EP1044316B1 - Method for drilling and completing a hydrocarbon production well - Google Patents

Method for drilling and completing a hydrocarbon production well Download PDF

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Publication number
EP1044316B1
EP1044316B1 EP98966700A EP98966700A EP1044316B1 EP 1044316 B1 EP1044316 B1 EP 1044316B1 EP 98966700 A EP98966700 A EP 98966700A EP 98966700 A EP98966700 A EP 98966700A EP 1044316 B1 EP1044316 B1 EP 1044316B1
Authority
EP
European Patent Office
Prior art keywords
casing
borehole
tubing
casings
expanded
Prior art date
Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
Expired - Lifetime
Application number
EP98966700A
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German (de)
English (en)
French (fr)
Other versions
EP1044316A1 (en
Inventor
Wilhelmus Christianus Maria Lohbeck
Franz Marketz
Robert Bruce Stewart
Current Assignee (The listed assignees may be inaccurate. Google has not performed a legal analysis and makes no representation or warranty as to the accuracy of the list.)
Shell Internationale Research Maatschappij BV
Original Assignee
Shell Internationale Research Maatschappij BV
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Shell Internationale Research Maatschappij BV filed Critical Shell Internationale Research Maatschappij BV
Priority to EP98966700A priority Critical patent/EP1044316B1/en
Publication of EP1044316A1 publication Critical patent/EP1044316A1/en
Application granted granted Critical
Publication of EP1044316B1 publication Critical patent/EP1044316B1/en
Anticipated expiration legal-status Critical
Expired - Lifetime legal-status Critical Current

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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

Definitions

  • the invention relates to a method for drilling and completing a hydrocarbon production well, such as a well for the production of oil and/or gas.
  • hydrocarbon production wells are created by first drilling a large borehole section in which a large diameter casing is inserted and cemented in place to stabilize the borehole wall. Subsequently a borehole extension of a smaller diameter is drilled and a casing is inserted into said extension such that said further casing extends from the bottom of said extension to the top of the borehole whereupon said further casing is cemented in place inside the borehole extension and also inside the previously set casing.
  • the production liner is normally connected to the lower end of a production tubing which is lowered through the casing string such that it spans the length of the borehole from the wellhead until the vicinity of the hydrocarbon bearing formation, where the tubing is sealingly secured to the casing by means of a production packer.
  • the diameter of the upper part of the borehole near the earth surface and internal diameter of the upper casing part may well exceed half a metre, whereas the internal diameter of the production tubing through which hydrocarbons are produced is between 10 and 25 centimetres.
  • This known expandable casing may be located between a surface casing arranged in an upper part of the wellbore and a production casing arranged in a lower part of the wellbore. Since the surface and production casings are not expanded downhole this known well casing technique still either involves the use of conventional casing parts that require the drilling of an oversized borehole or the expansion of a casing string which is inserted and expanded after the full length of the borehole has been drilled, which is not always possible.
  • French patent application No. 2 741 907 discloses a well lining method in which a flexible hose is used, which after insertion into the well is inflated by injection of a heavy liquid and subsequently hardened by polymerization.
  • a difficulty with the known method is that a two-step inflation and chemical curing process is time consuming and generates a fragile tubular which may have an irregular strength and shape.
  • the method according to the invention is characterized in that the casings that are sequentially inserted and expanded in the borehole are plastically expanded in radial direction by moving an expansion mandrel having a tapering ceramic surface which defines a semi-top angle A which is between 15° and 30° therethrough in a longitudinal direction.
  • the first casing extends from the earth surface into the borehole and any subsequent casing only partly overlaps a previously set casing.
  • the length along which subsequent casing sections overlap each other is less than 10% of the length of each casing itself and also that along at least a substantial part of the length of the borehole from the earth surface to the vicinity of the hydrocarbon bearing formation the variation in diameter of the borehole is less than 10%.
  • At least two casings that are subsequently inserted into the borehole each extend to the wellhead.
  • a production tubing is inserted into the borehole such that the production tubing extends from the earth surface to the vicinity of the hydrocarbon formation; and the tubing is radially expanded inside the string of expanded casings.
  • the casings and optionally the tubing are plastically expanded in radial direction by moving an expansion mandrel therethrough in a longitudinal direction and they are 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 and wherein an expansion mandrel is used which has along part of its length a tapering non-metallic surface.
  • the expansion mandrel has a tapering ceramic surface and that the tubing and casings are 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.
  • the production tubing and at least one of the casings consists of a tubular which is inserted into the borehole by reeling the tubular from a reeling drum.
  • the production tubing and/or at least one of the casings may be made up of a series of pipe sections that are interconnected at the wellhead by screw joints, welding or bonding to form an elongate pipe of a substantially cylindrical shape that can be expanded and installed downhole in accordance with the method according to the invention.
  • a borehole 1 that extends from the earth surface 2 through a number of underground formation layers 3, 4, 5 and 6 into an oil and/or gas bearing formation layer 7.
  • the upper casing 8 is inserted into the upper borehole section 1A and radially expanded by means of an expansion mandrel 16.
  • the expanded casing 8 may be secured to the borehole wall by means of an annular body (not shown) of cement or a bonding agent.
  • the expanded casing 8 may be secured to the borehole wall by friction. Such friction may be generated by providing the outer surface of the casing 8 with spikes (not shown) and/or by radially pressing the casing into the formation 3.
  • the drill bit is lowered through the upper casing 8 to the bottom of the first borehole section 1A and the second section 1B of the borehole 1 is drilled.
  • the second casing 9 is lowered through the first casing 8 to the bottom of the second borehole section 1B and radially expanded by means of the expansion mandrel 16.
  • the second casing 9 will further expand the first casing 8 which generates a strong bond and seal generated by frictional and compressive forces.
  • the length over which the casings 8 and 9 overlap each other is relatively small, preferably less than 10% of the length of the shortest casing 8 and 9 and the bottom of the upper casing 8 may be pre-expanded and/or provided with slits or grooves (not shown) which widen up or break open during the expansion process.
  • the second casing 9 is secured to the borehole wall in the same way as the first casing 8. Furthermore the second and any further borehole sections 1B, 1C and 1D are drilled by means of an underreamer bit which is able to drill the whole length of the borehole 1 at substantially the same diameter.
  • the third and fourth borehole sections 1C and 1D are each drilled and cased in the same manner as described with reference to the second borehole section 1B.
  • section 1D there is shown the expansion mandrel 16 which is moved downwardly in longitudinal direction through the lowermost casing 11, thereby radially expanding the casing 11 in a manner which is described in more detail with reference to Fig. 4.
  • FIG. 2 there is shown the borehole 1 of Fig. 1 in which a production tubing 17 is being installed by longitudinally moving an expansion mandrel 18 therethrough.
  • the tubing 17 is expanded to an outer diameter which is substantially equal to the inner diameter of the expanded casings so that the production tubing 17 forms an internal cladding to the casings 8, 9, 10 and 11 and the walls of the tubing 17 and casings 8, 9, 10 and 11 mutually reinforce each other.
  • the lower end of the production tubing that extends beyond the lower end of the lowermost casing 11 into the oil and/or gas bearing formation 7 may be provided with staggered axial slots (not shown) which open up to a diamond shape as a result of the pipe expansion process in order to permit inflow of oil and/or gas from the formation 7 into the borehole 1, which fluids then flow up through the interior of the tubing 17 to the earth surface 2.
  • the inflow section at the lower end of the production tubing 17 may be provided with non-slotted apertures as well.
  • These apertures may be circular, oval or square holes that are punched into, or cut away from, the tubing wall and which are arranged in an overlapping or non-overlapping pattern which may be staggered or not.
  • expandable casings 8, 9, 10 and 11 may be provided with at least some slotted or non-slotted apertures in order to alleviate the forces required to expand these casings, in particular in the areas where the casings 8, 9, 10 and 11 overlap each other and in other areas, such as curved sections of the borehole 1, where expansion forces are high.
  • the production tubing 17 is not perforated in the areas where any of the casings 8, 9, 10 and 11 is perforated so as to retain a fluid tight seal between the interior of the tubing 17 and the surrounding formation layers 3, 4, 5 and 6.
  • FIG. 3 there is shown a borehole 20 that has been drilled into an underground formation 21.
  • a first casing 22 is installed and expanded.
  • the upper part of the borehole 20A has an internal diameter of about 25.4 cm.
  • the unexpanded first casing 22 has an outer diameter of about 18.8 cm when it is lowered into the borehole.
  • the expanded first casing 22 has an outer diameter of about 23.4 cm so that a small annulus is left around the expanded first casing 22 which is filled with cement 23.
  • the second part of the borehole 20B is drilled to an internal diameter of about 21 cm and a second casing 24 is inserted in unexpanded form into the borehole such that it extends from the top of the borehole 20 to the bottom of the second part 20B thereof.
  • the unexpanded second casing 24 has an outer diameter of 15.7 cm and is expanded inside the borehole 20 to an outer diameter of 19.5 cm.
  • the second casing 24 is cemented inside the second part of the borehole 20B and inside the first casing by an annular body of cement 23.
  • a third borehole section 20C having an internal diameter of 17.8 cm is drilled from the bottom of the second borehole section 20B into the formation 21, whereupon a third casing section 25 is inserted into the borehole 20 and expanded.
  • the unexpanded third casing 25 has an outer diameter of about 13 cm and is expanded to an outer diameter of about 16.3 cm.
  • a fourth borehole section 20D having an internal diameter of about 14.2 cm is drilled and a fourth casing 26 is inserted into the borehole 20 and subsequently expanded from an outer diameter of 10.1 cm to an outer diameter of about 13 cm.
  • a production tubing 27 is inserted and expanded against the inner surface of said casing 26 to form a clad tubing 27.
  • a coiled service conduit 28 is inserted into the production tubing 27 and sealingly connected near the bottom of the tubing 27 by a production packer 29.
  • the service conduit 28 contains perforations 30 just above the production packer so that oil and/or gas can be produced from the inflow region of the well, the bottom of the service conduit 28 and the perforations 30 into the production tubing 27.
  • one or more casings may still be an unexpandable conventional casing.
  • the upper casing may be a conventional casing, in which one or more telescoping expandable casing sections, as shown in Fig. 3, are inserted and the lower part of the borehole may be equipped with monobore casings as shown in Fig. 1 and 2.
  • FIG. 4 there is shown a borehole traversing an underground formation 41 and a casing 42 that is fixed within the borehole by means of an annular body of cement 43.
  • a production tubing 44 which is made of a dual phase, high-strength low-alloy (HSLA) steel or other formable high-strength steel is suspended within the casing 42.
  • HSLA high-strength low-alloy
  • An expansion mandrel 45 is moved in longitudinal direction through the tubing 44 thereby expanding the tubing 44 such that the outer diameter of the expanded tubing is slightly smaller than, or is about equal to, the internal diameter of the casing 42.
  • the expansion mandrel 45 is equipped with a series of ceramic surfaces 46 which restrict frictional forces between the pig and tubing 44 during the expansion process.
  • the semi top angle A of the conical ceramic surface that actually expands the tubing is about 25°.
  • 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 46 essentially at the outer tip or rim of said conical part and optionally also about halfway the conical part.
  • said semi top angle A is preferably selected between 15° and 30° and should always be between 5° and 45°.
  • the tapering part of the expansion mandrel 45 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 44 to decrease as a result of the expansion process.
  • the expansion mandrel 45 provided with a ceramic tapering surface 46 could expand a tubing 45 made of a formable steel such that the outer tubing diameter D2 after expansion was at least 20% larger than the outer diameter D1 of the unexpended tubing and that suitable formable steels are dual phase (DP) high-strength low alloy (HSLA) steels known as DP55 and DP60; 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 TRIP steel manufactured by the Nippon Steel Corporation.
  • DP dual phase
  • HSLA high-strength low alloy
  • the mandrel 45 is provided with a pair of sealing rings 47 which are located at such a distance from the conical ceramic surface 46 that the rings 47 face the plastically expanded section of the tubing 44.
  • the sealing rings serve to avoid that fluid at high hydraulic pressure would be present between the conical ceramic surface 46 of the mandrel 45 and the expanding tubing 44 which might lead to an irregularly large expansion of the tubing 44.
  • the expansion mandrel 45 is provided with a central vent passage 47 which is in communication with a coiled vent line 48 through which fluid may be vented to the surface.
  • a coiled kill and/or service line (not shown) may be lowered into the expanded tubing 44 to facilitate injection of kill and/or treatment fluids towards the hydrocarbon fluid inflow zone which is normally be done via the annulus between the production tubing and the well casing.
  • the tubing 44 is expanded to a smaller diameter then the residual annular space between the casing 42 and expanded tubing 44 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 48 and kill and/or service lines.
  • the mandrel 45 instead of moving the expansion mandrel 45 through the tubing 44 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.
  • casing 42 and the casings 8, 9, 10, 11, 22, 24, 25 and 26 that are shown in Fig. 1, 2 and 3 can be expanded using a similar expansion process as described for the expansion of the tubing 44 with reference to Fig. 4, if these casings are also made of a formable steel grade.
  • the expandable production tubing and expandable casings are made of a formable steel grade having a yield strength-tensile strength ratio which is lower than 0.8 and a yield strength which is at least 275 MPa.
  • 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.
  • 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 increased 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.

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  • Geology (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Mining & Mineral Resources (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Physics & Mathematics (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Earth Drilling (AREA)
  • Lubricants (AREA)
  • Organic Low-Molecular-Weight Compounds And Preparation Thereof (AREA)
  • Telephone Function (AREA)
EP98966700A 1997-12-31 1998-12-28 Method for drilling and completing a hydrocarbon production well Expired - Lifetime EP1044316B1 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
EP98966700A EP1044316B1 (en) 1997-12-31 1998-12-28 Method for drilling and completing a hydrocarbon production well

Applications Claiming Priority (4)

Application Number Priority Date Filing Date Title
EP97204157 1997-12-31
EP97204157 1997-12-31
PCT/EP1998/008549 WO1999035368A1 (en) 1997-12-31 1998-12-28 Method for drilling and completing a hydrocarbon production well
EP98966700A EP1044316B1 (en) 1997-12-31 1998-12-28 Method for drilling and completing a hydrocarbon production well

Publications (2)

Publication Number Publication Date
EP1044316A1 EP1044316A1 (en) 2000-10-18
EP1044316B1 true EP1044316B1 (en) 2002-09-18

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EP98966700A Expired - Lifetime EP1044316B1 (en) 1997-12-31 1998-12-28 Method for drilling and completing a hydrocarbon production well

Country Status (15)

Country Link
EP (1) EP1044316B1 (uk)
JP (1) JP4085403B2 (uk)
AU (1) AU740213B2 (uk)
BR (1) BR9814563A (uk)
CA (1) CA2316978C (uk)
DE (1) DE69808139T2 (uk)
DK (1) DK1044316T3 (uk)
EA (1) EA002563B1 (uk)
GC (1) GC0000041A (uk)
MY (1) MY129529A (uk)
NO (1) NO322486B1 (uk)
NZ (1) NZ505059A (uk)
OA (1) OA11527A (uk)
UA (1) UA71905C2 (uk)
WO (1) WO1999035368A1 (uk)

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WO2008138957A3 (en) * 2007-05-15 2009-01-15 Shell Int Research System for drilling a wellbore
GB2461471A (en) * 2007-05-15 2010-01-06 Shell Int Research System for drilling a wellbore
GB2461471B (en) * 2007-05-15 2012-02-15 Shell Int Research System for drilling a wellbore

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OA11527A (en) 2004-02-04
DK1044316T3 (da) 2002-11-04
NZ505059A (en) 2003-03-28
UA71905C2 (uk) 2005-01-17
CA2316978C (en) 2008-01-29
EA200000724A1 (ru) 2001-02-26
AU2418699A (en) 1999-07-26
EP1044316A1 (en) 2000-10-18
NO322486B1 (no) 2006-10-09
MY129529A (en) 2007-04-30
BR9814563A (pt) 2000-10-17
DE69808139T2 (de) 2003-06-05
NO20003402D0 (no) 2000-06-29
CA2316978A1 (en) 1999-07-15
GC0000041A (en) 2004-06-30
WO1999035368A1 (en) 1999-07-15
NO20003402L (no) 2000-08-25
AU740213B2 (en) 2001-11-01
JP2002500306A (ja) 2002-01-08
JP4085403B2 (ja) 2008-05-14
EA002563B1 (ru) 2002-06-27
DE69808139D1 (de) 2002-10-24

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