Expandable Tubular Technology – Drill Deeper, Farther, More Economically

Mark Rivenbark, Enventure Global Technology

Expandable tubular systems enable operators to access reserves that cannot be

reached economically with conventional technology. This industry breakthrough
meets urgent 21st century challenges posed by drilling in high pressure zones,
deepwater environments, and troublesome sub-salt plays.
Expandable casing is run after the hole section is drilled. A specially designed
expansion cone is then run through the casing to increase its diameter. Tests
have proven a routine expansion capability of 20%, at a rate of 25 to 60 ft/min.
Higher percentages of expansion appear feasible.
Before the advent of expandable casing, operators had to use sections of
progressively smaller diameter pipe as they drilled deeper, resulting in a
“telescoped” conduit. Using expandable tubular technology reduces this tapering
effect and decreases the likelihood of running out of hole diameter before
reaching potential pay zones. Using this technology operators can now drill
deeper vertical wells, extend the reach of deviated wells, and conquer those
deepwater wells that were previously considered impractical.
Our presentation will provide a review of the technology and several types of
jobs performed to date. Then we will look forward to the next generation of
expandable tubular technology and its applications.

Introduction
Major hydrocarbon deposits are often found in water depths of 3,000 feet or
more, and are considered as deepwater plays. Many of these wells are located in
frontier areas not readily serviced from existing infrastructures. These wells can
be vertical or horizontal in completion. Many wells present significant challenges
in getting casing strings to the various drilling horizons.
This paper presents the application of expandable tubular technology as it
relates to the successful drilling of deepwater wells. Over twenty wells of this type
have been drilled with solid expandable tubulars since early 2000. These wells
represent some of the earliest applications of this new technology.
Solid expandable tubular technology is applicable in a variety of deepwater
scenarios and in a wide range of casing sizes. These expandable systems
reduce the tapering effect experienced when casing strings are installed as
drilling challenges are encountered. Solid expandable tubulars have an
advantage as they result in less loss of diameter than conventional casing
strings. This technology affords the operator a better chance of reaching total
depth (TD) with a casing string size appropriate for production requirements. In
essence, a larger drain hole can be drilled into the pay zone of interest than
might be possible with conventional casing string designs. As of December 2002,
23 deepwater wells have been drilled with solid expandable tubular technology.

Incentives
As the search for oil moves into deeper water, maximizing oil production and
ultimate oil recovery are key factors to insure that the objectives of these very
expensive wells are achieved. Production and recovery maximization requires
that evaluation and remedial work tools, such as logging and CT acid stimulation,
and drill stem tests can access the drain hole. Drilling and completion challenges
in these fields also require that new approaches to achieve such objectives
remain economical.
Existing casing design methodology was reviewed and factored into the new
approach that was required to meet the objectives of the clients in these fields. It
was important to be able to use solutions that offered a high probability for
success and a reasonable chance to recover from any failure of the systems
deployed.

System Development
Casing designs previously used in both typical and deepwater wells have no
provision for preserving hole size other than starting out with ever bigger strings
of casing. Solid expandable tubulars, however, enable operators to both start the
well with smaller casing strings and conserve hole size when successive strings
need to be set. Also, the anchor hanger joint, which replaces a conventional liner
hanger, insures a good seal at the liner lap thus eliminating the possibility of a
squeeze job. With day rates running into the hundreds of thousands of dollars
per day, operators appreciate this added level of certainty. For the solid
expandable tubular system, an elastomer wrapped joint provides a feature that
insures a proper seal at the liner lap. These joints are expanded and sealed as
part of the normal process of expanding the casing. No additional trips are
required.
The solid expandable tubular system, which included the casing, anchor
hanger joint and launcher assembly, is run as a single assembly. Once on depth,
a dart is dropped to effect a seal and pressure is applied down the drillstring to
create a pressure chamber in the launcher assembly. The casing is expanded
from the bottom up and the liner is sealed back and hung off in the base casing
in one trip. The system is pressure tested and the shoe is then drilled out.

System Application
The installation of this equipment involves several critical steps. After the base
casing has been set a bi-center bit or some other type of hole opening device is
used to create the next hole section (Fig 1, Step 1). This process allows for a
proper annular area for the cement even after the casing has been expanded.
The expandable casing is made up with the expansion cone in the bottom-
hole assembly (BHA) (Fig 1, Step 2). The length of casing to be expanded is run
in the hole and made up with conventional flush-joint connectors. Once all of the
desired casing is run, then a false floor is rigged up.
The workstring is run into the casing and screwed into the hollow expansion
cone through the use of a safety sub. The workstring is then picked up along with
the expandable casing, as the casing is resting on the expansion cone face.
Because the workstring is attached to the expandable liner at the float shoe,
which the expansion cone is splined into, the casing is pulled into the hole by the
workstring rather than pushed into the hole as is the case when running
conventional liners.
Note: The work string is attached at the top of the liner during conventional liner
running jobs and, therefore the liner is pushed to bottom. When running an expandable
liner, the liner is attached at the bottom and pulled into the hole with the workstring. This
configuration allows any required torque (while rotating the liner) on the bottom of the
liner to facilitate getting the liner to bottom if it should stop going in the hole on its own.

Once the expandable liner has reached TD the cement job is pumped similar
to an inner-string cement job (Fig 1, Step 3). Because the cone is splined into the
float shoe, the liner can also be reciprocated to enhance the cement job. A latch-
down dart is pumped and when it seats inside of the float shoe, a pressure
chamber is formed. The pressure is increased until a set of rupture discs, located
in the top of the float shoe, are ruptured and allow the pressure to be applied to
the back side of the expansion cone. Once the expansion pressure is reached,
the casing is extruded off of the face of the cone until it reaches TD.
The next process resembles blowing the end of a wrapper off of a soda straw
(Fig 1, Step 4). The difference in the expansion process is that the casing is
extruded over the cone as it is being blown off of the workstring. Generally, 5,000
to 10,000 lbs is maintained on the bit. This weight allows the BHA to remain
positioned at TD, while the rig blocks hold up the rest of the workstring weight. As
the workstring is pumped out of the hole, the pressure is released before each
stand of drillpipe is unscrewed and set back.
The workstring is then re-pressurized and the expansion process continues,
expanding the casing through the still soft, retarded cement, until the entire liner
is expanded. Typical liner expansion time takes approximately 14 minutes per
stand.
The expandable liner is assembled with an expandable anchor hanger joint as
an integral part of the system top. Once the anchor hanger is expanded, the cone
exits the liner assembly and the expansion process is complete (Fig 1, Step 5).
Any excess cement is reversed out and the liner is positively pressure tested.
The aluminum float shoe is milled out (Fig 1, Step 6). The shoe can be tested
and the next hole section can be drilled.
 Openhole Drill Liner – Installation Sequence

Drill Out Run Cement Expand Expand Mill

Expandable Liner Liner Hanger Joint Out
Liner

Case Histories
As of December 2002, 23 deepwater wells have been drilled using solid
expandable casing liners. The following section summarizes the drilling highlights
of three of these wells.
Case History One. A 6 x 7-5/8 in. openhole liner was installed in a deepwater
well in the Gulf of Mexico (GoM) across a hole interval with possible lost
circulation conditions. The objective of this installation in over 4,000 ft of water
was to maintain sufficient casing ID and still reach the well’s projected target as
planned. Prior to the installation, the well was cased to over 20,000 ft and the
hole had been opened to 7 in. using a near bit reamer.
The openhole liner measured over 2,000 ft (pre-expansion) and consisted of
over 50 connections and run through some potentially tight clearances with no
trouble. The expansion process was successful with the top of the liner at
approximately 20,200 ft and the show at over 22,200 ft. The liner top seal tested
to 2,500 psi for 30 min following pop-out of the expansion cone.
 At the time, this 6 in. openhole liner was expanded at a record setting depth.
Another highlight of this installation was performing a cement squeeze job of the
shoe, prior to drilling out, through squeeze perforations. This procedure
consolidated the area around the float equipment and saved a trip during drill out
procedures.
Case History Two. The operator of a previously drilled ultra-deepwater well in
over 7,700 ft of water was planning on drilling a second well in the prospect area.
The first well in this same area was plugged before reaching TD. The initial well
required more casing strings than anticipated. Setting successive strings higher
than the well plan called for resulted in a much smaller hole than anticipated
before reaching the planned TD. The additional casing strings were needed to
address low drilling margins that were encountered. This well proved to be a
costly but educational learning experience in well design.
When the operator prepared to drill a second well, a 13-3/8 in. solid
expandable tubular liner installation and two contingency expandable liners were
incorporated into the drilling design. This course of action is why solid
expandable tubulars were originally designed. The optional contingency liners
were 9-5/8 x 11-3/4 in. and 7-5/8 x 9-5/8 in. These expandable applications were
designed into the drilling plan to give the operator an added margin for reaching
TD without losing significant hole size.
Two expandable liners, the 13-3/8 x 16 in. and the 9-5/8 x 11-3/4 in. were
ultimately set in this well, making it the world’s first well to have multiple openhole
solid expandable tubular installations. These two openhole liner installations
allowed the well to be drilled to TD with optimum hole size by minimizing casing
size reduction.

Future Plans
To date, operations in the wells mentioned have been so completely successful
that these and many other operators are planning their future deepwater wells
with the use of solid expandable tubulars. In fact plans are in the works to install
the first ever monodiameter well in deepwater in 2003.

Summary
The solid expandable tubular system as described in this paper has met the
objectives of allowing deepwater wells to be drilled without an undue compromise
in hole size. Additionally, the operators are meeting their company’s operational
and economic objectives. Operations from the case histories have been
completely successful and are encouraging the use of more solid expandable
tubulars in future wells.