Expandable Tubular Technology

ChevronTexaco Presentation

William C. Maurer, Ph.D.

Buddy King
Colin G. Ruan

April 27,2004

3
Expandable Tubular Technology
ChevronTexaco Presentation

William C. Maurer, Ph.D.

Buddy King
Colin G. Ruan

April 20,2004

4
Expandable Solid Casing System

8
 Expandable Solid Tubular Myths
 Require Special, Expensive Casing
 Must Handle Casing with “Kid Gloves”
 Cannot Expand Strong Casing (P110)
 Cannot Expand Large Casing (20”)
 Cannot Expand Off-the-Shelf Casing
 Strong Threaded Connections Not Possible
 Expanding Monobore Overlap Difficult
 Monobores Must be Expensive
 Shell IP Hinders Competition
9
 Existing Weak Connector Problems
 Major Cause of SET Failures
 Limit Ability to Expand Strong Casing (P110)
 Limit Amount Casing can be Expanded
 Reduce Burst and Collapse Strength
 Pull Apart During Expansion
 Require Special Casing
 Cannot Tolerate Casing “Dings” and Blemishes
 Require Outer Sleeve Reinforcement
 Thread Leakage Prevents Expansion
10
ENVENTURE Expansion System

Unexpanded Casing

Expansion Cone

Expanded Casing

High Pressure
(p=3000 to 4000 psi)

11
NOBLE Expansion System

Expandable Liner Hanger (TIW)

Running Tools (TIW)

Expandable Casing (LONE STAR)

Liner Coatings (CCS)

Cementing (CSI)
Expandable Threads (HYDRIL)

Cone Expander (NOBLE)

Mud Pressure
Expandable Packer (TIW)
Expanded Casing
Cementing Shoe (TIW)

12
NOBLE 2⅜” to 7⅝” Expandable Tests
(TIW)

13
 TIW Casing Expansion Tests

Setting Up for Testing

Testing Instrumentation

14
 7-5/8” Casing Expansion Test
7-5/8” 12 Deg Cone 16% Expansion

18
 4-1/2” Casing Expansion Test
4-1/2” J-55 Casing 30% Expansion 20 Deg. Cone Angle

19
Cone Variations
• Cone Angles
• Expansion Ratios
• Cone Finishes
• Cone Material
• Casing Sizes

(Anticlockwise)

20
 Casing Expansion Test Parameters
• Different Materials
 Carbon Steel

 Stainless Steel

• Cone Angles
• Different Sizes
• Solid/Perforated
• Different Hole Spacing
• Expansion Percentage

21
 7-5/8” N-80 Casing Force-Displacement Curve

240000
230000
220000
210000
200000
190000
180000
170000
160000
150000
Applied Force

140000
130000 PSI
120000
110000 Applied Force
100000
90000
80000
70000
60000
50000
40000
30000
20000
10000
0
1 AM
2 AM
2 AM
2 AM
2 AM
3 AM
3 AM
3 AM
4 AM
4 AM
4 AM
4 AM
5 AM
5 AM
5 AM
5 AM
6 AM
6 AM
6 AM
6 AM
7 AM
7 AM

7 AM
8 : AM
AM
11 :37
11 :54
11 :09
11 :26
11 :42
11 :58
11 :14
11 :30
11 :46
11 :02
11 :18
11 :34
11 :50
11 :06
11 :22
11 :38
11 :54
11 :10
11 :26
11 :42
11 :58
11 :14

11 :30
11 :46
02
1
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3
:3

:3
:3
11

A force of 210,000 pounds was required to push the cone through the casing.
Note the pressure drop when we intentionally stopped the test and then resumed with
about the same force required for expansion before and after the intentional stopping.
22
 Force/Displacement Measurements
Various Casing Material:
• J-55
• N-80
• 316 SS

Various Casing Coatings:

• Sandblasted
• Honed
• Moly-Coated
• Uncoated

23
TIW Test Well

24
NOBLE 16” & 20” Expandable Tests
(Texas A&M)

25
20” Expander Cone being Machined

26
Texas A&M 1.5 Million Pound Test Frame

29
Expanding 20” X-56 - 104 lb/ft Casing

Cone

20” Casing

30
20” Casing Expanded to 23”

31
16” L80 – 84 lb/ft Casing (15% Expansion)

Cone
Cone

32
16” Casing Expanded to 18.4” (15%)

33
Expanded 20” Casing Bores
Smooth w/ No Galling

35
A&M Instrumentation

36
 Force-Displacement Curves
Max 20” 581 kips – Max 16” 657 kips

Casing Expansion

700
600
500
Load (kip)

400 20 Inch
300 16 Inch

200
100
0
0 5 10 15 20 25
Displacement (inch)

37
 Surface Expandable Well Design
Conventional Top-Hole Expandables ™
Wellhead & BOP Wellhead & BOP

36” @200’ 36” @200’

(Structural Pipe) (Structural Pipe)

30” @600’ 30” @600’

Trouble Zone @800’ Trouble Zone @800’
26” @900’

26” @1,200’ 20”→24” @1,200’

20” @1,500’ 20”→22” @1,500’

(Surface Casing)

13⅝” @2,000’ 20” @2,000’

38
 16” & 20” Expandable Test Conclusions

• World’s first Expansion of Large Casing

• Expanded 20” to 23”
• Casing in Excellent condition
• Cone Forces Within Acceptable Limits
• Model Predictions Accurate
• Large Potential Market for Offshore Drilling
• Hydril is Developing 20” Expandable Connection
• Will Reduce Deep Water Drilling Costs

40
NOBLE 7⅝” Pumping Tests
(TIW)

42
 TIW Pumping Test Schematic

High Pressure Pumping System

Safety Head

Gauge
High Pressure
Flow Meter Valve

Tank
Expandable Casing Displacement
Transducer

43
 Casing Pumping Test
7-5/8”–29.7ppf–N80

6’ 40’ 15’

Launcher
7-5/8” Casing
Threaded Nut Threaded
(STUB ACME) Nut

Flow 6,000 psi Cone Guide 1” Thread 6,000 psi

Hydril Threads

44
Launchers For 7-5/8” Casing Pumping Test

45
TIW Pumping Test

46
Expander Cone Assembled on Carrier

47
 TIW Make Up Machine

Note brass inserts used on casing

to prevent scarring connections

49
 7-5/8” Test Section Ready for Testing

Brass inserts
for make-up

Note string installed to pig for

displacement measurement

50
7-5/8” Casing Being Expanded

51
TIW Pumping Test 1

52
Severely Galled Cone (No Coating)

55
Severely Galled Casing (No Cone Coating)

56
 Improved Titanium-Nitride Coated Cone (No Galling)

Note slight marks

57
Hydril 723 Connection after Expansion
(8,000 psi Test Pressure)

58
 API Casing Burst Pressure

2 yieldt Stress-Strain Curve of a Typical #316 Stainless Tubular

Pbr  0.875 90,000

ultimate
d 80,000

70,000

60,000

where Pbr = Burst Pressure

Stress, psi
50,000
yield
yield = Yield Strength 40,000 0.875yield
30,000
Young's Modulus 1,860,000 (psi)
t = Thickness 20,000
Yield Strength
Tensile Strength
46,400
81,400
(psi)
(psi)
Proof Strength 1% Offset 51,000 (psi)

d = Casing OD 10,000
Proof Strength 2% Offset
Total Elongation
Maximum Elongation
54,200
52.3
51.2
(psi)
(%)
(%)
0
0 10 20 30 40 50

Strain, %

Applied Drilling Engineering

SPE Textbook Series, Vol. 2, p308

59
 Hydril Pin & Box Unscrewed
after Expansion (Excellent Condition)

Hydril pin
w/ brass protector
Hydril box

60
 Hydril 731 Expandable Wedge
Thread
 Stronger Threads Critical to SET Success
 Hydril 731 Wedge Thread 30 to 60% Stronger
 Wedge Design Holds Threads Together
 Off-The-Shelf Casing With Normal “Dings” and Defects
 Eliminates Special Handling of Casing
 Increases Reliability & Reduces Cost
 Gives Noble a Major Competitive Advantage

61
7-5/8” Casing Collapse Tests

62
Collapse Test – Expanded 7-5/8” 29.7 lb/ft. Casing

63
Collapse Test – Expanded 7-5/8” 29.7 lb/ft. Casing

64
 Collapse Test – Expanded 7-5/8” 29.7 lb/ft. Casing

Note bulge in pipe at 2750 psi

65
66
Mathematical Modeling

67
Noble Casing-Expansion Computer Model

68
 Axial Load vs Cone Angle

Axial Cone Load vs. Cone Angle

180

160

140
Axial Load, 1,000 lbf

120

100

80

60

40

20

0
0 10 20 30 40 50 60 70 80 90

Cone Half Angle, deg

69
 Cone Pressure vs Percent Expansion

Liquid Pressure vs. Tubular ID Expansion

6,000

5,000

Burst
Liquid Pressure, psi

4,000

3,000

2,000

1,000

0
0 5 10 15 20 25 30 35

ID Expansion, %
70
Predicted vs Measured Cone Forces

71
Computer
Modeling

72
7⅝” N–80 Casing API Burst Pressure

73
7⅝” N–80 Casing Collapse Pressure

74
 FEA Modeling by NNC

Mandrel Push Force with Displacement along Tubular Hoop Stress across Tubular thickness (at Free End) after
Expansion
200.0 0

180.0 -100
Lower Bound
Upper Bound
160.0 -200

140.0 -300
HOOP Stress (MPa)
Tool Extrusion Force (Te)

120.0 -400

100.0 -500

80.0 -600

60.0 Lower Bound

-700
Upper Bound
Lower Bound (No Friction)
40.0 Upper Bound (No Friction) -800

20.0 -900

0.0 -1000
-200.0 -100.0 0.0 100.0 200.0 300.0 400.0 500.0 0.0 1.0 2.0 3.0 4.0 5.0 6.0 7.0 8.0 9.0 10.0
Travel of M andrel's M ax Diameter along Tubular (mm) Node Position across Tubular Thickness (mm)
75
Monobore Systems

76
 Monobore Well

Wellhead

Expandable Liner Hanger

Overlap
Expandable Seal
Expandable Casing
Expandable Thread

77
78
Advantages of Monobores
 Deeper Water Capabilities
 Faster Drilling & Lower Cost
 Less Environmental Damage
 Less Casing & Bits
 Less Mud & Cement
 Smaller Rigs & Risers
 Smaller Work Boats
 Fewer Cuttings 79
 Monobores Require Smaller Rigs
 Smaller, Lower Cost Rigs
 Smaller Risers & BOPs
 Lower Hook Loads
 Lower Horsepower & CO2 Emissions
 Less Deck Space
 Reduced Riser Tensioning
 Reduced Mooring Requirements
80
 Tubular Expansion System

Unexpanded
Casing

Expansion
Cone

Expanded
Casing
Pressure

81
Expander Pressure in Casing Expansion

82
 Monobore Expansion Pressure
8.835” Monobore ID, 9⅝” Expandable Casings

8.835” ID

7⅝” ID

0.605”

Expand Casing Expand Casing &

Overlap
Required Liquid
5,417 psi 4,851 psi
Pressure
ID Expansion 28.5%
83
 Monobore Expansion Pressure
8” Monobore ID, 7⅝” Expandable Casings

8” ID

7⅝” ID

0.188”

Expand Casing Expand Casing &

Overlap
Required Liquid
1,978 psi 5,756 psi
Pressure
ID Expansion 16 %
84
 Existing Monobore System I
Single-Stage Expansion (Top-down)
Start to Expand Expand
Expand Overlap Casing

Burst 5,745 psi

15,166 psi
Base Casing
9⅝”, 40 ppf, L–80
Cone

Expandable Liner Hanger

(Overlap) Cone

Burst 5,491 psi

7,386 psi
Expandable Casing
7⅝”, 29.7 ppf, L–80

Cone

(A) (B) (C)

85
 Existing Monobore System II
Single-Stage Expansion (Bottom-up)
Start to Expand Expand
Expand Casing Overlap

Base Casing
9⅝”, 40 ppf, L–80

Expandable Liner Hanger Cone

(Overlap)

Expandable Casing

Burst 5,491 psi

7⅝”, 29.7 ppf, L–80

15,166 psi
Cone

Burst 5,491 psi

7,386 psi

Cone

(A) (B) (C)

86
 Existing Monobore System III
Dual-Stage Expansion (Bottom-up & Top-down)
Start to Stage I Stage II Stage II
Expand Bottom-Up Expand Overlap Expand Casing

Burst 5,745 psi

Base Casing

4,816 psi
9⅝”, 40 ppf, L–80

Burst 5,427 psi

Cone 1
Exp. Liner Hanger

2,200 psi
(Overlap) Cone 2

Expandable Casing
7⅝”, 29.7 ppf, L–80 Burst 5,885 psi
5,416 psi

Cone 2

Cone 1

(A) (B) (C) (D)

87
 NOBLE Monobore System I
Dual-Stage Expansion (Single Expandable Cone)
Start to Stage I Lower and Stage II Stage II
Expand Expand Casing Expand Cone Expand Casing Expand Overlap
9⅝”, 40 ppf, L–80
Base Casing

Original
Cone Expanded
Cone
Expandable Casing
7⅝”, 29.7 ppf, L–80

Burst 5,885 psi

Burst 5,427 psi

5,416 psi

Expanded

4,816 psi
Cone

Burst 5,427 psi

2,200 psi
Original
Expanded
Cone
Cone
(A) (B) (C) (D) (E)
88
 NOBLE Monobore System II
Dual-Stage Expansion (Expandable & Non-Expandable Cones)
Expand Cone 2 Stage I Lower Work Stage II Stage II
and Start to Expand Casing String and Latch Cone 2 and Expand Overlap
Expand Casing Cone 1 Expand Casing
9⅝”, 40 ppf, L–80
Base Casing

Cone 1

Expanded
Cone 1
Cone 2

Cone 1
Expandable Casing
7⅝”, 29.7 ppf, L–80

Burst 5,885 psi

Expanded
Cone 2

Burst 5,427 psi

5,416 psi

4,816 psi
Cone 1

Burst 5,427 psi

2,200 psi
Cone 1

Expanded Expanded Expanded

Cone 2 Cone 2 Cone 2
(A) (B) (C) (D) (E)
89
 NOBLE Monobore System III
Dual-Stage Expansion (Dual Expandable Cone)
Start to Stage I Expand Stage II Stage II
Expand Casing Expand Casing Cone 2 Expand Casing Expand Overlap

Burst 5,745 psi

4,816 psi
9⅝”, 40 ppf, L–80
Base Casing

Cone 1

Burst 5,427 psi

Expanded

2,200 psi
Cone 2
Cone 1
Cone 1
Cone 2
Expanded
Cone 2
Expandable Casing
7⅝”, 29.7 ppf, L–80

Burst 5,885 psi

Cone 1
5,416 psi

Expanded
Cone 2

Cone 1

Cone 2

(A) (B) (C) (D) (E)

90
 Monobore Casing Burst Problem

 Larger Diameter Casing is Better

 Thinner Casing is Better

 Casing Strength has Minimal Effect

97
 PROPOSED NOBLE MONOBORE JIP

98
 Noble Drilling DEA Monobore Project

 6 to 8 Operators
 $0.5 to $1 Million Fee
 Drill Wilcox Monobore Test Well
 Each Operator Drills One 7-5/8” or 9-5/8” Monobore Well
 Complete Monobores with Production Strings
 Participants – Share Field Data, Observe Field Tests
 Noble – Manage Project, Engineering, Well Planning
 TIW – Equipment Design, Field Tools
 Hydril - Expandable Wedge Connections
 IP – To Service Companies to Allow Commercialization
 Operator Benefit – Accelerate Monobore Implementation
99
 Monobore Wilcox Test Wells
 $1 million JIP Funding
 5000 to 6000 ft Wilcox Wells
 Fayette County, Texas Area (near Houston)
 No Well Control Problems
 No Borehole Stability Problems
 7-5/8” Monobore Sections (1000 – 3000 ft)
 Test Expansion Tools & Procedures
 LEXXUS OIL Contributes Well , Assumes Risk

100
 JIP Candidates

International Oil Companies

 BP
 ChevronTexaco
 ConocoPhillips
 ExxonMobil
 Shell

101
 JIP Candidates
National Oil Companies
 Abu Dhabi – ADNOC
 Argentina/Spain – REPSOL
 Brazil – Petrobras
 China – CNPC, CNOOC, SINOPEC
 Denmark – Maersk
 France – Total, Gaz de France
 India – ONGC
 Indonesia – PERTAMINA
 Italy – ENI/AGIP
 Japan – JNOC
 Malaysia – Petronas
 Mexico – Pemex
 Norway – Statoil, Norsk Hydro
 Russia – Lukoil, Tatneft, GAZPROM
 Venezuela – PDVSA
102
 JIP Candidates
Large Independents
 Amerada Hess  Newfield
 Anadarko  Oxy
 Chesapeake  Pioneer
 Devon  Samedan
 Spinnaker
 Dominion
 Unocal
 El Paso
 Vastar
 Kerr-McGee
 Murphy
103
 Solid Tubular Conclusions
 Expandable Tubulars will have major impact
 Solid Expandable Tubulars reduce costs
 Expandable Screens increase production
 Expandable Screens Eliminate Sand Production
 Monobore wells “Holy Grail” of Expandables
 Monobores hindered by lack of field tests
 Noble monobores ready for commercialization
 Noble forming monobore JIP
 JIP will drill shallow test monobore
 6 to 8 JIP Participants will each drill one monobore
 JIP will accelerate monobores by 5 to 10 years

104
Expandable Sand Screens

105
 Expandable Sand Screen Myths

 Difficult to Expand Screens Over 30%

 Compliant Sand Screens Must be Weak
 Cannot Rotate Unexpanded Compliant Screens
 Compliant Screens Apply Low Contact Pressure
 Connection Failures a Major Problem
 Require Short-Life Roller Expanders
 Screens Difficult & Expensive to Manufacture
 Liner Hangers a Major Problem
 High Reliability & Low Cost Difficult to Achieve
106
Time Savings with Expandable Screens
(Weatherford)

Time (Days)

107
Cost Savings with Expandable Screens
(Weatherford)

108
 Expandable Sand Screen Applications

Flow Area

Increase Eliminate Reduce Sand Increase

Flow Area Hot Spots Production Drawdown &
Flow Rate

109
 Pressure Drops in Sand Screen

v Q Q
Equation P    (Laminar Flow in Pipe)
d 2 Ad 2 d 4

Example Parameter Conventional Expanded

Screen Screen
(inches) (inches)
Hole ID 6 6
Screen OD 5 6
Base Pipe OD 4.5 5.5
Base Pipe ID 4.1 5.1

PES  4.1 
4

   100%  42%
PCS  5.1 

Remarks • Expanding a 5” screen in a 6” hole reduces pressure drop in base

pipe by 58%
• Significantly increases production rates in high flow rate wells
(1,000 to 10,000 BPD) and with long screens (1,000 to 5,000 ft)

110
 Eroded Screen and Base Pipe
(World Oil, 2001)

Packer

Screen Hot Spot

Plugging (erosion)

Formation

Annulus Open

111
Eroded Screen and Base Pipe
(World Oil, 2001)

112
 Expandable Screen Packers
Eliminate Hot Spots
Packer

Packer

Formation

113
Sand Screen Mechanics

114
Particle Size Sand Distribution Plot
(World Oil, 2001)

115
 Sand Formation

Prior to Drilling Flowing

(Fines Migration)

Fluid
Flow

Coarse Fine Sand

Grains Grains Screen

116
Excessively-Fine Screen

Low P High P

Fluid
Flow

Plug Sand
(Fines) Screen

117
Optimum Size Screen

High P Low P

Sand Fines
Screen
118
 Reservoir Radial Fluid Flow

pe 2  k h pe  pw 
Steady-State Flow Q
 lnre rw 
where Q = Flow rate
k = Formation permeability
h = Formation thickness
rw pw pe = Pressure at boundary
pw = Pressure at wellbore
Flow  = Fluid viscosity
re = Radius at boundary
rw = Radius at wellbore
Reservoir

Formation

119
Sand Cementation

Sand Grain

Cement

Oil

Formation

120
 Excessive Drawdown
Medium P Low P

Medium
Drawdown

Wellbore Wall
( Q < QC )

Sand Screen

Medium Q
Sand

Low P High P

High Drawdown
( Q > QC )

Sand Screen

Low Q
Sand

Bridging
121
 Effect of Formation and Screen Damage
on Flow Rate

Undamaged Reservoir Damaged Reservoir

Formation Damage
P/2

Formation Pressure
Formation Pressure

Formation
Damage

P
Formation
P/2
Formation

Distance from Wellbore Distance from Wellbore

122
 Critical Flow Rate

Flow
Sand Formation

Sand Screen
Wellbore
Sand Sand
FP FP Grain
Grain

Low Flow Rate High Flow Rate

( Q < QC ) ( Q > QC )

123
 Sand Grain Mechanics
(Conventional)
Failure: FP > FS
FS
Flow
FP = Pressure Force
FP FS = Shear Resistance
Sand Grain

P

124
 Gravel Packing

Medium P Low P Low P

Medium Drawdown
( Q < QC )

Sand Screen

Medium Q
Sand Gravel Pack

125
Compliant Sand Screens

126
 Compliant Sand Screen

High P Low P

Compliant Sand Screen

High Drawdown
( Q < QC )

High Q
Sand

Contact Force

127
 Sand Grain Mechanics
(Compliant Screen)
Failure: FP > FS + FSC
FS
Flow
FP = Pressure Force
FP FSC FS = Shear Resistance
Sand Grain
FSC = Screen Force

P

128
 Reservoir Radial Fluid Flow

2  k h pe  pw 
pe Steady-State Flow Q
 lnre rw 
where Q = Flow rate
k = Formation permeability
rw pw h = Formation thickness
pe = Pressure at boundary
pw = Pressure at wellbore
Flow  = Fluid viscosity
re = Radius at boundary
Reservoir rw = Radius at wellbore
Formation

129
 Production Increases with
Expandable Screens (Weatherford)

Production Increase, %
130
Commercial Sand Screens

131
 Sand Screen Systems

Unexpanded Expanded

Conventional Fixed Compliant Compliant

Cone Cone/Rollers Screen
Fixed Cone

• Numerous • Baker Hughes Cone • Noble

Companies • Halliburton • Noble
• Noble Rollers
• Schlumberger • Tatneft
• Weatherford • Weatherford

133
 Conventional Sand Screen System
(No Cone)

Completion Fluid

Conventional Wellbore and Screen Gravel Pack

(Optional)

Numerous Companies
134
 Expandable Sand Screen System
(Fixed Cone)

Completion
Fluid
Expanded
Screen Large Flow
Area
Wellbore

Fixed
Cone Gap

Unexpanded
Screen

Baker Hughes Halliburton Noble Schlumberger Weatherford

135
Baker-Hughes Screen Expansion System

136
 Baker-Hughes Screen Components
Base Pipe
 Hole pattern optimized for
maximum expansion and
production

 Perforated base pipe provides

greater strength for expanded
screen

137
Halliburton Screen Expansion System

138
 Expandable Sand Screen System
(Compliant Rollers)

Completion
Fluid Expanded
Screen

Residual c
Pressure
Compliant
Rollers

Wellbore
Unexpanded
Screen

Weatherford Tatneft
139
 Weatherford Screen Expansion System
Pros Cons
• Wellbore face compliance • Limited roller life
• Initiate expansion anywhere • Hard on tubular connections
• Seamless tubulars
• Low friction
• Inexpensive system

140
ESS Expandable
Sand Screen Joint

141
 EXPRESS vs. Slotted Base Pipe

Weatherford Baker
Feature Slotted Basepipe Perforated Basepipe
Crush Resistance Poor Excellent
Filtering Unexpanded Poor (little inflow area) Excellent
Rotational Performance Cannot rotate +/- 4,000 ft-lbs
Collapse Resistance < 400 psi (weave has no support) > 1,000 psi
Burst Resistance < 400 psi (weave has no support) > 1,000 psi
Maximum Expansion 40-50% 20-30%

142
NOBLE Sand Screen Tests
(TIW)

143
 Noble Sand Screen Expansion Tests

4-1/2” 316 - SS - 20% Expansion & 20 Deg. Cone Angle

v 12-B Note cat eyes beginning to form

144
 Noble Sand Screen Tests
4-1/2” – 316 Sand Screen Expanded
with 12º/20% Cone

12º/20% Cone expanded 12º/20% Cone expanded

in 4-1/2” SS screen in 4-1/2” SS screen
(Shroud not welded on either end) (Shroud welded on both ends) 145
 4-1/2" OD. - 316 Stainless Steel
Perforated Basepipe

80,000 700

70,000
600
Applied Force, lbs

60,000
500

Pressure, psi
50,000
400
40,000
300
30,000

200
20,000

10,000 100

0 0
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
Time, min.

Note pressure drop as cone moves thru perforations 146

Post Expansion Screen Analysis
Maurer Test #28

Section 2 was cut along

the horizontal axis
approximately in
halves, to allow
disassembly and
analysis. Every effort
was made to keep the
sample in a state as
close as possible to the
state it was in
immediately after the
expansion test.
However, it should be
noted that the
horizontal cut released
the mesh sandwich and
no tension was present
in the mesh construct.
(Sample 3 was left
intact to show the
Sectional Analysis From TIW compressing effect of
February 4, 2004 Expansion Test expansion.) 1

Maurer Test #28

This 10 Power
Magnification of the
polished edge of piece 4
illustrates the efficient and
effective capture of the
mesh layers into a unified
and well supported
filtration package. The
uniformity of the
expansion inherent in
using a cone expander
results in a uniformly
compressed mesh
package within the
construct.

Sectional Analysis From TIW

February 4, 2004 Expansion Test 7 147
NOBLE Sand Screens

148
NOBLE Expandable Sand Screen System

Liner Hanger (TIW)

Piston Tool (TIW)

Expandable Threads (TIW)

Expandable Packer (TIW)

Expanded Sand Screen

Cone Expander (NOBLE)

Expandable Sand Screen (STREN)

Bottom Sub (TIW)

149
 Noble Sand Screen Thruster System
Single-Acting Piston
Run to bottom Expand wall anchor, Retract wall Push housing Expand wall
pump piston and anchor down with anchor and
cone down drillpipe weight repeat process
Liquid

Drillpipe
Swivel
(optional)
Wall
Anchor

Housing
Piston

Cone

150
STREN Expandable Sand Screen

151
Noble Sand Screen Expansion
Tools

152
Sand Screen Expander Pistons

153
Sand Screen Expansion Tools

154
Retractable Sand Screen Cone
(Collapsed)

155
Sand Screen Collapsible Cone and Mandrel
(Expanded)

156
 Tubular Thread Expansion

Unexpanded
Casing

Expansion Expanding
Thread
Cone

Expanded
Casing
Force
157
 Noble Sand Screen Connection

Non-Upset Connection (Conventional)

After Expansion

25%
Before Expansion

Upset Connection (Invention)

After Expansion

25% 0% 25%

Before Expansion

158
4-1/2” 316 SS Casing Swaged to 5-1/2” with Buttress Threads

159
 NOBLE Expandable Sand Screen System
(Compliant Cone)

Completion Expanded
Fluid Screen

Residual
Pressure
Compliant
Cone

Wellbore
Unexpanded
Screen

Noble
161
 NOBLE Compliant “Cone” Expander

Rock Formation

Expanded Screen

Compliant Member
Unexpanded Screen
Push Force

Actuator Completion
Non-Compliant Head Fluid

162
 NOBLE Compliant “Cone” Expander
Concepts
Gas Pressure

Rollers (optional) Spring

Cone

3 4
163
NOBLE Compliant “Cone” Expander
Concepts (cont’d.)
Spring

Hollow Spheres

8
164
NOBLE Compliant “Cone” Expander
Concepts (cont’d.)
Memory Alloy

10

Explosive Propellant

11 12
165
NOBLE Compliant “Cone” Expander
Concepts (cont’d.)
Screw Expander Swellable Material

13 14

Percussion Device

16
166
 NOBLE Expandable Sand Screen System
(Compliant Screen)
Compressed
Material

Expanded
Completion
Screen
Fluid

Wellbore Residual
Pressure

Fixed
Cone Uncompressed
Material

Unexpanded
Screen

Noble
167
 NOBLE Compliant Screen Material
(Elastic or Plastic)
Uncompressed Compressed

Solid

Voids

Formation

Pressure
t t/2

  60%   20%
k = 3 darcies k = 1 darcy

Noble
168
 NOBLE Expandable Sand Screen System
(Compliant Screen)

Expanded Compressed
Shroud Material

Expanded
Completion
Screen
Fluid

Wellbore Residual
Pressure

Fixed
Cone Uncompressed
Material

Unexpanded Unexpanded
Shroud Screen

Noble
169
 NOBLE Compliant Sand Screen

Before Expansion After Expansion

Perforated Outer
Base Pipe Shroud

Compressible Member

Compressible Member
Filter Medium

Formation

Formation
Pressure
Wellbore

Compliant Sand Screen

Noble
170
NOBLE Expandable Sand Screen System
(Neutrally-Buoyant Particles)

Expanded Liner Hanger

Work String Weight

Expanded Compliant Screen

Expanded Thread

Cone Expander
Barrier

Unexpanded Screen

Neutrally-Buoyant Particles

Bottom Sub (TIW)

171
NOBLE Expandable Sand Screen System
(Neutrally-Buoyant Particles)

Before Expansion After Expansion

Formation

Formation
172
 Noble Expandable Sand Screens

 High-Torque, Rotatable Screens (> 4000 ft–lbs)

 High Collapse Strength (>2000 psi)
 Fast, Strong Piston Expansion System
 Strong Upset Connections
 Retractable Expander Cones
 Tri-Screen Filtration
 Up to 35% Expansion
 Strong Cone-Expandable Compliant Screens
 High-Strength Liner Hangers
173
The End

174
NOBLE Patents Pending

175
 Patent 1
Combined Tubular Expansion/Cementing System
Ready to Expand Casing and Liner Lower Cone to Bottom Stab Cone into Squeeze Cement
Casing Hanger Expanded with Drillpipe Cementing Shoe through Drillpipe
Liner Hanger

Cement
Wiper Rubbers

Stinger
Drillpipe
Unexpanded Casing

Plug
Expanded Casing

Cement Slurry
Cone
Wellbore

Latch

Cementing
Shoe

(A) (B) (C) (D) (E)

176
 Patent 2
Single-Piston Tubular Expander

Drillpipe
Fluid Pressure
Piston

Casing

Liner Hanger

Drill Collar

Expanded Screen

Cone or Compliant Expander

Unexpanded Screen

177
 Patent 3
Multiple Pass Expansion System

Single-Stage Dual-Stage
a a/2 a/2

Cone Cone Cone

F/2 F/2
F F F
F

178
 Patent 3
Multiple Pass Reduce Cone Pressure

179
 Patent 4
Expandable System Utilizing Swivel

Expandable
Expandable Threads
Sand Screen
Non-Rotating Cone Expander

Expandable Screen

Rotating Work String

Swivel Bottom Sub

Expandable Liner Hanger

180
 Patent 5
Honing Casing to Reduce Cone Pressure

181
 Patent 6
Multiple Expansion Sand Screen

Expandable
Base Pipe

Expandable
Inner Member

Completion Fluid

Sand Screen

182
 Patent 7
Compliant Sand Screen Expander

Completion Expanded
Fluid Screen

Residual
Pressure
Compliant
Cone

Wellbore
Unexpanded
Screen

183
 Patent 7
Compliant Sand Screen Expander

Rock Formation

Expanded Screen

Compliant Member
Unexpanded Screen
Push Force

Actuator Completion
Non-Compliant Head Fluid

184
 Patent 8
Compliant Screen Utilizing Neutrally-Buoyant Particles in Annulus

Expandable Liner Hanger

Work String Weight

Expandable Screen
Expandable Threads

Cone Expander
Barrier

Unexpandable Screen

Near Neutrally-Buoyant Particles

Bottom Sub (TIW)

185
 Patent 8
Compliant Screen Utilizing Neutrally-Buoyant Particles in Annulus

Before Expansion After Expansion

Formation

Formation
186
 Patent 9
Compliant Sand Screen Utilizing Compressible Element

Compressed
Material

Expanded
Completion
Screen
Fluid

Wellbore Residual
Pressure

Fixed
Cone Uncompressed
Material

Unexpanded
Screen

187
 Patent 9
Compliant Sand Screen Compressible Element

Before Expansion After Expansion

Perforated Outer
Base Pipe Shroud

Compressible Member

Compressible Member
Filter Medium

Formation

Formation
Pressure
Wellbore

Compliant Sand Screen

188
 Patent 10
Surface Expandable Well Design

Conventional Top-Hole Expandables ™

Wellhead & BOP Wellhead & BOP

36” @200’ 36” @200’

(Structural Pipe) (Structural Pipe)

30” @600’ 30” @600’

Trouble Zone @800’ Trouble Zone @800’
26” @900’

26” @1,200’ 20”→24” @1,200’

20” @1,500’ 20”→22” @1,500’

(Surface Casing)

13⅝” @2,000’ 20” @2,000’

189
 Patent 10
20” Casing Expanded to 23”

190
 Patent 11
Tubular Thread Expansion

Unexpanded
Casing

Expansion Expanding
Thread
Cone

Expanded
Casing
Force
191
 Patent 11
Expandable Tubular Connection

Non-Upset Connection (Conventional)

After Expansion

25%
Before Expansion

Upset Connection (Invention)

After Expansion

25% 0% 25%

Before Expansion

192
The End

193