Failure analysis and solution study of 203 mm solid expandable tubular

Liao, Xingsong; Qi, Yuekui; Zhu, Xiaohua; Cheng, Feilong; Fu, Daqi; Shi, Changshuai; Huang, Manliang; Qin, Feixiang

doi:10.1016/j.engfailanal.2019.08.001

Cited by 14 publications

(6 citation statements)

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“…The expansion stress during expanding process may exceed the tensile strength, then leading to plastic failure, even fracture. This phenomenon was also reported by Liao, et al [29]. And the large residual stress also has a great effect on the structure integrity of expanded tubular.…”

Section: Discussionsupporting

confidence: 78%

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

Luo¹,

Wenchun²,

Zhou³

et al. 2020

Int J Metall Met Phys

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Expansion rate is key parameter to the manufacture of expandable tubular. In this paper, the effects of expansion rate on stress evolution of twinning induced plasticity (TWIP) steel expansion tubular were discussed in detail. A user subroutine UMAT using twin shear stress (TSS) yield criterion is employed to simulate the expanding process. The results show that the predicted residual stresses agree with the experiment very well. The axial expanding stress showed the layered distribution along the thickness direction and the hoop tensile stress is mainly located in the corner of expanded area. With the steady increases of expansion rate, the expanding axial, hoop and TSS stresses are all increased, and the increasing rate is decreased gradually. The residual stresses are tensile in inner surface and compressive in outer surface. Both the hoop and axial stresses are all increased with the increases of expansion rate. The suggested expansion rate should be controlled below 35%.

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Section: Discussionsupporting

confidence: 78%

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

Luo¹,

Wenchun²,

Zhou³

et al. 2020

Int J Metall Met Phys

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“…The surface-to-surface contact region of tubular and mandrel during expansion is required to be critically investigated and analyzed, since the higher magnitude of contact pressure at the interface may cause tubular thinning which leads to its premature failure (Khan et al 2017;Liao et al 2019). An analysis of contact pressure (CP), in case of fix-free and fixfix boundary conditions, shows four pressure peaks at the interface of tubular and mandrel, as shown in Fig.…”

Section: Finite Element Simulationsmentioning

confidence: 99%

“…However, no significant effects of expansion rate on length shortening is observed (Khan et al 2017). Recently, a series of work related to the damage and failure criteria is reported by (Liao et al 2019;. In this, Liao et al, analyzed the microstructure of SET through scanning electron microscope (SEM) and studied the failure analysis macroscopically using finite element analysis method.…”

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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“…Reasonable expansion cone structure parameters are more conducive to expansion forming. The optimization of the expansion cone is very necessary and has practical signi cance [11,19]. The structure of the expansion cone has a signi cant impact on the expansion force of SET technology and the residual stress of the tube.…”

Section: Analysis Of Sensitive Parameters Of Expansion Conementioning

confidence: 99%

“…After decades of development, it has achieved tremendous development in plugging, repairing casing, and optimizing the wellbore structure [4]. In recent years, a large number of scholars and engineers have conducted research on many aspects of the technologyThey mainly focused on the selection of materials, the optimization of the expansion cone, the collapse after expansion, the expansion force, etc., and achieved remarkable achievements [5][6][7][8][9][10][11][12][13][14]. In general, there are few studies on open hole wells, and these studies are mainly on casing damaged wells [15].…”

Section: Introductionmentioning

confidence: 99%

Study on the Technology of Solid Expandable Tubular in Open-Hole Well

Zhu¹,

Cheng²,

Shi³

et al. 2020

Preprint

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During the production and drilling of open hole wells, due to the uncertainty and complexity of the rock,The naked hole section is prone to accidents such as collapse of the shaft wall and leakage. In order to solve the above problems, this paper proposes the plugging technology of solid expandable tubualr(SET) in open-hole wells. Based on experimental data,this paper established a dynamic three-dimensional model which considers friction and contact. The author puts forward the applicability criterion of open hole and studies the sensitivity parameters of expansion cone. The research results show that when SET specifications are determined, the borehole size of the open hole well has a great influence on the contact pressure, residual stress, driving force and other factors after the SET is formed, and to a certain extent affects the subsequent service. In addition, the structural parameters of the expansion cone also have a great influence on the plastic forming of SET. The results of this paper provide guidelines and theoretical basis for the use of SET technology in open hole wells.

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Failure analysis and solution study of 203 mm solid expandable tubular

Cited by 14 publications

References 1 publication

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

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

Study on the Technology of Solid Expandable Tubular in Open-Hole Well

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Failure analysis and solution study of 203 mm solid expandable tubular

Cited by 14 publications

References 1 publication

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

Effects of Expansion Rate on Stress Evolution of TWIP Expandable Tubular Based on TSS Criterion

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

Study on the Technology of Solid Expandable Tubular in Open-Hole Well

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Product

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Failure analysis and solution study of 203 mm solid expandable tubular