Liner deployment assembly having full time debris barrier

1. An assembly for hanging a tubular string in a wellbore, comprising:

a packoff comprising a fastener and a seal for engaging an inner surface of the tubular string; and

a setting tool, comprising:

a debris cap for engaging an upper end of the tubular string, thereby forming a buffer chamber between the debris cap and the packoff;

a mandrel having a port formed through a wall thereof;

a piston: disposed along the mandrel, having an upper face in fluid communication with the port, and operable to stroke the debris cap relative to the mandrel, thereby setting a hanger of the tubular string;

an actuator sleeve extending along the mandrel and connected to the piston;

a packer actuator comprising a housing connected to the debris cap above the buffer chamber and a fastener for engaging a profile of the actuator sleeve, wherein the packer actuator is disposed above the buffer chamber; and

a latch releasably connecting the housing to the mandrel.

2. The assembly of claim 1 , wherein the latch comprises:

an inner sleeve connected to the mandrel;

an outer sleeve connected to the housing; and

a fastener releasably connecting the inner and outer sleeves.

3. The assembly of claim 2 , wherein:

the actuator sleeve comprises a ratchet sleeve and a lock sleeve,

the setting tool further comprises a push sleeve releasably connected to the outer sleeve and releasably connected to the lock sleeve, and

the push sleeve holds the lock sleeve in a position engaged with the fastener of the latch.

4. The assembly of claim 3 , wherein:

the setting tool further comprises a shearable pin carried by the lock sleeve,

the mandrel has a slot formed in and along an outer surface thereof for receiving the shearable pin,

the setting tool further comprises a fastener carried by the actuator sleeve for engaging a profile formed in the outer surface of the mandrel, and

the profile has an upper straight shoulder for connecting the mandrel and the actuator sleeve in a downward direction.

5. The assembly of claim 4 , wherein:

the setting tool further comprises a debris sleeve and a dog,

the dog is disposed in an opening formed through a wall of the debris cap and movable between an extended position and a retracted position,

the debris sleeve has a cam profile formed in an outer surface thereof for holding the dog in the extended position, and

a shearable fastener releasably connecting the debris sleeve to the debris cap.

6. The assembly of claim 4 , wherein:

the setting tool further comprises a cylinder connected to the mandrel,

an actuation chamber is formed between the cylinder and the mandrel, and

at least a portion of the piston is disposed in the actuation chamber and divides the chamber into an upper portion and a lower portion.

7. The assembly of claim 5 , wherein:

a lower end of the debris cap has a torsion profile formed therein,

an upper end of the cylinder has a torsion profile formed therein,

the torsion profiles are complementary, thereby being operable to torsionally connect the debris barrier and the cylinder,

the latch comprises an outer sleeve connected to the housing, and

the outer sleeve has reamer blades formed in an upper face thereof.

8. The assembly of claim 5 , wherein:

the debris cap has an inlet passage and an outlet passage formed therethrough, and

the setting tool further comprises an inlet check valve disposed in the inlet passage and an outlet check valve disposed in the outlet passage.

9. The assembly of claim 5 , wherein:

the debris cap has a fill passage formed therethrough closed by a plug, and

the debris cap has a relief passage formed therethrough closed by a rupture disk.

10. The assembly of claim 1 , wherein the packer actuator further comprises:

a keeper disposed in the housing;

an indicator sleeve disposed in the housing;

a shearable fastener releasably connecting the indicator sleeve to the housing;

a thrust bearing disposed between the keeper and the indicator sleeve; and

a radial bearing disposed between the keeper and the housing.

11. The assembly of claim 1 , further comprising:

a catcher having a seat for receiving a setting plug;

a passage for being in fluid communication with a lower face of the piston and bypassing the seat.

12. The assembly of claim 11 , further comprising:

a running tool connectable to the mandrel and operable to longitudinally and torsionally connect to the tubular string,

wherein:

the catcher is connectable to the running tool, and

the passage is formed in and along a wall of the running tool and formed in and along a wall of the catcher.

13. The assembly of claim 12 , wherein the running tool comprises:

a running mandrel connectable to the mandrel of the setting tool;

a latch for releasably connecting the tubular string to the running mandrel and comprising:

a longitudinal fastener for engaging a longitudinal profile of the tubular string; and

a torsional fastener for engaging a torsional profile of the tubular string;

a lock keeping the latch engaged in the locked position;

a piston for releasing the lock and having a lower face in fluid communication with a bore of running mandrel and an upper face in fluid communication with the passage; and

a clutch for selectively torsionally connecting the torsional fastener to the body.

14. The assembly of claim 11 , wherein the catcher is operable to release the seat and the setting plug from a body thereof and move the seat and the setting plug into a capture chamber.

15. The assembly of claim 11 , further comprising:

a damper connectable to the catcher

a stinger connectable to the damper;

a release connectable to the stinger;

a spacer connectable to the packoff; and

a plug release system connectable to the spacer and comprising:

an equalization valve; and

a wiper plug releasably connected to the equalization valve and operable to engage the inner surface of the tubular string.

16. A system, comprising:

the assembly claim 1 ; and

the tubular string comprising:

a polished bore receptacle (PBR) for engagement with the debris cap;

a packer connected to the PBR and having a metallic gland carrying an outer seal and an inner seal and a wedge operable to expand the metallic gland;

a hanger having an upper portion connected to the packer;

a body carrying the hanger and packer and having a latch profile for engagement with the running tool; and

a shearable fastener connecting the hanger upper portion to the body.

17. A method of hanging a tubular string in a wellbore, comprising:

running the tubular string into the wellbore using a pipe string and a deployment assembly having:

a debris cap releasably connected to and closing an upper end of the tubular string,

a packoff releasably connected to and engaged with the tubular string, and

a buffer fluid disposed in a chamber formed between the debris cap and the packoff;

pumping a setting plug through the pipe string to the deployment assembly, thereby operating a piston thereof to set a hanger of the tubular string;

after setting the hanger, lowering the pipe string, thereby setting a packer of the tubular string; and

after setting the packer, raising the pipe string, thereby releasing the debris cap and opening the chamber of the buffer fluid.

18. The method of claim 17 , wherein:

the deployment assembly further has a mandrel and a seat connected to the mandrel,

the piston has an upper face in communication with a port formed through the mandrel above the seat, and

the setting plug is pumped to the seat.

19. The method of claim 17 , wherein:

the deployment assembly further has a packer actuator disposed above and connected to the debris cap,

the debris cap is releasably connected to the mandrel,

the piston also releases the debris cap from the mandrel, and

the method further comprises, after setting the hanger and before setting the packer, raising the mandrel and the piston, thereby engaging the packer actuator with the piston.

20. The method of claim 17 , wherein:

the deployment assembly further comprises a plug release system, and

the method further comprises, after setting the hanger and before setting the packer:

pumping cement slurry into the pipe string;

launching a dart into the pipe string;

pumping chaser fluid into the pipe string, thereby driving the dart and cement slurry through the pipe string and deployment assembly and seating the dart into a wiper plug of the plug release system.