The Development and Applications of Solid Expandable Tubular Technology

Cales, Gerry

doi:10.2118/2003-136

Cited by 8 publications

(4 citation statements)

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“…1,2 More than 150 successful cases of SET-based drilling and recompletion works have already been reported. 3–5…”

Section: Introductionmentioning

confidence: 99%

“…The function of swelling elastomer in an SET application is that of a joint, both for sealing and anchoring the system. Some of the most common expandable tubular applications are expandable open-hole liner, 5 ,6 expandable cased-hole liner, 4 expandable open-hole clad, 4 and expandable liner hanger. 7 These elastomers are also being used as swell packers for zonal isolation of cased or uncased well bores.…”

Section: Introductionmentioning

confidence: 99%

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Comparison between fresh and exposed swelling elastomer

Pervez

Qamar

Velden³

2012

Journal of Elastomers & Plastics

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Last decade has seen growing use of swelling elastomers in various applications by the oil and gas industry. Elastomers with special properties have been developed to sustain the specific downhole conditions of temperature, pressure, and chemical environment in different wells. Apart from targeted short-term tests conducted by rubber developers and drilling application companies, little is known about material characterization of such elastomers. Even these test results are not generally available in the public domain due to proprietary rights. In particular, an important factor that has not been previously explored is the effect of exposure on material response of swelling elastomers. Zonal isolation packers and other forms of elastomer-mounted tubulars are often stacked in open yards for a long time before their deployment in wells. Properties of elastomers may significantly change due to their exposure to air, sunlight, and humidity. Some results from a comparative study of the behavior of fresh and exposed samples of an ethylene propylene diene monomer (EPDM)-type water-swelling elastomers are reported here. Methodology of the swelling test was developed in consultation with petroleum engineers and rubber manufacturers. Other experiments were designed and performed in line with standard ASTM test methods. Properties of elastomers that are investigated are hardness, compression set, tensile set, tensile properties, and swelling behavior. Elastomer samples were allowed to swell for a total test duration of 1000 h. Two specimen geometries were tested for swelling: unconfined disc samples to study the behavior of free elastomer and plate samples (elastomer vulcanized on steel plate) to emulate the actual seal performance. Swelling was carried out in salt solutions of different concentrations and at different temperatures. Hardness of exposed elastomer samples (EPDM1) was generally higher than that of fresh samples (EPDM2). Similarly, exposed elastomer showed significantly higher amount of compression set when compared with fresh elastomer. Short-duration tensile set values (10 min test) were almost the same for both sample types. However, tensile set results for the longer-duration tests (10 h and 20 h) were higher for exposed samples. Surprisingly, stress–strain graphs for both fresh and exposed elastomers were almost linear, while rubber-type materials typically show a highly nonlinear behavior. Values of modulus of elasticity and stress at fracture were considerably higher for exposed samples. In contrast, percentage elongation results were higher for fresh samples. Amount of swelling against swelling time showed an up-and-down trend for both the sample types. At the same temperature and under brine solution of the same concentration, fresh elastomer generally swelled far more than the exposed one. The overall observation from the variety of experimental results is that exposure to sun and moisture for extended periods of time reduces the flexibility and swelling capacity of these elastomers.

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“…1,2 More than 150 successful cases of SET-based drilling and recompletion works have already been reported. 3–5…”

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Comparison between fresh and exposed swelling elastomer

Pervez

Qamar

Velden³

2012

Journal of Elastomers & Plastics

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“…Metcalfe et al [9] tested the process of expanding with rotatory expansion mandrel in the casings. Lance [10,11] completed mechanical property tests in the laboratory and expansion tests in the field, confirming the feasibility of the laboratory results. Mack et al [12,13] conducted experimental studies on the expansion force of K55 and L80 casings.…”

Section: Introductionmentioning

confidence: 74%

Dynamic Analysis of Solid Expandable Tubular and Its Applications in Tahe Oilfield

Tang

Zhou

et al. 2015

Arab J Sci Eng

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For ultra-deep horizontal wells in Tahe Oilfield in China, the solid expandable tubular (SET) technology was applied in the buildup section to isolate unstable mud stone with clays above the pay zone. This technology satisfies the requirements of geological water avoidance, and a larger hole size is adopted in the pay zone. This paper proposed a finite element dynamic model to analyze the expansion of the SET, and the impacts of the following factors on the expansion force required for the expandable tubular were analyzed: yield strength of the tubular material, solid tubular expansion ratio, the coefficient of friction between the expansion cone and the tubular, the angle of the expansion cone, movements velocity of the expansion cone, and DLS (dogleg severity). The calculation results indicate that a higher expansion ratio, a higher yield strength, and a higher friction coefficient of the SET result in a larger expansion force to different degrees, whereas the other factors have little effect on the expansion force. The dynamic expansion force calculation model established in this paper is consistent with the actual conditions, and the simulation calculation results can be applied to provide theoretical guidance for SET expansion operations.

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“…The notion of solid expandable tubular (SET) technology in the oil and gas industry was first proposed by Shell in the late 1990s to trim down the telescopic effect in the casing design as wells were drilled to deeper depths. [1,2] During operation, the SET is preset to the desired position of an oil and gas borehole, an expansion cone is used to cause axial movement by hydraulic or mechanical forces, and the SET expands radially to cause permanent plastic deformation. This allows it to sit closely against the casing or borehole wall so that the desired downhole operation can be accomplished.…”

Section: Introductionmentioning

confidence: 99%

Multi-scale elastoplastic mechanical model and microstructure damage analysis of solid expandable tubular*

Guo

Liu

et al. 2020

Chinese Phys. B

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We present an in-depth study of the failure phenomenon of solid expandable tubular (SET) due to large expansion ratio in open holes of deep and ultra-deep wells. By examining the post-expansion SET, lots of microcracks are found on the inner surface of SET. Their morphology and parameters such as length and depth are investigated by use of metallographic microscope and scanning electron microscope (SEM). In addition, the Voronoi cell technique is adopted to characterize the multi-phase material microstructure of the SET. By using the anisotropic elastoplastic material constitutive model and macro/microscopic multi-dimensional cross-scale coupled boundary conditions, a sophisticated and multi-scale finite element model (FEM) of the SET is built successfully to simulate the material microstructure damage for different expansion ratios. The microcrack initiation and growth is simulated, and the structural integrity of the SET is discussed. It is concluded that this multi-scale finite element modeling method could effectively predict the elastoplastic deformation and the microscopic damage initiation and evolution of the SET. It is of great significance as a theoretical analysis tool to optimize the selection of appropriate tubular materials and it could be also used to substantially reduce costly failures of expandable tubulars in the field. This numerical analysis is not only beneficial for understanding the damage process of tubular materials but also effectively guides the engineering application of the SET technology.

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The Development and Applications of Solid Expandable Tubular Technology

Cited by 8 publications

References 0 publications

Comparison between fresh and exposed swelling elastomer

Comparison between fresh and exposed swelling elastomer

Dynamic Analysis of Solid Expandable Tubular and Its Applications in Tahe Oilfield

Multi-scale elastoplastic mechanical model and microstructure damage analysis of solid expandable tubular*

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