This document summarizes a paper presented at Offshore Europe 2005 that discusses realizing single-diameter wellbore technology using solid expandable tubulars. It provides details on:
- The development of expandable technology and its progression to enable single-diameter wells.
- A field test of the technology that successfully deployed and expanded 9-5/8 inch liners in a single trip.
- The multi-functional tool string used, including elements for expansion and contingencies.
- How the technology allows extended reach drilling and can increase reserves while reducing development costs.
Optimizing completions in deviated and extended reach wells is a key to safe drilling and optimum
production, particularly in complex terrain and formations. This work summarizes the systematic methodology
and engineering process employed to identify and refine the highly effective completions solution used in ERW
completion system and install highly productive and robust hard wares in horizontal and Extended Reach Wells
for Oil and Gas. A case study of an offshore project was presented and discussed. The unique completion design,
pre-project evaluation and the integrated effort undertaken to firstly, minimize completion and formation damage.
Secondly, maximize gravel placement and sand control method .Thirdly, to maximize filter cake removal
efficiencies. The importance of completions technologies was identified and a robust tool was developed .More
importantly, the ways of deploying these tools to achieve optimal performance in ERW’s completions was done.
The application of the whole system will allow existing constraints to be challenged and overcome successfully;
these achievements was possible, by applying sound practical engineering principle and continuous optimization,
with respect to the rig and environmental limitation space and rig capacity.
Keywords: Well Completions , Deviated and Extended Rearch Wells , Optimization
Design optimization of excavator bucket using Finite Element MethodIjripublishers Ijri
An excavator is a typical hydraulic heavy-duty human-operated machine used in general versatile construction operations,
such as digging, ground leveling, carrying loads, dumping loads and straight traction. Normally backhoe excavators
are working under worst working conditions. Due to severe working conditions, excavator parts are subjected to
high loads and must work reliably under unpredictable working conditions. Thus, it is necessary for the designers to
provide not only an equipment of maximum reliability but also of minimum weight and cost, keeping design safe under
all loading conditions.
LOCOMOTIVE WHEEL ASSEMBLY DESIGN OPTIMIZATION USING FINITE ELEMENT ANALYSISIjripublishers Ijri
Underground mining is the regular happening work around the world, mainly in India for coal, iron ore, gypsum
etc…………..
Transportation of the material is the major criteria for underground mining most commonly locomotive trolleys, belt
conveyors (or) screw type conveyors are used to carry the material from underground to surface.
Locomotive trolleys are the most efficient transportation system for underground system even for human transportation
also it can be used.
Now all the mining companies are using belt type (or) screw type conveyors because of regular maintenance (or) replacement
of locomotive trolleys, but screw conveyors and belt type conveyors are making heavily wastage falling from belt
conveyors and crushed wastage from screw conveyor.
This project deals with design optimization for improving the life of locomotive trolley.
3D models will be prepared according to company standards.
FEM based analysis will be conducted on assembly to find the location of maximum stress.
Static and model analysis will be carried out by applying suitable materials and modifying part by observing the above
analysis.
Optimizing completions in deviated and extended reach wells is a key to safe drilling and optimum
production, particularly in complex terrain and formations. This work summarizes the systematic methodology
and engineering process employed to identify and refine the highly effective completions solution used in ERW
completion system and install highly productive and robust hard wares in horizontal and Extended Reach Wells
for Oil and Gas. A case study of an offshore project was presented and discussed. The unique completion design,
pre-project evaluation and the integrated effort undertaken to firstly, minimize completion and formation damage.
Secondly, maximize gravel placement and sand control method .Thirdly, to maximize filter cake removal
efficiencies. The importance of completions technologies was identified and a robust tool was developed .More
importantly, the ways of deploying these tools to achieve optimal performance in ERW’s completions was done.
The application of the whole system will allow existing constraints to be challenged and overcome successfully;
these achievements was possible, by applying sound practical engineering principle and continuous optimization,
with respect to the rig and environmental limitation space and rig capacity.
Keywords: Well Completions , Deviated and Extended Rearch Wells , Optimization
Design optimization of excavator bucket using Finite Element MethodIjripublishers Ijri
An excavator is a typical hydraulic heavy-duty human-operated machine used in general versatile construction operations,
such as digging, ground leveling, carrying loads, dumping loads and straight traction. Normally backhoe excavators
are working under worst working conditions. Due to severe working conditions, excavator parts are subjected to
high loads and must work reliably under unpredictable working conditions. Thus, it is necessary for the designers to
provide not only an equipment of maximum reliability but also of minimum weight and cost, keeping design safe under
all loading conditions.
LOCOMOTIVE WHEEL ASSEMBLY DESIGN OPTIMIZATION USING FINITE ELEMENT ANALYSISIjripublishers Ijri
Underground mining is the regular happening work around the world, mainly in India for coal, iron ore, gypsum
etc…………..
Transportation of the material is the major criteria for underground mining most commonly locomotive trolleys, belt
conveyors (or) screw type conveyors are used to carry the material from underground to surface.
Locomotive trolleys are the most efficient transportation system for underground system even for human transportation
also it can be used.
Now all the mining companies are using belt type (or) screw type conveyors because of regular maintenance (or) replacement
of locomotive trolleys, but screw conveyors and belt type conveyors are making heavily wastage falling from belt
conveyors and crushed wastage from screw conveyor.
This project deals with design optimization for improving the life of locomotive trolley.
3D models will be prepared according to company standards.
FEM based analysis will be conducted on assembly to find the location of maximum stress.
Static and model analysis will be carried out by applying suitable materials and modifying part by observing the above
analysis.
Design and Analysis of Impregnation Chamber Used In Vacuum Pressure Impregnat...IOSR Journals
The simple explanation is that in nature and in manufacturing, things leak. Vacuum impregnation
stops leak. The ultimate goal of vacuum impregnation is to seal leak/migration paths without impacting the
functional, assembly or appearance characteristics of a part. The impregnation chamber which is used in VPI
process operates maximum up to 80 to 150 psi.it is important to analyse and design the pressure vessel that will
provide safety, durability and serviceability to the company. Accomplishing this task will require a very good
understanding of behaviour and a good knowledge of parameters that affecting the pressure vessel due to
varying loads, pressure and thickness of shell element. The most important one is that the given geometry of
pressure vessel must be analysed to assure it should meet the design standards
Design, analysis and development of special purpose tools for composite manuf...eSAT Journals
Abstract Advanced materials are widely used in high performance structures that profit from their high strength; high stiffness and low weight .Composite products are realized using different manufacturing processes to meet the functional, production rate, size and shape of the part. Now days most of the industries are mainly focusing on improvements in manufacturing techniques to reduce efforts as well as material wastage. Wet layup, compression molding, resin transfer molding, filament winding, pultrusion are the some of the well established process in composites. The present work mainly focused on some of the improvements in layup process and filament winding process. In layup process improvements, design and development of special purpose tool for noodle preparation (i.e. Radius fillers) for composite T, I, H sections is carried out. Comparison made on the existing and proposed design for the feasibility. In filament winding process improvements, design and development of special purpose mandrel for complex shaped filament wound composite parts is carried out based on the industrialization concept. Later part of work extended to the study of impact of winding angle on the filament wound composite part using NASTRAN software. Keywords: Layup, Noodle preparation (i.e. Radius fillers), Filament winding, Mandrel, Winding angle, NASTRAN.
EOS client, Startup Vetoflow, using DMLS to produce probes for measuring spee...Machine Tool Systems Inc.
Please find attached a case study about the production of probes for measuring speed and temperature in turbo engines. These probes have been invented by the Startup Vetoflow. The formation of the company was supported by the 3D Printing Cluster. A network which was founded by EOS, Strascheg Center for Entrepreneurship and UnternehmerTUM.
Selection of Roof Casting Formwork Systems for the Bird Island Project: Case ...Muhammad Umar
Selection of Roof Casting Formwork Systems for the Bird
Island Project: Case Study.
The paper illustrates the complexities involved in the selection and deployment of a formwork system through a study of
the concrete formwork selection on the Bird Island Flats Tunnel project. This $290 million project was a part of the Central Artery/Tunnel
project in Boston, Massachusetts. Because the conventional shoring methods could not produce the output needed to meet the project
schedule and budget, the contractor solicited proposals from formwork manufacturers and chose the system from CONESCO Industries.
The purpose of this project is to design a system for Arbutus Medical that enables a commercially-available power tool to be used as a sterilizable, low-cost surgical saw.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
Design and Analysis of Impregnation Chamber Used In Vacuum Pressure Impregnat...IOSR Journals
The simple explanation is that in nature and in manufacturing, things leak. Vacuum impregnation
stops leak. The ultimate goal of vacuum impregnation is to seal leak/migration paths without impacting the
functional, assembly or appearance characteristics of a part. The impregnation chamber which is used in VPI
process operates maximum up to 80 to 150 psi.it is important to analyse and design the pressure vessel that will
provide safety, durability and serviceability to the company. Accomplishing this task will require a very good
understanding of behaviour and a good knowledge of parameters that affecting the pressure vessel due to
varying loads, pressure and thickness of shell element. The most important one is that the given geometry of
pressure vessel must be analysed to assure it should meet the design standards
Design, analysis and development of special purpose tools for composite manuf...eSAT Journals
Abstract Advanced materials are widely used in high performance structures that profit from their high strength; high stiffness and low weight .Composite products are realized using different manufacturing processes to meet the functional, production rate, size and shape of the part. Now days most of the industries are mainly focusing on improvements in manufacturing techniques to reduce efforts as well as material wastage. Wet layup, compression molding, resin transfer molding, filament winding, pultrusion are the some of the well established process in composites. The present work mainly focused on some of the improvements in layup process and filament winding process. In layup process improvements, design and development of special purpose tool for noodle preparation (i.e. Radius fillers) for composite T, I, H sections is carried out. Comparison made on the existing and proposed design for the feasibility. In filament winding process improvements, design and development of special purpose mandrel for complex shaped filament wound composite parts is carried out based on the industrialization concept. Later part of work extended to the study of impact of winding angle on the filament wound composite part using NASTRAN software. Keywords: Layup, Noodle preparation (i.e. Radius fillers), Filament winding, Mandrel, Winding angle, NASTRAN.
EOS client, Startup Vetoflow, using DMLS to produce probes for measuring spee...Machine Tool Systems Inc.
Please find attached a case study about the production of probes for measuring speed and temperature in turbo engines. These probes have been invented by the Startup Vetoflow. The formation of the company was supported by the 3D Printing Cluster. A network which was founded by EOS, Strascheg Center for Entrepreneurship and UnternehmerTUM.
Selection of Roof Casting Formwork Systems for the Bird Island Project: Case ...Muhammad Umar
Selection of Roof Casting Formwork Systems for the Bird
Island Project: Case Study.
The paper illustrates the complexities involved in the selection and deployment of a formwork system through a study of
the concrete formwork selection on the Bird Island Flats Tunnel project. This $290 million project was a part of the Central Artery/Tunnel
project in Boston, Massachusetts. Because the conventional shoring methods could not produce the output needed to meet the project
schedule and budget, the contractor solicited proposals from formwork manufacturers and chose the system from CONESCO Industries.
The purpose of this project is to design a system for Arbutus Medical that enables a commercially-available power tool to be used as a sterilizable, low-cost surgical saw.
International Journal of Engineering Research and DevelopmentIJERD Editor
Electrical, Electronics and Computer Engineering,
Information Engineering and Technology,
Mechanical, Industrial and Manufacturing Engineering,
Automation and Mechatronics Engineering,
Material and Chemical Engineering,
Civil and Architecture Engineering,
Biotechnology and Bio Engineering,
Environmental Engineering,
Petroleum and Mining Engineering,
Marine and Agriculture engineering,
Aerospace Engineering.
CHINA’S GEO-ECONOMIC OUTREACH IN CENTRAL ASIAN COUNTRIES AND FUTURE PROSPECTjpsjournal1
The rivalry between prominent international actors for dominance over Central Asia's hydrocarbon
reserves and the ancient silk trade route, along with China's diplomatic endeavours in the area, has been
referred to as the "New Great Game." This research centres on the power struggle, considering
geopolitical, geostrategic, and geoeconomic variables. Topics including trade, political hegemony, oil
politics, and conventional and nontraditional security are all explored and explained by the researcher.
Using Mackinder's Heartland, Spykman Rimland, and Hegemonic Stability theories, examines China's role
in Central Asia. This study adheres to the empirical epistemological method and has taken care of
objectivity. This study analyze primary and secondary research documents critically to elaborate role of
china’s geo economic outreach in central Asian countries and its future prospect. China is thriving in trade,
pipeline politics, and winning states, according to this study, thanks to important instruments like the
Shanghai Cooperation Organisation and the Belt and Road Economic Initiative. According to this study,
China is seeing significant success in commerce, pipeline politics, and gaining influence on other
governments. This success may be attributed to the effective utilisation of key tools such as the Shanghai
Cooperation Organisation and the Belt and Road Economic Initiative.
Online aptitude test management system project report.pdfKamal Acharya
The purpose of on-line aptitude test system is to take online test in an efficient manner and no time wasting for checking the paper. The main objective of on-line aptitude test system is to efficiently evaluate the candidate thoroughly through a fully automated system that not only saves lot of time but also gives fast results. For students they give papers according to their convenience and time and there is no need of using extra thing like paper, pen etc. This can be used in educational institutions as well as in corporate world. Can be used anywhere any time as it is a web based application (user Location doesn’t matter). No restriction that examiner has to be present when the candidate takes the test.
Every time when lecturers/professors need to conduct examinations they have to sit down think about the questions and then create a whole new set of questions for each and every exam. In some cases the professor may want to give an open book online exam that is the student can take the exam any time anywhere, but the student might have to answer the questions in a limited time period. The professor may want to change the sequence of questions for every student. The problem that a student has is whenever a date for the exam is declared the student has to take it and there is no way he can take it at some other time. This project will create an interface for the examiner to create and store questions in a repository. It will also create an interface for the student to take examinations at his convenience and the questions and/or exams may be timed. Thereby creating an application which can be used by examiners and examinee’s simultaneously.
Examination System is very useful for Teachers/Professors. As in the teaching profession, you are responsible for writing question papers. In the conventional method, you write the question paper on paper, keep question papers separate from answers and all this information you have to keep in a locker to avoid unauthorized access. Using the Examination System you can create a question paper and everything will be written to a single exam file in encrypted format. You can set the General and Administrator password to avoid unauthorized access to your question paper. Every time you start the examination, the program shuffles all the questions and selects them randomly from the database, which reduces the chances of memorizing the questions.
Literature Review Basics and Understanding Reference Management.pptxDr Ramhari Poudyal
Three-day training on academic research focuses on analytical tools at United Technical College, supported by the University Grant Commission, Nepal. 24-26 May 2024
6th International Conference on Machine Learning & Applications (CMLA 2024)ClaraZara1
6th International Conference on Machine Learning & Applications (CMLA 2024) will provide an excellent international forum for sharing knowledge and results in theory, methodology and applications of on Machine Learning & Applications.
HEAP SORT ILLUSTRATED WITH HEAPIFY, BUILD HEAP FOR DYNAMIC ARRAYS.
Heap sort is a comparison-based sorting technique based on Binary Heap data structure. It is similar to the selection sort where we first find the minimum element and place the minimum element at the beginning. Repeat the same process for the remaining elements.
Using recycled concrete aggregates (RCA) for pavements is crucial to achieving sustainability. Implementing RCA for new pavement can minimize carbon footprint, conserve natural resources, reduce harmful emissions, and lower life cycle costs. Compared to natural aggregate (NA), RCA pavement has fewer comprehensive studies and sustainability assessments.
1. Copyright 2005, Society of Petroleum Engineers
This paper was prepared for presentation at Offshore Europe 2005 held in Aberdeen,
Scotland, U.K., 6–9 September 2005.
This paper was selected for presentation by an SPE Program Committee following review of
information contained in a proposal submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at
SPE meetings are subject to publication review by Editorial Committees of the Society of
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers is
prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300
words; illustrations may not be copied. The proposal must contain conspicuous
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
Abstract
The provenance of the single-diameter well consists of over
350 commercial installations of solid expandable tubular
systems and a concise, yet encompassing development plan.
The maturation of expandable technology has led to successful
design, construction and testing of individual components and
the subsequent subsystem that will ultimately help realize the
single-diameter well.
This evolutionary step brings the energy industry that
much closer to a fundamental change in wellbore construction.
The single-diameter well represents a paradigm shift in the
way wells are drilled and results in significant benefits that
include conserving resources, saving time, and creating a
smaller environmental footprint. All of these features result in
considerable savings that reflect the practicality of this value-
added technology.
This paper will explain the overall scope, approach and
implementation essential to realizing the single-diameter well.
In addition, this paper will explain how the technical
development of necessary tools for the single-diameter well
brings significant savings to drilling operations. Using
business cases, this paper will detail where the value of
application is realized. In conclusion, this paper will outline
future possibilities for the technology and how it will impact
the industry.
Introduction
The legacy of single-diameter technology stems directly from
the development of solid expandable tubulars. Extensive and
progressive testing by Enventure and Shell has rapidly
improved single-diameter technology. Manipulating the
diameter of pipe downhole has taken these systems from an
emerging technology to a viable wellbore construction option.
Incorporating these systems into the drilling design retains
wellbore ID and decreases the tapering effect. Developing a
process to retain wellbore ID by using these systems in
tandem virtually eliminates wellbore tapering. This concept
constitutes the premise of the single-diameter wellbore
advantage.
Proving the Concept
A proof–of–concept well, completed in South Texas by
Shell Exploration and Production Company (SEPCO) in July
2002, used one single-diameter section that required two
dedicated trips to complete the expansion. The system used
conventional expandable technology for the first trip,
hydraulically expanding from the bottom up, to achieve the
required partial inside diameter (ID). A combination hydraulic
and mechanical expansion trip from the top down followed,
achieving the final required ID (Figure 1).
With the basic construction principles proven, the
challenge now was to translate these elements into a practical
and more universally cost-effective working system. A project
team, consisting of the operator’s research group and asset
team and the expandable service company, began to move the
development beyond the proof of concept stage.
First, the team refined the base concept to a slightly
different configuration. The improved system concept expands
a bell section on the bottom of the expandable casing creating
an overlap. This section allows the subsequent string to be
expanded and clad inside the bell for hanging and pressure
sealing. The remaining liner length is then expanded using a
basic pipe expansion method. Expanding the liner top into the
previous bell section forms a metal-to-metal seal. The
necessity for zonal isolation was identified as a key issue and
addressed by underreaming the hole section to provide an
adequate cement sheath.
Next, team members concurred that the existing post-
expanded casing specification and completion scenario were
acceptable and turned their attention to system functionality.
The numbers of trips to complete an installation and risk
mitigation were identified as the two primary considerations
directly related to the deepwater environment and spread rate
cost. The bell section expansion, main liner section and
overlap needed to be consolidated into one trip. Adequate self-
contained contingencies also needed to be part of the design.
From the reviews, analysis and discussions, the more
refined concept and base operational overview emerged that
identified the needed design elements. The next task consisted
of designing a multi-functional tool to integrate all sub-
systems and assure self-contained contingencies. This
direction diverged from conventional solid expandable tubular
tool configurations and designs since most of the
conceptualized tools did not exist. These conditions
SPE 96655
Realizing Single-Diameter Wellbore Technology
K. Waddell, Enventure Global Technology LLC
2. 2 SPE 96655
necessitated an extensive design task to fulfill all of the
requirements.
The Tool String Elements and Contingencies
A deliberate and methodical planning, designing and
implementation philosophy produced a tool string that works
in conjunction with all subsystems and provides the means for
contingencies. This multi-functional tool consists of seven
major elements and three minor elements (Figure 2). From
top to bottom:
• Sizing mill – hydraulically activated tool used to cut and
pull excess casing/ballast casing clad in the bell section.
• Anchor – hydraulically activated tool used to anchor the
tension actuator to the casing during expansion. This
device is designed to grip in only one direction.
• Safety sub – specially threaded connection that has low
breakout torque. This device is used for contingency
release.
• Tension actuator – multiple piston hydraulic actuator that
is used to expand casing until the packer is set.
• Cup sub – provides surface area for hydraulic expansion.
• Casing lock – carries the weight of the casing as the tool
string moves down hole.
• Extender – hydraulically activated tool used to deploy the
cones and packer outside the case to initiate expansion.
• Expandable cones – hydraulically expanded and used to
form the bell section for the subsequent casing clad and
expand the main liner body. Sizes: 10.95 and 10.40 in.
• Packer setting tool – available as a mechanical setting tool
or a hydraulic setting tool.
• Packer – primarily used to seal off the end of the casing to
provide pressure integrity during hydraulic expansion and
as a retainer during cementing operations. The packer
contains a sliding valve to provide flexibility in the
cementing sequence.
The single-diameter tool string contingencies center on the
following key elements:
• Safety sub system – is based on a wavy shoulder low
torque connection. The box connection of the sub looks
up on the downhole single-diameter tool string. Its
counterpart pin connection looks down on the end of the
workstring. The system ties the inner liner workstring into
the single-diameter tool string/liner during liner
deployment operations.
During remediation operations, it can be backed-off to
retrieve the largest outside diameter (OD) tools, tension
actuator, anchor and sizing mill to provide maximum
flexibility for jarring or fishing operations. The sub and
connection are standard parts of solid expandable tubular
systems and have been run downhole trouble-free over
300 times.
• Tension actuator and anchor – provide the ability to
generate expansion force if there is a loss of hydraulic
integrity from a connection leak or casing breech. It is
also available should additional force be necessary
beyond the capacity of hydraulic expansion.
• Cones – equipped with a retracting device that is activated
by rupturing a 5,000 psi burst disk in the assembly. This
mechanism retracts both cones to a reduced drift OD.
Once completed, this contingency allows for the retrieval
of the tool string through the unexpanded casing ID.
Field Execution
The test well for the single-diameter expansion tool, in late
2004, was executed with a full Class III BOP stack, health,
safety and environmental (HSE) systems, closed loop mud
system and zero discharge tolerance. This live well was the
means by which the following objectives were satisfied:
• Full compliance with HSE policies and zero recordable
incidents
• Deploy and expand 9-5/8 in. single-diameter liners in the
well
• Test the merits of expansion against and into the
formation to achieve hydraulic isolation without cement
and/or mechanical isolation tools
To best facilitate system application, wellbore preparation
followed a carefully laid out plan. Below a 20 in. conductor at
101 ft, 16 in. structural casing was set at 450 ft followed by
11-3/4 in. surface casing set at 2,089 ft. The surface casing
string consisted of 65 lb/ft, L80 casing and three joints of 47
lb/ft, LSX-80, proprietary expandable casing and connections.
This casing string served as the shoe track and the pre-formed
bell section for cladding back the subsequent single-diameter
liner with a metal-to-metal expansion and 100% hydraulic
seal.
A pendulum assembly with a 10.25 in. rock bit and near-
bit reamer, pinned for a 12-1/2 in. hole, drilled the +500 ft
hole section for deployment of the 9-5/8 in., 36 lb/ft, LSX-80
expandable liner and the concentric single-diameter tool string
assembly. After cementing the surface casing, the shoe track
was drilled out with a 10.25 in. bit, short collar and one-degree
bent sub. This assembly cleaned out cement without damaging
the face of the surface casing, which was subsequently used to
expand against with the expanded liner. Running an
expandable liner requires specialized casing handling
equipment and procedures to protect the OD of the casing and
connections.
The Single-diameter Expansion Process
To help facilitate deployment of the single-diameter expansion
system an installation process was developed in conjunction
with the tool. After hole preparation, two casing joints are run
in the hole with the bottom part of the single-diameter tool
string assembly pre-installed inside the casing. Several joints
of casing are then run inside the surface casing followed by
the tool string that is deployed inside the casing. Both the
casing and the concentric tool string are then run in the hole
simultaneously using a false rotary table. When on bottom, the
casing and tool string is picked up approximately 50 ft, and a
dart is pumped. The pumped dart actuates the extender, which
pushes the packer and cones outside the liner and the casing
locks retract. Once outside the casing, hydraulic pressure
opens the upper cone assembly to its full 10.95 in. OD and the
lower cone to its full 10.40 in. OD. Pressure cycles begin to
mechanically expand the bottom joint of casing to 10.95 in.
ID, which forms the bell section and allows expanding back
the next single-diameter liner inside the bell with metal-to-
metal expansion (Figure 3 – Stage 1).
3. SPE 96655 3
Once the bell section is formed, the pressure is released
and the upper cone is retracted and pulled up inside the
unexpanded liner. The 10.40 in. cone assembly is pulled up
against the expansion face (Figure 3 – Stage 2). After
expanding the first two joints, the rest of the liner can either be
mechanically or hydraulically expanded (Figure 4 – Stage 3).
If hydraulically expanded, the packer is mechanically set by
rotating in the expanded 10.40 in. liner. Cement is pumped
below the packer for stability on the drillout and on the
backside if annular cement isolation is desired.
After cement is in place, the remainder of the liner is
hydraulically expanded up into the surface casing shoe track.
Options for the liner-to-casing seal include the following
proven techniques:
• Metal-to-metal seal by expanding the liner to 10.40 in. ID
and 11.00 in. OD inside the 47 lb/ft, 11.75 surface casing.
• Conventional elastomers run on the top two to three liner
joints. (The metal-to-metal seal was used in the subject
test. Subsequent cased-hole logging and positive pressure
testing indicated a solid hydraulic seal in the expandable
liner lap area.)
Upon completing expansion, the tool string is pulled to the
surface and laid down. A proprietary sizing mill assembly is
run inside the casing and pulled up into the 10.40 in.
expanded/unexpanded casing interface (Figure 4 – Stage 4).
The sizing mill arms extend to cut the liner. Both the tool
string and the cut, unexpanded casing is pulled to surface and
laid down. A cased-hole casing evaluation log follows each
expansion to assess expansion faces, expansion ovality and
casing condition. In the actual field application, all subject
logs indicated highly uniform expansion IDs with minimal to
no ovality and minimal distortion of the cutting face.
Actualizing the Potential
Solid expandable tubular technology was primarily designed
to address conditions that lead to casing being set before
planned. Using the technology to cover a swelling shale or lost
circulation zone allows drilling to continue with only a
fraction of hole size loss if using conventional expansion
systems, or no hole size loss if using single-diameter systems.
During the course of its short history, solid expandable
tubulars have demonstrated substantial cost savings and value
generation through a variety of downhole applications
including:
• Expanding solid tubulars through milled window exits.1
• Incorporating expandable tubulars into the drilling
design.2
• Installing 13Cr solid expandable systems to maximize gas
production.3
While the numbers generated from these enabling installations
have been significant, they have been achieved on a single-
well basis. What have not been fully delineated or explored
are the full enabling possibilities of the technology in full-
blown field developments.
The advantage of using solid expandable technology in a
multi-well or field development is in leveraging the cost
savings and value creation to be multiplied over the entire
scope of the project. Therefore, the magnitude of the savings
and value are greatly increased. These significant cost savings
and value are realized through the technology’s ability to
• Reduce drilling-related risk and trouble time
• Improve capital efficiency on drilled wells and overall
field development by reducing well cost and structure size
• Enhance field-development flexibility including
scheduling and planning
• Reduce cost-structure in field development
• Accelerate reserves
Pushing the Envelope
A legacy of successful installations, a broadening applications
envelope, and continued development has led to the next
evolutionary step in the technology - single-diameter solid
expandable tubulars. Like its conventional predecessor, single-
diameter advancement depends on a sound value proposition
to progress the technology from field testing to the asset level.
A specific application with field-development repercussions
has garnered much attention for its substantial business case.
This application consists of marrying single-diameter
technology and extended reach drilling (ERD). The coupling
of these two leading edge technologies will positively impact
well and field capital and operational cost in several key areas,
resulting in economically viable alternative development
scenarios.
Expandable technology is seen as a way to reduce the
overall non-productive time (NPT) incurred during the
construction of an extended reach well. By addressing drilling
problems as they occur and casing off challenging intervals
without any loss of diameter, great improvements in
operational efficiency will be gained.
The technology’s proven, simulated and engineered
potential provides the foundation for a significant increase in
the lateral reach of many extended reach wellbores.5
Torque
and drag on an extended reach well is often seen as the critical
factor that limits achievable reach. Geometric conditions such
as dogleg severity (DLS) and casing openhole size vs. drill
string size can influence torque and drag as well. Successive
installations of expandable, single-diameter systems can
significantly reduce the friction/drag forces that can limit
lateral reach and still preserve ID as required. In turn these
systems can afford higher weight-on-bit at comparable depths
versus conventional drilling technology. The current envelope
for ERD is ~10,000 m, and by using solid expandable tubular
technology with significant friction reduction, the envelope
could be extended another 5,000 m (Figure 5).
This extended lateral reach results in increased reservoir
contact that can lead to increased production per well. More
production from fewer wells can ultimately lower required
field well counts with an improved drilling cost structure
profile. In select offshore applications, this technology can in
turn result in lower platform installation requirements without
reserve reductions. The potential exists to increase reserves by
tapping flank or step-out reserves. In many subsea
applications, the technology can result in fewer subsea
templates, flowlines, pipelines and production center
requirements (Figure 6). Optimizing drilling operations can
lower facility and project capital requirements while
improving platform or subsea facility installation flexibility
4. 4 SPE 96655
and phasing. Enhancing development flexibility with
minimum economics is an attractive proposition. In subsea
applications improved development phasing includes seabed
geohazards, such as escarpments or Arctic iceberg risks.
Reducing the subsea infrastructure requirements further
mitigates project risk and improves field economic returns
(Figure 7).
Additional Advantages
Capitalizing on the possibilities has taken solid expandable
technology from a contingency system to a viable drilling plan
option to an instrumental factor in designing the task-specific
rig. This approach incorporates single-diameter technology to
work as part of an overall system that downsizes well
infrastructure without compromising the bottomhole
completion. The system includes a smaller wellhead,
Christmas tree and riser. These reductions lower the overall
capital cost for a take-point which in turn makes sub-sea
targets and marginal reserves more economically feasible.
An application advantage exists in the form of using
single-diameter tubulars to extend the shoe during drilling
operations without reduction of ID. This application is
particularly advantageous in exploration wells where the
drilling hazards are not well defined or are unknown. By using
the technology to extend the shoe and maintain ID, the
operator is guaranteed a workable ID at target depth for
production testing or to run evaluation tools.
Another meritable by-product to emerge from using solid
expandable tubular technology is its environmental appeal.
Many of the same factors that reduce expenditures, such as
downsizing, also reduce the environmental footprint of these
operations—less mud required, fewer cuttings needing
disposal, smaller rigs that create less of a disturbance to the
area.
Conclusion
The successful application of solid expandable technology
over the past six years has fed the development of single-
diameter wellbore technology. The proficiency being gained
with this unique and exclusive technology serves to further its
evolution. Proving reliability and establishing economic
advantage of expandable technology reinforces the projected
potential of the single-diameter concept that will usher in a
paradigm shift in wellbore construction6
and field
development. The industry is only recently beginning to
realize the many profitable applications of single-diameter
expansion systems.
As the market for hydrocarbon fuels continues to grow so
will the burden to find and develop oil and gas fields.
Exploration and production will require technology that goes
not only further and faster but provide maximum flexibility,
reliability and value. Solid expandable tubular systems have
demonstrated their ability to extend drilling depths at a faster
rate. This technology is already impacting drilling operations
with advantages that encompass saving time and reducing
drilling costs to decreasing the environmental disturbance
during drilling and production operations. The viability of
current systems and the promise of developing technology
continue to drive the evolution of expandables. But the effort
to make the single-diameter wellbore a practical construction
option cannot be driven by service companies alone. A key to
realizing the single-diameter well lies in the industry’s
willingness to accept, apply, and promote expansion of the
technology’s enabling capability, benefits, and potential.
References
1. Grant, T., Enventure Global Technology; Inventive Solid
Expandable Tubular Applications Capitalize on Window of
Opportunity: Openhole Liner System Prevents Loss of Hole
Size in Sidetracking Operations; AADE-05-NTCE-19
AADE 2005 National Technical Conference and
Exhibition, held at the Wyndam Greenspoint in Houston,
Texas, April 5-7, 2005.
2. Carstens, C., Unocal Corporation; Blasingame, K.,
Enventure Global Technology; Solid Expandable Tubular
Technology: The Value of Planned Installation Vs.
Contingency; SPE/IADC 92622 SPE/IADC Drilling
Conference held in Amsterdam, The Netherlands, 23-25
February 2005.
3. Siemers, G. and Ukomah, T., NAM; Mack, R., Shell; and
Noel, G., and Donald, J., Enventure Global Technology;
Development and Field Testing of Solid Expandable
Corrosion Resistant Cased-hole Liners to Boost Gas
Production in Corrosive Environments; OTC 15149 2003
Offshore Technology Conference held in Houston, Texas,
U.S.A., 5–8 May 2003.
4. DeMong, K., Halliburton; Rivenbark, M., Enventure
Global Technology; Hussain, K., Kuwait Oil Company;
Planning the Well Construction Process for the Use of
Solid Expandable Casing, SPE 85303 SPE/IADC Middle
East Drilling Technology Conference & Exhibition held in
Abu Dhabi, UAE, 20-22 October 2003.
5. DeMong, K., Halliburton; Rivenbark, M., Enventure
Global Technology; Breakthroughs Using Solid
Expandable Tubulars to Construct Extended Reach Wells,
SPE 87209 IADC/SPE held in Dallas, Texas USA, March,
2004.
6. Waddell, K., Enventure Global Technology; Advances in
Monodiameter Well Technology: The Next Step to Cost-
Effective Optimization, SPE 90818 SPE Annual Technical
Conference and Exhibition held in Houston, Texas, U.S.A.,
26–29 September 2004.
5. 5 SPE 96655
Figure 1 – Illustration of top-down expansion process.
Figure 2 – Single-diameter tool string with major and minor elements.
Step 1
Run conventional
bottom-up system and
clad
Step 2
Drill out bottom
plug
Step 3
Run top-down system;
over expand previous
casing
Step 4
Drill ahead and run
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