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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
Liner Hangers Liner Hangers
Expandable Liner Hanger TechnologyExpandable Liner Hanger Technology
Field Results Obtained in Ecuador Using Different Models of ExpaField Results Obtained in Ecuador Using Different Models of Expandable Liner ndable Liner HangersHangers
Ecuador Field Results Reproduced Using Commercial Simulators Ecuador Field Results Reproduced Using Commercial Simulators
ConclusionsConclusions
AcknowledgmentsAcknowledgments
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Case off open hole more rapidly.Case off open hole more rapidly.Casing takes a long time to run, drill pipe takes less.
Complete wells with less weight landed on wellheads.Complete wells with less weight landed on wellheads.Casing weighs a lot. Wellheads have a finite load limit.
Provide improved cement jobs and prevent lost circulation.Provide improved cement jobs and prevent lost circulation.Cementing past long strings of pipe can cause high pressure at the bottom of the casing. This can cause the formation to breakdown. Less casing, less pressure.
Permit drilling with a tapered drill string.Permit drilling with a tapered drill string.For deep wells, the bigger the drill pipe the better.
Rig CapacityRig CapacityRigs, can only hold so much. Less weight, lower operational risks.
Economics.Economics.Casing costs money!
Typical Reasons for Running LinersTypical Reasons for Running Liners
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Used to Used to ““hanghang”” the liner in the existing casing. the liner in the existing casing.
Supports the liner load.Supports the liner load.
Prevents the liner from going into compression.Prevents the liner from going into compression.
Allows liner to be cemented if necessary.Allows liner to be cemented if necessary.
Can be combined with a liner packer. Can be combined with a liner packer.
Liner HangersLiner Hangers
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MechanicalMechanicalActuated by right or left hand rotation of the drill pipe.
Typically run on vertical wells.
HydraulicHydraulicActuated by pressure.
Typically run on horizontal wells or directional wells.
ExpandableExpandableIncreased bypass area due to smaller OD of the system.Increased bypass area due to smaller OD of the system.
No moving mechanisms in the annulus. Hydraulic balanced.No moving mechanisms in the annulus. Hydraulic balanced.
Can be washed/reamed/drilled to depth.Can be washed/reamed/drilled to depth.
Top Down expansion of hanger and packer.Top Down expansion of hanger and packer.
Confirmation that hanger is set and running tool released prior Confirmation that hanger is set and running tool released prior to cementing.to cementing.
Types of Liner HangersTypes of Liner Hangers
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Able to rotate or drill in a liner. Able to rotate or drill in a liner.
Bigger byBigger by‐‐pass area.pass area.
Able to hang liner and release from liner prior to cementation.Able to hang liner and release from liner prior to cementation.
Packer is set hydraulically without reliance on plug bump.Packer is set hydraulically without reliance on plug bump.
Leverages off proven and highly successful expandable metal sealLeverages off proven and highly successful expandable metal sealtechnology.technology.
Pressure differential 10Kpsi above, 7.5Kpsi below.Pressure differential 10Kpsi above, 7.5Kpsi below.
Torque Rating 40KftTorque Rating 40Kft‐‐lbs.lbs.
Able to apply slack off to push liner into the Able to apply slack off to push liner into the wellborewellbore (200 K (200 K compression).compression).
Can be washed, reamed, and even drilled to setting depth.Can be washed, reamed, and even drilled to setting depth.
Plug bump desired but not imperative to success.Plug bump desired but not imperative to success.
Verify release of running tool prior to pumping cement.Verify release of running tool prior to pumping cement.
Set liner top packer after cement job.Set liner top packer after cement job.
Expandable Liner HangerExpandable Liner Hanger TechnologyTechnology
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Expandable HangerExpandable Hanger Technology: byTechnology: by--pass area developmentpass area development
OriginalBy‐pass area First improvement
By‐pass area
CurrentBy‐pass area
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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
#
Well name Date Hanger before set
(PSI @ 10 BPM)
Hanger after set
(PSI @ 10 BPM)1 Eden Yuturi J‐83 29‐Oct‐08 1200 17002 Yanaquincha Este A‐11 7‐Dic‐08 1050 19003 Yanaquincha Este A‐12 6‐Ene‐09 1250 18004 Eden Yuturi J‐84 16‐Ene‐09 1200 17505 Eden Yuturi D‐85 23‐Feb‐09 1200 18156 Yanaquincha Este A‐13 02‐Mar‐09 1150 @ 7 Bpm 1550 @ 6 Bpm7 Jivino A‐16 12‐Mar‐09 1150 14908 Eden Yuturi B‐10 14‐Mar‐09 1460 18759 Eden Yuturi D‐86 21‐Mar‐09 850 137510 Yanaquincha Este A‐14 2‐Abr‐09 1100 160011 Jivino A‐17 8‐Abr‐09 980 180012 Eden Yuturi D‐87 12 Abr‐09 960 @ 8.5 Bpm 980 @ 8.5 Bpm13 Eden Yuturi A‐99 05‐May‐09 1350 145014 Jivino A‐18 07‐May‐09 850 100015 Eden Yuturi D‐88 08‐May‐09 1100 118016 Yanaquincha Este A‐15 09‐May‐09 1500 155017 Eden Yuturi D‐89 30‐May‐09 1170 120018 Jivino A‐19 05‐Jun‐09 1020 108419 Dumbique 2I 12‐Jun‐09 1800 190020 Eden Yuturi D‐90 17‐Jun‐09 1250 127521 Laguna A‐13 10‐Jul‐09 1000 120022 Eden Yuturi D‐113 18‐Jul‐09 1050 110023 Limoncocha 31 14‐Aug‐09 1350 150024 Limoncocha 32 09‐Sep‐09 1200 1400
Operational conditions in PetroAmazonas (Wells). During expandable liner hanger installations
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Statistical ResultsStatistical Results
Differential Pressure (set and unset Exapandable liner Hanger). Pumping @ 10 BPM PetroAmazonas Wells (Field data)
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
Well number
Differential pressure be
tween set and un
set e
xpandable liner hanger
Standard and old ExpandableLiner Hanger
New model ExpandableLiner Hanger
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Expandable Liner Hanger Running SequenceExpandable Liner Hanger Running Sequence
RIH, circulate and clean the hole.RIH, circulate and clean the hole.Drop setting ball, pressure upDrop setting ball, pressure up
First Stroke to set the hangerFirst Stroke to set the hangerRelease setting toolRelease setting toolBlow out setting ballBlow out setting ballReset tool for second StrokeReset tool for second Stroke
Check that tool is released.Check that tool is released.Pump & cement, monitor for plugs bumpPump & cement, monitor for plugs bumpApply pressure for second stroke to set packerApply pressure for second stroke to set packerPick up tool above liner top and proceed to test Pick up tool above liner top and proceed to test the sealthe sealPull out of hole with the running toolPull out of hole with the running tool
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Expandable Liner Hanger Packer SpecificationsExpandable Liner Hanger Packer Specifications
Liner size (in.)
Liner Weight Range (lb/ft)
Casing size (in.)
Casing Weight Range (lb/ft)
Setting Pressure (psi)
Maximum OD (in.)
Minimum OD (in,)
5.000 15 ‐ 18 7 26 ‐ 29 4,500 5.813 4.2237.000 26 ‐ 35 3,000 8.250 6.1887.625 29.7 ‐ 39 4,000 8.344 6.820
9.625 47 ‐ 53.5
Expandable Liner Hanger Specifications
80 Ksi Extension
125 Ksi Extension
80 Ksi Extension125 Ksi
Extension7" ‐ 26#/ft 3.5 57" ‐ 29#/ft 2.6 2.7 2.6 4.1
9 5/8" ‐ 47#/ft9 5/8" ‐ 53.5#/ft9 5/8" ‐ 47#/ft9 5/8" ‐ 53.5#/ft 3.5
Bypass AreaUnset (in.2)
5.000
7.000
7.6253.7 4.5
2.8
6.5 6.95
Set (in.2)Casing
Size/WeightLiner size (in.)
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Expandable Liner Hanger Packer SpecificationsExpandable Liner Hanger Packer Specifications…… (Cont(Cont’’d)d)
Size (in.)Pressure
Rating from above (psi)
Pressure Rating from bellow (psi)
Temperature Operating Range (F)
5 x 7 11,500 10,5007 x 9.625
7.625 x 9.62510,000
3007,500
Liner Hanger Seal
Size (in.) Material Burst (psi)Yield
Collapse (psi)
Tensile Rating (lb)
5 x 7 12,343 11,391 453,6107 x 9.625 10,415 9,737 664,558
7.625 x 9.625 125 Ksi MYS 14,434 13,600 1,033,547
80 Ksi MYS
Hanger Body
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Typical Cementing Program (Typical Cementing Program (PetroAmazonasPetroAmazonas))
Pump 5 bbl to fill linesPump 5 bbl to fill linesTest cement lines 6000 psiTest cement lines 6000 psiPump 30 bbl casing CleanPump 30 bbl casing CleanPump 5 bbl of waterPump 5 bbl of waterPump 30 bbl of casing cleanPump 30 bbl of casing cleanCirculate until clean returnsCirculate until clean returnsMix lead slurry +/Mix lead slurry +/‐‐ 15 15 ppgppgPump Mud plus surfactant 30 bblPump Mud plus surfactant 30 bblPump casing clean 30 Pump casing clean 30 BlsBls @ 5 @ 5 bpmbpmPump fresh water 5 bblPump fresh water 5 bblPump Clean mud 12 Pump Clean mud 12 ppgppg @ 5 @ 5 bpmbpmPump clean mud 110 Pump clean mud 110 BlsBls 12 12 ppgppgPump lead slurry 14 Pump lead slurry 14 ppgppg @ 5 @ 5 bpmbpmPump tail slurry 15.5 Pump tail slurry 15.5 ppgppg @ 5 @ 5 bpmbpmRelease plugRelease plugDisplace with mud at 10 Displace with mud at 10 bpmbpmCheck for plug bumpCheck for plug bump
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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.
Pressure drop predictionthrough expandable linerhanger, during circulating
operations.
Conclude about results
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
Rate Gal/min
Rate Bls/min
Real pressure (psig) *
Simulated pressure (psig)**
168 4 150 254252 6 860 561336 8 990 990420 10 1650 1540504 12 2200 2200
* Real pumping pressure (field data)** Simulated pumping pressureEquivalent flow area (3.9 sq. in). (Hanger has been set)Drilling fluid weight 10.5 ppg
Pumping conditions
Results comparison. Pressure drop determinationduring circulating operations using conventional Liner Hanger.
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Pumping pressure during well circulating process using conventional Hanger Comparison between real and simulation data (10.5 ppg completion fluid)
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
Pumping ra te (Bls/min )
Pum
ping
pressure (psig)
Real data Simu lat ed results (3 .9 in2)
Field Results Reproduced Using Commercial Simulator Field Results Reproduced Using Commercial Simulator
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Pumping pressure comparison (simulated) using new expandable liner hanger
(16.5 ppg completion fluid)
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
Pumping rate (Bls/min)
Pumping pressure (psig)
3.9 in2 equivalent flow area 6.5 in2 equivalent flow area
Field Results Reproduced Using Commercial Simulator Field Results Reproduced Using Commercial Simulator
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ConclusionsConclusions
There is a reduction in pressure drop during cementing operationThere is a reduction in pressure drop during cementing operations using s using new model of expandable liner hanger versus traditional and old new model of expandable liner hanger versus traditional and old expandable liner hangers models.expandable liner hangers models.
Documented reduction in pressure drop during cementing jobs has Documented reduction in pressure drop during cementing jobs has been been above 400 psi approximately (average) when circulating @ 10 BPM above 400 psi approximately (average) when circulating @ 10 BPM using using the new Expandable Liner Hanger.the new Expandable Liner Hanger.
Using commercial software it was possible to reproduce field resUsing commercial software it was possible to reproduce field results. This ults. This methodology is being used for predicting possible behavior and pmethodology is being used for predicting possible behavior and planning lanning actions before expandable liner hanger installations.actions before expandable liner hanger installations.
Optimum design must consider circulating area of tie back extensOptimum design must consider circulating area of tie back extension and ion and liner hanger.liner hanger.
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Conclusions (contConclusions (cont’’d)d)
Pressure drop results obtained during cementing circulation jobsPressure drop results obtained during cementing circulation jobs, using , using expandable liner hangers, depends on the liner configuration andexpandable liner hangers, depends on the liner configuration and well well survey. In this sense, the coefficient of discharge calculated isurvey. In this sense, the coefficient of discharge calculated in each case, n each case, during the simulation process, could be adjusted for other linerduring the simulation process, could be adjusted for other linerconfigurations.configurations.
For other applications such as liner drill/ream down operations,For other applications such as liner drill/ream down operations, this study this study may help to predict down hole conditions and to avoid operationamay help to predict down hole conditions and to avoid operational l problems due pressure spikes or reduced flow area.problems due pressure spikes or reduced flow area.
This study helps to understand changes in pressure behavior in lThis study helps to understand changes in pressure behavior in liner iner hanger installations, during fluid displacement across differenthanger installations, during fluid displacement across different flow areas flow areas improving cemented job conditions.improving cemented job conditions.
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Acknowledgement Acknowledgement
With With PetroAmazonasPetroAmazonas personnel support and using personnel support and using PetroAmazonasPetroAmazonas wells wells was possible to optimize by pass area of expandable liner hangerwas possible to optimize by pass area of expandable liner hangers.s.
Currently optimal by pass area (taking into account engineering,Currently optimal by pass area (taking into account engineering, HS&E and HS&E and customer technical criteria), is 6.5 incustomer technical criteria), is 6.5 in22 after set.after set.
Pressure drop reduction during circulating operations were documPressure drop reduction during circulating operations were documented ented using real wells (using real wells (PetroAmazonasPetroAmazonas) under real operational conditions.) under real operational conditions.