Downhole setting tool with dual hydraulic release

Patent metadata

Field	Value
Publication number	US-12428923-B1
Application number	US-202418792875-A
Country	US
Kind code	B1
Filing date	Aug 2, 2024
Priority date	Aug 2, 2024
Publication date	Sep 30, 2025
Grant date	Sep 30, 2025

Abstract

A downhole tool includes a mandrel and a lower sleeve positioned at least partially within the mandrel. The lower sleeve defines a first seat that is configured to receive a first impediment. The first impediment being received within the first seat triggers a primary hydraulic release of the downhole tool from a second downhole tool in a wellbore. The downhole tool also includes an upper sleeve positioned at least partially within the mandrel. The upper sleeve defines a second seat that is configured to receive a second impediment. The upper sleeve is configured to move in a downward direction from a first upper sleeve position to a second upper sleeve position in response to the second impediment being received in the second seat, which triggers a secondary hydraulic release of the downhole tool from the second downhole tool in the event that the primary hydraulic release fails.

First claim

What is claimed is:

1. A downhole tool, comprising:
a mandrel;
a lower sleeve positioned at least partially within the mandrel, wherein the lower sleeve defines a first seat that is configured to receive a first impediment, and wherein the first impediment being received within the first seat triggers a primary hydraulic release of the downhole tool from a second downhole tool in a wellbore;
an upper sleeve positioned at least partially within the mandrel, wherein the upper sleeve defines a second seat that is configured to receive a second impediment, wherein the upper sleeve is configured to move in a downward direction from a first upper sleeve position to a second upper sleeve position in response to the second impediment being received in the second seat, which triggers a secondary hydraulic release of the downhole tool from the second downhole tool in the event that the primary hydraulic release fails; and
a collet, wherein the primary hydraulic release and the secondary hydraulic release both attempt to cause the collet to disengage with the second down hole tool, thereby releasing the downhole tool from the second downhole tool in the wellbore.

2. The downhole tool of claim 1 , wherein the mandrel comprises an upper portion, an intermediate portion, and a lower portion, and wherein the lower sleeve is positioned at least partially within the lower portion of the mandrel.

3. The downhole tool of claim 2 , wherein the upper sleeve is positioned at least partially within the intermediate portion of the mandrel.

4. A downhole tool, comprising:
a mandrel;
a lower sleeve positioned at least partially within the mandrel, wherein the lower sleeve defines a first seat that is configured to receive a first impediment, and wherein the first impediment being received within the first seat triggers a primary hydraulic release of the downhole tool from a second downhole tool in a wellbore;
an upper sleeve positioned at least partially within the mandrel, wherein the upper sleeve defines a second seat that is configured to receive a second impediment, wherein the upper sleeve is configured to move in a downward direction from a first upper sleeve position to a second upper sleeve position in response to the second impediment being received in the second seat, which triggers a secondary hydraulic release of the downhole tool from the second downhole tool in the event that the primary hydraulic release fails; and
a support dog positioned at least partially around the upper sleeve, wherein the support dog is configured to move from a first support dog position to a second support dog position in response to the upper sleeve moving from the first upper sleeve position to the second upper sleeve position.

5. The downhole tool of claim 4 , further comprising a collet support positioned at least partially around the support dog, wherein the collet support is configured to move from a first collet support position to a second collet support position in response to the support dog moving from the first support dog position to the second support dog position.

6. The downhole tool of claim 5 , wherein the collet support defines a radial flow bypass port, wherein the radial flow bypass port is obstructed when the collet support is in the first collet support position, and wherein the radial flow bypass port is unobstructed when the collet support is in the second collet support position, thereby enabling circulation from a bore of the mandrel to an annulus outside of the downhole tool.

7. The downhole tool of claim 5 , wherein the collet support defines an axial slot, wherein an alignment screw extends from the mandrel at least partially though the axial slot, wherein the alignment screw extending at least partially through the axial slot allows the collet support to move from the first collet support position to the second collet support position and prevents the collet support from rotating with respect to the mandrel.

8. The downhole tool of claim 5 , wherein the support dog is positioned radially between the upper sleeve and the collet support.

9. The downhole tool of claim 8 , wherein the support dog extends radially through the mandrel.

10. The downhole tool of claim 5 , further comprising a collet positioned at least partially around the mandrel, wherein the collet is configured to disengage with the second downhole tool in response to the collet support moving from the first collet support position to the second collet support position.

11. A downhole tool that is configured to set a liner hanger system in a wellbore, the downhole tool comprising:
a mandrel comprising an upper portion, an intermediate portion, and a lower portion;
a lower sleeve positioned at least partially within the lower portion of the mandrel, wherein the lower sleeve defines a first seat that is configured to receive a first impediment, and wherein the first impediment being received within the first seat triggers a primary hydraulic release of the downhole tool from the liner hanger system;
an upper sleeve positioned at least partially within the intermediate portion of the mandrel, wherein the upper sleeve defines a second seat that is configured to receive a second impediment, wherein the upper sleeve is configured to move in a downward direction from a first upper sleeve position to a second upper sleeve position in response to the second impediment being received in the second seat, which triggers a secondary hydraulic release of the downhole tool from the liner hanger system in the event that the primary hydraulic release fails;
a support dog positioned at least partially around the upper sleeve, wherein the support dog is configured to move from a first support dog position to a second support dog position in response to the upper sleeve moving from the first upper sleeve position to the second upper sleeve position;
a collet support positioned at least partially around the support dog, wherein the collet support is configured to move from a first collet support position to a second collet support position in response to the support dog moving from the first support dog position to the second support dog position; and
a collet positioned at least partially around the mandrel, wherein the collet is configured to disengage with the liner hanger system in response to the collet support moving from the first collet support position to the second collet support position.

12. The downhole tool of claim 11 , wherein an outer surface of the upper sleeve has a larger diameter portion and a smaller diameter portion.

13. The downhole tool of claim 12 , wherein the support dog extends radially through the intermediate portion of the mandrel, wherein the support dog is aligned with the larger diameter portion of the outer surface of the upper sleeve when the upper sleeve is in the first upper sleeve position, and wherein the support dog moves inward and becomes aligned with the smaller diameter portion of the outer surface of the upper sleeve when the upper sleeve is in the second upper sleeve position.

14. The downhole tool of claim 13 , wherein the collet support is positioned at least partially around the intermediate portion of the mandrel, wherein the support dog engages the collet support and thereby prevents the collet support from moving in the downward direction from the first collet support position to the second collet support position when the support dog is aligned with the larger diameter portion of the outer surface of the upper sleeve, and wherein the support dog becomes disengaged with the collet support and thereby permits the collet support to move in the downward

Assignees

• Innovex Downhole Solutions Inc

Inventors

• Driller Brent
• Marr Graeme Thomas
• Morrison Callum

Classifications

• E21B23/0413

  using means for blocking fluid flow, e.g. drop balls or darts (using balls or the like for actuating downhole valves E21B34/142) · CPC title

• E21B33/04 Primary

  Casing heads; Suspending casings or tubings in well heads · CPC title

• E21B43/105 Primary

  Expanding tools specially adapted therefor · CPC title