Development and Commercial Deployment of an Expandable Monobore Liner Extension

Stockmeyer, Carl F.; Tillman, David L.; Weirich, John B.; Sehnal, Zdenek

doi:10.2118/102150-ms

All Days 2006

DOI: 10.2118/102150-ms

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Development and Commercial Deployment of an Expandable Monobore Liner Extension

Carl F. Stockmeyer

David L. Tillman

John B. Weirich

et al.

Abstract: TX 75083-3836, U.S.A., fax 01-972-952-9435. AbstractFor a number of years, the exploration and production industry has sought to prove the feasibility of monobore expandable liner extensions as an advantageous alternative to conventional casing designs. Included as part of the initial casing design, the goal of an expandable monobore liner extension is to enable the operator to drill deeper exploration and production wells with larger hole sizes at the reservoir. As a contingency plan, the goal is to enable th… Show more

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Monobore Expandable Liner Extension Deployment Saves Well From Abandonment

et al. 2011

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Caving, sloughing, and swelling shale sections, combined with lost returns below 13-3/8-in. casing, were encountered in an Egyptian well. Before the 12.25-in. hole section was completed, shales packed off the drillstring and part of the bottomhole assembly (BHA) was left in the hole. Casing (9-5/8-in.) was run as deep as hole conditions allowed, with a recess shoe to enable a monobore expandable liner extension. Following drillout of the shoe, conditions presented the same challenges previously experienced. The 8-in.outside diamer (OD) liner extension system was run, but well conditions prevented getting the liner to depth and it was pulled out of the hole. Conditioning trips with increased mud weight up to 12.3 pounds per gallon (ppg), reaming and backreaming, along with an open hole cementing effort, were performed for stabilization. A second attempt was made to run in the hole. The hanger located in the recess shoe profile of the 9-5/8-in. casing and the system was expanded to the same inside diameter as the casing above. The expanded liner’s shoe was now located just above the previously left BHA, but the trouble zone sections were isolated with no reduction in hole size from the previous casing. The expanded liner was pressure tested to 1,000 psi before cementing. Recess shoe ports were enabled and initial circulation established, and the wellbore did indeed pack off and build pressure, preventing full annular cement. Pressure inside the casing was applied and 15 barrels (bbl) of cement were squeezed into the hole. A casing exit was milled in the expanded monobore liner to enable bypassing the BHA that was left in the hole from previous drilling operations. The case history explored in this paper highlights overcoming substantial issues using expandable drilling liner technology via a monobore liner extension that resulted in successful installation and circulation. The preplanning, installation considerations, expansion process, lessons learned and post-deployment results will be discussed.

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Monobore Expandable Liner Extension Deployment Saves Well From Abandonment

et al. 2011

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Monobore Expandable Liner Extension Saves Well With Problematic Drilling Programme from Abandonment

et al. 2011

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To circumvent or minimize non-productive time (NPT) in wells where drilling programs with problematic drilling sections would be expected, the Monobore Expandable Liner Extension System (MELES) was developed. A recent exploration project in Egypt predicted costly and time consuming drilling hazards in their well programme and planned the MELES as a contingency system should these situations be realized. While drilling the 12.25-in. hole section below the 13-3/8-in. casing, situations with caving, sloughing, and swelling shale sections, combined with lost returns were encountered. Before the 12.25-in. hole section was completed, shales packed off the drillstring and part of the bottomhole assembly (BHA) was left in the hole. The MELES was no longer a contingency, but would now be required in the casing design to reach the target evaluation depth with a sufficient hole size of 6.0-in. Casing (9-5/8-in.) was run as deep as hole conditions allowed, with a recess shoe to enable the monobore expandable liner extension below. Following drillout of the recess shoe, open hole conditions presented the same challenges previously experienced. The 8-in.outside diameter (OD) liner extension system was run, but well conditions prevented getting the expandable liner to depth and it was pulled out of the hole. Conditioning trips with increased mud weight up to 12.3 pounds per gallon (ppg), reaming and backreaming, along with an open hole cementing effort, were performed for stabilization. A second attempt was made to run in the hole. The hanger located in the recess shoe profile of the 9-5/8-in. casing and the system was expanded to the same inside diameter as the casing above. The expanded liner's shoe was now located just above the previously left BHA, but the trouble zone sections were isolated with no reduction in hole size from the previous casing. The expanded liner was pressure tested to 1,000 psi before cementing. Recess shoe ports were enabled and initial circulation established, and the wellbore did indeed pack off and build pressure, preventing full annular cement. Pressure inside the casing was applied and 15 barrels (bbl) of cement were squeezed into the hole. A casing exit was milled in the expanded monobore liner to enable bypassing the BHA that was left in the hole from previous drilling operations. The case history explored in this paper highlights overcoming substantial issues using expandable drilling liner technology via a monobore liner extension that resulted in successful installation and circulation. The preplanning, installation considerations, expansion process, lessons learned and post-deployment results will be discussed.

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Development and First Application of Monobore Openhole Expandable Clad in the Tarim Oilfield

Guo

Yin

et al. 2018

Day 2 Tue, January 30, 2018

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The application of the first open-hole expandable liner in Tarim Basin has demonstrated the value of the numerical models developed to assess the effects of the required large expansion ratio, particularly on connection sealability. This paper discussed the modeling, the assessment of the highly expanded thread form, lab testing to confirm its performance, and the field application. The expandable casing was required to span 127 m of open-four hole to prevent the closure of a section of mobile mudstone. The 10 ¾ in. in originally planned across the interval could not be run due to the tight hole, and the expandable was successful in allowing the well to continue below the mudstone in an 8 ½ in. hole. The concern was the effect of the large expansion ratio on the sealability of the connector. ABAQUS was utilized to build a model which was then calibrated with ten groups of expansion tests with a variable diameter cone. Tests included both internal and external pressure loads. Expansion ratios of 20.2% were achieved in the lab without tube failure or thread leakage at the loads expected in the Tarim Basin application. The casing was successfully installed and expanded in June 2016, and drilling continued to the planned total depth. The success of the modeling in lab and field applications creates confidence that the model itself can be used to develop designs for other loading conditions in other applications with minimal full-scale lab testing. While there is an additional opportunity in the Tarim Oilfield, confidence in a generalized model will encourage engineers to assess other opportunities. The ability to predict expansion stresses and sealability are also seen as the first step for the operator in the development of a monobore system that provides full pass-through and a casing-to-casing seal that can be deployed economically in the low-cost Tarim Basin operations.

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Development and Commercial Deployment of an Expandable Monobore Liner Extension

Cited by 3 publications

References 0 publications

Monobore Expandable Liner Extension Deployment Saves Well From Abandonment

Monobore Expandable Liner Extension Deployment Saves Well From Abandonment

Monobore Expandable Liner Extension Saves Well With Problematic Drilling Programme from Abandonment

Development and First Application of Monobore Openhole Expandable Clad in the Tarim Oilfield

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