SPE 110622

Understanding Post-Expansion Properties of Solid Expandable Tubulars

Chuck Butterfield, Sarah Flaming, Rodger Lebedz, and Michael Thigpen, Enventure Global Technology, and Rick Hill, EWI

Copyright 2007, Society of Petroleum Engineers

This paper was prepared for presentation at the 2007 SPE Annual Technical Conference and
Exhibition held in Anaheim, California, U.S.A., 1114 November 2007.
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Abstract
As an enabling technology, solid expandable tubulars continue
to revolutionize the design and construction of oil and gas
wells. Although solid expandable systems are now widely
accepted as a viable casing alternative, some operators do not
apply the technology in their wells. Limited information
regarding the tubulars post-expansion performance properties
creates uncertainty in the application of solid expandable
tubulars. A better understanding of how the pipe properties are
affected by the expansion process is imperative to optimizing
the benefits of system application.
Using American Petroleum Institute (API) performance
equations on post-expanded tubulars do not clearly identify
the limits of the pipe. Testing is underway to create accurate
predictive models for expansion force and post-expansion
collapse. These full-scale laboratory tests, using API methods
where applicable, determine how the expansion process
changes collapse resistance and residual stress. Pre and post
expansion mechanical and material properties are analyzed
using American Society for Testing and Materials (ASTM)
methods. Testing for H2S and CO2 environments employ the
NACE methods.
This paper describes the testing procedures and results of
the post-expansion performance property testing. These
findings will be compared and contrasted to API standards for
conventional pipe. In addition, the paper will discuss industry
implications for determining solid expandable tubular
standards.
Introduction
Solid expandable tubulars have an installation legacy that has
provided a solution to save casing points and preserve hole
size in drilling and workover operations alike. These enabling
systems have successfully been incorporated into the original
drilling design1, installed to mitigate unexpected troublesome
formations, turned existing wells into big-bore producers2 and

been seamlessly combined with other revolutionary

technologies to address downhole challenges3,4.
With wider use of solid expandable tubulars, interest in
their performance properties has grown, particularly with
respect to collapse resistance. Historically, collapse testing of
expandable pipe has been limited. The tests that have been
performed indicate that the collapse resistance of expanded
pipe is closely approximated by the conventional API collapse
equations. However, API collapse strength theory is
empirically based. The equations do not consider the residual
stress that may be present after expansion. In addition, the API
equations are based on tests conducted many years ago.
Manufacturing processes, tolerance control, and material
performance have all improved since that time.
The energy industry has a limited understanding of the
post-expanded properties of solid expandable tubulars even
with over 700 installations globally. Although the industry has
a knowledgeable grasp on the application of OCTG in
designing well applications, taking the same pipe and
mechanically yielding it to a larger size is the source of
operator skepticism. Questions raised include:
How do the pipe properties change after expansion?
Does any residual stress adversely affect pipe properties?
Does the pipe work harden?
Does the pipe have or still retain its resistance to H2S and
CO2?
The concern most commonly raised is the effect on
collapse and H2S resistance. Some operators arbitrarily
degrade expandable pipe collapse properties due to residual
stress because of the lack of comprehensive data. Similarly,
some operators will not use expandables in minor H2S
environments for the same lack of confidence. Specific testing
was recently conducted to address these concerns and provide
the basis for solid expandable pipe standards.
Testing methodology
To develop confidence in the understanding of post-expansion
pipe properties, a plan was initiated to investigate expanded
pipe with a broad range of expansion ratios, across a range of
pipe sizes from various manufacturers. Material properties
were tested both pre-expansion and post-expansion to better
study relationships between percent expansion and various
performance parameters.
All pipe specimens were marked with a tracking
identification number that was referenced to the manufacturer,
heat and lot, the material test report (MTR) that contains some
of the pre-expanded material properties, the expansion

percentage and a serial number that identified the specific joint

from which it was cut.
All joints were expanded hydraulically in a horizontal
orientation in the yard. The expansion assemblies and
procedures used were the same as those that would be used on
a real rig. After expansion, the joints were cut into test
samples and sent to the respective labs for physical collapse
testing and mechanical properties testing.
To reinforce the credibility of the testing, Det Norse
Veritas (DNV) was contracted to assist in the verification of
the testing methods and results.
Collapse Testing
Testing Conditions
The collapse resistance testing investigated the effects of the
expansion process on collapse resistance. Post-expanded
collapse specimens from six different pipe sizes, two different
manufacturers and seven different expansion ratios were
evaluated. In total, 105 specimens were collapsed (Figure 1).
To design a cost-effective collapse program, each size of
pipe at every expansion ratio was not physically tested.
Instead a test matrix was developed to provide data with a full
range of post-expansion D/t values and expansion ratios that
provided the critical parameter relationships for curve fitting
and ultimately translation to other sizes and expansion ratios.
The expansion ratios in the test matrix were chosen because
they are the most commonly used and when combined with
the various pipe sizes, created a matrix with a full D/t spread.
API 5C3 guidelines were followed during all testing
operations. Samples were cut to a length of eight times the
post-expanded outside diameter (OD). OD and thickness
measurements were taken from each sample at eight locations
around the circumference at each of the five locations along
the length. Averaged values were used to calculate ovality and
eccentricity for each sample (Figure 2).
The collapse fixture used consisted of a center
mandrel/floating end cap type fixture (Figure 3). This type of
collapse fixture uses a mandrel that runs through the center of
the pipe sample and attaches to two end caps held in place off
from the ends of the sample. The mandrel takes the forces
generated by pressure on the end caps and also holds the end
caps at a distance from the ends of the pipe sample to
eliminate any end loading on the sample during collapse.
Flexible rubberized tape was used to seal the ends of the pipe
sample to the end caps, and internal pressure was vented
through the mandrel out into atmosphere. The whole system
was placed inside a water-filled pressure vessel where the
pressure was slowly increased until collapse was indicated on
the pressure chart by a down spike.
Test Results and Findings
The empirical collapse resistance data was compared to an
API calculated equivalent value. This means that the asdelivered, mill-tested yield strength and post-expanded D/t
were used to calculate an API collapse resistance value. This
value was compared to the actual empirical test value. The
results can be seen in Figure 4.

SPE 110622

The following relevant trends were observed in the data

from the collapse resistance testing:
In 5.5 in., 6.0 in. and 7.625 in. sizes (D/t = 19 to 24), EX80 post-expanded pipe collapse resistance was only 7%
on average less than an API calculated value. The worst
single sample was 14% below API calculation.
As D/t increases, the difference between the actual and
API calculated collapse values decreases until around
D/t= 33, where the actual becomes greater than API
calculated and trends higher (elastic regime).
In 9.625 in., 11.75 in. and 13.375 in. (D/t = 33 to 43), EX80 post-expanded pipe collapse resistance was 6% on
average, higher than an API calculated value. The best
single sample was 17% above API calculation.
As the expansion ratio increases (per pipe size), the
difference between the actual collapse resistance data and
the API calculated values decreases.
Manufacturer had very little effect on collapse resistance.
Ovality and eccentricity were consistently below
minimums throughout all collapse specimens (Figure 5
and 6).
Sour Service Evaluation
Testing Condition
In February 2006, findings were reported of a full scale sour
service test conducted on a section of 5-1/2 in. OD EX-80
ERW pipe that had been cold expanded to a diameter of 6-1/4
in. The test conditions simulated the actual field conditions
with produced fluids containing significant quantities of H2S
and CO2, as per NACE standard5. The test duration was
defined as 30 days and the test temperature as 80C. Using a
total pressure of 238 bar; the partial pressure of H2S was 3.57
bar and the partial pressure of CO2 was 11.9 bar. During the
test period the temperature and pressure were reduced to
ambient to facilitate full body ultrasonic inspection of the
expanded pipe section. In-situ pH measurements indicated a
starting pH of 2.8 and a final pH of 3.4, thereby confining the
aggressiveness of the solution.
Test Results and Findings
After 30 days of exposure to the simulated sour service test
conditions, the expanded pipe section showed no sign of
hydrogen inducted cracking (HIC), sulfide stress cracking
(SSC) or stress-oriented hydrogen induced cracking (SOHIC).
Continuous monitoring confirmed the aggressive nature of the
prescribed test conditions and periodic ultrasonic inspection
showed no evidence of either crack initiation or propagation.
The cool down required to facilitate the ultrasonic inspection
did not result in the initiation of either planar or through-wall
cracking. The full-scale testing confirmed the expected inservice performance of expanded casing and tubing when
exposed to sour service conditions.

SPE 110622

Conclusion
From this testing, a better and more comprehensive
understanding of actual post-expansion properties was gained
that will not only help further development of more robust
solid expandable systems but provide an improved
understanding in the energy industry. The extensive empirical
testing has given a greater confidence in post-expansion
properties of expandable casing, allowing more accuracy in
casing design of wells. The collapse testing has broadened the
understanding of how the expansion process and residual
stresses affects the casing and compared these finding to API
calculations. This information is the beginning to developing
solid expandable pipe standards and equations for the industry.
An example of technology enhancement is the recently
developed high-collapse expandable system that was
successfully installed in an offshore well.6 As the industry
drills deeper and further for hydrocarbons in more extreme
conditions, technology must keep pace with these demanding
applications. Knowing the parameters, limits and ability of
expanded pipe will further facilitate and expedite the recovery
of valuable reserves in future operations.
References
1

Carstens, C., Unocal; Blasingame-Strittmatter, K.,

Enventure Global Technology; Solid Expandable Tubular
Technology: The Value of Planned Installation Vs.
Contingency; SPE/IADC Drilling Conference held in
Amsterdam, The Netherlands, 23-25 February 2005.
Inyau Bada, I., Maekiaho L., and Ain, F., Shell Malaysia
Exploration and Production; Nijveld, E., and Tan, I., Shell
International Exploration and Production; Book, L.,
Enventure Global Technology; Dubedout, L., Vallourec &
Mannesmann Tubes; Maximizing Production with 13Cr
Solid Expandable Tubulars in Sarawak Gas Fields,
IADC/SPE 88027, IADC/SPE Asia Pacific Drilling
Technology Conference and Exhibition held in Kuala
Lumpur, Malaysia, 1315 September 2004.
Rivenbark, M., Enventure Global Technology; Abouelnaaj,
K., Saudi Aramco; Solid Expandable Tubulars Facilitate
Intelligent-Well Technology Application in Existing
Multilateral Wells, SPE-102934-PP, 2006 SPE Annual
Technical Conference and Exhibition held in San Antonio,
Texas, U.S.A., 2427 September 2006.
Touboul, N., Total; Womble, L., and Kotrla, J., Cameron
Drilling Systems; Keith, N., Enventure Global Technology;
New Technologies Combine to Reduce Drilling Costs in
Ultra-deepwater Applications, SPE 90830, SPE Annual
Technical Conference and Exhibition held in Houston,
Texas, U.S.A., 2629 September 2004.
NACE Standard TM0177, Laboratory Testing of Metals
for Resistance to Specific Forms of Environmental
Cracking in H2S Environments.
Furniss, T., and Simpson, A., Enventure Global
Technology; High-collapse Tubulars Address Common
Problems Found in Extreme Conditions; DOT #184, Deep
Offshore Technology Conference held in Stavanger,
Norway, 1012 October 2007.

SPE 110622

Size
5.5 in.

6.0 in.
7.625 in.

9.625 in.

11.75 in.
13.375 in.

Expansion
%
0
6
10
16
0
8
16
0
6
12
18
10
16
0
6
10
14

D/t
18.1
19.4
20.3
21.8
19.7
21.7
23.7
20.3
21.8
23.4
25.1
30.9
33.3
31.3
33.8
39.8
41.8

Collapse # from
# from
Regime Vendor 1 Vendor 2
plastic
4
4
plastic
4
4
plastic
2
4
plastic
6
4
plastic
4
0
plastic
5
0
transition
6
0
plastic
4
3
plastic
4
3
transition
4
3
transition
4
3
transition
4
0
elastic
4
0
elastic
4
3
elastic
4
3
elastic
4
0
elastic
4
0

Figure 1 Collapse Resistance Test Matrix.

Figure 2 Collapse Specimen Measurement Locations.

SPE 110622

Figure 3 Collapse Chamber and Fixture.

Expanded EX-80 Empirical -vs- API Calculated

Collapse Resistance
Vendor 1
Vendor 2

5200

Pressure (psi)

API Calculated

4200

3200

2200

1200

200
18

20

22

24

26

28

30

32

34

D/t
Figure 4 Collapse Resistance Data.

36

38

40

42

44

46

SPE 110622

Percent Ovality of
Post Expanded
Collapse Samples
1.0
0.9
0.8

Percent %

0.7
0.6
0.5
0.4
0.3
0.2
0.1
0.0

Figure 5 Percent Ovality.

SPE 110622

Percent Eccentricity of
Post Expanded
Collapse Samples
13
12
11
10
Percent %

9
8
7
6
5
4
3
2
1
Figure 6 Percent Eccentricity.