch. Such dogs or lugs may be spring loaded to assist in either their outward movement, such as by loading onto a cone or otherwise, or resisting movement of the dogs or lugs outward until the actuating device, whether hydraulic, magnetic, RFID or other, is triggered. Host string devices other than couplings, such as specialized tubing joints, may be used to engage the hanger latches. In some embodiments, a separate device may be installed inside the host string prior to running the hanging string to create an engagement shoulder or similar structure to receive the collet latches. Embodiment devices may include devices according to Applicant&#39;s U.S. patent application Ser. No. 14/844,192, entitled Shortened Tubing Baffle with Large Sealable Bore, filed on Sep. 3, 2015, which is incorporated herein in its entirety by reference. The slips of such devices may be used to engage a host string while the enlarged section of the mandrel at the upper end of such baffles may be used as an engagement shoulder for receiver the collet latches. Alternative embodiments which may be shortened by removal of the elastomeric elements are also with the scope for installation with the host string. Further alternatives to the described arrangements will be apparent from a review of the embodiments of the disclosure and such alternatives are within the scope of the invention as claimed.