Liner hanger assembly having running tool with expandable member and method

1. A downhole system having a liner hanger assembly comprising:

a liner hanger having an inner surface defining a passage;

a running tool extending into the passage, the running tool including a tubular having an outer surface and an expandable member disposed circumferentially around the tubular and supported on at least one of the inner surface and the outer surface, the other of the inner surface and the outer surface including a securement area having a variable diameter section including multiple adjacent distinct diameter portions, the expandable member configured to increase in volume from a first condition to a second condition at a surface location and connect with the securement area, wherein the second condition of the expandable member connects the running tool to the liner hanger; and

a release mechanism disposed between the liner hanger and the tubular, the release mechanism including a wire helically wrapped about the tubular, the wire having a first end connected to the tubular and a second end connected to the liner hanger, the release mechanism being configured to selectively break a seal between the running tool and the liner hanger when the expandable member is in the second condition wherein the wire is configured to break through the expandable member upon rotation of the tubular with respect to the liner hanger.

2. The downhole system of claim 1 , wherein the expandable member includes a swellable material.

3. The downhole system of claim 1 , wherein an outer diameter of the expandable member in the second condition is greater than an outer diameter of the expandable member in the first condition.

4. The downhole system of claim 1 , wherein the securement area includes first and second diameters, the first diameter greater than the second diameter, the expandable member in the second condition extends into the first diameter locking the liner hanger to the tubular.

5. The downhole system of claim 1 , further comprising a liner string connected to a downhole end of the liner hanger.

6. The downhole system of claim 1 , wherein the expandable member is disposed in the first condition on an exterior surface of the tubular and/or on an interior surface of the liner hanger, and the tubular is longitudinally movable with respect to the liner hanger in the first condition of the expandable member, and the tubular is longitudinally fixed with respect to the liner hanger in the second condition of the expandable member.

7. The downhole system according to claim 1 , wherein the expandable member includes a first expandable member provided on the inner surface of the liner hanger and a second expandable member provided on the outer surface of the tubular, the first expandable member and the second expandable being configured to increase in volume in the second condition so as to engage with one another and form the securement area.

8. The downhole system according to claim 1 , wherein the multiple distinct diameters define a sawtooth-shaped profile.

9. A method of assembling a liner hanger assembly, the method comprising:

disposing an expandable member in a first condition circumferentially around a tubular;

arranging the tubular and expandable member within a liner hanger at a surface location, the liner hanger including an inner surface having a securement area having a variable diameter section including multiple adjacent distinct diameter portions;

expanding the expandable member to have a second condition into the securement area and to connect the tubular to the liner hanger at the surface location; and

attaching a release mechanism to the tubular and the liner hanger before disposing the expandable member around the tubular, the release mechanism including a wire helically wrapped about the tubular, wherein disposing the expandable member around the tubular includes at least partially trapping the wire between the tubular and the expandable member, the wire being configured to break through the expandable member upon rotation of the tubular with respect to the liner hanger.

10. The method of claim 9 , wherein expanding the expandable member at the surface location includes introducing an activator fluid within an annulus between the liner hanger and the tubular.

11. The method of claim 10 , wherein introducing the activator fluid includes placing the liner hanger and the expandable member within a tub of the activator fluid.

12. The method of claim 9 , further comprising connecting a liner string to a downhole end of the liner hanger after expanding the expandable member.

13. The method of claim 9 , wherein arranging the tubular and expandable member within a liner hanger at the surface location includes positioning the expandable member at a sawtooth-shaped profile defining the securement area.

14. A method of operating a liner hanger assembly having a running tool and a liner hanger, the method comprising:

running the liner hanger having an inner surface downhole using the running tool having an outer surface, the running tool connected to the linger hanger by an expandable member through an interaction with a securement area having a variable diameter section including multiple adjacent distinct diameter portions, the expandable member having an increase in volume from a first condition to a second condition at a surface location prior to running the liner hanger downhole; and,

setting the liner hanger within an outer tubular at a downhole location;

wherein the running tool is configured to carry a weight of the liner hanger using the expandable member during run-in; and

after setting the liner hanger, rotating the running tool relative to the liner hanger to break a seal created by the expandable member using a release mechanism including a wire helically wrapped about the running tool, the wire breaking through the expandable member to break the seal.

15. The method of claim 14 , wherein the expandable member includes a swellable material exposed to an activator fluid at the surface location, the swellable material extending into the securement area.

16. The method of claim 14 , wherein the running tool is connected to the linger hanger by an expandable member through an interaction with a sawtooth-shaped profiled defining the securement area.