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To cite this article: T. Pervez , S. Z. Qamar , Omar S. Al-Abri & R. Khan (2012) Experimental
and Numerical Simulation of In-Situ Tube Expansion for Deep Gas Wells, Materials and
Manufacturing Processes, 27:7, 727-732, DOI: 10.1080/10426914.2011.648037
Download by: [Sultan Qaboos University] Date: 30 January 2016, At: 21:14
Materials and Manufacturing Processes, 27: 727–732, 2012
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2011.648037
Growing energy demand is forcing the petroleum industry to reevaluate resources found in unconventional gas formations and utilizing
low-production zones. Extracting oil and gas from these difficult and deep reservoirs require new knowledge which should lead to develop
solutions in lifting those reserves to the surface. Centuries-old manufacturing process of tube forming has found an interesting and extended
application in petroleum well drilling and delivery. The in-situ expansion of tube is aimed at expanding its diameter by pushing or pulling a
mandrel through it. The expansion process is strongly nonlinear due to material and contact nonlinearities. The goal is to achieve desired
Downloaded by [Sultan Qaboos University] at 21:14 30 January 2016
tube expansion smoothly as well as maintain minimum post expansion material and mechanical properties. The objective of this research is
to conduct experiments to expand the tube under simulated downhole conditions. Finite element analysis is also used to simulate the expan-
sion process, and the results are compared with experimental data. The force required for expanding the tube, thickness reduction in tube
wall thickness, and length shortening under fixed-free end condition are estimated. Good agreements were found between numerical and
experimental results. Thickness reduction greater than 12% lowers collapse strength by 50% making it unsuitable for deep wells.
727
728 T. PERVEZ ET AL.
model under tension and compression for tube sinking. must be able to maintain hydraulic integrity to provide
For tube flaring process, Lu [11] developed an analytical sufficient resistance against burst and collapse during
solution relating tube flaring ratio and tube end strain service. It should have constant diameter and wall thick-
rate to the tool stroke and velocity. Recently, Celentano ness over the entire length of the expanded section and
et al. [12] conducted thorough analysis of the mechanical should maintain its strength.
behavior of a steel tube during its sinking drawing. Since the tube as well as the mandrel experience high
Al-Hiddabi et al. [13] used the equilibrium conditions interfacial stresses, as expansion proceeds, the selection
and plasticity theories to develop analytical model for of the mandrel geometry and material is also crucial.
tube expansion with a conical expansion tool under very The shape of the mandrel also plays a critical role for
simplified conditions. The results showed the variation successful completion of the expansion process. Further-
in the force required to expand the tube with respect more, critical data such as wall thickness, length changes,
to expansion ratio (ER), friction coefficient, mandrel post-expansion strength, ductility, burst, and collapse
geometry, and the tube’s material yield strength. This strengths are needed for safe and reliable use.
model was further extended by Karrech et al. [14] to
predict the stress field in the expansion zone and the TEST-RIG FOR EXPANSION
dissipation of energy from which an optimized mandrel
The experimental setup for expanding tubes with ERs
shape can be determined.
varying from 8% to 30% has been designed and com-
However, in case of an in-situ expansion (downhole
missioned in the Engineering Research Laboratory.
environment), there is no room to make mistakes and
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the minimum required clearance between the production FIGURE 4.—Variation in expansion force with respect to expansion ratio.
line and the tube.
The most critical aspect of expanding a tube is the
effect of the expansion process on its burst and collapse elastic collapse is not sharp but covers a significant range
strengths. Table 1 shows the effect of ER on the tube’s of Do=t values. While for thin-to-thick wall tube, the
burst and collapse strengths after expansion. According collapse strength can be calculated using the empirical
to API standard, the burst pressure for thick-wall tube relation
can be established using Barlow’s equation [15]:
2t F1
PBr ¼ 0:875 rY ð1Þ PCr ¼ rY F2 F3 ð3Þ
Do Do =t
where Do and t represent the outer diameter and the where F’s are empirical coefficients depending on tube
thickness of the tube, respectively. The equation assumes material. For current study, F1 ¼ 3.071, F2 ¼ 0.0667,
87.5% of the minimum yield strength (rY) of the tube. It and F3 ¼ 1955. The results for burst and collapse strength
is important to note that the expansion process causes for two tube sizes, different boundary conditions and
increase in the tube diameter and decrease in wall thick- ERs are given in Table 2. The results showed that the
ness, and hence this may convert the tube from being post-expansion burst and collapse resistance decreases
thick-to-thin wall depending on Do=t ratio. For thin-wall linearly, as the ER increases. Furthermore, the collapse
tube, the burst pressure can be determined using the and the burst resistance lowers sharply when the tube is
following relation: restricted at one end. This is true regardless of the tube
size. The effect of the axial restraint is more severe on
2t collapse and burst strengths due to large thickness
PBr ¼ 0:875 rY ð2Þ reduction.
Dt
It is necessary for field engineers to estimate the expan-
where Di is the tube inner diameter. The post expansion sion requirements before proceeding with downhole
tube collapse strength is also very important to safe- expansion in order to select appropriate expansion tools
guard the well against formation collapse. To determine and avoid any unexpected failure. Figures 4–6 show the
collapse strength, API has used the theory of elastic variation in the expansion force and length and thickness
stability to determine collapse strength for thin-wall variations as a function of ER. An increase in ER results
tubes. The transition from yield-strength collapse to in an increase of expansion force, thickness reduction,
TABLE 2.—Effect of axial restraint on burst and collapse resistance of expandable tube.
174.625 193.675 9.525 16.36 18.3 20.3 Fix-Free 6.4 22.8 24.8 47.238 21.669
Fix-Fix 8.55 23.3 25.3 46.153 20.164
182.88 203.2 10.16 19.4 18.0 20.0 Fix-Free 8.84 23.6 25.6 45.650 19.288
Fix-Fix 13.69 24.9 26.9 43.650 15.722
IN-SITU TUBE EXPANSION FOR DEEP GAS WELLS 731
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