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Abstract
Initial liner top integrity is a primary concern for most
operators. If the liner top fails routine or regulatory integrity
tests, expensive and time-consuming remedial operations
increase direct costs for equipment and services. This
remediation delays well completion, which ultimately delays
revenue generation. These expenses often exceed the initial
cost of the liner equipment. Liner top failure continues to
challenge the industry despite improvements in integrally run
liner top packers, special cements, and cementing pratices.
Even newer generation liner top packers, run either integrally
with the liner hanger or as a second trip packer, have multiple
sealing surfaces that must function under rigorous conditions
to achieve liner top isolation.
The expandable liner hanger has been developed and
successfully field-tested as an alternative to conventional
cone and slip liner hangers and liner top isolation packer
systems. The expandable liner hanger combines the functions
of the liner hanger and the isolation packer into a single
component. The expandable liner hanger uses elastomeric
bands to provide the axial load capacity of a conventional
liner hanger and the annular sealing capability of the liner top
isolation packer. The expandable liner hanger is expanded
hydraulically with the liner running/setting tool assembly.
During expansion, the elastomeric bands are compressed into
contact with the ID of the supporting/intermediate casing,
virtually eliminating the annular space between the liner
hanger and the casing.
This paper discusses expandable liner hanger design
criteria and testing undertaken to qualify the expandable liner
hanger as a reliable liner top isolation system. Initial field
installations and the lessons learned are also discussed.
Introduction
The importance of the liner-casing overlap is illustrated by the
efforts and expense taken by operators to ensure hydraulic
integrity of the overlap. Typical methods of achieving pressure
integrity include the following:
Cement squeezes, including a liner top packer as a
component of the initial liner hanger setting
One or more second-trip liner top isolation packers
installed to control gas migration at the liner top
The typical liner top is complex in its design (Fig. 1) and can
develop leaks due to a myriad of causes1.
A recent informal survey of several GOM operators
revealed that 30 to 50% of pressure seals in overlaps fail. One
operator made a concerted effort to improve liner running and
cementing procedures. Data gathered over an 18-month period
was used to shed light on possible causes of overlap failure by
gathering information on liner/casing sizes, types of
equipment, overlap length, mud data, annular cross section,
equipment, and service suppliers. The study concluded the
chances of having a liner overlap seal failure did not depend
on any single factor and the chances for an incident were
nearly the same regardless of the factors associated with any
given well2.
The development and successful deployment of solid
expandable tubulars improved the probability of eliminating
liner top leaks and reducing the associated remediation costs.
The expandable liner hanger is a byproduct of developing
expandable openhole and expandable cased-hole liners3. The
design features of the anchor joint elastomeric seals used to
seal and anchor the expanded liner to the casing ID were
adapted to run and hang conventional, non-expanded liners
(Fig. 2).
Expandable Liner Hanger Design
Initial design criteria for the expandable liner hanger include
the following:
Incorporate solid expandable tubular features into
expandable anchor joints to provide maximum axial load
capacity and pressure integrity at the liner/casing annulus
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Fig. 3 Finite-element analysis used to study stresses during the design of the expandable liner hanger system.
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Top of liner
at 8,211 ft
9-5/8 in. at 8,737 ft
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