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Experimental and numerical investigation of expandable tubular structural integrity for well applications

Pervez T.

Journal of Achievements in Materials and Manufacturing Engineering

2010

Vol. 41, nr 1-2

147-154

Purpose: The ever-increasing energy demand has forced researchers to search for new and cheaper solutions for oil and gas production. The recent development of solid expandable tubulars (SETs) has resulted in design of slim oil and gas wells. The large plastic deformation experienced by the tubular under down-hole environment may result in premature and unexpected failures. The objective of this research is to investigate the structural integrity of SET for well applications to avoid such failures. Design/methodology/approach: In order to achieve the objectives, simulation work was carried out using finite element method and experimental tests were conducted on full size tubular for validation of numerical results. Findings: The required drawing force for expansion under different expansion ratios, surplus deformation, variations in tubular thickness and length were estimated numerically and experimentally. The differences in values using two approaches vary from 5% to 12%. Tubular wall thickness decreases as the mandrel angle, expansion ratio, and friction coefficient increase. Research limitations/implications: The issue of maximum expansion a tubular can be subjected to needs to be further investigated. Furthermore, the pre and post-expansion material properties need immediate attention of researchers to fulfil the dream of low-cost expandable solution. Practical implications: In recent years, solid expandable tubular technology has already made significant inroads in replacing conventional telescopic oil wells. It allows design and realization of slim wells, accessing difficult and ultra-deep reservoirs, well remediation, zonal isolation, drilling of directional and horizontal wells, etc. Originality/value: SET is an emerging technology for oil and gas industry. The current findings are very valuable for researchers and well engineers to design slim wells and enhance the productivity of older wells.