CA2260191C - Method for expanding a steel tubing and well with such a tubing - Google Patents
Method for expanding a steel tubing and well with such a tubing Download PDFInfo
- Publication number
- CA2260191C CA2260191C CA002260191A CA2260191A CA2260191C CA 2260191 C CA2260191 C CA 2260191C CA 002260191 A CA002260191 A CA 002260191A CA 2260191 A CA2260191 A CA 2260191A CA 2260191 C CA2260191 C CA 2260191C
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- tubing
- expansion
- expanded
- steel
- mandrel
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- 238000000034 method Methods 0.000 title claims abstract description 53
- 229910000831 Steel Inorganic materials 0.000 title claims abstract description 42
- 239000010959 steel Substances 0.000 title claims abstract description 42
- 238000005482 strain hardening Methods 0.000 claims abstract description 16
- 239000000919 ceramic Substances 0.000 claims description 19
- 239000012530 fluid Substances 0.000 claims description 17
- 238000004519 manufacturing process Methods 0.000 claims description 13
- 229910045601 alloy Inorganic materials 0.000 claims description 7
- 239000000956 alloy Substances 0.000 claims description 7
- 238000007789 sealing Methods 0.000 claims description 7
- 239000004215 Carbon black (E152) Substances 0.000 claims description 6
- 230000009977 dual effect Effects 0.000 claims description 6
- 229930195733 hydrocarbon Natural products 0.000 claims description 6
- 150000002430 hydrocarbons Chemical class 0.000 claims description 6
- 229910000963 austenitic stainless steel Inorganic materials 0.000 claims description 5
- 239000007787 solid Substances 0.000 claims description 4
- 229910001566 austenite Inorganic materials 0.000 claims description 3
- 230000007423 decrease Effects 0.000 claims description 3
- 238000013022 venting Methods 0.000 claims description 3
- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 claims description 2
- 229910001928 zirconium oxide Inorganic materials 0.000 claims description 2
- 230000001154 acute effect Effects 0.000 claims 2
- 238000005086 pumping Methods 0.000 claims 2
- 238000002474 experimental method Methods 0.000 description 11
- 239000000463 material Substances 0.000 description 3
- 229910052751 metal Inorganic materials 0.000 description 3
- 239000002184 metal Substances 0.000 description 3
- 230000015572 biosynthetic process Effects 0.000 description 2
- 238000002347 injection Methods 0.000 description 2
- 239000007924 injection Substances 0.000 description 2
- 238000005272 metallurgy Methods 0.000 description 2
- 150000002739 metals Chemical class 0.000 description 2
- 229910000794 TRIP steel Inorganic materials 0.000 description 1
- 238000005452 bending Methods 0.000 description 1
- 230000009286 beneficial effect Effects 0.000 description 1
- 239000004568 cement Substances 0.000 description 1
- 229910010293 ceramic material Inorganic materials 0.000 description 1
- 238000005253 cladding Methods 0.000 description 1
- 238000004581 coalescence Methods 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- 230000000052 comparative effect Effects 0.000 description 1
- 238000013461 design Methods 0.000 description 1
- 230000000694 effects Effects 0.000 description 1
- 238000005242 forging Methods 0.000 description 1
- 230000017525 heat dissipation Effects 0.000 description 1
- 238000011065 in-situ storage Methods 0.000 description 1
- 238000003780 insertion Methods 0.000 description 1
- 230000037431 insertion Effects 0.000 description 1
- 230000001788 irregular Effects 0.000 description 1
- 238000012423 maintenance Methods 0.000 description 1
- 230000006911 nucleation Effects 0.000 description 1
- 238000010899 nucleation Methods 0.000 description 1
- 230000001681 protective effect Effects 0.000 description 1
- 238000004088 simulation Methods 0.000 description 1
- 230000002195 synergetic effect Effects 0.000 description 1
Classifications
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B43/00—Methods or apparatus for obtaining oil, gas, water, soluble or meltable materials or a slurry of minerals from wells
- E21B43/02—Subsoil filtering
- E21B43/10—Setting of casings, screens, liners or the like in wells
- E21B43/103—Setting of casings, screens, liners or the like in wells of expandable casings, screens, liners, or the like
- E21B43/105—Expanding tools specially adapted therefor
-
- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D7/00—Modifying the physical properties of iron or steel by deformation
- C21D7/02—Modifying the physical properties of iron or steel by deformation by cold working
- C21D7/10—Modifying the physical properties of iron or steel by deformation by cold working of the whole cross-section, e.g. of concrete reinforcing bars
- C21D7/12—Modifying the physical properties of iron or steel by deformation by cold working of the whole cross-section, e.g. of concrete reinforcing bars by expanding tubular bodies
-
- E—FIXED CONSTRUCTIONS
- E21—EARTH OR ROCK DRILLING; MINING
- E21B—EARTH OR ROCK DRILLING; OBTAINING OIL, GAS, WATER, SOLUBLE OR MELTABLE MATERIALS OR A SLURRY OF MINERALS FROM WELLS
- E21B17/00—Drilling rods or pipes; Flexible drill strings; Kellies; Drill collars; Sucker rods; Cables; Casings; Tubings
Landscapes
- Engineering & Computer Science (AREA)
- Life Sciences & Earth Sciences (AREA)
- Geology (AREA)
- Mining & Mineral Resources (AREA)
- Chemical & Material Sciences (AREA)
- Mechanical Engineering (AREA)
- Environmental & Geological Engineering (AREA)
- Fluid Mechanics (AREA)
- General Life Sciences & Earth Sciences (AREA)
- Geochemistry & Mineralogy (AREA)
- Physics & Mathematics (AREA)
- Crystallography & Structural Chemistry (AREA)
- Materials Engineering (AREA)
- Metallurgy (AREA)
- Organic Chemistry (AREA)
- Earth Drilling (AREA)
- Heat Treatment Of Steel (AREA)
- Forging (AREA)
- Metal Extraction Processes (AREA)
- Rigid Pipes And Flexible Pipes (AREA)
Abstract
A tubing (4) made of a formable steel grade which is subject to strain hardening without incurring any necking or ductile fracturing as a result of the expansion process is expanded by moving an expansion mandrel (5) having a non-metallic tapering outer surface through the tubing, thereby increasing the strength of the tubing while expansion forces remains low.
Description
METHOD FOR EXPANDING A STEEL TUBING AND WELL WITH SUCH A
TUBING
The invention relates to expansion of tubings. More particularly the invention relates to a method of expanding a steel tubing by moving an expansion mandrel through the tubing.
Numerous methods and devices are known for expansion of tubings.
European patent specification 643794 discloses a method of expanding a casing against the wall of an underground borehole wherein the casing is made of a malleable material which preferably is capable of plastic deformation of at least 25% uniaxial strain and the casing may be expanded by an expansion mandrel which is pumped, pulled or pushed through the casing.
Other expansion methods and devices are disclosed in German patent specification No. 1583992 and in US patent specification Nos. 3,203,483; 3,162,245; 3,167,122;
3,326,293; 3,785,193; 3,489,220; 5,014,779; 5,031,699;
5,083,608 and 5,366,012.
Many of the known expansion methods employ an initially corrugated tube and the latter prior art reference employs a slotted tube which is expanded downhole by an expansion mandrel.
The use of corrugated or slotted pipes in the known methods serves to reduce the expansion forces that need to be exerted to the tube to create the desired expansion.
A method is known from US patent specification No. 5,366,012. In this known method a slotted tube is expanded by an expansion mandrel having a tapering expansion section.
TUBING
The invention relates to expansion of tubings. More particularly the invention relates to a method of expanding a steel tubing by moving an expansion mandrel through the tubing.
Numerous methods and devices are known for expansion of tubings.
European patent specification 643794 discloses a method of expanding a casing against the wall of an underground borehole wherein the casing is made of a malleable material which preferably is capable of plastic deformation of at least 25% uniaxial strain and the casing may be expanded by an expansion mandrel which is pumped, pulled or pushed through the casing.
Other expansion methods and devices are disclosed in German patent specification No. 1583992 and in US patent specification Nos. 3,203,483; 3,162,245; 3,167,122;
3,326,293; 3,785,193; 3,489,220; 5,014,779; 5,031,699;
5,083,608 and 5,366,012.
Many of the known expansion methods employ an initially corrugated tube and the latter prior art reference employs a slotted tube which is expanded downhole by an expansion mandrel.
The use of corrugated or slotted pipes in the known methods serves to reduce the expansion forces that need to be exerted to the tube to create the desired expansion.
A method is known from US patent specification No. 5,366,012. In this known method a slotted tube is expanded by an expansion mandrel having a tapering expansion section.
It is an object of the present invention to provide a method for expanding an at least partly solid, i.e. unslotted, tubing which requires exertion of a low force to expand the tubing and which provides a tubing having a larger diameter and higher strength than the unexpanded tubing and which can be carried out with a tubing which already may have a tubular shape before expansion.
The method according to the invention thereto comprises the step of moving an expansion mandrel of which the tapering expansion section has a tapering ceramic outer surface through an at least partly solid tubing which is made of a formable steel grade which is subject to strain hardening without incurring any necking and ductile fracturing as a result of the expansion process.
A broad aspect of the invention provides a method of expanding an at least partly solid steel tubing which is made of a formable steel grade subject to strain hardening, the method comprising the step of moving an expansion mandrel having a tapering expansion section which has a tapering ceramic outer surface, through the tubing thereby plastically expanding the tubing.
As a result of strain hardening the tubing becomes stronger during the expansion process since for any further increment of expansion always a higher stress is required than for the preceding expansion.
It has been found that the use of a formable steel grade for the tubing in combination with a ceramic tapering outer surface of the expansion mandrel has a synergetic effect since the resulting expanded tubing will have an adequately increased strength while the expansion forces remain low. The low yield strength and high ductility of the tubing before expansion enables, if the tubing is to be - 2a -used in an underground borehole, the use of a tubing which is reeled from a reeling drum into the borehole.
It is observed that in the art of metallurgy the terms strain-hardening and work-hardening are synonyms and are both used to denote an increase of strength caused by plastic deformation.
The term formable steel grade as used in this specification means that the tubing is able to maintain its structural integrity while being plastically deformed into various shapes.
Ways of determining forming characteristics of a steel are set out in the Metals Handbook, 9th edition, volume 14, Forming and Forging, issued by ASM
Internationa.L, Metals Park, Ohio (USA).
The term necking refers to a geometrical effect leading to non-uniform plastic deformations at some location by occurrence of a local constriction. From the point of nec:{ing on, the continual work hardening in the necked region no longer compensates for the continual reduction of the smallest cross-section in the neck, and therefore, the load carrying capacity of the steel decreases. W:Lth continuing loading, practically all further plasi--ic deformation is restricted to the region of the neck, so that a highly non-uniform deformation occurs to develop in the necked region until fracture occurs.
The term ductile fracturing means that a failure occurs if pliistic deformation of a component that exhibits duc,--ile behaviour is carried to the extreme so that the component separates locally into two pieces.
Nucleation, growth and coalescence of internal voids propagate to failure, leaving a dull fibrous rupture surface. A detailed description of the terms necking and ductile frac-:uring is given in the handbook "Failure of Materials in Mechanical Design" by J.A. Collins second edition, issl.ied by John Wiley and Sons, New York (USA) in 1993.
Preferably the tubing is made of a high-strength steel grade with formability and having a yield strength-tensile strength ratio which is lower than 0.8 and a yield strength of at least 275 MPa. When used in this specification, the term high-strength steel denotes a steel with a yield strength of at least 275 MPa.
It is also preferred that the tubing is made of a formable steel grade having a yield stress/tensile stress ratio which is between 0.6 and 0.7.
Dual phase (DP) high-strength, low-alloy (HSLA) steels lack a definite yield point which eliminates Luders band formation during the tubular expansion process which ensures good surface finish of the expanded tubular.
Suitable HSLA dual phase (DP) steels for use in the method according to the invention are grades DP55'"' and DP60TM developed by Sollac having a tensile strength of at least 550 MPa and grades SAFH 540 DTM and SAFH 590 DT' developed by Nippon Steel Corporation having a tensile strength of at least 540 MPa.
It is observed that US patent specification No. 4,938,266 discloses a method for producing dual phase steels.
Other suitable steels are the following formable high-strength steel grades - an ASTM A106 high-strength low alloy (HSLA) seamless pipe;
- an ASTM A312 austenitic stainless steel pipe, grade TP 304 L;
- an ASTM A312 austenitic stainless steel pipe, grade TP 316 L; and - a high-retained austenite high-strength hot-rolled steel (low-alloy TRIP steel) such as grades SAFH 590 ETM, SAFH 690 E'"" and SAFH 780 ETM developed by Nippon Steel Corporation.
The above-mentioned DP and other suitable steels each have a strain hardening exponent n of at least 0.16 which allows an expansion of the tubing such that the external diameter of the expanded tubing is at least 20% larger than the external diameter of the unexpanded tubing.
Detailed explanations of the terms strain hardening, work hardening and the strain hardening exponent n are given in chapters 3 and 17 of the handbook "Metal Forming-Mechanics and Metallurgy", 2nd edition, issued by Prentice Hall, New Jersey (USA), 1993.
Suitably, the expansion mandrel contains an expansion section that has a conical ceramic outer surface. It is observed that US patent specification No. 3,901,063 discloses a plug having a conical ceramic outer surface for use in tube-drawing operations. If the expansion mandrel is pumped through the tubing then the mandrel preferably comprises a sealing section which is located at such a distance from the tapering expansion section that when the expansion mandrel is moved through the tubing by means of exerting a hydraulic pressure behind the mandrel tr.e sealing section engages a plastically expanded part of the tubing. This will generally be achieved if said distance is at least three times the wall thickness of the expanded tubing.
The use of' a ceramic conical surface reduces friction forces during the expansion process and by having a sealing section which engages the expanded tube it is avoided that hydraulic forces would result in an excessive expansion of the tubing.
In such caLse it is preferred that the expansion mandrel contains a vent line for venting to the surface any fluids that are present in the borehole and tubing ahead of the expansion mandrel.
Alternatively the tubing is expanded such that the outer diameter of the expanded tubing is slightly smaller than the internal diameter of the borehole or of any casing that is present in the borehole and any fluids that are present in the borehole and tubing ahead of the ;aN1ENDED SHEEi' - Sa -expansion mandrel are vented to surface via the annular space that remains open around the tubing after the expansion process.
MD03/TS6025PC7.' AMENDED SHEET
The method according to the invention thereto comprises the step of moving an expansion mandrel of which the tapering expansion section has a tapering ceramic outer surface through an at least partly solid tubing which is made of a formable steel grade which is subject to strain hardening without incurring any necking and ductile fracturing as a result of the expansion process.
A broad aspect of the invention provides a method of expanding an at least partly solid steel tubing which is made of a formable steel grade subject to strain hardening, the method comprising the step of moving an expansion mandrel having a tapering expansion section which has a tapering ceramic outer surface, through the tubing thereby plastically expanding the tubing.
As a result of strain hardening the tubing becomes stronger during the expansion process since for any further increment of expansion always a higher stress is required than for the preceding expansion.
It has been found that the use of a formable steel grade for the tubing in combination with a ceramic tapering outer surface of the expansion mandrel has a synergetic effect since the resulting expanded tubing will have an adequately increased strength while the expansion forces remain low. The low yield strength and high ductility of the tubing before expansion enables, if the tubing is to be - 2a -used in an underground borehole, the use of a tubing which is reeled from a reeling drum into the borehole.
It is observed that in the art of metallurgy the terms strain-hardening and work-hardening are synonyms and are both used to denote an increase of strength caused by plastic deformation.
The term formable steel grade as used in this specification means that the tubing is able to maintain its structural integrity while being plastically deformed into various shapes.
Ways of determining forming characteristics of a steel are set out in the Metals Handbook, 9th edition, volume 14, Forming and Forging, issued by ASM
Internationa.L, Metals Park, Ohio (USA).
The term necking refers to a geometrical effect leading to non-uniform plastic deformations at some location by occurrence of a local constriction. From the point of nec:{ing on, the continual work hardening in the necked region no longer compensates for the continual reduction of the smallest cross-section in the neck, and therefore, the load carrying capacity of the steel decreases. W:Lth continuing loading, practically all further plasi--ic deformation is restricted to the region of the neck, so that a highly non-uniform deformation occurs to develop in the necked region until fracture occurs.
The term ductile fracturing means that a failure occurs if pliistic deformation of a component that exhibits duc,--ile behaviour is carried to the extreme so that the component separates locally into two pieces.
Nucleation, growth and coalescence of internal voids propagate to failure, leaving a dull fibrous rupture surface. A detailed description of the terms necking and ductile frac-:uring is given in the handbook "Failure of Materials in Mechanical Design" by J.A. Collins second edition, issl.ied by John Wiley and Sons, New York (USA) in 1993.
Preferably the tubing is made of a high-strength steel grade with formability and having a yield strength-tensile strength ratio which is lower than 0.8 and a yield strength of at least 275 MPa. When used in this specification, the term high-strength steel denotes a steel with a yield strength of at least 275 MPa.
It is also preferred that the tubing is made of a formable steel grade having a yield stress/tensile stress ratio which is between 0.6 and 0.7.
Dual phase (DP) high-strength, low-alloy (HSLA) steels lack a definite yield point which eliminates Luders band formation during the tubular expansion process which ensures good surface finish of the expanded tubular.
Suitable HSLA dual phase (DP) steels for use in the method according to the invention are grades DP55'"' and DP60TM developed by Sollac having a tensile strength of at least 550 MPa and grades SAFH 540 DTM and SAFH 590 DT' developed by Nippon Steel Corporation having a tensile strength of at least 540 MPa.
It is observed that US patent specification No. 4,938,266 discloses a method for producing dual phase steels.
Other suitable steels are the following formable high-strength steel grades - an ASTM A106 high-strength low alloy (HSLA) seamless pipe;
- an ASTM A312 austenitic stainless steel pipe, grade TP 304 L;
- an ASTM A312 austenitic stainless steel pipe, grade TP 316 L; and - a high-retained austenite high-strength hot-rolled steel (low-alloy TRIP steel) such as grades SAFH 590 ETM, SAFH 690 E'"" and SAFH 780 ETM developed by Nippon Steel Corporation.
The above-mentioned DP and other suitable steels each have a strain hardening exponent n of at least 0.16 which allows an expansion of the tubing such that the external diameter of the expanded tubing is at least 20% larger than the external diameter of the unexpanded tubing.
Detailed explanations of the terms strain hardening, work hardening and the strain hardening exponent n are given in chapters 3 and 17 of the handbook "Metal Forming-Mechanics and Metallurgy", 2nd edition, issued by Prentice Hall, New Jersey (USA), 1993.
Suitably, the expansion mandrel contains an expansion section that has a conical ceramic outer surface. It is observed that US patent specification No. 3,901,063 discloses a plug having a conical ceramic outer surface for use in tube-drawing operations. If the expansion mandrel is pumped through the tubing then the mandrel preferably comprises a sealing section which is located at such a distance from the tapering expansion section that when the expansion mandrel is moved through the tubing by means of exerting a hydraulic pressure behind the mandrel tr.e sealing section engages a plastically expanded part of the tubing. This will generally be achieved if said distance is at least three times the wall thickness of the expanded tubing.
The use of' a ceramic conical surface reduces friction forces during the expansion process and by having a sealing section which engages the expanded tube it is avoided that hydraulic forces would result in an excessive expansion of the tubing.
In such caLse it is preferred that the expansion mandrel contains a vent line for venting to the surface any fluids that are present in the borehole and tubing ahead of the expansion mandrel.
Alternatively the tubing is expanded such that the outer diameter of the expanded tubing is slightly smaller than the internal diameter of the borehole or of any casing that is present in the borehole and any fluids that are present in the borehole and tubing ahead of the ;aN1ENDED SHEEi' - Sa -expansion mandrel are vented to surface via the annular space that remains open around the tubing after the expansion process.
MD03/TS6025PC7.' AMENDED SHEET
The invention also relates to a well provided with a tubing which is expanded using the method according to the inventior-. In such case the tubing may serve as production tubing through which hydrocarbon fluid is transported to the surface and a reelable service and/or kill line passes through at least a substantial part of the length of: the tubing, through which line fluid can be pumped towarcis the bottom of the borehole while hydrocarbon fluid is produced via the surrounding production tubing. The use of such an expanded production tubing allows the use of almost the full wellbore for the transport of hydrocarbon fluids so that a relatively slim borehole may be utilized to attain the desired production rate.
Alternatively the tubing may be expanded against the inner surface of a casing which is present in the bore-hole. In such case the tubing may either be used as a production ttibing and/or as a protective cladding for protecting the well casing against corrosive well fluids and damage from tools that may be lowered into the well during maintenance and workover operations.
These anci other objects, features and advantages of the method and well system according to the present invention will be apparent from the accompanying claims, abstract and the following detailed description with reference to the accompanying drawing, in which Fig. 1 is schematic longitudinal sectional view of an underground borehole in which a tubing is expanded in accordance w:-th the method according to the invention.
Now referring to Fig. 1, there is shown a borehole traversing arl underground formation 1 and a casing 2 that is fixed within the borehole by means of an annular body of cement 3.
Alternatively the tubing may be expanded against the inner surface of a casing which is present in the bore-hole. In such case the tubing may either be used as a production ttibing and/or as a protective cladding for protecting the well casing against corrosive well fluids and damage from tools that may be lowered into the well during maintenance and workover operations.
These anci other objects, features and advantages of the method and well system according to the present invention will be apparent from the accompanying claims, abstract and the following detailed description with reference to the accompanying drawing, in which Fig. 1 is schematic longitudinal sectional view of an underground borehole in which a tubing is expanded in accordance w:-th the method according to the invention.
Now referring to Fig. 1, there is shown a borehole traversing arl underground formation 1 and a casing 2 that is fixed within the borehole by means of an annular body of cement 3.
A production tubing 4 which is made of a dual phase, high-strength low-alloy (HSLA) steel or other formable high-strength steel is suspended within the casing 2.
An expansion mandrel 5 is moved in longitudinal direction through the tubing 4 thereby expanding the tubing 4 such that the outer diameter of the expanded tubing is slightly smaller than or is about equal to the internal diarreter of the casing 2.
The expansion mandrel 5 is equipped with a series of ceramic surfaces 6 which restrict frictional forces between the pig and tubing 4 during the expansion process. In the example shown the semi top angle A of the conical cerair.ic surface that actually expands the tubing is about 25 . It has been found that zirconium oxide is a suitable ceramic material which can be formed as a smooth conical ring. Experiments and simulations have shown that if the semi cone top angle A is between 20 and 30 the pipe deforms such that it obtains an S-shape and touches the tapering part of the ceramic surface 6 essentially at the outer tip or rim of said conical part and optionally also about halfway the conical part.
The experiments also showed that it is beneficial that the expanding tubing 4 obtains an S-shape since this reduces the length of the contact surface between the tapering part of the ceramic surface 6 and the tubing 4 and thereby also reduces the amount of friction between the expansior.~. mandrel 5 and the tubing 4.
Experiments have also shown that if said semi top angle A is smaller than 15 this results in relatively high frictior.al forces between the tube and pig, whereas is said top angle is larger than 30 this will involve redundant plastic work due to plastic bending of the tubing 4 which also leads to higher heat dissipation and to disruptions of the forward movement of the pig 5 through the tubing 4. Hence said semi top angle A is preferably selected between 15 and 30 and should always be between 5 and 45 .
ExperimentS have also shown that the tapering part of the expansion mandrel 5 should have a non-metallic outer surface to avoid galling of the tubing during the expansion process. The use of a ceramic surface for the tapering part of the expansion mandrel furthermore caused the average roughness of the inner surface of the tubing 4 to decrease as a result of the expansion process. The experiments have also shown that the expansion mandrel 5 provided with a ceramic tapering surface 6 could expand a tubing 5 made of a forinable steel such that the outer tubing diameter D2 after expansion was at least 20% larger than the outer diameter Dl of the unexpended tubing and that suitable formable steels are dual phase (DP) high-strength low.alloy (HSLA) steels known as DP55TM and DP60TM; ASTM A106 HSLA seamless pipe, ASTM A312 austenitic stainless steel pipes, grades TP 304 L and TP 316 L and a high-retained austenite high-strength hot rolled steel, known as TRIPTM steel manu-factured by the Nippon Steel Corporation.
The mandrel 5 is provided with a pair of sealing rings 7 which are located at such a distance from the conical ceramic surface 6 that the rings 7 face the plastically expanded section of the tubing 4. The sealing rings serve to avoid that fluid at high hydraulic pressure would be present between the conical ceramic surface 6 of the mandrel 5 and the expanding tubing 4 which might lead to an irregularly large expansion of the tubing 4.
An expansion mandrel 5 is moved in longitudinal direction through the tubing 4 thereby expanding the tubing 4 such that the outer diameter of the expanded tubing is slightly smaller than or is about equal to the internal diarreter of the casing 2.
The expansion mandrel 5 is equipped with a series of ceramic surfaces 6 which restrict frictional forces between the pig and tubing 4 during the expansion process. In the example shown the semi top angle A of the conical cerair.ic surface that actually expands the tubing is about 25 . It has been found that zirconium oxide is a suitable ceramic material which can be formed as a smooth conical ring. Experiments and simulations have shown that if the semi cone top angle A is between 20 and 30 the pipe deforms such that it obtains an S-shape and touches the tapering part of the ceramic surface 6 essentially at the outer tip or rim of said conical part and optionally also about halfway the conical part.
The experiments also showed that it is beneficial that the expanding tubing 4 obtains an S-shape since this reduces the length of the contact surface between the tapering part of the ceramic surface 6 and the tubing 4 and thereby also reduces the amount of friction between the expansior.~. mandrel 5 and the tubing 4.
Experiments have also shown that if said semi top angle A is smaller than 15 this results in relatively high frictior.al forces between the tube and pig, whereas is said top angle is larger than 30 this will involve redundant plastic work due to plastic bending of the tubing 4 which also leads to higher heat dissipation and to disruptions of the forward movement of the pig 5 through the tubing 4. Hence said semi top angle A is preferably selected between 15 and 30 and should always be between 5 and 45 .
ExperimentS have also shown that the tapering part of the expansion mandrel 5 should have a non-metallic outer surface to avoid galling of the tubing during the expansion process. The use of a ceramic surface for the tapering part of the expansion mandrel furthermore caused the average roughness of the inner surface of the tubing 4 to decrease as a result of the expansion process. The experiments have also shown that the expansion mandrel 5 provided with a ceramic tapering surface 6 could expand a tubing 5 made of a forinable steel such that the outer tubing diameter D2 after expansion was at least 20% larger than the outer diameter Dl of the unexpended tubing and that suitable formable steels are dual phase (DP) high-strength low.alloy (HSLA) steels known as DP55TM and DP60TM; ASTM A106 HSLA seamless pipe, ASTM A312 austenitic stainless steel pipes, grades TP 304 L and TP 316 L and a high-retained austenite high-strength hot rolled steel, known as TRIPTM steel manu-factured by the Nippon Steel Corporation.
The mandrel 5 is provided with a pair of sealing rings 7 which are located at such a distance from the conical ceramic surface 6 that the rings 7 face the plastically expanded section of the tubing 4. The sealing rings serve to avoid that fluid at high hydraulic pressure would be present between the conical ceramic surface 6 of the mandrel 5 and the expanding tubing 4 which might lead to an irregularly large expansion of the tubing 4.
The expansion mandrel 5 is provided with a central vent passage 7 which is in communication with a coiled vent line 8 through which fluid may be vented to the surface. After completion of the expansion process the pig 5 may be pulled up to surface by the vent line and a coiled kill and/or service line (not shown) may be lowered into the expanded tubing 4 to facilitate injection of kill and/or treatment fluids towards the hydrocarbon f'luid inflow zone which is normally be done via the annulus between the production tubing and the well casing. However, if the tubing 4 is expanded to a smaller diameter then the residual annular space between the casing 2 and expanded tubing 4 can be used for venting of fluids during the expansion process and for injection of fluids during the production process, in which case there is no need for using a vent line 8 and kill and/or s.ervice lines.
In conventional wells it is often necessary to use a production tubing having an outer diameter which is less than 50% of the inner diameter of the well casing to enable a smooth insertion of the tubing even if the well is deviated and the casing has an irregular inner surface. Therefore it is apparent that the in-situ tubing expansion method according to the present invention enhances an efficient use of the wellbore.
It will be understood that instead of moving the expansion mar.Ldrel through the tubing by means of hydraulic pressure, the mandrel can also be pulled through the tubing by means of a cable or pushed through the tubing by means of pipe string or rod.
The method according to the invention can also be used to expand tubings that are used outside a wellbore, for example to expand oilfield tubulars at surface facilities or to expand a tubing inside an existing tubing which has been damaged or corroded.
The invention will now be further described on the basis of the following comparative experiments.
Experiment 1 An expansion mandrel having a conical ceramic surface (semi top angle A of cone = 20 ) was moved through a conventional oil field tubular, known as casing grade L80 13% Cr, which is a widely used casing type, having an initial outer diameter of 101.6 mm (4"), an initial wall thickness of 5.75 mm, a burst pressure of 850 bar and a strain hardening exponent n = 0.075. The expansion mandrel was designed such that the outer diameter of the expanded tubular would be 127 mm, so that the increase in diameter would be 20%. The tubular burst during the expansion process. Analysis showed that the ductility limit of the material had been exceeded so that ductile fracturing occurred.
Experiment 2 An experiment was carried out with a coiled tubing of the type QT-800 which is increasingly used as a pro-duction tubing in oil or gas wells. The tubing had an initial outer diameter of 60.3 mm, a wall thickness of 5.15 mm, a burst pressure of 800 bar and a strain hardening exponent n= 0.14. An expansion mandrel was moved through the tubing which mandrel comprised a conical ceramic surface such that the semi top angle A of a cone enveloping the conical surface was 5 and which was designed such that the outer diameter of the expanded tubing would be 73 mm (increase of about 210). This tubing burst during the expansion process. Analysis revealed that due to high friction forces the expansion pressure had exceeded the burst pressure of the pipe during the expansion process.
Experiment 3 An experiment was carried out with a seemless pipe made of a formable steel grade known as ASTM
A 106 Grade B. The pipe had an initial outer diameter of 101.6 mm (4"), an initial wall thickness of 5.75 mm and a strain hardening exponent n = 0.175.
An expansion mandrel was pumped through the pipe, which mandrel comprised a ceramic conical surface such that the semi top angle A of a cone enveloping the conical surface was 20 and such that the outer diameter of the expanded pipe was 127 mm (5") and the outer diameter incileased by 21%.
The pipe was expanded successfully and the hydraulic pressure exerted to the mandrel to move the mandrel through the pipe was between 275 and 300 bar. The burst pressure of the expanded pipe was between 520 and 530 bar.
In conventional wells it is often necessary to use a production tubing having an outer diameter which is less than 50% of the inner diameter of the well casing to enable a smooth insertion of the tubing even if the well is deviated and the casing has an irregular inner surface. Therefore it is apparent that the in-situ tubing expansion method according to the present invention enhances an efficient use of the wellbore.
It will be understood that instead of moving the expansion mar.Ldrel through the tubing by means of hydraulic pressure, the mandrel can also be pulled through the tubing by means of a cable or pushed through the tubing by means of pipe string or rod.
The method according to the invention can also be used to expand tubings that are used outside a wellbore, for example to expand oilfield tubulars at surface facilities or to expand a tubing inside an existing tubing which has been damaged or corroded.
The invention will now be further described on the basis of the following comparative experiments.
Experiment 1 An expansion mandrel having a conical ceramic surface (semi top angle A of cone = 20 ) was moved through a conventional oil field tubular, known as casing grade L80 13% Cr, which is a widely used casing type, having an initial outer diameter of 101.6 mm (4"), an initial wall thickness of 5.75 mm, a burst pressure of 850 bar and a strain hardening exponent n = 0.075. The expansion mandrel was designed such that the outer diameter of the expanded tubular would be 127 mm, so that the increase in diameter would be 20%. The tubular burst during the expansion process. Analysis showed that the ductility limit of the material had been exceeded so that ductile fracturing occurred.
Experiment 2 An experiment was carried out with a coiled tubing of the type QT-800 which is increasingly used as a pro-duction tubing in oil or gas wells. The tubing had an initial outer diameter of 60.3 mm, a wall thickness of 5.15 mm, a burst pressure of 800 bar and a strain hardening exponent n= 0.14. An expansion mandrel was moved through the tubing which mandrel comprised a conical ceramic surface such that the semi top angle A of a cone enveloping the conical surface was 5 and which was designed such that the outer diameter of the expanded tubing would be 73 mm (increase of about 210). This tubing burst during the expansion process. Analysis revealed that due to high friction forces the expansion pressure had exceeded the burst pressure of the pipe during the expansion process.
Experiment 3 An experiment was carried out with a seemless pipe made of a formable steel grade known as ASTM
A 106 Grade B. The pipe had an initial outer diameter of 101.6 mm (4"), an initial wall thickness of 5.75 mm and a strain hardening exponent n = 0.175.
An expansion mandrel was pumped through the pipe, which mandrel comprised a ceramic conical surface such that the semi top angle A of a cone enveloping the conical surface was 20 and such that the outer diameter of the expanded pipe was 127 mm (5") and the outer diameter incileased by 21%.
The pipe was expanded successfully and the hydraulic pressure exerted to the mandrel to move the mandrel through the pipe was between 275 and 300 bar. The burst pressure of the expanded pipe was between 520 and 530 bar.
Claims (16)
1. A method of expanding an at least partly solid steel tubing which is made of a formable steel grade subject to strain hardening, the method comprising the step of moving an expansion mandrel having a tapering expansion section which has a tapering ceramic outer surface, through the tubing thereby plastically expanding the tubing.
2. The method of claim 1, wherein the tubing is made of a formable steel grade having a yield strength-tensile strength ratio which is lower than 0.8 and a yield strength of at least 275 MPa.
3. The method of claim 1 or 2, wherein the tubing is made of a steel having a yield strength-tensile strength ratio which is between 0.6 and 0.7.
4. The method of claim 1, 2 or 3, wherein the tubing is made of a dual phase (DP) high-strength low alloy (HSLA) steel.
5. The method of claim 4, wherein the tubing is made of Sollac grade DP55.TM. or DP60.TM. having a tensile strength of at least 550 MPa or Nippon grade SAFH 540 D.TM. or SAFH 590 D.TM..
6. The method of claim 1, 2 or 3, wherein the tubing is made of a formable high-strength steel grade which is selected from the following group of steel grades:
- an ASTM A106 high-strength low alloy (HSLA) seamless pipe;
- an ASTM A312 austenitic stainless steel pipe, grade TP 304 L;
- an ASTM A312 austenitic stainless steel pipe, grade TP 316 L; and - a high-retained austenite high-strength hot rolled steel which is known as TRIP.TM. steel.
- an ASTM A106 high-strength low alloy (HSLA) seamless pipe;
- an ASTM A312 austenitic stainless steel pipe, grade TP 304 L;
- an ASTM A312 austenitic stainless steel pipe, grade TP 316 L; and - a high-retained austenite high-strength hot rolled steel which is known as TRIP.TM. steel.
7. The method of any one of claims 1 to 6, wherein the tubing is expanded such that the external diameter of the expanded tubing is at least 20% larger than the external diameter of the unexpanded tubing and wherein the strain hardening exponent n of the formable steel of the tubing is at least 0.16.
8. The method of any one of claims 1 to 7, wherein the expansion mandrel comprises a tapering expansion section which has a smooth ceramic outer surface which is oriented at an acute angle A which is between 5° and 45° with respect to a longitudinal axis of the mandrel and which induces the tubing to expand such that the average roughness of the inner surface of the tubing decreases as a result of the expansion process.
9. The method of claim 8, wherein the ceramic outer surface of the tapering expansion section is made of zirconium oxide and is oriented at an acute angle A which is between 15° and 30° with respect to a longitudinal axis of the mandrel.
10. The method of any one of claims 1 to 9, wherein the tubing is expanded by pumping the expansion mandrel through the tubing.
11. The method of claim 7, wherein the tubing is expanded by pumping the expansion mandrel through the tubing and wherein the expansion mandrel comprises a sealing section which is located at such a distance from the expansion section that when the expansion mandrel is pumped through the tubing the sealing section engages a plastically expanded part of the tubing.
12. The method of claim 10 or 11, wherein the tubing is expanded inside an underground borehole and the expansion mandrel contains a vent line for venting any fluids that are present in the tubing ahead of the expansion mandrel to the surface.
13. The method of claim 10 or 11, wherein the tubing is expanded inside an underground borehole such that the outer diameter of the expanded tubing is slightly smaller than the internal diameter of the borehole or of any casing that is present in the borehole and any fluids that are present in the borehole and tubing ahead of the expansion mandrel are vented to surface via the annular space that remains open around the tubing after the expansion process.
14. The method of any one of claims 1 to 13, wherein the tubing is lowered into an underground borehole after reeling the tubing from a reeling drum.
15. A well provided with a tubing which is expanded using the method of any one of claims 1 to 14, wherein the tubing serves as a production tubing through which hydrocarbon fluid is transported to the surface and a reelable service or kill line passes through at least a substantial part of the length of the interior of the tubing, through which line fluid can be pumped towards the bottom of the borehole while hydrocarbon fluid is produced via the surrounding production tubing.
16. A well provided with a tubing which is expanded using the method according to any one of claims 1 to 12, wherein the tubing is expanded against the inner surface of a casing which is present in the borehole.
Applications Claiming Priority (3)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| EP96201809 | 1996-07-01 | ||
| EP96201809.9 | 1996-07-01 | ||
| PCT/EP1997/003489 WO1998000626A1 (en) | 1996-07-01 | 1997-06-30 | Method for expanding a steel tubing and well with such a tubing |
Publications (2)
| Publication Number | Publication Date |
|---|---|
| CA2260191A1 CA2260191A1 (en) | 1998-01-08 |
| CA2260191C true CA2260191C (en) | 2007-11-27 |
Family
ID=8224125
Family Applications (1)
| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CA002260191A Expired - Lifetime CA2260191C (en) | 1996-07-01 | 1997-06-30 | Method for expanding a steel tubing and well with such a tubing |
Country Status (14)
| Country | Link |
|---|---|
| EP (1) | EP0907822B1 (en) |
| JP (1) | JP4289686B2 (en) |
| AU (1) | AU723337B2 (en) |
| BR (1) | BR9710016A (en) |
| CA (1) | CA2260191C (en) |
| DE (1) | DE69739166D1 (en) |
| DK (1) | DK0907822T3 (en) |
| EA (1) | EA000543B1 (en) |
| ID (1) | ID17661A (en) |
| MY (1) | MY116920A (en) |
| NO (1) | NO317755B1 (en) |
| NZ (1) | NZ333945A (en) |
| OA (1) | OA10949A (en) |
| WO (1) | WO1998000626A1 (en) |
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- 1997-06-27 MY MYPI9702927 patent/MY116920A/en unknown
- 1997-06-30 EA EA199900072A patent/EA000543B1/en not_active IP Right Cessation
- 1997-06-30 AU AU34420/97A patent/AU723337B2/en not_active Expired
- 1997-06-30 WO PCT/EP1997/003489 patent/WO1998000626A1/en active Application Filing
- 1997-06-30 EP EP97930490A patent/EP0907822B1/en not_active Expired - Lifetime
- 1997-06-30 NZ NZ333945A patent/NZ333945A/en not_active IP Right Cessation
- 1997-06-30 CA CA002260191A patent/CA2260191C/en not_active Expired - Lifetime
- 1997-06-30 DE DE69739166T patent/DE69739166D1/en not_active Expired - Lifetime
- 1997-06-30 ID IDP972266A patent/ID17661A/en unknown
- 1997-06-30 JP JP50385298A patent/JP4289686B2/en not_active Expired - Lifetime
- 1997-06-30 DK DK97930490T patent/DK0907822T3/en active
- 1997-06-30 BR BR9710016A patent/BR9710016A/en not_active IP Right Cessation
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1998
- 1998-12-29 NO NO19986171A patent/NO317755B1/en not_active IP Right Cessation
- 1998-12-31 OA OA9800252A patent/OA10949A/en unknown
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| AU723337B2 (en) | 2000-08-24 |
| NO986171D0 (en) | 1998-12-29 |
| CA2260191A1 (en) | 1998-01-08 |
| EA000543B1 (en) | 1999-10-28 |
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| MY116920A (en) | 2004-04-30 |
| NO317755B1 (en) | 2004-12-13 |
| EP0907822A1 (en) | 1999-04-14 |
| BR9710016A (en) | 1999-08-10 |
| JP2001508144A (en) | 2001-06-19 |
| AU3442097A (en) | 1998-01-21 |
| EP0907822B1 (en) | 2008-12-17 |
| EA199900072A1 (en) | 1999-06-24 |
| NZ333945A (en) | 2000-03-27 |
| NO986171L (en) | 1999-02-22 |
| DK0907822T3 (en) | 2009-03-02 |
| JP4289686B2 (en) | 2009-07-01 |
| ID17661A (en) | 1998-01-15 |
| DE69739166D1 (en) | 2009-01-29 |
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