IADC/SPE 87212 New Expandable Cladding Technique Enables Extended Length Casing Repair

Matthew Jabs, Baker Oil Tools, Charles E. Harmon, C.E. Harmon Oil Inc.; Steve C. Harmon, C.E. Harmon Oil Inc.; Robert E. Harmon, C.E. Harmon Oil Inc.

Copyright 2004, IADC/SPE Drilling Conference This paper was prepared for presentation at the IADC/SPE Drilling Conference held in Dallas, Texas, U.S.A., 24 March 2004. This paper was selected for presentation by an IADC/SPE Program Committee following review of information contained in a proposal submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the International Association of Drilling Contractors or Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the International Association of Drilling Contractors or Society of Petroleum Engineers, their officers, or members. Papers presented at IADC/SPE meetings are subject to publication review by Editorial Committees of the International Association of Drilling Contractors and Society of Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the International Association of Drilling Contractors and Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300 words; illustrations may not be copied. The proposal must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435

Abstract In June 2003 a project in south central Oklahoma incorporated the first use of an expandable metal casing patch technology to repair a damaged well bore casing section. The cladding was deployed to correct a casing collapse problem that occurred when an offset injector well went online and caused the existing casing to fail. The well has been an oil producer and was originally drilled in the early 1950s. This technology provides the operator with the ability to create a definitive casing repair with pressure integrity and minimal well restriction. Background The SE Velma Sims Unit is located in Carter County, Okla., along the prolific Velma trend in Sho-Vel-Tum field, in the transitional area between the Anadarko and Ardmore Basins. The Sims sand was unitized in June 1965 for gas injection operations, with Conoco elected as operator. The SEVSU underlies both the SE Velma Humphreys Sand Unit (SEVHU), operated by C. E. Harmon Oil, Inc. and the Velma Camp Deese Unit (VCDU), operated by Lamamco Drilling Co. Conoco sold their interest in the SEVSU, effective January 1, 1996, and C. E. Harmon Oil, Inc. became the unit operator. Crestal gas injection was used from 1965 to 1978, with updip wells converted to injectors and downdip wells for producers. Increased recoveries were experienced by many wells in the unit. However, with increasing gas prices in the mid to late 1970s, several water injection pilots were initiated in the SEVSU. The response from water injection was favorable, and gas injection was discontinued in 1978. There are currently 25 active producers, 5 water injectors and no inactive wells in the SEVSU.

The first infill water injection well, SEVSU #152, was drilled in 1972. A total of ten infill wells have been drilled in the SEVSU. The infill wells are positioned in the mid-structure locations along the entire length of the unit, so that the central portion of the NW-SE trending Sims sands are developed on less than 10 acre spacing. Water injection operations in the SEVSU were fully expanded from 1978 to 1984, after gas injection operations were terminated. Waterflooding has been successful in the southern-most fault block in the unit. However, due to the complex stratigraphy and faulted nature causing compartmentalization in the Sims, waterflooding in other parts of the unit has had mixed results. A new injection well was added in April, 1998, with conversion of SEVSU #163 from production to injection. Response has been observed at offset wells SEVSU #112 and 118, which have recently received AFE approval for larger pumping equipment. This well was an oil producer which started to have excessive water productions when a offset well was turned into an injector. Log analysis showed a collapse in the casing of SEVSU #96 suspected to be caused by the increased formation pressure created by the offset injector well. The operator required a method to restore definitive casing integrity and prevent water inflow from injector. The correction further had to allow a submersible pump unit to pass through, therefore maintaining internal diameter (ID) was essential. New Expandable Cladding Technique The solution was a new expandable cladding technique by Baker Oil Tools that enables extended length casing repair and would allow max ID after placed in the wellbore as well as a definitive pressure integrity seal of the annulus area. The casing would be relined with a metal support structure -- a casing inside of casing. This system would allow the placement of a .25 thick metal cladding section that would result in an approximately .50 reduction in wellbore ID after placement. The cladding would provide a collapse rating of over 2,500 psi with a definitive nitril/metal seal at the top and bottom sections. The system is deployed and expanded utilizing an innovative hydraulic piston/anchor system that allows flexibility in the length of the deployed clad from short sections to unlimited lengths. The cladding was secured to the host casing via a top and bottom seal section which incorporated nitril rubber elements and profile grooves which anchor the clad material when expanded to the ID of the host casing.

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IADC/SPE 87212

The cladding system is made up of modular sections that are threaded together to allow the length of the cladding assembly to be tailored to the applications. (Fig. 1) The cladding itself is made up of .25 thick metal sleeve manufactured from ERW steel material. Mechanical properties can be compared to an L-80 equivalent casing after expansion. The sections of cladding can be made to any length, but for commercial applications 20ft and 40ft sections have been produced. These sections are anchored and sealed to the host casing by a top and bottom section. The anchor/seal sections contain a nitril sealing element and a machined profile that secure and seal the cladding when expanded against the ID of the host casing. The system is assembled much like conventional tubing or casing string, using rig floor slips, lifting subs, and make up tongs. The running process for the clad system is as follows: pick up lower anchor/seal section and secure in slips with safety collar, pick clad pipe section with lift subs and thread/torque to seal/anchor section, pick up remaining clad pipe section repeating process until desired length of cladding has been run, pick up top anchor/seal section and attach to clad section, pick up running/expansion tool and lock into top anchor/seal section, run cladding to depth via tool on drill pipe. Field Deployment The process for deploying the clad consisted of a drift run to make sure the well was clean of obstructions and then set of a bridge plug to keep the well full of fluid. The cladding was assembled as previously outlined and hung off in the rig floor. The running tool was then retrieved and stabbed into the tool and secured. The clad and running/expansion tool was then run to setting depth. The tool was run to depth with the ball on seat. At depth, pressure was applied to the assembly to begin expanding the clad. (Fig. 2) The expansion/running tool is a hydraulically activated operated system. When pressure is applied to the system via drill pipe ID a hydraulic anchor is activated which secures the tool in the wellbore. As pressure builds, the hydraulic piston begins to move, driving an expansion cone connected to it through the cladding expanding it outwards. When the piston has moved a full stroke, pressure release valves are tripped, which allows the pressure to drop, giving a surface indication that the tool stroke has been completed. The remaining pressure is bled off, which releases the securing anchor, and the drill string is lowered to close the piston. The cycle is repeated as needed to expand the given length cladding. The first cycle of the tool drives the expansion cone through the top section of the cladding which contains the nitrile sealing elements and machined profile, which grips the ID of the host casing. This secures and seals the top of the cladding to the wellbore. This allows the running/expansion tool to automatically release from the cladding during the first stroke while preventing the rest of the unexpanded cladding from sliding down hole. With the tool released from the cladding the tool has the ability to be recycled as needed to fully expand the cladding. Rig site set up consisted of using a skid mounted pump unit connected to the drill pipe via a power swivel unit. Due to the length of the cladding being deployed, a power swivel unit with a 5,000 psi high pressure flex line was employed to

facilitate faster workover string connection and easier work site operations. An air operated pressure bleed off actuator was placed in the pressure line to further increase efficiency. Final project results yielded 675ft of expandable metal cladding installed inside 7 casing with the expansion process completed in 3-1/2 hours. The clad was deployed at a starting depth of approx. 3,800ft 7 20# vertical well section with an ending depth of approx. 4,475ft in heavier 23# weight casing. (Fig. 3) A Baker Centrilift Slimline 3.75 DD submersible pump with a 4.5 shroud was run in SEVSU #96. A production test on September 6, 2003 was 24 BOPD with 1,217 BWPD. Conclusion Since the introduction of this technology multiple deployments of this system have been conducted. Applications have ranged from similar casing support to blanking off water inflow sections of perforated zones. Future developments revolve around the use of adjustable cones that will allow the fusing of the clad to the host casing for the complete ID length and different casing sizes. Acknowledgments Charles E. Harmon, President of C.E. Harmon Oil Inc. and SPE Member Steve C. Harmon, Senior Engineer and SPE Member Robert E. Harmon, Senior Geologist

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Running Sleeve, Top Anchor/Seal

Clad

Bottom Anchor/Seal

Fig. 1 Cladding System Basic Components

Fig. 2 Cladding Expansion Process

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IADC/SPE 87212

Fig. 3 Final Wellbore Configuration

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ESP