Application of numerical simulation in the solid expandable tubular repair for casing damaged wells

Xu, Bin; Zhang, Yanping; Wang, Hui; Hongwei, Yin; Tao, Jia

doi:10.1016/s1876-3804(09)60152-x

Cited by 29 publications

(6 citation statements)

References 2 publications

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“…In order to analyze the stress, strain, and residual stress induced in the solid expandable tubular applied in repairing casing damaged in wells, Binggui et al [23] used the commercial finite element method (FEM) package ANSYS to model and simulate the problem. The expansion process induces residual stress in the tubular after expansion.…”

Section: Literature Reviewmentioning

confidence: 99%

Indirect Extrusion: A Multifaceted Approach of Sub-surface Tubular Expansion

Pervez¹,

Qamar²,

Al-Abri³

et al. 2018

Extrusion of Metals, Polymers and Food Products

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Extrusion and indirect extrusion is a very old manufacturing process used in multitudes of applications mainly focused on transportation, household and power industries. Indirect extrusion has found an interesting application in petroleum industry, which resulted in resolving many unsolvable issues over the last few decades. The current and expected future global demand for hydrocarbons became a driving force for researchers to find new comprehensive and cheaper solutions for hydrocarbon production. The challenges faced in oil and gas fields, while drilling, constructing and operating new and old vertical/horizontal wells, are many. The use of indirect extrusion for insitu expansion of sub-surface tubulars used in wells revolutionized the drilling and completion as opposed to one and half decade back. The emergence of solid expandable tubular technology has changed the basics of how we design and construct wells. The original development of the technology was to overcome the challenges faced by the petroleum industry to reach ultra-deep reservoirs, off-shore drilling, drilling in highpressure/difficult zones and repair/maintenance of old/ageing wells. However, it gained significant interest of researchers and operators in providing solutions to wide-range problems. The development of a computational framework using finite element method (FEM) enabled to determine the force required for expansion and resulting dimensional changes in final product, which is of direct assistance to the field engineers. The effect of friction and stress variations along contact surface is also determined.

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Section: Literature Reviewmentioning

confidence: 99%

Indirect Extrusion: A Multifaceted Approach of Sub-surface Tubular Expansion

Pervez¹,

Qamar²,

Al-Abri³

et al. 2018

Extrusion of Metals, Polymers and Food Products

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show abstract

“…A review of selected literature on down-hole tubular expansion (Cales et al 2001;Dupal et al 2002;Mack 2005;Carstens and Scrittmatter 2006;Binggui et al 2009) shows that most of the research and development work was carried out mainly by technology deployment companies to find short term and problem specific solutions. The experience of field engineers and a few simple lab trials were mainly instrumental in devising solutions without having substantial theoretical basis and appropriate scientific validation.…”

Section: Solid Expandable Technologymentioning

confidence: 99%

Tube Expansion Under Various Down-Hole End Conditions

Sánchez

Al-Abri

2013

Jou. Eng. Res.

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Fossil hydrocarbons are indispensables commodities that motorize the global economy, and oil and gas are two of those conventional fuels that have been extracted and processed for over a century. During last decade, operators face challenges discovering and developing reservoirs commonly found up to several kilometers underground, for which advanced technologies are developed through different research programs. In order to optimize the current processes to drill and construct oil/gas wells, a large number of mechanical technologies discovered centuries ago by diverse sectors are implemented by well engineers. In petroleum industry, the ancient tube forming manufacturing process founds an application once well engineers intend to produce from reservoirs that cannot be reached unless previous and shallower troublesome formations are isolated. Solid expandable tubular is, for instance, one of those technologies developed to mitigate drilling problems and optimize the well delivery process. It consists of in-situ expansion of a steel-based tube that is attained by pushing/pulling a solid mandrel, which permanently enlarge its diameters. This non-linear expansion process is strongly affected by the material properties of the tubular, its geometry, and the pipe/mandrel contact surface. The anticipated force required to deform long sections of the pipe in an uncontrollable expansion environment, might jeopardize mechanical properties of the pipe and the well structural integrity. Scientific-based solutions, that depend on sound theoretical formulation and are validated through experiments, will help to understand possible tubular failure mechanisms during its operational life. This work is aimed to study the effect of different loading/boundary conditions on mechanical/physical properties of the pipe after expansion. First, full-scale experiments were conducted to evaluate the geometrical and behavioral changes. Second, simulation of deformation process was done using finite element method and validated against experimental results to assess the effects on the post-expansion tubular properties. Finally, the authors bring a comparison study where in a semi-analytical model is used to predict the force required for expansion.

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“…These results in innovating effective and efficient procedures like carbonated water injection, steam injection, localized fracking through pressurized water, enhancement of fluidity using nanoparticles, and Solid Expandable Tubular (SET) packers for repairing damaged wells and zonal isolation (Yuan and Wood 2018;Esene et al 2019). Solid expandable tubular is considered as advanced technology to resolve multiple challenges which are span from side-tracking, patching of fractured wells, water shut-off, and zonal isolation (Binggui et al 2009;Li 2015). More importantly, SET has been proven an economical well completion technique where significant cost can be reduced as compared to conventional telescopic casings.…”

Section: Introductionmentioning

confidence: 99%

Finite element modeling and simulations of solid expandable tubular in multistage tubular-mandrel system

Alfozan

2022

Mechanical Engineering Journal

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Solid Expandable Tubular (SET) has been proven a promising technology in overcoming several unresolved challenges like isolating unwanted substances, sidetracking, and well repair and patching in horizontal wells. A novel multistage expansion system of SET is found to be an efficient way of reducing expansion cost while conserving tubular structural integrity. However, due to the complexity of multistage system, an estimation of post-expansion properties of tubular, especially in variable physical conditions, becomes a challenge in making the technology viable and cost-effective. In the current work, numerical modeling is utilized to evaluate the effects of multiple physical conditions, tubular-mandrel contact and tubular's boundary conditions, on the postexpansion properties of tubular. Initially, a finite element model of multistage tubular-mandrel system is developed using the real well conditions in finite element software ABAQUS. The real boundary conditions of tubular at the field, fixed-free and fixed-fixed, are incorporated in finite element model. Moreover, a nonlinear material model, using the experimental results of uniaxial tensile tests, is used to model tubular's material behavior, while mandrel is considered as rigid body. A surface-to-surface contact conditions are defined through Coulomb's friction law with varying coefficient of friction. The finite element simulation results are compared with the experimental observations of single-stage tubular-mandrel system and found to be in good agreement. Finally, further simulations are performed to evaluate the deformation behavior of tubular using contact pressure, equivalent stress, tubular thickness variation, length shortening, and equivalent plastic strain. It is observed that the contact and boundary conditions of tubular have significant effects on tubular post-expansion properties.

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Application of numerical simulation in the solid expandable tubular repair for casing damaged wells

Cited by 29 publications

References 2 publications

Indirect Extrusion: A Multifaceted Approach of Sub-surface Tubular Expansion

Indirect Extrusion: A Multifaceted Approach of Sub-surface Tubular Expansion

Tube Expansion Under Various Down-Hole End Conditions

Finite element modeling and simulations of solid expandable tubular in multistage tubular-mandrel system

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