Successful Field Appraisal Well Makes Single-Diameter Wellbore a Reality

Huang

Journal of Pressure Vessel Technology

et al. 2019

This paper focuses on the expansion process of twinning-induced plasticity (TWIP) steel tubular undergoing the large circumferential plastic deformation in expandable tubular technology. The expansion process was performed by propagating a mandrel through the tubular mechanically. This paper aimed at developing the mathematical models to predict the expansion force required for the radial expansion of the TWIP steel tubular using the rigid-perfectly plastic model and the linear hardening rigid plastic model, respectively. The volume incompressible condition together with the Tresca yield criterion was used to describe the plastic behavior of the tubular material in the expansion process. Besides, the finite element analysis of the expansion process was developed using the commercial software abaqus to validate the theoretical results and determine the scope of application of the derived expansion force formula. Further to this, the effect of the process parameters, such as the expansion ratio, friction coefficient and the cone angle, on the expansion force was investigated. It was found that the expansion force difference of two models have similar variation trend. The accuracy and applicability of the expansion force formula using the linear hardening rigid plastic model improve as the expansion ratio increases and the expansion cone angle decreases.

Study on the Expansion Force of TWIP Steel Expandable Tubular in Solid Expandable Tubular Technology

Huang

Journal of Pressure Vessel Technology

et al. 2019

IADC/SPE Asia Pacific Drilling Technology Conference and Exhibition

Dynamic Formations Rendered Less Problematic with Solid Expandable Technology

Jennings

2008

To reach drilling objectives in dynamic formations requires robust technology that can adapt to unpredictable wellbore conditions. Such is the case with operations in Asia Pacific; a very tectonically active region. The shifting plates put the earth's crust under extreme stress, which has a propensity to cause various difficult drilling conditions including:FaultsHigh pore pressureWellbore instability These issues are difficult to predict, both in occurrence and true vertical depth (TVD), and are usually mitigated by running an unplanned string of casing. Unexpected conditions requiring a casing point put the drilling plan at risk when reservoir objectives are hole-size dependent. Standard oil country tubular goods (OCTG) reduce the wellbore inside diameter (ID) every time a casing string is set. When the situation dictates setting casing higher than planned, solid expandable technology has successfully minimized wellbore reduction and enabled the operator to get back to the casing program with an optimized hole size. Planning solid expandable systems into wellbore construction as a design element, rather than a contingency plan, has averted numerous problems identified during the drilling process. Conventional solid expandable systems minimize loss of hole size, while single-diameter expandable systems (including openhole cladding) provide solutions without loss of hole size. By utilizing single-diameter technology, zones and formations can be sealed, allowing the next hole section to be drilled with the same bit as the previous. In this capacity, expandable systems become an enabling technology for previously undrillable wells. This paper will discuss how solid expandable tubular systems have evolved to include a technology suite of options that addresses drilling challenges in active formations. Case histories will be used to illustrate the technical and economic value brought to projects by way of solid expandable system application. Introduction The Asia Pacific region contains significant hydrocarbon potential in environments ranging from prolific, shallow-depth reservoirs to heavily-faulted, folded formations. Continental shelf margins as well as deep and ultra-deep marine environments have been explored and developed in this geologically-diverse area. Land and offshore basins yield production formations found in deltaic, fluvial environments, and stacked pay sections. This hydrocarbon-rich region is replete with ongoing tectonic movement, earthquakes, underwater landslides, lost circulation zones, and uncontrolled mud flows, as well as geologically stable and simple depositional environments. The prevalent conglomerate, igneous, clastic, and carbonate-laden formations present a variety of drilling challenges to regional operations. Dynamic conditions add an extra element of difficulty when addressing the usual drilling problems such as lost circulation from a weak formation or borehole instabilities caused by complex lithologies. In an effort to preempt some of these problems, operators have taken to utilizing solid expandable tubulars by incorporating them into the initial wellbore design in both drilling and workover projects. Focusing on opportunity for the application of solid expandable technologies rather than on a need-based strategy has helped mitigate challenges once considered the hard boundaries that defined drilling limits and completion restrictions. The effectiveness of solid expandable tubulars to mitigate challenges has been well documented with over 920 applications to date. 1, 2, 3, 4, 5 Since the first installation in late 1999, the technology has evolved to include a suite of systems capable of addressing varied challenges even in extreme environments and dynamic formations.

SPE Rocky Mountain Petroleum Technology Conference

Expanding Solutions for Unconventional Oil and Gas Recovery

Wallace

Fritsch

2009

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.