OA10949A - 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 PDF

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Publication number
OA10949A
OA10949A OA9800252A OA9800252A OA10949A OA 10949 A OA10949 A OA 10949A OA 9800252 A OA9800252 A OA 9800252A OA 9800252 A OA9800252 A OA 9800252A OA 10949 A OA10949 A OA 10949A
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OAPI
Prior art keywords
tubing
expansion
steel
expanded
mandrel
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OA9800252A
Inventor
Martin Donnelly
Alban Michel Faure
Wilhelmus Christianus Lohbeck
Franz Marketz
Robert Bruce Stewart
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Shell Int Research
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Publication of OA10949A publication Critical patent/OA10949A/en

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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
    • 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

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  • Engineering & Computer Science (AREA)
  • Geology (AREA)
  • Mining & Mineral Resources (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Chemical & Material Sciences (AREA)
  • Geochemistry & Mineralogy (AREA)
  • Mechanical Engineering (AREA)
  • General Life Sciences & Earth Sciences (AREA)
  • Physics & Mathematics (AREA)
  • Environmental & Geological Engineering (AREA)
  • Fluid Mechanics (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Materials Engineering (AREA)
  • Crystallography & Structural Chemistry (AREA)
  • Earth Drilling (AREA)
  • Metal Extraction Processes (AREA)
  • Heat Treatment Of Steel (AREA)
  • Forging (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

1 010949
METHOD FOR EXPANDING A STEEL TUBING AND WELL WITH SUCH ATUBING
The invention relates to expansion of tubings. Moreparticularly the invention relates to a method ofexpanding a Steel tubing by rnoving an expansion mandrelthrough the tubing. 5 Numerous methods and devices are known for expansion of tubings.
European patent spécification 643794 discloses amethod of expanding a casing against the wall of anunderground borehole wherein the casing is made of a 10 malléable material which preferably is capable of plastic deformation of at least 25% uniaxial strain and thecasing may be expanded by an expansion mandrel which ispumped, pulled or pushed through the casing.
Other expansion methods and devices are disclosed in 15 German patent spécification No. 1583992 and in US patent spécification 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 20 initially corrugated tube and the latter prior art reference employs a slotted tube which is expandeddownhole by an expansion mandrel.
The use of corrugated or slotted pipes in the knownmethods serves to reduce the expansion forces that need 25 to be exerted to the tube to create the desired expansion. A method in accordance with the preamble of claim 1is known from US patent spécification No. 5,366,012. Inthis known method a slotted tube is expanded by an 30 expansion mandrel having a tapering expansion section. 2 010949
It is an object of the présent invention to provide amethod for expanding an at least partly solid, i.e.unslotted, tubing which requires exertion of a low forceto expand the tubing and which provides a tubing having aiarger diameter and higher strength than the unexpandedtubing and which can be carried out with a tubing whichalready may hâve a tubular shape before expansion.
The method according to the invention theretocomprises the step of moving an expansion mandrel ofwhich the tapering expansion section has a taperingceramic outer surface through an at least partly solidtubing which is made of a formable Steel grade which issubject to strain hardening without incurring any neckingand ductile fracturing as a resuit of the expansionprocess.
As a resuit of strain hardening the tubing becomesstronger during the expansion process since for anyfurther incrément of expansion always a higher stress isrequired than for the preceding expansion.
It has been found that the use of a formable steelgrade for the tubing in combination with a ceramictapering outer surface of the expansion mandrel has asynergetic effect since the resulting expanded tubingwill hâve an adequately increased strength while theexpansion forces remain low. The low yield strength andhigh ductility of the tubing before expansion enables, ifthe tubing is to be used in an underground borehole, theuse of a tubing which is reeled from a reeling drum intothe borehole.
It is observed that in the art of metallurgy theterms strain-hardening and work-hardening are synonymsand are both used to dénoté an increase of strengthcaused by plastic deformation.
The term formable steel grade as used in thisspécification means that the tubing is able to maintain - 3 - 010949 its structural integrity while being plastically deformedinto various shapes.
Ways of determining forming characteristics of aSteel are set out in the Metals Handbook, 9th édition,volume 14, Forming and Forging, issued by ASM
International, Metals Park, Ohio (USA).
The term necking refers to a geometrical effectleading to non-uniform plastic deformations at somelocation by occurrence of a local constriction. From thepoint of necking on, the continuai work hardening in thenecked région no longer compensâtes for the continuairéduction of the smallest cross-section in the neck, andtherefore, the load carrying capacity of the Steeldecreases. With continuing loading, practically ailfurther plastic deformation is restricted to the régionof the neck, so that a highly non-uniform deformationoccurs to develop in the necked région until fractureoccurs.
The term ductile fracturing means that a failureoccurs if plastic deformation of a component thatexhibits ductile behaviour is carried to the extreme sothat the component séparâtes locally into two pièces.Nucléation, growth and coalescence of internai voidspropagate to failure, leaving a dull fibrous rupturesurface. A detailed description of the terms necking andductile fracturing is given in the handbook "Failure ofMaterials in Mechanical Design" by J.A. Collins secondédition, issued by John Wiley and Sons, New York (USA) in1993 .
Preferably the tubing is made of a high-strengthSteel grade with formability and having a yield strength-tensile strength ratio which is lower than 0.8 and ayield strength of at least 275 MPa. When used in this 4 010949 spécification, the term high-strength Steel dénotés asteel with a yield strength of at least 275 MPa.
It is aiso preferred that the tubing is made of aformable steel grade having a yield stress/tensile stressratio which is between 0.6 and 0.7.
Dual phase (DP) high-strength, low-alloy (HSLA)steels lack a definite yield point which éliminâtesLuders band formation during the tubular expansionprocess which ensures good surface finish of the expgndedtubular.
Suitable HSLA dual phase (DP) steels for use in themethod according to the invention are grades DP55 andDP60 developed by Sollac having a tensile strength of atleast 550 MPa and grades SAFH 540 D and SAFH 590 Ddeveloped by Nippon Steel Corporation having a tensilestrength of at least 540 MPa.
It is observed that US patent spécificationNo. 4,938,266 discloses a method for producing dual phasesteels.
Other suitable steels are the following formablehigh-strength steel grades an ASTM A106 high-strength low alloy (HSLA) seamlesspipe; 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-rolledsteel (low-alloy TRIP steel) such as gradesSAFH 590 E, SAFH 690 E and SAFH 780 E developed byNippon Steel Corporation.
The above-mentioned DP and other suitable steels eachhâve a strain hardening exponent n of at least 0.16 whichallows an expansion of the tubing such that the external 010949 diameter of the expanded tubing is at least 20% largerthan the external diameter of the unexpanded tubing.
Detailed explanations of the terms strain hardening,work hardening and the strain hardening exponent n aregiven in chapters 3 and 17 of the handbook "MétalForming-Mechanics and Metallurgy", 2n<^ édition, issued byPrentice Hall, New Jersey (USA), 1993.
Suitably, the expansion mandrel contains an expansionsection that has a conical ceramic outer surface. It-isobserved that US patent spécification No. 3,901,063discloses a plug having a conical ceramic outer surfacefor use in tube-drawing operations. If the expansionmandrel is pumped through the tubing then the mandrelpreferably comprises a sealing section which is locatedat such a distance from the tapering expansion sectionthat when the expansion mandrel is moved through thetubing by means of exerting a hydraulic pressure behindthe mandrel the sealing section engages a plasticallyexpanded part of the tubing. This will generally beachieved if said distance is at least three times thewall thickness of the expanded tubing.
The use of a ceramic conical surface reduces frictionforces during the expansion process and by having asealing section which engages the expanded tube it isavoided that hydraulic forces would resuit in anexcessive expansion of the tubing.
In such case it is preferred that the expansionmandrel contains a vent line for venting to the surfaceany fluids that are présent in the borehole and tubingahead of the expansion mandrel.
Alternatively the tubing is expanded such that theouter diameter of the expanded tubing is slightly smallerthan the internai diameter of the borehole or of anycasing that is présent in the borehole and any fluidsthat are présent in the borehole and tubing ahead of the 010949 expansion mandrel are vented to surface via the annularspace that remains open around the tubing after theexpansion process. - 6 - 01 0949
The invention also relates to a well provided with atubing which is expanded using the method according tothe invention. In such case the tubing may serve asproduction tubing through which hydrocarbon fluid istransported to the surface and a reelable service and/orkill line passes through at least a substantial part ofthe length of the tubing, through which line fluid can bepumped towards the bottom of the borehole whilehydrocarbon fluid is produced via the surroundingproduction tubing. The use of such an expanded productiontubing allows the use of almost the full wellbore for thetransport of hydrocarbon fluids so that a relatively slimborehole may be utilized to attain the desired productionrate.
Alternatively the tubing may be expanded against theinner surface of a casing which is présent in the bore-hole. In such case the tubing may either be used as aproduction tubing and/or as a protective cladding forprotecting the well casing against corrosive well fluidsand damage from tools that may be lowered into the wellduring maintenance and workover operations.
These and other objects, features and advantages ofthe method and well System according to the présentinvention will be apparent from the accompanying daims,abstract and the following detailed description withreference to the accompanying drawing, in whichFig. 1 is schematic longitudinal sectional view of anunderground borehole in which a tubing is expanded inaccordance with the method according to the invention.
Now referring to Fig. 1, there is shown a boreholetraversing an underground formation 1 and a casing 2 thatis fixed within the borehole by means of an annular bodyof cernent 3. 7 010949 A production tubing 4 which is made of a dual phase,high-strength low-alloy (HSLA) steel or other formablehigh-strength steel is suspended within the casing 2.
An expansion mandrel 5 is moved in longitudinaldirection through the tubing 4 thereby expanding thetubing 4 such that the outer diameter of the expandedtubing is slightly smaller than or is about equal to theinternai diameter of the casing 2.
The expansion mandrel 5 is equipped with a sériés ofceramic surfaces 6 which restrict frictional forcesbetween the pig and tubing 4 during the expansionprocess. In the example shown the semi top angle A of theconical ceramic surface that actually expands the tubingis about 25°. It has been found that zirconium ôxide is asuitable ceramic material which can be formed as a smoothconical ring. Experiments and simulations hâve shown thatif the semi cône top angle A is between 20° and 30° thepipe deforms such that it obtains an S-shape and touchesthe tapering part of the ceramic surface 6 essentially atthe outer tip or rim of said conical part and optionallyalso about halfway the conical part.
The experiments also showed that it is bénéficiaithat the expanding tubing 4 obtains an S-shape since thisreduces the length of the contact surface between thetapering part of the ceramic surface 6 and the tubing 4and thereby also reduces the amount of friction betweenthe expansion mandrel 5 and the tubing 4.
Experiments hâve also shown that if said semi topangle A is smaller than 15° this results in relativelyhigh frictional forces between the tube and pig, whereasis said top angle is larger than 30° this will involveredundant plastic work due to plastic bending of thetubing 4 which also leads to higher heat dissipation and - θ - 010949 to disruptions of the forward movement of the pig 5through the tubing 4. Hence said semi top angle A ispreferably selected between 15° and 30° and should alwaysbe between 5° and 45°.
Experiments hâve also shown that the tapering part ofthe expansion mandrel 5 should hâve a non-metallic outersurface to avoid galling of the tubing during theexpansion process. The use of a ceramic surface for thetapering part of the expansion mandrel furthermore causedthe average roughness of the inner surface of thetubing 4 to decrease as a resuit of the expansionprocess. The experiments hâve also shown that theexpansion mandrel 5 provided with a ceramic taperingsurface 6 could expand a tubing 5 made of a formablesteel such that the outer tubing diameter D2 afterexpansion was at least 20% larger than the outer diameterDI of the unexpended tubing and that suitable formablesteels are dual phase (DP) high-strength low alloy (HSLA)steels known as DP55 and DP60; ASTM A106 HSLA seamlesspipe, ASTM A312 austenitic stainless Steel pipes, gradesTP 304 L and TP 316 L and a high-retained austenite high-strength hot rolled steel, known as TRIP steel manu-facturée! by the Nippon Steel Corporation.
The mandrel 5 is provided with a pair of sealingrings 7 which are located at such a distance from theconical ceramic surface 6 that the rings 7 face theplastically expanded section of the tubing 4. The sealingrings serve to avoid that fluid at high hydraulicpressure would be présent between the conical ceramicsurface 6 of the mandrel 5 and the expanding tubing 4which might lead to an irregularly large expansion of thetubing 4. -9- 010949
The expansion mandrel 5 is provided with a centralvent passage 7 which is in communication with a coiledvent line 8 through which fluid may be vented to thesurface. After completion of the expansion process thepig 5 may be pulled up to surface by the vent line and acoiled kill and/or service line (not shown) may belowered into the expanded tubing 4 to facilitateinjection of kill and/or treatment fluids towards thehydrocarbon fluid inflow zone which is normally be donevia the annulus between the production tubing and thewell casing. However, if the tubing 4 is expanded tô asmaller diameter then the residual annular space betweenthe casing 2 and expanded tubing 4 can be used forventing of fluids during the expansion process and forinjection of fluids during the production process, inwhich case there is no need for using a vent line 8 andkill and/or service Unes.
In conventional wells it is often necessary to use aproduction tubing having an outer diameter which is lessthan 50% of the inner diameter of the well casing toenable a smooth insertion of the tubing even if the wellis deviated and the casing has an irregular innersurface. Therefore it is apparent that the in-situ tubingexpansion method according to the présent inventionenhances an efficient use of the wellbore.
It will be understood that instead of moving theexpansion mandrel through the tubing by means ofhydraulic pressure, the mandrel can also be pulledthrough the tubing by means of a cable or pushed throughthe tubing by means of pipe string or rod.
The method according to the invention can also beused to expand tubings that are used outside a wellbore,for example to expand oilfield tubulars at surface 10 010949 facilities or to expand a tubing inside an existingtubing which has been damaged or corroded.
The invention will now be further described on thebasis of the following comparative experiments.
Experiment 1
An expansion mandrel having a conical ceraraic surface(semi top angle A of cône = 20°) was moved through aconventional oil field tubular, known as casing grade L8013% Cr, which is a widely used casing type, having aninitial outer diameter of 101.6 mm (4"), an initial wallthickness of 5.75 mm, a burst pressure of 850 bar and astrain hardening exponent n = 0.075. The expansionmandrel was designed such that the outer diameter of theexpanded tubular would be 127 mm, so that the increase indiameter would be 20%. The tubular burst during theexpansion process. Analysis showed that the ductilitylimit of the material had been exceeded so that ductilefracturing occurred.
Experiment 2
An experiment was carried out with a coiled tubing ofthe type QT-800 which is increasingly used as a pro-duction tubing in oil or gas wells. The tubing had aninitial outer diameter of 60.3 mm, a wall thickness of5.15 mm, a burst pressure of 800 bar and a strainhardening exponent n = 0.14. An expansion mandrel wasmoved through the tubing which mandrel comprised aconical ceramic surface such that the semi top angle A ofa cône enveloping the conical surface was 5° and whichwas designed such that the outer diameter of the expandedtubing would be 73 mm (increase of about 21%). Thistubing burst during the expansion process. Analysisrevealed that due to high friction forces the expansion 11 010949 pressure had exceeded the burst pressure of the pipeduring the expansion process.
Experiment 3
An experiment was carried out with a seemless pipe5 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 astrain hardening exponent n = 0.175.
An expansion mandrel was pumped through the pipe, 10 which mandrel comprised a ceramic conical surface such that the semi top angle A of a cône enveloping theconical surface was 20° and such that the outer diameterof the expanded pipe was 127 mm (5") and the outerdiameter increased by 21%. 15 The pipe was expanded successfully and the hydraulic pressure exerted to the mandrel to move the mandrelthrough the pipe was between 275 and 300 bar. The burstpressure of the expanded pipe was between 520 and530 bar.

Claims (16)

  1. >025 PCT 010949 C L A I M S
    1. A method of expanding a Steel tubing (4) which ismade of a formable Steel grade, the method comprising thestep of moving an expansion mandrel (5) having a taperingexpansion section (6) through the tubing (4) therebyplastically expanding the tubing, characterized in thatan at least partly solid tubing (4) is expanded which ismade of a formable steel grade which is subject to strainhardening without incurring any necking and ductilefracturing as a result of the expansion process and thatthe tapering expansion section (6) of the expansionmandrel (5) has a tapering ceramic outer surface.
  2. 2. The method of claim 1, wherein the tubing (4) is madeof a formable steel grade having a yield strength-tensilestrength ratio which is lower than 0.8 and a yieldstrength of at least 275 MPa.
  3. 3. The method of claim 1 or 2, wherein the tubing (4) ismade of a steel having a yield strength-tensile strengthratio which is between 0.6 and 0.7.
  4. 4. The method of claim 1, 2 or 3, wherein the tubing (4)is made of a dual phase (DP) high-strength low alloy(HSLA) steel.
  5. 5. The method of claim 4, wherein the tubing (4) is madeof Sollac grade DP55 or DP60 having a tensile strength ofat least 550 MPa or Nippon grade SAFH 540 D or SAFH 590 D.
  6. 6. The method of claim 1, 2 or 3 wherein the tubing (4)is made of a formable high-strength steel grade which isselected from the following group of steel grades: an ASTM A106 high-strength low alloy (HSLA) seamlesspipe; an ASTM A312 austenitic stainless steel pipe, gradeTP 304 L; 13 010949 an ASTM A312 austenitic stainless Steel pipe, gradeTP 316 L; and a high-retained austenite high-strength hot rolledSteel which is known as TRIP Steel.
  7. 7. The method of any preceding claim, wherein the tubingis expanded such that the external diameter of theexpanded tubing is at least 20% larger than the externaldiameter of the unexpanded tubing (4) and wherein thestrain hardening exponent n of the formable Steel of .thetubing (4) is at least 0.16.
  8. 8. The method of any preceding claim, wherein theexpansion mandrel (5) comprises a tapering expansionsection (6) which has a smooth ceramic outer surfacewhich is oriented at an acute angle A which is between 5°and 45° with respect to a longitudinal axis of themandrel (5) and which induces the tubing (4) to expandwithout inducing any galling of the tubing and such thatthe average roughness of the inner surface of the tubing(4) decreases as a resuit of the expansion process.
  9. 9. The method of claim 8, wherein the ceramic outersurface of the tapering expansion section (6) is made ofzirconium oxide and is oriented at an acute angle A whichis between 15° and 30° with respect to a longitudinalaxis of the mandrel (5).
  10. 11. The method of any preceding claim, wherein the tubing(4) is expanded by pumping the expansion mandrel (5)t’nrough the tubing (4) .
  11. 12. The method of claim 7 and 11, wherein the expansionmandrel (5) comprises a sealing section (7) which islocated at such a distance from the expansion section (6)that when the expansion mandrel (5) is pumped through thetubing (4) the sealing section (7) engages a plasticallyexpanded part of the tubing.
  12. 13. The method of claim 11 or 12, wherein the tubing (4)is expanded inside an underground borehole and the 010949 expansion mandrel (5) contains a vent line (8) forventing any fluids that are présent in the tubing (4)ahead of the expansion mandrel (5) to the surface.
  13. 14. The method of claim 11 or 12, wherein the tubing (4)is expanded inside an underground borehole such that theouter diameter (D2) of the expanded tubing (4) isslightly smaller than the internai diameter of theborehole or of any casing (2) that is présent in theborehole and any fluids that are présent in the boreholeand tubing (4) ahead of the expansion mandrel are ventedto surface via the annular space that remains open aroundthe tubing (4) after the expansion process.
  14. 15. The method of any preceding claim, wherein the tubing(4) is lowered into an underground borehole after reelingthe tubing from a reeling drum.
  15. 16. A well provided with a tubing (4) which is expandedusing the method of any preceding claim, wherein thetubing (4) serves as a production tubing through whichhydrocarbon fluid is transported to the surface and areelable service and/or kill line passes through at leasta substantial part of the length of the interior of thetubing (4), through which line fluid can be pumpedtowards the bottom of the borehole while hydrocarbonfluid is produced via the surrounding production tubing(4) .
  16. 17. A well provided with a tubing (4) which is expandedusing the method according to any one of daims 1-13,wherein the tubing is expanded against the inner surfaceof a casing (2) which is présent in the borehole.
OA9800252A 1996-07-01 1998-12-31 Method for expanding a steel tubing and well with such a tubing OA10949A (en)

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EP96201809 1996-07-01

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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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