A recent multi-well program in central Texas illustrates that conventional intent can produce unconventional opportunity. The aforementioned drilling campaign was in its second year of using solid expandable technology to attain a slimmer well profile in a series of high pressure/high temperature (HPHT) gas wells. The wellbore design included in a 6 x 7–5/8 in. solid openhole liner expanded across the Upper Bossier formation that enabled 14–3/4 in. surface casing while still reaching TD at ~15,000 ft with 4–1/2 in. casing. This design improved the rate of penetration resulting in reduced overall drilling costs and in turn a savings of approximately $1M per well. Over 40 openhole systems had been successfully expanded by way of conventional installation when a process modification enhanced the already significant benefits of using solid expandable tubulars. Conventional installation usually requires underreaming or hole enlargement to expand and cement the liner. The hard rock formation and the swellable elastomers employed on the openhole system eliminated the need for underreaming or cementing. Zonal isolation was achieved by setting the elastomers at the shoe of the expandable liner. The operator estimated that by dispensing with these steps an additional four to six days of rig time was saved. The current and future need for hydrocarbons has not diminished. This global demand is a main driver to develop more comprehensive downhole solutions. Every technical advantage is needed to help bring unconventional oil and gas plays within practical and economic reach. This paper explains how solid expandable tubulars have provided operators with a valuable tool to enhance drilling operations and mitigate wellbore challenges. This paper outlines the increasing and potential application realm of solid expandable tubulars and describes how incorporating these systems into the initial well design optimize the possibilities and potential of the technology. Introduction Even with the extreme fluctuation of energy prices and the current state of economic uncertainty, the future need for hydrocarbons shows little sign of waning. These variables have impacted oil and gas recovery projects, whether by abridging drilling programs or exploring unconventional plays with atypical methods. A large percentage of the world's future energy demands will be fulfilled by unconventional natural gases that include tight gas, coalbed methane (CBM), shale gas, deep earth gas, geo-pressured gas, and methane hydrates. Many unconventional gas reservoirs require the formation to be fractured hydraulically to improve the formation productivity by providing a conductive path and joining the existing fractures and cleats in the reservoir (Zahid 2007). Unconventional oil, such as heavy and tight oils or those from tar sands and shale, may be more costly to produce but their development remains an interesting proposition nonetheless. Although heavy oils can be pumped similarly to conventional oils, they require more extensive refining. As with tar sands, extracting oil from shale or tight formations is more complex than conventional oil recovery, which contributes to the expense.

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.

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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