OIL COUNTRY TUBULAR GOODS

Industry experience with solid expandable tubular technology

Part 1 – Technology overview and two of five case histories illustrate lessons learned in successful / unsuccessful installations

Kenneth K. Dupal, Shell Deepwater Development, Inc.; Donald B. Campo, Shell Exploration & Production Technology; John E. Lofton, Chevron Petroleum Technology Co.; Don Weisinger, BP; R. Lance Cook, Michael D. Bullock, Thomas P. Grant and Patrick L. York, Enventure Global Technology, L. L. C.

Previously published papers / articles have discussed the concepts of solid expandable tubular (SET) technology¹ and effect of the expansion process on system tubulars^2,3 and connectors.⁴ Here, the basics of SET technology are reviewed, emphasizing how early products have been applied in the drilling environment. Case histories will demonstrate that SET products can provide additional tools for the drilling "tool box," ultimately cutting drilling costs. To date, 31 jobs have been performed, of which five did not meet intended objectives. Since "learnings" often are the result of problems, heavy emphasis will be placed on problems and the lessons learned.

SETs have been installed in both open- and cased-hole wellbores from November 1999, in a variety of environments in wells on land, offshore and in deep water, to solve a range of drilling and completion challenges.

This two-part report discusses in depth five drilling case histories, including: descriptions of drilling challenges surrounding use of SETs and their next-best alternatives; risk analysis leading to the use of SETs; discussion of the advantages and disadvantages; and operational lessons learned during installations.

This article overviews the technology, with a description of how the expansion system works, and provides more detail on expandable openhole liners – one of three expandable products developed to date. Two case-history applications by Chevron on a Gulf of Mexico Shelf well and a BP/Vastar installation attempt in Gulf of Mexico ultra-deepwater are presented and discussed. And, a separate discussion presents the several advantages of the technology in deepwater applications.

Part 2 will continue case-history presentations with descriptions and analyses of three installations: 1) Shell E&P’s attempt in a 12,000-ft South Texas onshore well; 2) Shell’s onshore field test to validate implementation of an ultra-deepwater system; and 3) the operator’s actual tubular expansion project on a Gulf of Mexico well in 7,800-ft water. Lessons learned in all projects are discussed.