future_ii

8/2/2019 future_II

http://slidepdf.com/reader/full/futureii 1/20

ExpandableExpandable TubularsTubulars for Ultradeepwaterfor Ultradeepwater

DrillingDrilling -- Leading The WayLeading The Way..

SPE GCS Drilling Study GroupSPE GCS Drilling Study Group1111thth April 2001April 2001

PaulPaul GoodfellowGoodfellowShell Exploration & Production Co.Shell Exploration & Production Co.

8/2/2019 future_II


Expandable Tubulars for Ultradeepwater Drilling

• Ultradeepwater Challenges

• Technology Options/ Selection

• Development and testing

• Open H ole Liner System Details

• Initial Applications and results

• Future Applications

8/2/2019 future_II


Shell Deepwater - A Global Perspective

Malampaya

Trinidad/ Surinam

Brazil

Ormen Lange

Bonga

Gabon

CongoAngola

Egypt

Oman

WoS

Morocco

Malaysia

Gulf of Mexico(SEPCo)

Canada

8/2/2019 future_II


SEPCo’s Challenge

Ultradeepwater Gulf of Mexico

• H ow to design wells for low

drilling margin conditions (large

number of Casing strings)?

• H ow to deliver these wells in a

cost effective way?

• Wells have failed to reach

objective depth due to insufficient

number of casing strings to

accommodate the pore pressure

profile.

• H ow to trial new technologies in

this high cost environment.

Ultra-Deepwater GOMPore Pressure and Fracture Pressure

87,000

8,000

9,000

10,000

11,000

12,000

13,000

14,000

15,000

Depth

(ft,TVD)

16,000

17,000

18,000

19,000

20,000

21,000

22,000

23,000

9 10 11 12 13 14 15 16

26"

20"

18"

16"

16 SET

13-3/8"

11-3/4"

9-5/8"

TD

EMW (PPG)

FPG

Expected PPG

Casing

E G T 0 0 1 6 3

8/2/2019 future_II


Technology Options (1997)

Technology Option

A) Increased

BOP/ Riser/ wellhead Size

B) Dual Gradient Drilling

Technology

C) Expandable Tubular

Technology

D) “Large Bore” 18 3/ 4”Wellhead system

Comment/ Assessments

A) Larger Rig; Larger equipment;

riser dynamics

B) Probably the best technical

solution - high risk & long lead

time

C) Moderate technical risk (lab &

small length testing only); High

value if successful

D) Low technical risk; ability togain one string of casing vs. a

typical well plan

8/2/2019 future_II


Technology Selection

• Large bore wellhead system and 18” casing development

(Low risk and fairly quick)

• Expandable tubular technology - this was viewed as an

enabling technology with the potential to add significant

value in the long-term but required a longer

development time frame.

• The key question is…. ‘ Where do you trial suchtechnology..’

8/2/2019 future_II


Expandable Casing Size Selection

Constraints

• Use traditional casing sizes in a typical well plan (including large bore wellhead

system)

• Run a conventional API size casing after using an expandable casing string

• 7 1/ 2” hole at TD

Size selection

Previous Casing ExpanadableTubular

Next casing

16” 84 # / ft 13 3/ 8” XPD 13 3/ 8”

11 ¾” 60 # / ft 9 5/ 8” XPD 9 5/ 8”

9 5/ 8” 53.5 # / ft 7 5/ 8” XPD 7 ½” hole

8/2/2019 future_II


Expandable Technology Development

Questions/ decisions at the Design Phase

• Expansion Process (top down vs. bottom up)

• Pipe Material (API grades vs. special alloys)

• Connection Development (expandable flush connection vs. welding)

• Mandrel Design/ Lubrication

• Cementing Techniques, casing accessories (conventional cement and

float equipment vs. new material)

• “Rig friendly” equipment and procedures

8/2/2019 future_II


Expandable Tubular Fundamentals

Engineering Principle

• “Cold Work” steel downhole

• Deform material by increasingstress to the plastic

deformation region without

exceeding ultimate strength

(failure)

E G T 0 0 1 4 7

8/2/2019 future_II


Expandable Tubular Fundamentals

Bottom-up Expansion

• Expansion Mandrel housed in

extrnal upset thin-walled

launcher shoe

• After dart latches in shoe,

pressure chamber is created

• Pipe is expanded radially via a

combination of hydraulic andtensile forces.

8/2/2019 future_II


Installation Sequence for Open Hole Liner

Condition mud,

cement liner

Latch plug ExpandLiner

ExpandHanger Jt

Drill Hole RunExpandable

Liner

ExitHangerJoint

Mill OutShoe

8/2/2019 future_II


13 3/ 8” x 16” system testing

Gasmer Test Well (1998)• Proof of concept for 13 3/ 8” casing expansion

• 128’ of 13 3/ 8” J55 successfully expanded and sealed.

2 Onshore tests SEPCo South Texas

• Raul Tijerina # 1 (1999).~ 600’ 13 3/ 8” LSX 80

– Successful test of tools, procedures, cement

– successful expansion and pressure test

• Thomas Rife # 13 (2000). 2016’ of 13 3/ 8” LSX 80

– Successful expansion

– Pipe collapsed near bottom due to exit velocity of the

pig!

E G T 0 0 1 6 4

Workstringwith

Exp. Cone

on Bottom

Liner-HangerJoint With

ElastomericCoating

16-in. Casing(455 FT)

17-1/2-in. Hole TD = 2,300 ft

LauncherSubassembly

Pre-Expansion13-3/8 × 16-in.Expandable

OHL(2,016 ft)

Post-Expansion13-3/8 × 16-in.

ExpandableOHL(1,930 ft)

8/2/2019 future_II


Additional Testing

McAllen Ranch 106

• 6” x 7 5/ 8”

• Up to 6000 psi differential pressure conditions

• 785’ pre-expanded length

• pipe stuck after running to bottom

• expanded 482’, lost pressure

• pipe failure due to “stuck - stuck” conditions

Learning's/ Actions

• Additional Testing of stuck-stuck mechanism

• Re-design pig/ stabilization• Lead to real world understanding of load conditions

not anticipated by theory (loads due to differential

sticking and collapse load at pop out).

8/2/2019 future_II


Initial Offshore Applications

• Chevron WC 17 (7 5/ 8” x 9 5/ 8”)– 985’ pre-expanded length

– Successful run & expansion to case of pressured formation prior to

reducing mud weight

– Squeeze of casing shoe required

• Vastar MC (7 5/ 8” x 9 7/ 8”)

– 2095’ pre-expanded length

– expanded 1193’ & lost pressure.

– Mechanically expanded 33’ - parted liner

– Failure due to connection design

• Subsequent 6 OH applications by Enventure have all been for SEPCo

(3 offshore and 3 on land)

8/2/2019 future_II


AC 557 Well - 2000

(1) 13 3/ 8” x 16”

• 1186’ (pre-expansion) liner

• Initial dart did not bump

• 2nd dart bumped (2nd dartcovered rupture disk - could not

expand)

• Release inner string & RIH with

jars. Jar on pipe while WO coil

tubing equipment to drill out top

dart. Rupture disk sheared.

Expanded casing & tested

• Drill shoetrack w/ mill &

squeezed casing shoe

(2) 9 5/ 8” x 11 3/ 4”

• 1521’ (pre-expansion) liner

• plug bumped early

• drilled out shoe track w/ mill.Low LOT. Squeezed shoe

• No major problems

•Two Expandable Liners in the base well plan, others available for contingencies if

required.

8/2/2019 future_II


There is no mystery with Expandables …….

Gasmere test (1998)

First SET run on AC557

8/2/2019 future_II


Conclusions from AC 557

• Utilization of expandable tubulars allowed the well to be drilled through the primary

objectives.

• Success of these applications provides confidence that expandable tubular technology

can be applied on wider scale for ultrdeepwater applications

• Expandable Technology evolved from a concept to field utilization in 3 yrs.

• Lab Tests and initial Test Well Program were key in understanding the technology and

enhancing the system design - learn from the failures in a low cost environment.

• Successful Application on Ultradeepwater Well (2 expandable casings in one well).

Now a standard feature in the engineers tool box.

• 13 3/ 8” & 9 5/ 8” SET sizes have value for Ultradeepwater applications with current

18 3/ 4” BOP systems

8/2/2019 future_II


Where is SEPCo going with Expandable Technology...

• An enabling technology for ultradeepwater wells. We have already

started to ‘slenderize’ our wells.

• Nested expandables leading to the monodiameter well and the use of

compact rigs for deepwater/ deep wells is not that far in the future.

Clad / Re-Entry Slender

Future

Mono-DiameterStandard

Current

8/2/2019 future_II


9-5/8 inExpanded Solution #3

Casing Design ofTrue Monobore

18-3/4 inBOP

13-5/8 inBOP

10 in BOP

Expanded Solution #2

9-5/8 in

Casing Design with NestedExpandables

21 inRiser

16 inRiser

12 inRiser

9-5/8 in

Expanded Solution #1

Requires:• Enhanced 2nd Generation Semi• Station Keeping

30 inStructurePipe

30 inStructurePipe

30 inStructurePipe

20 in

16 in

13.375 in

11.750 in

9.6250 in

7.625 or 7.0 in

TD TD TD E G T 0 0 1 8 9

13-3/8 in 9-5/8 in

Conventional Casing Design

Requires:• 5th Generation Semi or Drill Ship

• Special Manufactured Wellhead

This technology when

linked with other

technologies such as dual

gradient drilling and

advanced synthetic pre-

set mooring systems can

radically change the cost

structure for ultradeep

water exploration and

development.

Where is SEPCo going with Expandable Technology...

8/2/2019 future_II


AC 557 Well Benefits

• Utilization of expandable

tubulars allowed well to be

drilled through the primary

objectives• New technology allowed three

additional strings of casing to be

installed vs. a conventional well

plan

20”

16”

13 3/ 8”

11 3/ 4”

9 5/ 8”

7 5/ 8”

6 3/ 4” H ole @ TD

Objectives not reached

22”

18”

16”

13 3/ 8” SET

13 3/ 8”

11 3/ 4”

9 5/ 8” SET

8 5/ 8”

7 7/ 8” H ole at TD

Conventional

Casing Plan

Casing Plan withNew Technology

future_ii

Documents