Patent Description:
Liner hangers are used to suspend a liner from another tubular string in a wellbore. Conventional hydraulic liner hangers are actuated in response to pressure above a threshold to set slips. During run-in, an increase in fluid circulation through the liner string may be necessary to facilitate moving the liner string through the deviations and/or turns of the wellbore. The increase in fluid circulation in the liner string may inadvertently actuate the liner hanger in the wellbore above the intended setting location. Unintended setting of the liner hanger results in the need to remove the liner string and to conduct a subsequent wellbore operation.

There exists a need for a liner hanger setting tool that prevents premature actuation of the liner hanger.

<CIT> a method for drilling a borehole with a borehole liner. The method includes: providing a drill string of drill pipe including a center bore, a distal end, a bit assembly at the distal end; hanging a liner from the drill string, thereby forming an annular space between the drill string and the liner and with the bit assembly extending from a lower end of the liner; positioning the drill string with the liner attached thereto in a borehole such that a second annular space is formed between the liner and the borehole wall; operating the bit assembly to proceed with drilling the borehole; and circulating drilling fluid down through the center bore of the drill string out through the bit assembly and down through the second annular space between the liner and the borehole wall, the drilling fluid returning up through the annular space between the drill string and the liner. An apparatus for use in this method is also described. <CIT> surge immune liner setting tool. The setting tool includes: a tubular mandrel having an actuation port formed through a wall thereof; a debris barrier for engaging an upper end of the tubular string; and a piston having an upper face in fluid communication with the actuation port. The setting tool further includes: an actuator sleeve extending along the mandrel and connected to the piston; a latch releasably connecting the debris barrier to the actuator sleeve and for releasably connecting the debris barrier to the tubular string; a packoff connected to the mandrel below the piston and operable to seal against an inner surface of the tubular string, thereby forming a buffer chamber between the debris barrier and the packoff; and a passage. The passage is in fluid communication with a lower face of the piston, is formed in a wall of and along the mandrel, and bypasses the packoff. <CIT> discloses a mechanical liner drilling cementing system. A packer setting tool sets a liner top packer by mechanical rotation of the running tool and set down weight following cementing of a liner. The packer setting tool includes a tubular release body mounted on an end of the running tool. An annular dog sub circumscribes a portion of the release body. The dog sub is linked to the release body with a shear screw. A thread on an outer surface of the release body engages a thread on an inner surface of the dog sub to define a threaded connection between the dog sub and the release body. When the running tool rotates, the thread on the release body rotates with respect to the thread on the dog sub driving the release body in an axial direction fracturing the shear screw and urges an adapter sleeve against the packer assembly to set the packer assembly.

The present disclosure generally relates to a setting tool for a liner hanger and a methods for completing downhole operations.

A setting tool for a downhole tool includes a tubular housing having a central bore. The setting tool further includes a first seal and a second seal disposed about an exterior of the tubular housing. The setting tool further includes a first port formed through the tubular housing and disposed between the first seal and the second seal. The setting tool further includes a first sleeve disposed in the central bore and movable from a closed position to an open position, the first sleeve having a seat. The setting tool further includes at least one first shearable member configured to releasably attach the first sleeve to the tubular housing in the closed position. The setting tool further includes at least one fluid bypass disposed in the tubular housing and configured to allow fluid communication around the first seal and the second seal. The central bore and the first port are in fluid communication when the first sleeve is in the open position.

A method of conducting a wellbore operation using the setting tool includes deploying a liner string into a wellbore to a setting depth. The liner string includes a liner hanger assembly including the liner hanger with an actuation assembly, and a liner hanger deployment assembly attached to the liner hanger assembly and including the setting tool, wherein the setting tool is configured to isolate the actuation assembly from fluid communication with the central bore of the setting tool. The method further includes actuating the setting tool to allow fluid communication between the central bore and the actuation assembly. The method further includes actuating the liner hanger.

It is to be noted, however, that the appended drawings illustrate only exemplary embodiments and are therefore not to be considered limiting of its scope, may admit to other equally effective embodiments.

<FIG> illustrate a liner string <NUM>. The liner string <NUM> includes a liner hanger deployment assembly (LHDA) <NUM>, as shown in <FIG>, and a liner hanger assembly (LHA) <NUM>, as shown in <FIG>. The LHDA <NUM> may include a packoff <NUM>, a packer actuator <NUM>, a running tool <NUM>, a setting tool <NUM>, and a plug assembly <NUM>. The LHA <NUM> may include a polished bore receptacle (PBR) <NUM>, threads <NUM>, a packer <NUM>, a liner hanger <NUM>, and a liner <NUM>. The LHA <NUM> may also include a landing collar (not shown), a float collar (not shown), and float shoe (not shown) at a lower end. <FIG> illustrates the LHDA <NUM> disposed within the LHA <NUM>. An annulus <NUM> is between the LHDA <NUM> and the LHA <NUM>.

During run-in of the liner string <NUM>, the LHDA <NUM> is disposed in the bore <NUM> and releasably attached to the LHA <NUM>. As shown in <FIG>, the LHDA <NUM> is attached to the LHA <NUM> via the engagement of threads <NUM> of the running tool <NUM> with the threads <NUM> during run-in. The LHDA <NUM> may be released from the LHA <NUM> downhole, such as by unthreading the threaded connection between threads <NUM> and <NUM>. The setting tool <NUM> is disposed in the liner hanger <NUM> during run-in of the liner string <NUM>. Circulation through the liner string <NUM> may be increased during run-in to facilitate moving the liner string <NUM> through deviations or turns in the wellbore. The setting tool <NUM> prevents premature actuation of the liner hanger <NUM> during run-in of the liner string <NUM>. Once run-in of the liner string <NUM> is complete, the setting tool <NUM> is actuated to allow the actuation of the liner hanger <NUM> in response to fluid pressure. In some embodiments, the setting tool <NUM> can be actuated prior to the completion of run-in once the liner string <NUM> is close to the setting depth. After actuation of the setting tool <NUM>, the liner hanger <NUM> is actuated in response to reaching a pressure threshold.

The packer <NUM> may include a tubular mandrel <NUM>, a packing element <NUM>, one or more shearable members <NUM>, and an actuation sleeve assembly <NUM>. The actuation sleeve assembly <NUM> is maintained in an initial position by the one or more shearable members <NUM>. The PBR <NUM> abuts one end of the sleeve actuation assembly <NUM>. The actuation sleeve assembly <NUM> is configured to compress the packing element in response to force applied to the PBR <NUM> from the packer actuator <NUM>.

The packer actuator <NUM> may be similar to the packer actuator disclosed in <CIT>. The packer actuator <NUM> includes a plurality of dogs <NUM> movable from a retracted position to an extended position. The dogs <NUM> are maintained in the retracted position by engagement with the inner surface of the PBR <NUM>. In some embodiments, after the liner hanger <NUM> is set and the LHDA <NUM> is released from the LHA <NUM>, the LHDA <NUM> can be lifted until the dogs <NUM> are withdrawn from the PBR <NUM> to allow the dogs <NUM> to move to the expanded position. The LHDA <NUM> may then be lowered relative to the LHA <NUM> until the dogs <NUM> seat on the top of the PBR <NUM>. Force (e.g., weight) is then applied to the top of the PBR <NUM> via the dogs <NUM>, which transfers the force to the sleeve actuation assembly <NUM>. Once the one or more shearable members <NUM> shear, the actuation sleeve assembly <NUM> moves relative to the tubular mandrel <NUM> to compress the packing element <NUM> until it expands into engagement with the wellbore or casing surrounding the packer <NUM>. Thus, the packer actuator <NUM> is used to actuate the mechanically actuated packer <NUM> to seal the annulus surrounding the LHA <NUM> by expanding the packing element <NUM> of the packer <NUM>. Upon completing operations downhole, the LHDA <NUM> is tripped out of the wellbore. The LHA <NUM>, however, remains in the wellbore.

<FIG> illustrates an embodiment of a setting tool <NUM>. The setting tool <NUM> may include a tubular housing <NUM>, a sleeve <NUM>, a first seal 230a, a second seal 230b, one or more ports <NUM>, one or more shearable members <NUM>, and a fluid bypass <NUM>. The tubular housing <NUM> defines a central bore <NUM>. To facilitate manufacturing and assembly, the tubular housing <NUM> may include one or more sections 210a-h connected together, such as by threaded couplings and/or fasteners. Seals <NUM> may be placed between the interconnecting tubular housing sections 210a-h to prevent fluid in the central bore <NUM> from leaking to the environment outside of the setting tool <NUM>, and vice versa. The seals <NUM> maintain pressure integrity of the setting tool <NUM>. The tubular housing <NUM> has a connection at each end, such as a pin 201a and a box 201b. The first seal 230a and the second seal 230b are disposed about the exterior of the tubular housing <NUM>. The first seal 230a and the second seal 230b are configured to sealingly engage with an inner surface of the bore <NUM> of the LHA <NUM> and to straddle a port <NUM> of the liner hanger <NUM>. For example, the first and second seals 230a,b may sealing engage with the inner surface of a tubular mandrel <NUM> of the liner hanger <NUM>.

The fluid bypass <NUM> is disposed in the tubular housing <NUM>. The fluid bypass extends from one or more openings 262a to one or more openings 262b. The fluid bypass <NUM> allows fluid communication above and below the first and second seals 230a,b when the seals 230a,b are sealingly engaged with the inner surface of the bore <NUM> of the LHA <NUM>, such as the inner surface of the tubular mandrel <NUM> (see <FIG>). Thus, the fluid bypass <NUM> allows for fluid communication around the seals 230a,b. The fluid bypass <NUM> is not in fluid communication with the one or more ports <NUM>.

<FIG> show cross sections of the setting tool <NUM> to better illustrate the fluid bypass <NUM> and setting tool <NUM>. The one or more openings 262a are formed in the tubular housing section 210b. The fluid bypass <NUM> can be formed from a combination of gaps between tubular sections and/or bores present in the tubular sections forming the tubular housing <NUM>. For example, one or more gaps 270a may be present between the tubular housing sections 210a and 210c, and one or more gaps 270b may be present between tubular housing sections 210f and <NUM><NUM>. As shown in <FIG> and <FIG>, one or more bores 272a may be formed in the tubular housing section 210d. As shown in <FIG> and <FIG>, one or more bores 272b may be formed in the tubular housing section 210e. The dashed lines in tubular housing section 210d, as shown in <FIG>, illustrate the one or more bores 272a. The gaps 270a,b, the bores 272a,b, and the openings 262a,b form the fluid bypass <NUM>. Thus, fluid may flow between openings 262a,b via the gaps 270a,b and bores 272a,b. In some embodiments, the number of bores 272a is less than the number of bores 272b, and vice versa. In some embodiments, the fluid bypass <NUM> may be a plurality of individual fluid bypasses formed in the tubular housing <NUM> that are isolated from one another.

The packoff <NUM> seals against the inner surface of the LHA <NUM>, such as the inner surface of the packer <NUM>. As a result, a portion 101a of the annulus <NUM> is bounded by the packoff <NUM> and the first seal 230a. A portion 101b of the annulus <NUM> is below the second seal 230b. The fluid bypass <NUM> allows the portion 101a of the annulus <NUM> between packoff <NUM> and first seal 230a to be in fluid communication with the portion 101b of the annulus below the second seal 230b. This allows the annulus portion 101a to fill with wellbore fluid during run-in and to equalize pressure with the annulus portion 101b. Without the fluid bypass <NUM>, the annulus portion 101a would be isolated from the wellbore fluids. If the annulus portion 101a was isolated from the wellbore fluids, then a pressure difference between the annulus portion 101a and the annulus surrounding the outside of the LHA <NUM> would increase with depth, thereby increasing the risk of a collapse of the LHA <NUM>, such as the collapse of the portion of the LHA150 between the first seal 230a and the packoff <NUM>. The collapse risk is caused, in part, by the thickness and material of the LHA <NUM>. A collapse may prevent the LHDA <NUM> from being tripped out of the LHA <NUM>, which might require tripping both the LHDA <NUM> and LHA <NUM> from the wellbore. The fluid bypass <NUM> alleviates the pressure difference and allows the liner string <NUM> to be run-in to greater depths.

Prior to the actuation of the setting tool <NUM>, fluid communication between the central bore <NUM> and the one or more ports <NUM> is blocked by the sleeve <NUM>. Some of the ports <NUM> are threaded ports 240t for receiving a shearable member <NUM> that releasably attaches the sleeve <NUM> to the tubular housing <NUM>. The one or more ports <NUM>, including the threaded ports 240t, are formed through tubular housing <NUM>, such as through tubular housing section 210d. As shown in <FIG> and <FIG>, the shearable members <NUM> are disposed in the threaded ports 240t. However, one or all of the shearable members <NUM> may be disposed at another location in the tubular housing <NUM> instead of being disposed in the threaded ports 240t. The ports <NUM>, including the threaded ports 240t, are disposed between the first and second seals 230a,b.

The sleeve <NUM> is disposed in the central bore <NUM>. The sleeve <NUM> is movable from a closed positon (<FIG>) to an open position (<FIG>). When in the closed position, the sleeve <NUM> is releasably attached to the tubular housing <NUM>, such as tubular housing section 210d, by the one or more shearable members <NUM>. In some embodiments, the shearable members <NUM> may be threaded into a corresponding hole in the sleeve <NUM>. In some embodiments, the shearable members <NUM> may be partially disposed in a groove or recess of the sleeve <NUM>. In the open position, the shearable members <NUM> have sheared, and the sleeve <NUM> has moved relative to the tubular housing <NUM> to expose the one or more ports <NUM> to fluid communication with the central bore <NUM>. The sleeve <NUM> may include one or more seals <NUM> disposed around the sleeve <NUM> to prevent fluid communication between the central bore <NUM> and the one or more ports <NUM> while the sleeve <NUM> is in the closed position. The sleeve <NUM> includes a seat <NUM> configured to catch a first object <NUM>, such as a ball or a dart. The seat <NUM> may be coupled to the sleeve <NUM>, such as coupled to one end of the sleeve <NUM>, or the seat <NUM> may be integrally formed with the sleeve <NUM>. A seal <NUM> may be disposed around the seat <NUM>. When the first object <NUM> is engaged with the seat <NUM>, pressure can be increased in the central bore <NUM> above the first object <NUM> to actuate the setting tool <NUM>. The pressure is increased above the first object <NUM> until the one or more shearable members <NUM> are sheared, which frees the sleeve <NUM> to move from the closed position to the open position. The axial travel of the sleeve <NUM> may be limited by the abutment of the sleeve <NUM> with a shoulder <NUM> of the tubular housing <NUM>.

<FIG> illustrates an exemplary liner hanger <NUM>. The liner hanger <NUM> may include the tubular mandrel <NUM>, a slip assembly <NUM>, and a slip actuation assembly <NUM>. The tubular mandrel <NUM> defines a central bore <NUM> of the liner hanger <NUM> and includes the port <NUM>. The liner hanger <NUM> can have more than one port <NUM>. The slip assembly <NUM> may include a first abutment member <NUM> and a plurality of slips <NUM> configured to ride up one or more ramps <NUM> coupled to the tubular mandrel <NUM>. The slip actuation assembly <NUM> may include a piston member <NUM>, a second abutment member <NUM>, a sleeve member <NUM>, one or more shearable members <NUM>, and a piston chamber <NUM> disposed between a first seal <NUM> and a second seal <NUM>.

The sleeve member <NUM> is attached to the tubular mandrel <NUM>, such as by a plurality of fasteners. The piston member <NUM> is attached to the second abutment member <NUM> at one end. The second seal <NUM> is coupled to the piston member <NUM>. The piston member <NUM> is releasably attached to the sleeve member <NUM> via the one or more shearable members <NUM>. In some embodiments, the one or more shearable members <NUM> may be configured to shear at a lower pressure than the pressure necessary to shear the one or more shearable members <NUM>. The first seal <NUM> is disposed between the tubular mandrel <NUM> and the piston member <NUM>, and the first seal <NUM> is affixed to the tubular mandrel <NUM>. The piston chamber <NUM> is in fluid communication with the port <NUM>.

In order to set the slips <NUM>, pressure is increased in the piston chamber <NUM> until the force acting on the piston head <NUM> of the piston member <NUM> is sufficient to shear the one or more shearable members <NUM>. Then, the piston member <NUM>, second seal <NUM>, and the second abutment member <NUM> move, in response to the fluid in piston chamber <NUM>, relative to the tubular mandrel <NUM> until the second abutment member <NUM> engages the first abutment member <NUM>. Once engaged, the first abutment member <NUM> moves in response to the continued movement of the second abutment member <NUM> and piston member <NUM> until the slips <NUM> ride up the ramps <NUM> into engagement with a casing or an inner surface of the wellbore.

<FIG> illustrates the setting tool <NUM> disposed in the central bore <NUM> of the liner hanger <NUM>. The LHDA <NUM> is still attached to the LHA <NUM>. The seals 230a,b are shown as engaged with the tubular mandrel <NUM>. A pressure chamber <NUM> is disposed between the seals 230a,b when the seals 230a,b are engaged with the inner surface of the bore <NUM> of the LHA <NUM>. The port <NUM> is disposed between the seals 230a,b such that it is in fluid communication with the pressure chamber <NUM>. The pressure chamber <NUM> is isolated from fluid communication with the central bore <NUM> via the sleeve <NUM>. The pressure chamber <NUM> is isolated from the annulus portions 101a by the first seal 230a. The pressure chamber <NUM> is isolated from the annulus portion 101b by the second seal 230b. The pressure chamber <NUM> may be at atmospheric pressure, or it may be pressurized to a set pressure. The pressure chamber <NUM>, and thus the piston chamber <NUM>, is isolated from fluid communication with the central bore <NUM> during run-in to avoid inadvertent actuation of the liner hanger <NUM>.

An exemplary operation sequence of the liner string <NUM> including the setting tool <NUM> and liner hanger <NUM> is illustrated in <FIG>. The setting tool <NUM> and the liner hanger <NUM> are shown disposed in a casing <NUM>. As shown in <FIG>, the setting tool <NUM> and liner hanger <NUM> are at the setting depth in the wellbore. Once the liner hanger <NUM> is in position at the setting depth, the setting tool <NUM> is ready to be actuated. The first object <NUM> is dropped into the wellbore where it will engage with the seat <NUM> as shown in <FIG>. After the first object <NUM> engages the seat <NUM>, pressure is increased above the first object <NUM> until the one or more shearable members <NUM> shear and the sleeve <NUM> moves from the closed position to the open position as shown in <FIG>. When the sleeve <NUM> is in the open position, fluid communication is established between the one or more ports <NUM> and the port <NUM>. With the pressure chamber <NUM> no longer isolated from the central bore <NUM>, the pressure chamber <NUM> may fill with wellbore fluid. The operator may wait a certain period of time to allow the pressure chamber <NUM> to fill with wellbore fluids. As shown in <FIG>, pressure may continue to be increased above the first object <NUM> until the one or more shearable members <NUM> shear. As a result, the slip actuation assembly <NUM> moves the slips <NUM> up the ramps <NUM> to the set position. However, the one or more shearable members <NUM> may be designed to shear at the pressure necessary to shear the one or more shearable members <NUM>. A test may be conducted to confirm the liner hanger <NUM> has been set, such as by pulling or pushing on the liner string <NUM> from the surface to confirm that the slips <NUM> are set. Then, the LHDA <NUM> may be released from the LHA <NUM>. In one example, the LHDA <NUM> is rotated relative to the LHA <NUM> to unthread the threaded connection between thread <NUM> and thread <NUM>. Release of the LHDA <NUM> from the LHA <NUM> may be verified by lifting the LHDA <NUM> a predetermined distance and checking the weight on a load sensor to confirm that the LHA <NUM> is no longer attached. Pressure can be increased above the first object <NUM> until the first object <NUM> passes through the seat <NUM> as shown in <FIG>. The first object <NUM> will travel downhole, and the first object <NUM> may engage with or pass through the plug assembly <NUM> or other wellbore equipment below the seat <NUM>. In some embodiments, the object <NUM> is removed from the seat <NUM> prior to releasing the LHDA <NUM> from the LHA <NUM>.

In some embodiments, once the LHDA <NUM> is released from the LHA <NUM>, a cementation operation may begin. For example, a second object <NUM>, such as a cementation dart or a ball, may be dropped into the liner string <NUM> above the cement. The second object <NUM> travels downhole until it engages the seat <NUM> as shown in <FIG>. Pressure may be increased above the second object <NUM>, if necessary, to pass the second object through the seat <NUM>. The second object <NUM> may continue to travel through the LHDA <NUM>, and the second object <NUM> may engage the plug assembly <NUM> or other wellbore equipment below the seat <NUM>. <FIG> illustrates the setting tool <NUM> disposed in the liner hanger <NUM> after the second object <NUM> has passed through the seat <NUM>. Additional objects may be dropped as necessary to complete the cementation operation.

Once the cementation operation is complete, the LHDA <NUM> may be lifted until the dogs <NUM> are removed from the PBR <NUM>, which results in the dogs <NUM> moving from the unexpanded position to the expanded position. Then, the LHDA <NUM> is lowered relative to the LHA <NUM> until the dogs <NUM> seat on the top of the PBR <NUM>. Then, force (e.g., weight) can be applied to the LHDA <NUM> to set the mechanically actuated packer <NUM> via the dogs <NUM> seated on the PBR <NUM>. After the packer <NUM> is set, then the LHDA <NUM> may be tripped out of the wellbore. In some embodiments, the packer <NUM> may be set without completing a cementation operation.

<FIG> illustrates an alternative setting tool <NUM> for use with the liner string <NUM>. The setting tool <NUM> may be substituted for the setting tool <NUM> in the LHDA <NUM>. The setting tool <NUM> has similar components as setting tool <NUM>, and the similar components are identified using similar reference numbers.

<FIG> illustrates setting tool <NUM>. The setting tool <NUM> may include a tubular housing <NUM>, a first sleeve <NUM>, a second sleeve <NUM>, a first seal 1230a, a second seal 1230b, one or more first ports <NUM>, one or more second ports <NUM>, one or more first shearable members <NUM>, one or more second shearable members <NUM>, and a fluid bypass <NUM>. The tubular housing <NUM> defines a central bore <NUM>. To facilitate manufacturing and assembly, the tubular housing <NUM> may include one or more sections 1210a-h connected together, such as by threaded couplings and/or fasteners. Seals <NUM> may be placed between the interconnecting tubular housing sections 1210a-h to maintain the sealing and pressure integrity of the setting tool <NUM>. The tubular housing <NUM> has a connection each end, such as a pin 1201a a box 1201b. The first seal 1230a and the second seal 1230b are disposed about the exterior of the tubular housing <NUM>. The first and second seals 1230a,b are configured to sealing engage with the inner surface of the bore <NUM> of the LHA <NUM> and to straddle the port <NUM> of the liner hanger <NUM>. For example, the seals 1230a,b are configured to sealingly engage against the inner surface of the tubular mandrel <NUM> of the liner hanger <NUM>. While the first and second seals 1230a,b are engaged with the inner surface of the bore <NUM> of the LHA <NUM>, a pressure chamber <NUM> is present between the seals 1230a,b.

The one or more first ports <NUM> are formed through the tubular housing <NUM>, such as through tubular housing section 1210d. Some of the first ports <NUM> are threaded ports 1240t for receiving the one or more first shearable members <NUM> that releasably attach the first sleeve <NUM> to the tubular housing <NUM>. As shown in <FIG> and <FIG>, the one or more first shearable members <NUM> are disposed in the threaded ports 1240t. However, the one or more first shearable members <NUM> may be disposed at another location in the tubular housing <NUM> instead of being disposed in the threaded ports 1240t. The one or more first ports <NUM>, including the threaded ports 1240t, are disposed between the first and second seals 1230a,b.

The first sleeve <NUM> is disposed in the central bore <NUM>. The first sleeve <NUM> is movable from a closed positon (<FIG>) to an open position (<FIG>). When in the closed position, the first sleeve <NUM> is releasably attached to the tubular housing <NUM>, such as tubular housing section 1210d, by the one or more first shearable members <NUM>. The first sleeve <NUM> includes a seat <NUM> configured to catch a first object <NUM>, such as a ball or a dart. The seat <NUM> may be coupled to the first sleeve <NUM>. For example, the seat <NUM> can be coupled to one end of the first sleeve <NUM>. In another example, the seat <NUM> may be integrally formed with the first sleeve <NUM>. A plurality of seals <NUM> may be disposed around the first sleeve <NUM> and the seat <NUM>. When the first object <NUM> is engaged with the seat <NUM>, pressure can be increased in the central bore <NUM> above the first object <NUM> to actuate the setting tool <NUM>. The pressure is increased above the first object <NUM> until the one or more first shearable members <NUM> are sheared. Thereafter, the first sleeve <NUM> is allowed to move from the closed position to the open position.

The second sleeve <NUM> is disposed in the central bore <NUM> and is releasably attached to the tubular housing <NUM>, such as being releasably attached to tubular housing section 1210e, when in the open position. One or more seals <NUM> may be disposed about the second sleeve <NUM>, and the seals <NUM> may straddle the one or more second ports <NUM>. When the second sleeve <NUM> is in the open position (<FIG>), the central bore <NUM> is in fluid communication with one or more second ports <NUM> formed in the tubular housing <NUM>. In some embodiments, and as shown in <FIG>, the second sleeve <NUM> includes one or more ports <NUM> that are aligned with the one or more second ports <NUM> when the second sleeve <NUM> is in the open position. The one or more second ports <NUM> may be formed in the tubular housing section 1210e and some of the one or more second ports <NUM> may be threaded 1242t. The one or more second ports <NUM>, including the threaded ports 1242t, are disposed between the first and second seals 1230a,b. As shown in <FIG> and <FIG>, the second sleeve <NUM> is releasably attached to the tubular housing <NUM> via one or more second shearable members <NUM>. In some embodiments, and as shown in <FIG>, the second sleeve <NUM> is not pressure balanced. A chamber <NUM> is disposed between the second sleeve <NUM> and the tubular housing <NUM>. The chamber <NUM> is isolated from the central bore <NUM> and the one or more second ports <NUM> via the seals <NUM>. The chamber <NUM> may be at atmospheric pressure or the chamber may contain a fluid at a specific pressure, such as <NUM> psi (approximately <NUM> MPa) for example. As the setting tool <NUM> travels deeper into the wellbore, the pressure differential between the chamber <NUM> and the central bore <NUM> increases. The pressure in the pressure chamber <NUM> increases with depth, since the pressure chamber <NUM> is in fluid communication with the central bore <NUM>. The pressure in the chamber <NUM> and the one or more second shearable members <NUM> are configured to actuate the second sleeve <NUM> at a desired depth. For example, the number, thickness, and material of the one or more second shearable members <NUM> and/or the pressure in the chamber <NUM> can be adjusted based on the desired depth at which the second sleeve <NUM> moves to the closed position. Thus, when the setting tool <NUM> reaches the desired depth, the second shearable members <NUM> shear due to the pressure difference between the pressure acting on the second sleeve <NUM> in the central bore <NUM> and the pressure in the chamber <NUM>. The desired depth at which the second sleeve <NUM> actuates to move to the closed position is the set depth of the pressure chamber <NUM>. When the second sleeve <NUM> is in the closed position, the pressure chamber <NUM> is isolated from the central bore <NUM>, preventing the pressure in the pressure chamber <NUM> from continuing to increase.

In some embodiments, flow rate can be used to actuate the second sleeve <NUM>. Fluid flow above a predetermined rate will be sufficient to increase the pressure in the central bore <NUM> to act upon the second sleeve <NUM> to shear the one or more second shearable members <NUM>. After release, the second sleeve <NUM> is allowed to move to a closed position to block flow from the central bore <NUM> through the one or more second ports <NUM>. However, the flow rate necessary to shear the one or more second shearable members <NUM> and to move the second sleeve <NUM> is insufficient to actuate the slip actuation assembly <NUM>. In some embodiments, the second sleeve <NUM> is actuated after catching an object in a seat of the second sleeve <NUM>. The second sleeve <NUM> is moved to the closed position by increasing pressure above the object engaged in the seat of the second sleeve <NUM> until the one or more second shearable members <NUM> shear. In some embodiments, the second sleeve <NUM> is pressure balanced and further includes a seat to catch an object. The second sleeve <NUM> can move from the open position to the closed position in response to a pressure build-up above the object that is sufficient to shear the one or more second shearable members <NUM>.

The fluid bypass <NUM> is disposed in the tubular housing <NUM> to allow communication above and below the first and second seals 1230a,b when the seals 1230a,b are sealingly engaged with the inner surface of the bore <NUM> of the LHA <NUM>, such as the inner surface of the tubular mandrel <NUM>. Thus, the fluid bypass <NUM> allows for fluid communication around the seals 1230a,b. The fluid bypass extends from one or more openings 1262a to one or more openings 1262b. The fluid bypass <NUM> is not in fluid communication with the one or more first ports <NUM> or the one or more second ports <NUM>. The fluid bypass <NUM> allows the annulus portion 101a of the liner string <NUM> between the packoff <NUM> and the first seal 1230a to be in fluid communication with the annulus portion 101b below the second seal 1230b. Thus, annulus portion 101a of the annulus <NUM> between the packoff <NUM> and first seal 1230a can fill with wellbore fluid during run-in to achieve pressure equalization to minimize the risk of collapse of a portion of the LHA <NUM> between the packoff <NUM> and the first seal 1230a.

<FIG> show cross sections of the setting tool <NUM> to better illustrate the fluid bypass <NUM> and setting tool <NUM>. The fluid bypass <NUM> can be formed from a combination of gaps and/or bores present in the tubular housing <NUM>. For example, one or more gaps 1270a may be present between the tubular housing sections 1210a and 1210c and one or more gaps 1270b may be present between tubular housing sections 1210f and <NUM>. As shown in <FIG> (dashed lines) and <FIG>, one or more bores 1272a may be formed in the tubular housing section 1210d. As shown in <FIG> (dashed lines) and <FIG>, one or more bores 1272b may be formed in the tubular housing section 1210e. The gaps 1270a,b, bores 1272a,b, and openings 1262a,b form the fluid bypass <NUM>. In some embodiments, the number of bores 1272a is less than the number of bores 1272b, and vice versa. In some embodiments, the fluid bypass <NUM> may be a plurality of individual fluid bypasses formed in the tubular housing <NUM>.

<FIG> illustrates the setting tool <NUM> disposed in the liner hanger <NUM> when the LHDA <NUM> is attached to the LHA <NUM>. The pressure chamber <NUM> is isolated from the annulus portion 101a by the first seal 1230a. The pressure chamber <NUM> is isolated from the annulus portion 101b by the second seal 1230b. The pressure chamber <NUM> is in fluid communication with the central bore <NUM> via the one or more second ports <NUM> and the corresponding one or more ports <NUM> of the second sleeve <NUM>. Thus, any fluid initially in the pressure chamber <NUM>, such as air, may be at least partially displaced by wellbore fluids during run-in. At the pressure chamber <NUM> set depth, which is a predetermined depth, the second sleeve <NUM> is actuated and moves from the open position to the closed position. After the second sleeve <NUM> is actuated, the pressure chamber <NUM> is isolated from the central bore <NUM> by the first sleeve <NUM> and the second sleeve <NUM>. The now isolated pressure chamber <NUM> has a pressure that is equivalent to the fluid pressure at the depth where it was isolated from fluid communication with the central bore <NUM> by the second sleeve <NUM>. After actuating the second sleeve <NUM>, the liner string <NUM> is advanced to a greater depth while the pressure chamber <NUM> is isolated from fluid flow. The pressure chamber <NUM> is isolated from fluid flow by the first sleeve <NUM> and the second sleeve <NUM> to prevent inadvertent actuation of the slip actuation assembly <NUM>. It is believed that a greater final setting depth can be achieved than if the pressure chamber <NUM> remained at its initial run-in pressure. Once the liner string <NUM> is at setting depth, the first object <NUM> can engage with the first sleeve <NUM> to actuate of the first sleeve <NUM>. Pressure is increased above the first object <NUM> to shear the one or more first shearable members <NUM>, which allows the first sleeve <NUM> to move to the open position. Once the first sleeve <NUM> is in the open position, fluid pressure is increased until the slip actuation assembly <NUM> sets the slips <NUM>.

An actuation sequence of the illustrated embodiment of the setting tool <NUM> and liner hanger <NUM> is described in <FIG>. The setting tool <NUM> and the liner hanger <NUM> are shown disposed in a casing <NUM>. <FIG> illustrates the setting tool <NUM> and liner hanger <NUM> at a depth above the pressure chamber set depth. <FIG> illustrates the setting tool <NUM> and liner hanger <NUM> advanced to the pressure chamber set depth, such as a depth of <NUM>,000ft (<NUM>,<NUM>). Since the pressure chamber <NUM> is in communication with the central bore <NUM>, the pressure chamber <NUM> has a pressure equivalent to the pressure at the pressure chamber set depth. Pressure chamber set depth is determined, in part, on how much deeper the liner string <NUM> needs to be advanced in the wellbore. After the pressure chamber <NUM> set depth has been reached, the second sleeve <NUM> moves to the closed position. The pressure chamber <NUM> is now isolated from the central bore <NUM> of the setting tool <NUM>. The liner string <NUM> can now be advanced deeper in the wellbore, such as a depth of <NUM>,000ft (<NUM>,<NUM>), without a collapse event occurring. <FIG> illustrates the setting tool <NUM> and liner hanger <NUM> at setting depth, such as a depth of <NUM>,000ft (<NUM>,<NUM>). Once the liner hanger <NUM> is at setting depth, the first object <NUM> is dropped into the wellbore. The first object <NUM> engages the seat <NUM> as shown in <FIG>. After the first object <NUM> engages the seat <NUM>, pressure is increased above the first object <NUM> to actuate the first sleeve <NUM>, and thus actuate the setting tool <NUM>. The pressure is increased above the first object <NUM> until the one or more first shearable members <NUM> shear and the first sleeve <NUM> moves from the closed position to the open position as shown in <FIG>. When the first sleeve <NUM> is in the open position, fluid communication is reestablished between the pressure chamber <NUM> and the central bore <NUM> via the one or more first ports <NUM>. With the pressure chamber <NUM> no longer isolated, it adjusts to the new pressure present at the setting depth. As shown in <FIG>, pressure may continue to be increased above the first object <NUM> until the one or more shearable members <NUM> and the slip actuation assembly <NUM> moves the slips <NUM> up the ramps <NUM> into the set position. However, the one or more first shearable members <NUM> may be designed to shear at the same pressure as the one or more shearable members <NUM>. A test may be conducted to confirm that the liner hanger <NUM> has been set, such as by pulling or pushing on the liner string <NUM> from the surface to confirm that the slips <NUM> are set. Once the operator has determined that the liner hanger <NUM> is set, the LHDA <NUM> may be released from the LHA <NUM>, such as by rotating the LHDA <NUM> relative to the LHA <NUM> to unthread the threaded connection between threads <NUM> and <NUM>. Releasing and verifying release of the LHDA <NUM> can be accomplished in the same manner discussed above with respect to setting tool <NUM>. Then, pressure can be increased above the first object <NUM> until the first object <NUM> passes through the seat <NUM> as shown in <FIG>. The first object <NUM> may continue to travel downhole and engage the plug assembly <NUM> or other wellbore equipment below the seat <NUM>. The first object <NUM> may be removed from the seat <NUM> prior to releasing the LHDA <NUM> from the LHA <NUM>.

In some embodiments, a cementation operation may begin after the LHDA <NUM> is released from the LHA <NUM>. The cementation operation may include dropping additional objects into the wellbore that engage the plug assembly <NUM>. Once the cementation operation is completed, then the packer <NUM> can be set in a similar manner as discussed above. In some embodiments, the packer <NUM> may be set without completing a cementation operation. Once the LHDA <NUM> has completed its operations, the LHDA <NUM> may be retrieved from the wellbore.

<FIG> illustrates an alternative setting tool <NUM> for the liner string <NUM>. The LHDA <NUM> includes the setting tool <NUM> instead of the setting tools <NUM> or <NUM>. Setting tool <NUM> has similar components as setting tools <NUM>, <NUM> and the similar components are identified using similar reference signs.

The setting tool <NUM> may include a tubular housing <NUM>, a sleeve <NUM>, a first seal 2230a, a second seal 2230b, one or more threaded ports 2240t, one or more shearable plugs <NUM>, and a fluid bypass <NUM>. The tubular housing <NUM> defines a central bore <NUM>. To facilitate manufacturing and assembly, the tubular housing <NUM> may include one or more sections 2210a-h connected together, such as by threaded couplings and/or fasteners. Seals <NUM> may be placed between the interconnecting tubular housing sections to maintain sealing and pressure integrity of the setting tool <NUM>. The tubular housing <NUM> has a connection each end, such as a pin 2201a a box 2201b. The one or more threaded ports 2240t are formed through the tubular housing <NUM>, such as through tubular housing section 2210d. The one or more threaded ports 2240t, are disposed between the first and second seals 2230a,b. The first and second seals 2230a,b are configured to sealing engage with the inner surface of the bore <NUM> of the LHA <NUM> and to straddle the port <NUM>. For example, the seals 2230a,b may sealing engage with the inner surface of the tubular mandrel <NUM> of the liner hanger <NUM>. While the first and second seals 2230a,b are engaged with the inner surface of the bore <NUM>, a pressure chamber <NUM> is present between the seals 2230a,b. In some embodiments, the pressure chamber <NUM> is filled with air at atmospheric pressure. In some embodiments, the pressure chamber <NUM> is filled with a fluid at a set pressure.

The sleeve <NUM> is movable from a closed position to an open position. The sleeve <NUM> includes a seat <NUM> and a retainer <NUM>. The seat <NUM> may be coupled to or integrally formed with the sleeve <NUM>. The retainer <NUM> may be a retaining recess or a retaining bore formed through a wall of the sleeve <NUM> as shown in <FIG>. One or more seals <NUM> may be disposed about the seat <NUM>. The sleeve <NUM> is disposed in the central bore <NUM>. When the sleeve <NUM> is in the closed position, the sleeve <NUM> is releasably attached to the tubular housing <NUM> via one or more shearable plugs <NUM>. The shearable plugs <NUM> are a shearable member. A cross section of the shearable plug <NUM> is shown in <FIG>. The shearable plugs <NUM> may have threads <NUM>, a flow bore <NUM>, a closure member <NUM>, and a groove <NUM>. The threads <NUM> correspond to the threads of the threaded port 2240t. The one or more shearable plugs <NUM> are partially disposed in the one or more threaded ports 2240t and the retainer <NUM> to hold the sleeve <NUM> in the closed position. The closure member <NUM> is at least partially disposed in the retainer <NUM>. The retainer <NUM> may have threads corresponding to threads of the shearable plug <NUM> located about the shearable member <NUM>. As shown in <FIG>, the closure member <NUM> is a cap. An O-ring <NUM> may be placed in the groove <NUM> to seal against the inner surface of the threaded port 2240t.

Before the sleeve <NUM> is actuated to move from the closed position to the open position, fluid communication between the central bore <NUM> and the pressure chamber <NUM> is blocked by the shearable plug <NUM>. A first object <NUM>, such as a ball or a dart, can be engaged with the seat <NUM> to facilitate a pressure buildup above the first object <NUM> in order to actuate the sleeve <NUM>. The one or more shearable plugs <NUM> will fail along a shear plane in response to sufficient pressure such that a portion of the shearable plug <NUM>, such as the shearable member <NUM>, is sheared off by the sleeve <NUM> to expose the flow bore <NUM> as the sleeve <NUM> moves from the closed positon to the open position. Once the flow bore <NUM> is opened, a flow path is present between the central bore <NUM> and the pressure chamber <NUM>. In some embodiments the retainer <NUM> is configured to retain the sheared off portion of the shearable plug <NUM>, such as the closure member <NUM>, in order to prevent the sheared off portion from falling downhole.

The fluid bypass <NUM> is disposed in the tubular housing <NUM> to allow communication above and below the first and second seals 2230a,b when the seals 2230a,b are sealingly engaged with inner surface of the bore <NUM> of the LHA <NUM>. Thus, the fluid bypass <NUM> allows for fluid communication around the seals 2230a,b. The fluid bypass <NUM> allows the annulus portion 101a of the annulus <NUM> of the liner string <NUM> between by the packoff <NUM> and the first seal 2230a to be in fluid communication with the annulus portion 101b below the second seal 2230b. Thus, the annulus portion 101a of the annulus between the packoff <NUM> and first seal 2230a can fill with wellbore fluid during run-in and pressure equalize to minimize the risk of collapse of a portion of the LHA <NUM> between the packoff <NUM> and the first seal 2230a.

<FIG> show cross sections of the setting tool <NUM> to better illustrate the fluid bypass <NUM> and setting tool <NUM>. The fluid bypass extends from one or more openings 2262a to one or more openings 2262b. The fluid bypass <NUM> is not in fluid communication with the one or more threaded ports 2240t. The fluid bypass <NUM> can be formed from a combination of gaps and/or bores present in the tubular housing <NUM>. For example, one or more gaps 2270a may be present between the tubular housing sections 2210a and 2110c and one or more gaps 2270b may be present between tubular housing sections 2210f and <NUM>. As shown in <FIG> (dashed lines) and <FIG>, one or more bores 2272a may be formed in the tubular housing section 2210d. As shown in <FIG> (dashed lines) and <FIG>, one or more bores 2272b may be formed in the tubular housing section 2210e. The gaps 2270a,b, bores 2272a,b, and openings 2262a,b form the fluid bypass <NUM>. In some embodiments, the number of bores 2272a is less than the number of bores 2272b, and vice versa. In some embodiments, the fluid bypass <NUM> may be a plurality of individual fluid bypasses formed in the tubular housing <NUM>.

In some embodiments, the one or more ports are not threaded ports 2240t, and the shearable plugs <NUM> do not have threads <NUM> and are instead fastened into one or more of the ports with one or more fasteners, such as bolts. In some embodiments, the shearable plug <NUM> is made of metal. For example, the shearable plug <NUM> may be brass. In some embodiments, the shearable plug <NUM> may be formed from a plastic.

An actuation sequence of the setting tool <NUM> and liner hanger <NUM> is described in <FIG>. The setting tool <NUM> and liner hanger <NUM> are shown disposed in the casing <NUM> at a setting depth. As shown in <FIG>, the sleeve <NUM> is in the closed position. The pressure chamber <NUM>, and thus piston chamber <NUM>, is isolated from the central bore <NUM> by the one or more shearable plugs <NUM> when the sleeve <NUM> is in the closed position. The pressure chamber <NUM> is isolated from the annulus portion 101a by the first seal 2230a. The pressure chamber <NUM> is isolated from the annulus portion 101b by the second seal 2230b. After the liner hanger <NUM> reaches setting depth, a first object <NUM> is dropped into the wellbore where it will engage with the seat <NUM> as shown in <FIG>. After the first object <NUM> engages the seat <NUM>, pressure is increased above the first object <NUM> to actuate the sleeve <NUM>. The pressure is increased until the one or more shearable plugs <NUM> shear and the sleeve <NUM> moves from the closed position to the open position as shown in <FIG>. As shown, the closure member <NUM> is retained in the retainer <NUM>. When the sleeve <NUM> is in the open position, the pressure chamber <NUM>, and thus piston chamber <NUM>, is no longer isolated from the central bore <NUM>. Thus fluid communication is established between the central bore <NUM> and the slip actuation assembly <NUM> via the flow bore <NUM> and port <NUM>. For example, if the pressure chamber <NUM> was originally filed with air, it fills with wellbore fluids once the flow bore <NUM> is exposed. As shown in <FIG>, pressure may continue to be increased above the first object <NUM> until the one or more shearable members <NUM> shear and the slip actuation assembly <NUM> moves the slips <NUM> up the ramps <NUM> into the set position. In some embodiments, however, the one or more shearable plugs <NUM> may be designed to shear at the pressure necessary to shear the one or more shearable members <NUM>.

A test may be conducted to confirm that the liner hanger <NUM> has been set, such as by pulling or pushing on the liner string <NUM> from the surface to confirm that the slips <NUM> are set. Once the operator has determined that the liner hanger <NUM> is set, the LHDA <NUM> is released from the LHA <NUM>. Releasing and verifying release of the LHDA <NUM> can be accomplished in the same manner discussed above with respect to setting tool <NUM>. Then pressure can be increased above the first object <NUM> until the first object <NUM> passes through the ball seat <NUM>, as shown in <FIG>. In some embodiments, the first object <NUM> may be removed from the seat <NUM> prior to releasing the LHDA <NUM> from the LHA <NUM>.

In some embodiments, a cementation operation may begin once the LHDA <NUM> is released from the LHA <NUM>. For example, a second object <NUM>, such as a cementation dart or a ball, may be dropped into the liner string <NUM> above a cement. The second object <NUM> travels in the liner string <NUM> until it engages the seat <NUM>, as shown in <FIG>. Pressure may be increased above the second object <NUM>, if necessary, to pass the second object through the seat <NUM>. The second object <NUM> will continue to travel through the LHDA <NUM> until it engages the plug assembly <NUM> or other wellbore equipment below the seat <NUM>. <FIG> illustrates the setting tool <NUM> disposed in the liner hanger <NUM> after the second object <NUM> has passed through the seat <NUM>. Additional objects may be dropped as necessary to complete the cementation operation.

After the cementation operation is complete, the packer <NUM> may be set. In some embodiments, the packer <NUM> may be set without completing a cementation operation. Once the LHDA <NUM> has completed its wellbore operations, it may be retrieved from the wellbore.

In some embodiments, the setting tool <NUM> includes a second set of one or more ports that are selectively blocked by a second sleeve in a similar manner as the setting tool <NUM>. Thus, the liner string <NUM> can be deployed into the wellbore with the pressure chamber <NUM> in fluid communication with the central bore <NUM>. When a pressure chamber <NUM> set depth is reached, the second sleeve is actuated to isolate the pressure chamber <NUM> from the central bore <NUM>. The liner string <NUM> can be deployed further into the wellbore until the setting depth is reached. At the setting depth, the sleeve <NUM> can be actuated to allow fluid communication between the pressure chamber <NUM> and the central bore <NUM>.

While liner hanger <NUM> has been described, it is foreseeable that the setting tools <NUM>, <NUM>, <NUM> may be used to set downhole tools other than a liner hanger. For example, the setting tools <NUM>, <NUM>, <NUM> may be used to set a packer, and the first and second seals are straddle a port of the packer.

In some embodiments, the one or more shearable members <NUM>, <NUM>, <NUM> are shear screws.

An exemplary downhole operation of the liner string <NUM> begins by running the liner string <NUM> into the wellbore. Once the liner string reaches the setting depth, the respective setting tool <NUM>, <NUM>, <NUM> is actuated by increasing pressure above a first object <NUM>, <NUM>, <NUM> to allow the actuation of the liner hanger <NUM>. Fluid pressure is increased above the first object engaged with the respective setting tool <NUM>, <NUM>, <NUM> until the slips <NUM> are set. Then a test may be conducted to confirm that the slips <NUM> are set. Then, the LHDA <NUM> may be released from the LHA <NUM>. A test may be conducted to verify that the LHDA <NUM> has been released from the LHA <NUM>. Then a cementation operation may occur. Once the cementation operation is completed, the packer <NUM> may be actuated. The packer <NUM> may be actuated by applying force (e.g., weight) to the top of the PBR <NUM> via dogs <NUM> after the LHDA <NUM> is lifted to allow the dogs <NUM> to move to the expanded position. Once the LHDA <NUM> has completed its wellbore operations, it may be retrieved (e.g., tripped out) since it is no longer attached to the LHA <NUM>.

In some embodiments, the liner string <NUM> lands on the bottom of the wellbore. If this occurs, the liner hanger <NUM> might not be actuated to set the slips <NUM>. The LHDA <NUM> may be released from the LHA <NUM> before beginning a cementation operation. Once the cementation operation is completed, the packer <NUM> may then be set.

In some embodiments, the cementation operation occurs before the LHDA <NUM> is released from the LHA <NUM>.

In some embodiments, the slips <NUM> are set after the completion of the cementing operation.

In some embodiments, the liner string <NUM> includes a setting tool with a second sleeve, such as second sleeve <NUM>. The liner string <NUM> is first advanced to a depth sufficient to actuate (e.g., trigger) the second sleeve to isolate the downhole tool actuation assembly, such as the slip actuation assembly <NUM>.

In some embodiments, the plug assembly <NUM> includes one releasable plug which is actuated in response to an object dropped from the surface, such as the object used to actuate the setting tools <NUM>, <NUM>, <NUM>. In some embodiments, the plug assembly <NUM> includes more than one releasable plug, such as two releasable plugs or three releasable plugs. In some embodiments, objects dropped from the surface actuate other wellbore equipment below the setting tools <NUM>, <NUM>, <NUM>.

In some embodiments, the running tool <NUM> may not have threads <NUM> and the LHA <NUM> may not have threads <NUM>. Instead, the running tool <NUM> may have collets and/or dogs that engage with a profile of the LHA <NUM>. The running tool <NUM> is therefore releasably attached to the LHA <NUM> via the engagement of the collets and/or dogs with the profile. In some embodiments, the running tool may be similar to the running tool disclosed in <CIT>.

In some embodiments, the packoff <NUM> is disposed above the running tool <NUM>. In some embodiments, the packoff <NUM> is sealingly engaged with the inner surface of the PBR <NUM>.

In some embodiments, the LHDA <NUM> may include two or more setting tools to set multiple downhole tools of the LHA <NUM>. The object used to actuate the first setting tool may be used to set the other setting tools of the LHDA <NUM>.

In some embodiment, fluid communication around the first and second seals comprises fluid communication between a first and a second opening disposed proximate opposite ends of the tubular housing, wherein the first and second seals are disposed between the first and the second openings.

In some embodiments, the tubular housing is composed of a plurality of tubular housing sections, and wherein the fluid bypass includes one or both of: one or more gaps between the tubular housing sections, and one or more bores through individual tubular housing sections.

In some embodiments, multiple fluid bypasses are disposed in the tubular housing and configured to allow fluid communication around the first seal and the second seal.

In some embodiments, the first sleeve blocks fluid communication between the central bore and the first port in the closed position.

In some embodiment, the setting tool includes a second port formed through the tubular housing and disposed between the first and second seals. In some embodiments, the setting tool includes a second sleeve disposed in the central bore and movable from an open position to a closed position. In some embodiments, the setting tool includes a chamber between the second sleeve and the tubular housing. The second port and the central bore are in fluid communication when the second sleeve is in the open position, and wherein fluid communication between the second port and the central bore is blocked when the second sleeve is in the closed position.

In some embodiments, the setting tool includes at least one second shearable member configured to releasably attach the second sleeve to the tubular housing in the open position.

In some embodiments, the at least one second shearable member and the chamber are configured such that the at least one second shearable member shears at a predetermined depth, and wherein the second sleeve moves to the closed position in response to a fluid pressure in the central bore.

In some embodiments, the second sleeve includes one or more sleeve ports in fluid communication with the central bore and the second port when the second sleeve is in the open position.

In some embodiments, the at least one first shearable member is at least one shearable plug, the shearable plug including a flow bore and a closure member, wherein the closure member blocks fluid communication between the central bore and the flow bore when the first sleeve is in the closed position.

In some embodiments, the closure member is configured to shear from the shearable plug to expose the flow bore to fluid communication with the central bore as the first sleeve moves to the open position.

In some embodiments, wherein the first sleeve includes a retainer configured to retain the closure member that is sheared from the shearable plug.

In some embodiments, the method of conducing the wellbore operation further includes releasing the liner hanger deployment assembly from the liner hanger assembly.

In some embodiments, the method of conducing the wellbore operation further includes conducting a cementation operation.

In some embodiments, the method of conducing the wellbore operation further includes setting a packer of the liner hanger assembly.

In some embodiments of the method of conducing the wellbore operation, the setting tool includes a first sleeve and a second sleeve, wherein the second sleeve is configured to actuate at a first depth to isolate the actuation assembly from the central bore, and wherein the method further includes deploying the liner string to the first depth and actuating the second sleeve prior to deploying the liner string to the setting depth.

While the foregoing is directed to embodiments of the present disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow. from an open position to a closed position. In some embodiments, the liner string further includes a chamber in fluid communication with the liner hanger actuation assembly disposed between the setting tool and the liner hanger, wherein the chamber is isolated from the central bore when the first sleeve is in the closed position and the second sleeve is in the closed position, wherein the chamber is in fluid communication with the central bore when the first sleeve is in the closed position and the second sleeve is in the open position, and wherein the chamber is in fluid communication with the central bore when the first sleeve is in the open position and the second sleeve is in the closed position.

A method of actuating a liner hanger includes deploying a liner string including a liner hanger to a setting depth, wherein the liner string includes a setting tool disposed in the liner hanger, wherein the liner hanger includes an actuation assembly and a plurality of slips, and wherein the actuation assembly is isolated from fluid communication with a central bore of the setting tool at the setting depth. The method further includes opening a first fluid communication path between the central bore and the actuation assembly to establish fluid communication therebetween. The method further includes increasing the pressure in the central bore to actuate the actuation assembly to set the plurality of slips.

In some embodiments, the method of actuating a liner hanger includes prior to reaching the setting depth, deploying the liner string to a first depth. Upon reaching the first depth, a second fluid communication path between the central bore and the actuation assembly is closed to isolate the actuation assembly from fluid communication with the central bore.

In some embodiments, the method of actuating a liner hanger further includes retrieving the setting tool after setting the slips.

A setting tool for a downhole tool includes a tubular housing having a central bore. The setting tool further includes a first seal and a second seal disposed about an exterior of the tubular housing. The setting tool further includes a first port formed through the tubular housing and disposed between the first seal and the second seal. The setting tool further a first sleeve disposed in the central bore and movable from a closed position to an open position, the first sleeve having a seat. The setting tool further includes a shearable plug disposed in the first port and configured to releasably attach the first sleeve to the tubular housing in the closed position. The shearable plug further includes a flow bore. The shearable plug further includes a closure member blocking fluid communication between the flow bore and the central bore, wherein the closure member is configured to be sheared away to expose the flow bore to fluid communication with the central bore, wherein the closure member is sheared away by the movement of the first sleeve from the closed position to the open position.

In some embodiments of the setting tool, the first sleeve includes a retainer configured to retain the closure member that is sheared from the shearable plug.

In some embodiments, the setting tool further includes one or more second ports formed through the tubular housing and disposed between the first and second seals. In some embodiments, the setting tool further includes a second sleeve disposed in the central bore and movable from an open position to a closed position. In some embodiments, the setting tool further includes a chamber between the second sleeve and the tubular housing. In some embodiments, the setting tool further includes at least one second shearable member configured to releasably attach the second sleeve to the tubular housing in the closed position. The one or more second ports and the central bore are in fluid communication when the second sleeve is in the open position, and wherein fluid communication between the one or more second ports and the central bore is closed when the second sleeve is in the closed position.

In some embodiments of the setting tool, the at least one second shearable member and the chamber are configured such that the at least one second shearable member shears at a predetermined depth, and wherein the second sleeve moves to the closed position in response to a fluid pressure in the central bore.

In some embodiments of the setting tool, the second sleeve includes one or more sleeve ports in fluid communication with the central bore and the one or more second ports when the second sleeve is in the open position.

A method of conducting a wellbore operation includes deploying a liner string into a wellbore to a setting depth. The liner string includes a liner hanger assembly including a liner hanger with an actuation assembly, and a liner hanger deployment assembly attached to the liner hanger assembly and including a setting tool, wherein the setting tool is configured to isolate the actuation assembly from fluid communication with a central bore of the setting tool. The method further includes actuating the setting tool to allow fluid communication between the central bore and the actuation assembly. The method further includes actuating the liner hanger.

A method of hanging a liner in a wellbore includes deploying a liner string to a setting depth in the wellbore. The liner sting includes a liner hanger having an actuation assembly, wherein the liner hanger is coupled to the liner. The liner string further includes a setting tool disposed in the liner hanger. The setting tool includes a central bore. The setting tool further includes a first sleeve having a seat, wherein the first sleeve is movable from a closed position to an open position, and wherein fluid communication between the central bore and the actuation assembly is blocked when the first sleeve is in the closed position and unblocked when the first sleeve is in the open position. The setting tool further includes one or more first shearable members configured to retain the first sleeve in the closed position. The method further includes moving the first sleeve from the closed position to the open position by engaging a first object with the seat to shear the one or more first shearable members. The method further includes actuating the actuation assembly to hang the liner.

In some embodiments of a method of hanging the liner in the wellbore, prior to reaching the setting depth, deploying the liner hanger to a first depth, wherein a second sleeve of the setting tool moves from an open positon to a closed position in response to reaching the first depth to isolate the actuation assembly from the central bore.

Claim 1:
A setting tool (<NUM>) for a liner hanger (<NUM>), comprising:
a tubular housing (<NUM>) having a central bore (<NUM>);
a first seal (1230a) and a second seal (1230b) disposed about an exterior of the tubular housing (<NUM>);
a first port (<NUM>) formed through the tubular housing (<NUM>) and disposed between the first seal (1230a) and the second seal (1230b);
a first sleeve (<NUM>) disposed in the central bore (<NUM>) and movable from a closed position to an open position, the first sleeve (<NUM>) having a seat (<NUM>);
at least one first shearable member (<NUM>) configured to releasably attach the first sleeve (<NUM>) to the tubular housing (<NUM>) in the closed position;
at least one fluid bypass (<NUM>) disposed in the tubular housing (<NUM>) and configured to allow fluid communication around the first seal (1230a) and the second seal (1230b); and
wherein the central bore (<NUM>) and the first port (<NUM>) are in fluid communication when the first sleeve (<NUM>) is in the open position.