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Composite Casing Design and Method of Completion

IP.com Disclosure Number: IPCOM000237677D
Publication Date: 2014-Jul-02
Document File: 11 page(s) / 2M

Publishing Venue

The IP.com Prior Art Database

Abstract

This invention involves a composite casing made of steel-cement-steel and the process of installation while incorporating the production liner into final strength of the casing design and using of expansion and welding technologies to build monobore wellbore constructions. The composite concept uses pumpable and curable materials like cement as constructive element and is incorporating the production liner of a wellbore design into the final strength of the casing construction after final completion. The cement is supposed to take over the main compression loads as well has reinforcing components included (e.g. steel or fiber made parts taking over tensile loads, e.g. hollow ceramic, synthetic diamond or tungston balls). Advanced expansion technologies is used to build monobore wellbore tubing or reinforcing net constructions. The casing elements are set stepwise and in correlation to current operational differential pressure requirements. Step 1 – Drilling fluid in wellbore (mud) density set to compensate pore pressure. Pumping of LCM and tixotrop fluid to maintain lost zone. Restart circulation with pressure shock (small explosives). If not sufficient set thin patch on borehole wall. (e.g.folded liner on CT workstring). Step 2 – Fill up borehole with formation cement. Formation cement is soft with similar density as mud. Low density of cement e.g. adjusted with low dens balls (plastic, rubber, ceramic, hollow bodies). Good pressure distribution and sealing capability. Additional embodiment – circulate and mix cement downhole. Step 3 – Draw (with wire fixed on bottom) or push folded liner section into cement (e.g. with weight). Step 4 – Expand liner into cement until sufficient cement gap is reached. Profile liner to centralize liner and in sections if increased pressure resistance is required (e.g. in zones of particular overpressure). Additional cement and procedure features: Cement tixotropic, adjustable viscosity and density cement material behavior adjustable by ionization and movement cured or pre-cured cement by microwaves (e.g. trugh plastic frame) or via induction (Metal filled cement). Step 5 – Drilling and reaming of next section. Increase or decrease of mud weight in next drilling section of borehole possible without damaging parent formation and casing. Repeat step 2 to step 5. Step 6 – Set production liner non expanded, expanded or partially expanded section wise from bottom to top. Connection of liner elements DH required. (e.g. by means of expansion technologies). Step 7 – Finally pump composite cement between already set liner and production liner. Composite cement (cement between steel layer) low viscose and higher density, but as well filled with hollow bodies to improve strength and thermal isolation capabilities and has a high final strength. Additional embodiment – Cure cement from bottom to top or top to bottom by local heating, vibration, x-ray, etc. Finally reduce density of fluid in borehole to production fluid density and perform pressure testing, stimulation and operation. Additional Features are described below.

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Composite Casing Design and Method of Completion

This invention involves a composite casing made of steel-cement-steel and the process of installation while incorporating the production liner into final strength of the casing design and using of expansion and welding technologies to build monobore wellbore constructions.

The composite concept uses pumpable and curable materials like cement as constructive element and is incorporating the production liner of a wellbore design into the final strength of the casing construction after final completion. The cement is supposed to take over the main compression loads as well has reinforcing components included (e.g. steel or fiber made parts taking over tensile loads, e.g. hollow ceramic, synthetic diamond or tungston balls).  Advanced expansion technologies is used to build monobore wellbore tubing or reinforcing net constructions. The casing elements are set stepwise and in correlation to current operational differential pressure requirements.

           Step 1 – Drilling fluid in wellbore (mud) density set to compensate pore pressure. Pumping of LCM and tixotrop fluid to maintain lost zone. Restart circulation with pressure shock (small explosives).  If not sufficient set thin patch on borehole wall. (e.g.folded liner on CT workstring).

           Step 2 – Fill up borehole with formation cement.  Formation cement is soft with similar density as mud. Low density of cement e.g. adjusted with low dens balls (plastic, rubber, ceramic, hollow bodies). Good pressure distribution and sealing capability. Additional embodiment – circulate and mix cement downhole.

          Step 3 – Draw (with wire fixed on bottom) or push folded liner section into cement (e.g. with weight).

          Step 4 – Expand liner into cement until sufficient cement gap is reached. Profile liner to centralize liner and in sections if increased pressure resistance is required (e.g. in zones of particular overpressure). Additional cement and procedure features: Cement tixotropic, adjustable viscosity and density cement material behavior adjustable by ionization and movement cured or pre-cured cement by microwaves (e.g. trugh plastic frame) or via induction (Metal filled cement).

         Step 5 – Drilling and reaming of next section. Increase or decrease of mud weight in next drilling section of borehole possible without damaging parent formation and casing. Repeat step 2 to step 5.

         Step 6 – Set production liner non expanded, expanded or partially expanded section wise from bottom to top. Connection of liner elements DH required. (e.g. by means of expansion technologies).

         Step 7 – Finally pump composite cement between already set liner and production liner. Composite cement (cement between steel layer) low viscose and higher density, but as well filled with hollow bodies to improve strength and thermal isolation capabilities and has a ...