High Strength Composite Casings for Extended Reach Wells

downhole

composite

pipes

Akiet BV

Casing Solutions where steel falls short of expectations

• Dutch Company specialized in composite tubular

systems for deep down-hole applications

• Ten years of Composite R&D programs focused on

down hole applications only

downhole

composite

pipes

World Record

• HSCC™ successfully installed at

16,450 ft TVD

• Ran 7” casing in 8-3/8” hole

• Field proven glued connections and

steel-composite cross-overs

• Standard elevators and slips used

• Fit for purpose running gear

downhole

composite

pipes

Customer Need

• Horizontal and extended reach wells increase

productivity

• Friction from weight and buckling cause

limitations in running heavy steel casings

• Akiet developed light weight composite casings

with required strengths and OCTG dimensions

downhole

composite

pipes

Composites

• A combination of continuous fibers embedded in a resin

o Light weight ( ≈ 16.69 ppg) – almost in suspension in mud

o Anisotropic strength characteristics – engineered to application

o Internal wear-resistant liners possible

o Allow for See-Through-Logging™ (STL™)

downhole

composite

pipes

Akiet offer

• Composite well engineering

• Composite casing design

• Composite tubular manufacturing

• Slender, reliable couplings

• Installation services

downhole

composite

pipes

Composite Well Engineering

• Define all load cases including duration and fluid exposure

• A fluid or gas holding body may not crack: matrix failure as criterion to determine composite structure

• Check load versus design

• Prepare running program

downhole

composite

pipes

Composite Casing Design

• Proprietary software for very accurate buckling simulation based on anisotropic and non-anisotropic materials

• Finite Element Model to calculate lay-up design to match load requirements

• Variables take special manufacturing technology into account and include: o Fibre type, volume and orientation

o Resin type and volume (Wall thickness)

o Curing duration

downhole

composite

pipes

Extended Reach Well simulations

• Reach potential of >26,250 ft horizontal sections

• Light weight composite string below heavy steel casing optimises running weights

• No special installation techniques like floating required

• Installed without rotation: no load on connections

• Circulation possible to ease installation. Enables to:

o Apply pressure to ‘stiffen’ pipe

o Pump down casing

downhole

composite

pipes

Composite Tubulars

• Akiet has achieved breakthroughs by using different

technology than regular GRE winding

• High Strength (burst, collapse, tension, compression

and torque)

o Low void ratio

o Ideal fibre orientation in directions of highest loads

• Standard OCTG dimensions, 39 feet lengths

• Flexible yet sturdy

• Wear resistant, variety of liners available

downhole

composite

pipes

Slender Reliable Couplings

Proprietary field proven coupling technology

• Low offsets, slender design

• Ability to interface steel-composite, composite-

composite and composite-steel

• Stronger than tubular itself

• Glued in place with quick-drying cohesives

downhole

composite

pipes

Installation Services

Execution of running program

• Competent Staff

• Special Akiet alignment tools

• Standard drill floor layout

• Safe air-driven equipment

downhole

composite

pipes

Additional advantages over steel

• Light weight o Smaller rigs

o Drilling with casing possible (Enhanced Composite Casing Installation™), further reducing rig size

o Lower transport cost, helicopter transportable

o Easier and safer handling

• Corrosion resistant (CO2, H2S and more) o Longer well life

o Any damage does not cause corrosion

o No cement required for corrosion protection

• Transparent for logging measurements (See-Through-Logging™, STL™)

o Open hole tools usable in cased hole (E.g. Magnetic surveying)

o Time-lapse logging for advanced reservoir modelling

downhole

composite

pipes

Quality

• There is no certification for deep-well composite

casings because they did not exist

• Trial and testing program agreed with customer

• Example:

o First orders were tested under supervision of independant

agency TNO and Delft University of Technology

o Results were accepted by customers

downhole

composite

pipes

downhole

composite

pipes

Substantiation of claims

• Example test results of earlier order for pipe and connection 7”

Target load (incl Safety Factors)

Test result

Tension 89 klbs 280 klbs

Compression 32 klbs 100 klbs

Burst 3945 psi 3988 psi Collapse 2639 psi 3002 psi

Torsion 2212 ft.lbs 12022 1)ft.lbs 1) No failure at limit of testing gear

downhole

composite

pipes

Installation of 7” HSCC on Rig in Oman

Akiet BV www.akiet.com info@akiet.com +31 6 83 79 51 87

downhole

composite

pipes

Vertical weigth comparison Load for 3280ft well with 9-5/8” casing:

Conventional rig Super single rig

Material Specific Weight Buoyancy in mud

Hook load (klbs)

Steel casing 47.0 ppf 0.85 132

5” drill pipe 19.5 ppf 0.85 55

HSCC / ECCI 13.4 ppf 0.45 20

Mini rig