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Well Control Asia Pacific Well Control Asia Pacific -- Conference & ExhibitionConference & Exhibition

Expandable Liner Hangers: new technology for Expandable Liner Hangers: new technology for reducing pressure drop during circulating and reducing pressure drop during circulating and cementing operations in Ecuador.cementing operations in Ecuador.

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OverviewOverview

LinerHangersLinerHangers

ExpandableLinerHangerTechnologyExpandableLinerHangerTechnology

Field Results Obtained in Ecuador Using DifferentModels of ExpaField Results Obtained in Ecuador Using DifferentModels of Expandable Linerndable LinerHangersHangers

EcuadorFieldResultsReproducedUsingCommercialSimulatorsEcuadorFieldResultsReproducedUsingCommercialSimulators

ConclusionsConclusions

AcknowledgmentsAcknowledgments

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Caseoffopenholemorerapidly.Caseoffopenholemorerapidly.Casingtakesalongtimetorun,drillpipetakesless.

Completewellswithlessweightlandedonwellheads.Completewellswithlessweightlandedonwellheads.Casingweighsalot.Wellheadshaveafiniteloadlimit.

Provideimprovedcementjobsandpreventlostcirculation.Provideimprovedcementjobsandpreventlostcirculation.Cementing past long strings of pipe can cause high pressure at the bottom of thecasing.Thiscancausetheformationtobreakdown.Lesscasing,lesspressure.

Permitdrillingwithatapereddrillstring.Permitdrillingwithatapereddrillstring.Fordeepwells,thebiggerthedrillpipethebetter.

RigCapacityRigCapacityRigs,canonlyholdsomuch.Lessweight,loweroperationalrisks.

Economics.Economics.Casingcostsmoney!

Typical Reasons for Running LinersTypical Reasons for Running Liners

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UsedtoUsedtohanghang thelinerintheexistingcasing.thelinerintheexistingcasing.

Supportsthelinerload.Supportsthelinerload.

Preventsthelinerfromgoingintocompression.Preventsthelinerfromgoingintocompression.

Allowslinertobecementedifnecessary.Allowslinertobecementedifnecessary.

Canbecombinedwithalinerpacker.Canbecombinedwithalinerpacker.

Liner HangersLiner Hangers

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MechanicalMechanicalActuatedbyrightorlefthandrotationofthedrillpipe.

Typicallyrunonverticalwells.

HydraulicHydraulicActuatedbypressure.

Typicallyrunonhorizontalwellsordirectionalwells.

ExpandableExpandableIncreasedbypassareaduetosmallerODofthesystem.IncreasedbypassareaduetosmallerODofthesystem.

Nomovingmechanismsintheannulus.Hydraulicbalanced.Nomovingmechanismsintheannulus.Hydraulicbalanced.

Canbewashed/reamed/drilledtodepth.Canbewashed/reamed/drilledtodepth.

TopDownexpansionofhangerandpacker.TopDownexpansionofhangerandpacker.

ConfirmationthathangerissetandrunningtoolreleasedpriorConfirmationthathangerissetandrunningtoolreleasedpriortocementing.tocementing.

Types of Liner HangersTypes of Liner Hangers

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Abletorotateordrillinaliner.Abletorotateordrillinaliner.

BiggerbyBiggerbypassarea.passarea.

Abletohanglinerandreleasefromlinerpriortocementation.Abletohanglinerandreleasefromlinerpriortocementation.

Packerissethydraulicallywithoutrelianceonplugbump.Packerissethydraulicallywithoutrelianceonplugbump.

Leverages off proven and highly successful expandablemetal sealLeverages off proven and highly successful expandablemetal sealtechnology.technology.

Pressuredifferential10Kpsiabove,7.5Kpsibelow.Pressuredifferential10Kpsiabove,7.5Kpsibelow.

TorqueRating40KftTorqueRating40Kftlbs.lbs.

Able to apply slack off to push liner into theAble to apply slack off to push liner into the wellborewellbore (200 K(200 Kcompression).compression).

Canbewashed,reamed,andevendrilledtosettingdepth.Canbewashed,reamed,andevendrilledtosettingdepth.

Plugbumpdesiredbutnotimperativetosuccess.Plugbumpdesiredbutnotimperativetosuccess.

Verifyreleaseofrunningtoolpriortopumpingcement.Verifyreleaseofrunningtoolpriortopumpingcement.

Setlinertoppackeraftercementjob.Setlinertoppackeraftercementjob.

Expandable Liner HangerExpandable Liner Hanger TechnologyTechnology

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Expandable Liner HangerExpandable Liner Hanger TechnologyTechnology

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Expandable HangerExpandable Hanger Technology: byTechnology: by--pass area developmentpass area development

OriginalBypassarea Firstimprovement

Bypassarea

CurrentBypassarea

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Flow Area Comparison: two designs of expandable slipsFlow Area Comparison: two designs of expandable slips

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Field Results (Ecuador) Field Results (Ecuador) -- two different hanger designs two different hanger designs

Well

#

Wellname Date Hangerbeforeset

(PSI@10BPM)

Hangerafterset

(PSI@10BPM)1 EdenYuturiJ83 29Oct08 1200 17002 YanaquinchaEsteA11 7Dic08 1050 19003 YanaquinchaEsteA12 6Ene09 1250 18004 EdenYuturiJ84 16Ene09 1200 17505 EdenYuturiD85 23Feb09 1200 18156 YanaquinchaEsteA13 02Mar09 1150@7Bpm 1550@6Bpm7 JivinoA16 12Mar09 1150 14908 EdenYuturiB10 14Mar09 1460 18759 EdenYuturiD86 21Mar09 850 137510 YanaquinchaEsteA14 2Abr09 1100 160011 JivinoA17 8Abr09 980 180012 EdenYuturiD87 12Abr09 960@8.5Bpm 980@8.5Bpm13 EdenYuturiA99 05May09 1350 145014 JivinoA18 07May09 850 100015 EdenYuturiD88 08May09 1100 118016 YanaquinchaEsteA15 09May09 1500 155017 EdenYuturiD89 30May09 1170 120018 JivinoA19 05Jun09 1020 108419 Dumbique2I 12Jun09 1800 190020 EdenYuturiD90 17Jun09 1250 127521 LagunaA13 10Jul09 1000 120022 EdenYuturiD113 18Jul09 1050 110023 Limoncocha31 14Aug09 1350 150024 Limoncocha32 09Sep09 1200 1400

OperationalconditionsinPetroAmazonas(Wells).Duringexpandableliner hangerinstallations

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Statistical ResultsStatistical Results

DifferentialPressure(setandunsetExapandablelinerHanger).Pumping@10BPMPetroAmazonasWells(Fielddata)

0

100

200

300

400

500

600

700

800

900

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Wellnumber

Differentialpressurebe

tweensetandun

sete

xpandablelinerhanger

StandardandoldExpandableLinerHanger

NewmodelExpandableLinerHanger

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Expandable Liner Hanger Running SequenceExpandable Liner Hanger Running Sequence

RIH,circulateandcleanthehole.RIH,circulateandcleanthehole.Dropsettingball,pressureupDropsettingball,pressureup

FirstStroketosetthehangerFirstStroketosetthehangerReleasesettingtoolReleasesettingtoolBlowoutsettingballBlowoutsettingballResettoolforsecondStrokeResettoolforsecondStroke

Checkthattoolisreleased.Checkthattoolisreleased.Pump&cement,monitorforplugsbumpPump&cement,monitorforplugsbumpApplypressureforsecondstroketosetpackerApplypressureforsecondstroketosetpackerPickuptoolabovelinertopandproceedtotestPickuptoolabovelinertopandproceedtotestthesealthesealPulloutofholewiththerunningtoolPulloutofholewiththerunningtool

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Expandable Liner Hanger Packer SpecificationsExpandable Liner Hanger Packer Specifications

Linersize (in.)

LinerWeightRange(lb/ft)

Casingsize(in.)

CasingWeightRange(lb/ft)

SettingPressure(psi)

MaximumOD(in.)

MinimumOD (in,)

5.000 1518 7 2629 4,500 5.813 4.2237.000 2635 3,000 8.250 6.1887.625 29.739 4,000 8.344 6.820

9.625 4753.5

ExpandableLinerHangerSpecifications

80KsiExtension

125KsiExtension

80KsiExtension125Ksi

Extension7"26#/ft 3.5 57"29#/ft 2.6 2.7 2.6 4.1

95/8"47#/ft95/8"53.5#/ft95/8"47#/ft95/8"53.5#/ft 3.5

BypassAreaUnset(in.2)

5.000

7.000

7.6253.7 4.5

2.8

6.5 6.95

Set(in.2)Casing

Size/WeightLinersize(in.)

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Expandable Liner Hanger Packer SpecificationsExpandable Liner Hanger Packer Specifications (Cont(Contd)d)

Size(in.)Pressure

Ratingfromabove(psi)

PressureRatingfrombellow(psi)

Temperature OperatingRange(F)

5x7 11,500 10,5007x9.625

7.625x9.62510,000

3007,500

LinerHangerSeal

Size(in.) Material Burst(psi)Yield

Collapse(psi)

TensileRating(lb)

5x7 12,343 11,391 453,6107x9.625 10,415 9,737 664,558

7.625x9.625 125KsiMYS 14,434 13,600 1,033,547

80KsiMYS

HangerBody

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Typical Cementing Program (Typical Cementing Program (PetroAmazonasPetroAmazonas))

Pump5bbltofilllinesPump5bbltofilllinesTestcementlines6000psiTestcementlines6000psiPump30bblcasingCleanPump30bblcasingCleanPump5bblofwaterPump5bblofwaterPump30bblofcasingcleanPump30bblofcasingcleanCirculateuntilcleanreturnsCirculateuntilcleanreturnsMixleadslurry+/Mixleadslurry+/ 1515ppgppgPumpMudplussurfactant30bblPumpMudplussurfactant30bblPumpcasingclean30Pumpcasingclean30BlsBls @5@5bpmbpmPumpfreshwater5bblPumpfreshwater5bblPumpCleanmud12PumpCleanmud12ppgppg @5@5bpmbpmPumpcleanmud110Pumpcleanmud110BlsBls 1212ppgppgPumpleadslurry14Pumpleadslurry14ppgppg @5@5bpmbpmPumptailslurry15.5Pumptailslurry15.5ppgppg @5@5bpmbpmReleaseplugReleaseplugDisplacewithmudat10Displacewithmudat10bpmbpmCheckforplugbumpCheckforplugbump

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Obtain information

about: Survey,detailed well

schematic, BHA,circulating fluids, etc.

Determine coefficientof discharge (Cd),

taking into accountliner hanger

configuration andfield data.

Obtain realinformation (fielddata associated topressure drop) for

calibrating thesimulation model.

Reproduce field dataand validate Cd for

the specificcompletion and BHA

configuration.

Predict possiblepressure drop throughthe system taking intoaccount the new flowarea and circulating

fluids.

Pressuredroppredictionthroughexpandablelinerhanger,duringcirculating

operations.

Concludeaboutresults

Process Followed for Reproducing Field Results (Ecuador) Process Followed for Reproducing Field Results (Ecuador)

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Field Results Reproduced Using Commercial Simulator Field Results Reproduced Using Commercial Simulator

RateGal/min

RateBls/min

Realpressure(psig)*

Simulatedpressure(psig)**

168 4 150 254252 6 860 561336 8 990 990420 10 1650 1540504 12 2200 2200

*Realpumpingpressure(fielddata)**SimulatedpumpingpressureEquivalentflowarea(3.9sq.in).(Hangerhasbeenset)Drillingfluidweight 10.5ppg

Pumpingconditions

Resultscomparison.PressuredropdeterminationduringcirculatingoperationsusingconventionalLinerHanger.

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Pumpingpressureduringwellcirculating processusing conventionalHangerComparison between realandsimulationdata(10.5ppg completionfluid)

0

250

500

750

1 000

1 250

1 500

1 750

2 000

2 250

2 500

2 4 6 8 10 1 2 14

Pumpingra te (Bls/min )

Pum

ping

pressure(psig)

Real data Simu lat edresults (3 .9 in2)

Field Results Reproduced Using Commercial Simulator Field Results Reproduced Using Commercial Simulator

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Pumpingpressurecomparison(simulated)usingnewexpandablelinerhanger

(16.5ppgcompletionfluid)

0

250

500

750

1000

1250

1500

1750

2000

2250

2500

2750

3000

3250

3500

3750

4000

0 1 2 3 4 5 6 7 8 9 10 11 12 13

Pumpingrate(Bls/min)

Pumpingpressure(psig)

3.9in2equivalentflowarea 6.5in2equivalentflowarea

Field Results Reproduced Using Commercial Simulator Field Results Reproduced Using Commercial Simulator

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ConclusionsConclusions

There isa reduction inpressuredropduring cementingoperationThere isa reduction inpressuredropduring cementingoperationsusingsusingnew model of expandable liner hanger versus traditional and oldnew model of expandable liner hanger versus traditional and oldexpandablelinerhangersmodels.expandablelinerhangersmodels.

Documented reduction inpressuredropduring cementing jobshasDocumented reduction inpressuredropduring cementing jobshas beenbeenabove400psiapproximately(average)whencirculating@10BPMabove400psiapproximately(average)whencirculating@10BPMusingusingthenewExpandableLinerHanger.thenewExpandableLinerHanger.

Usingcommercialsoftware itwaspossibletoreproducefieldresUsingcommercialsoftware itwaspossibletoreproducefieldresults.Thisults.Thismethodology isbeingused forpredictingpossiblebehaviorandpmethodology isbeingused forpredictingpossiblebehaviorandplanninglanningactionsbeforeexpandablelinerhangerinstallations.actionsbeforeexpandablelinerhangerinstallations.

Optimumdesignmustconsidercirculatingareaof tiebackextensOptimumdesignmustconsidercirculatingareaof tiebackextensionandionandlinerhanger.linerhanger.

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Conclusions (contConclusions (contd)d)

Pressure drop results obtained during cementing circulation jobsPressure drop results obtained during cementing circulation jobs, using, usingexpandable liner hangers, depends on the liner configuration andexpandable liner hangers, depends on the liner configuration and wellwellsurvey.Inthissense,thecoefficientofdischargecalculated isurvey.Inthissense,thecoefficientofdischargecalculated ineachcase,neachcase,during the simulation process, could be adjusted for other linerduring the simulation process, could be adjusted for other linerconfigurations.configurations.

Forotherapplicationssuchaslinerdrill/reamdownoperations,Forotherapplicationssuchaslinerdrill/reamdownoperations, thisstudythisstudymay help to predict down hole conditions and to avoid operationamay help to predict down hole conditions and to avoid operationallproblemsduepressurespikesorreducedflowarea.problemsduepressurespikesorreducedflowarea.

This study helps to understand changes in pressure behavior in lThis study helps to understand changes in pressure behavior in linerinerhangerinstallations,duringfluiddisplacementacrossdifferenthangerinstallations,duringfluiddisplacementacrossdifferent flowareasflowareasimprovingcementedjobconditions.improvingcementedjobconditions.

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Acknowledgement Acknowledgement

WithWith PetroAmazonasPetroAmazonas personnel support and usingpersonnel support and using PetroAmazonasPetroAmazonas wellswellswaspossibletooptimizebypassareaofexpandablelinerhangerwaspossibletooptimizebypassareaofexpandablelinerhangers.s.

Currentlyoptimalbypassarea(takingintoaccountengineering,Currentlyoptimalbypassarea(takingintoaccountengineering, HS&EandHS&Eandcustomertechnicalcriteria),is6.5incustomertechnicalcriteria),is6.5in22 afterset.afterset.

Pressure drop reduction during circulating operations were documPressure drop reduction during circulating operations were documentedentedusingrealwells(usingrealwells(PetroAmazonasPetroAmazonas)underrealoperationalconditions.)underrealoperationalconditions.

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