Expandable Drillable Shoe Sequential Cone Expansion
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Solution Overview
Problem
In the oil and gas industry, the removal of unexpanded portions and shoe assemblies from expandable tubulars often requires multiple trips and complex tools, increasing the time needed to prepare the wellbore for drilling operations.
Innovation Solution
An expansion system comprising an adjustable cone assembly, a solid cone assembly, and a piston assembly, which allows for sequential expansion of the expandable tubular by shifting the adjustable cone assembly from a retracted to an expansion position, minimizing the external diameter before expansion and simplifying the drill-out process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If the expandable tubular is expanded to full diameter, then the wellbore preparation is complete, but the unexpanded portion creates a diametrical constriction that requires multiple trips and complex tools for removal
Solution Approach 1:
The expansion system is divided into multiple cone assemblies (first and second cone assemblies) that can expand different sections of the expandable tubular independently. This segmentation allows the unexpanded portion to be minimized or eliminated, removing the need for complex removal tools and multiple trips.
Solution Approach 2:
The cone assemblies are designed to be movable and adjustable within the expandable tubular. The cones can be positioned at different locations and expanded at different times, allowing dynamic control over which portions of the tubular are expanded. This dynamic capability enables optimization of the expansion process to eliminate constriction issues.
2Ease of operation
If multiple trips are made for milling and fishing operations, then the shoe assembly and unexpanded portion are removed, but the time required for wellbore preparation increases
Solution Approach 1:
The system performs preliminary expansion of the tubular sections before removal operations are needed. By expanding the tubular to the necessary diameter during the initial installation process, the need for subsequent milling and fishing operations is eliminated or minimized, saving significant time.
Solution Approach 2:
The expansion and removal functions are merged into a single integrated process. The cone assemblies not only expand the tubular but also facilitate their own removal by leaving minimal or no unexpanded portion, combining what were previously separate operations into one efficient process.
3Ease of manufacture
If the unexpanded portion is left in the wellbore, then the expansion process is simplified, but a diametrical constriction is created that must be removed
Solution Approach 1:
Different sections of the expandable tubular are expanded to different diameters based on local requirements. The cone assemblies can be positioned to expand only the specific sections that need to be expanded, leaving other sections unexpanded if needed, or expanding all sections to eliminate constriction issues entirely.
Data Source
AI summary
An expansion system is assembled by coupling a piston assembly and a solid cone assembly to an adjustable cone assembly within an expandable tubular having inner sleeve disposed in a portion thereof. The expansion system is run into a wellbore. The piston assembly is activated to move the solid cone assembly downward through the inner sleeve so as to expand the inner sleeve and the portion of the expandable tubular having the inner sleeve. The adjustable cone assembly is shifted from a retracted position to an expansion position within the inner sleeve. The adjustable cone assembly is moved upward through expandable tubular while leaving the solid cone assembly and the inner sleeve coupled to expandable tubular. The solid cone assembly and the inner sleeve may be drilled or milled.