Increasing Solid Expandable Tubular Technology Reliability in a Myriad of Downhole Environments

Abstract

Abstract Since the spectacular arrival of solid expandable tubulars four years ago, customers have embraced this technology as a revolutionary well constructionand production solution. Through innovative technical development and equipmentreliability, solid expandable tubulars continue to grow in acceptance anduse. Solid expandable tubulars have been used successfully to reach requiredtotal depth (TD) with adequate completion size, slim the well constructionprocess, and overcome abnormal pressures encountered down hole while drilling.In addition, this technology has been used to rejuvenate wellbores for welldeepening, casing reinforcement for stimulation, as a solution for corrosionproblems, and to cover leaks and perforations. As a result, the overall cost ofdrilling and production operations has been reduced. This expansion process requires the successful integration of the followingconditions and equipment: casing capable of surviving in-situ reformingfriction reduction between the expansion cone and the casingexpandable flush joint connectioncontainment of hydraulic pressures during the entire expansion processsurviving expansion in downhole environment During the last four years, solid expandable tubulars have been installed inmore than 113 wells. Reliability has improved from an average of 67% in 2000, to 83% in 2001, to over 95% in 2002. In the past, the reliability of solidexpandable tubulars has been measured by a limited set of criteria for jobsuccess. The reliability definition should be expanded to include otherperspectives of the total system. This paper will discuss actual downhole conditions, including well control, lost circulation, and high temperature/high mud weight, in which solidexpandable tubulars were used as a successful solution. This paper will alsodiscuss additional measurement perspectives with the goal of creating a 100%reliable technology.