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Expandable Tubulars for Ultradeepwater Drilling Ultradeepwater Challenges Technology Options/Selection Development and testing Open Hole Liner System Details Initial Applications and results Future Applications
Ormen Lange Egypt WoS Malampaya Morocco Malaysia Gulf of Mexico (SEPCo) Bonga Trinidad/ Surinam Brazil Oman
Canada
SEPCos Challenge
Ultradeepwater Gulf of Mexico How to design wells for low drilling margin conditions (large number of Casing strings)? How to deliver these wells in a cost effective way? Wells have failed to reach objective depth due to insufficient number of casing strings to accommodate the pore pressure profile. How to trial new technologies in this high cost environment.
Ultra-Deepwater GOM Pore Pressure and Fracture Pressure
EMW (PPG)
7,000 8,000 FPG 9,000 10,000 11,000 12,000 13,000 D e p t h 14,000 15,000 11-3/4" Expected PPG Casing 20" 18" 16" 16 SET 13-3/8" 26" 8 9 10 11 12 13 14 15 16
(ft, 16,000 TVD) 17,000 18,000 19,000 20,000 21,000 22,000 23,000
9-5/8"
EGT00163
TD
Technology Selection Large bore wellhead system and 18 casing development (Low risk and fairly quick) Expandable tubular technology - this was viewed as an enabling technology with the potential to add significant value in the long-term but required a longer development time frame. The key question is. Where do you trial such technology..
Size selection
Previous Casing 16 84 #/ft 11 60 #/ft 9 5/8 53.5 #/ft Expanadable Tubular 13 3/8 XPD 9 5/8 XPD 7 5/8 XPD Next casing 13 3/8 9 5/8 7 hole
Drill Hole
Latch plug
Expand Liner
Expand Hanger Jt
16-in. Casing (455 FT) Pre-Expansion 13-3/8 16-in. Expandable OHL (2,016 ft)
Launcher Subassembly
17-1/2-in. Hole
EGT00164
TD = 2,300 ft
Additional Testing
McAllen Ranch 106
6 x 7 5/8 Up to 6000 psi differential pressure conditions 785 pre-expanded length pipe stuck after running to bottom expanded 482, lost pressure pipe failure due to stuck - stuck conditions Learning's/Actions Additional Testing of stuck-stuck mechanism Re-design pig/stabilization Lead to real world understanding of load conditions not anticipated by theory (loads due to differential sticking and collapse load at pop out).
Subsequent 6 OH applications by Enventure have all been for SEPCo (3 offshore and 3 on land)
(1) 13 3/8 x 16
1186 (pre-expansion) liner Initial dart did not bump 2nd dart bumped (2nd dart covered rupture disk - could not expand) Release inner string & RIH with jars. Jar on pipe while WO coil tubing equipment to drill out top dart. Rupture disk sheared. Expanded casing & tested Drill shoetrack w/mill & squeezed casing shoe
Current
Future
An enabling technology for ultradeepwater wells. We have already started to slenderize our wells. Nested expandables leading to the monodiameter well and the use of compact rigs for deepwater/deep wells is not that far in the future.
18-3/4 in BOP
13-5/8 in BOP
12 in Riser
30 in Structure Pipe
10 in BOP
20 in
13-3/8 in
9-5/8 in
16 in
Expanded Solution #1
13.375 in
9-5/8 in
11.750 in
Expanded Solution #2
9-5/8 in
This technology when linked with other technologies such as dual gradient drilling and advanced synthetic preset mooring systems can radically change the cost structure for ultradeep water exploration and development.
9.6250 in
Expanded Solution #3
9-5/8 in
TD
TD
TD
EGT00189
7.625 or 7.0 in
Utilization of expandable tubulars allowed well to be drilled through the primary objectives New technology allowed three additional strings of casing to be installed vs. a conventional well plan