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Presentation Context

• Mechanical engineering design mindseto Managing loads -> Avoiding yield

• Ensuring well Integrity in demanding applicationso What happens when conventional solutions don’t

work or are inadequate?

• Three examples of innovation arising from new perspective

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Example 1: Strain-Based Thermal Casing Design

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Think Strain, not Stress

• Steel expands when heated

o ∆T = 300°C 0.4% strain

o 600 m of pipe grows 2.4 m

• Cemented pipe tries to expand

o Elastic stress of 800 MPa (116 ksi)

o Plus safety factor?

T=20°C T=300°C

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Most thermal tubulars “fail”!

• Assumes stiffness goes to zero at material yield

• Thermal tubulars can be designed to be deformation-tolerant

o Post-yield material properties are critical

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Designing for Strain-based loads

0.0%

1.0%

2.0%

3.0%

4.0%

5.0%

0 50 100 150 200 250 300 350

Pipe

Ovality

Temperature (°C)

177.8 mm Load Path 2: 8 MPa pressure, then temperature

244.5 mm Load Path 2: 6.9 MPa pressure, then temperature

SPE 151810

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Example 2: Well Integrity Logging

• Caliper tools

o Measuring corrosion

• Cross section not

always indicative of

wellbore

accessibility/Integrity

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Casing DeformationShear in

oil sands

caprock

Shear in

unconventional

shale

Drift

Diameter

Drift Mandrel Length

BHA 1

BHA 2

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Pad-Wide Deformation

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Example 3: Real-time Integrity Monitoring

• Top-drive casing running enables rotation

• Sand control liners sensitive to installation loadingo Need for engineering limits

• Loads predicted at design time

• Reality differs from expectations!

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Planning

Monitoring

Optimization &

Mitigation

Liner design based on

expected running loads

Measure actual surface loads

Mitigate running challenges

SPE 188148

Optimize on multiple timescales

Estimate downhole loads

Multi-Timescale View

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Rotating-In Real-time Liner Integrity MonitoringRotating-In

Combine:

• Surface loads & rates

• Downhole load limits

• T&D load calculations

To generate surface limits

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0%

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Measured Depth (m)

Load Ratio Normalized Running Rate

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0 500 1000 1500 2000

Measured Depth (m)

Load Ratio Normalized Running Rate

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0 500 1000 1500 2000

Measured Depth (m)

Load Ratio Normalized Running Rate

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120%

0 500 1000 1500 2000

Measured Depth (m)

Load Ratio Normalized Running Rate

0%

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120%

0 500 1000 1500 2000

Measured Depth (m)

Load Ratio Normalized Running Rate

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Measured Depth (m)

Load Ratio Normalized Running Rate

0%

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120%

0 500 1000 1500 2000

Measured Depth (m)

Load Ratio Normalized Running Rate

Applied load exceeds load limit

Driller

reacts

Liner Installation Case Study

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Final Thoughts

• What happens when conventional solutions don’t work or are inadequate?

o Opportunity!

o Seek new perspectives

o Avoid confirmation bias

o Don’t ask if it works… Ask why it works

o Lean heavily on engineering fundamentals