Solid Expandable Tubular Technology - A Year of Case Histories in the Drilling 
Environment

Dupal, Kenneth; Campo, Donald B.; Lofton, John; Weisinger, Don; Cook, R.; Bullock, Michael; Grant, Thomas D.; York, Patrick

doi:10.2523/67770-ms

Cited by 20 publications

(7 citation statements)

References 1 publication

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“…In their experiments, this was achieved using (ductile) expandable casing tube technology [18,88], swaged open with a pull-through mandrel and internal expansion cones. While expandable steel casings can be used in both new and existing wells, and have been applied effectively in remedial operations targeting punctured casings [6], it remains a relatively new technology [32]. This means that both legacy and presently operating wells, i.e.…”

Section: Introductionmentioning

confidence: 99%

Reaction-driven casing expansion: potential for wellbore leakage mitigation

2017

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It is generally challenging to predict the postabandonment behaviour and integrity of wellbores. Leakage is, moreover, difficult to mitigate, particularly between the steel casing and outer cement sheath. Radially expanding the casing with some form of internal plug, thereby closing annular voids and fractures around it, offers a possible solution to both issues. However, such expansion requires development of substantial internal stresses. Chemical reactions that involve a solid volume increase and produce a force of crystallisation (FoC), such as CaO hydration, offer obvious potential. However, while thermodynamically capable of producing stresses in the GPa range, the maximum stress obtainable by CaO hydration has not been validated or determined experimentally. Here, we report uniaxial compaction/expansion experiments performed in an oedometer-type apparatus on precompacted CaO powder, at 65°C and at atmospheric pore fluid pressure. Using this set-up, the FoC generated during CaO hydration could be measured directly. Our results show FoC-induced stresses reaching up to 153 MPa, with reaction stopping or slowing down before completion. Failure to achieve the GPa stresses predicted by theory is attributed to competition between FoC development and its inhibiting effect on reaction progress. Microstructural observations indicate that reaction-induced stresses shut down pathways for water into the sample, hampering ongoing reaction and limiting the magnitude of stress build-up to the values observed. The results nonetheless point the way to understanding the behaviour of such systems and to finding engineering solutions that may allow large controlled stresses and strains to be achieved in wellbore sealing operations in future.

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Section: Introductionmentioning

confidence: 99%

Reaction-driven casing expansion: potential for wellbore leakage mitigation

2017

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“…The launcher is a canister at the bottom of the expansion system that houses the expansion cone. 2,3 The production casing was a 5 x 4-1/2 in. tapered string rather than a 5 in.…”

Section: Methodsmentioning

confidence: 99%

Slimming the Wellbore Design Enhances Drilling Economics in Field Development

Tubbs¹,

Wallace

2006

All Days

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TX 75083-3836, U.S.A., fax 01-972-952-9435. AbstractStaying ahead of the curve sometimes requires reconsidering standard practices and vintage processes. One example that clearly illustrates this approach in the energy industry consists of planning solid expandable tubular technology into the casing design as a means to slim the wellbore. By incorporating the solid expandable tubular system at the beginning, the operator achieves a slimmer well profile while still maximizing hole size at total depth (TD), reduces drilling time to TD and reduces drilling costs.An operator in Texas epitomizes the advantage of this approach by using the 6 x 7-5/8 in. expandable openhole liner in deep gas wells to proactively address zones prone to loss circulation. The operator maintained hole size and realized significant worth from this enabling technology. This proactive approach saved the operator over $1M per well. Applying this technology across field development projects leads to substantial savings.For these wells, using solid expandable tubular systems to achieve a larger wellbore at TD resulted in the following features, advantages and benefits:• Higher rate-of-penetration (ROP) in long intermediate casing section (36% enhancement) • Overall drilling cost savings (15-20%) using slimmed wellbore vs. big bore pipe program • Improved drilling performance and lower equivalent circulation density (ECD) below the solid expandable tubular system This paper will detail how the planning and application of solid expandable tubular systems resulted in significant benefits. Drilling conditions, circumstances and environments will be discussed to illustrate how solid expandable tubular technology is conducive to efficient drilling operations. In addition, this paper will discuss the value realized from expandable applications and how these systems enhance the value of the customers' assets.

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“…1,2,3 The promise of gaining a casing seat without dropping hole size has encouraged a rapid acceptance of the technology. The growing experience base has led to a better understanding of how to use these products and improve job reliability.…”

Section: Solid Expandable Linersmentioning

confidence: 99%

Designer Casing for Deepwater HPHT Wells

Miller

Payne²,

Erpelding

2005

All Days

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TX 75083-3836, U.S.A., fax 01-972-952-9435. AbstractDeepwater high pressure, high temperature (HPHT) drilling environments present difficult challenges to well engineers. Typical deepwater pore pressure and fracture gradient profiles result in a narrow drilling window that can lead to seven to nine casing points. The high cost of these wells demands a high rate completion for economic payback, which defines the size of the production casing and liners. Drilling casings are restricted by the standardized 18-3/4" through bore diameter dictated by high pressure wellhead housings, blowout preventers, and riser systems. Furthermore, high pressures require thick wall casing, especially if sour service materials are specified. Satisfying all of these pressure and geometrical constraints requires some unconventional practices.Current and emerging technologies offer several ways to address this design dilemma. Riser-less drilling can be an effective way to delay running the high pressure wellhead, allowing for additional large diameter casing seats. Dual gradient drilling is a concept that can decrease the number of required casing points. Solid expandable liners provide a way to add or push casing points without the geometry impact of a conventional string. Managed pressure drilling may also show promise for eliminating a seat. However, heavy reliance on these new technologies may run counter to the guiding principle of keeping HPHT wells as simple and reliable as possible.This paper presents the concept of using conventional oil country tubular goods (OCTG) in unconventional sizes to increase the number of available casing points in deepwater wells. The method has several advantages in the areas of performance and reliability compared with the previously listed technologies. The decades of industry experience with conventional OCTG make the technology especially appropriate for containing high pressures and sealing off trouble formations.Related issues such as manufacturing lead time, costs, connections, and hangers are discussed. Several HPHT examples are included to illustrate the trade-offs with other design options.

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Solid Expandable Tubular Technology - A Year of Case Histories in the Drilling Environment

Cited by 20 publications

References 1 publication

Reaction-driven casing expansion: potential for wellbore leakage mitigation

Reaction-driven casing expansion: potential for wellbore leakage mitigation

Slimming the Wellbore Design Enhances Drilling Economics in Field Development

Designer Casing for Deepwater HPHT Wells

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