Metal-to-Metal Casing and Liner Solutions - slb.com/media/Files/completions/brochures/colossus-m... · operators to connect liners to a tieback string through a permanent and durable

Metal-to-Metal Casing and Liner SolutionsGas-tight technology for the life of the well

MetalmorphologyMetal-to-metal sealing and anchoring technology

Metalmorphology* metal-to-metal sealing and anchoring technology uses direct hydraulic pressure to shape metal downhole, enabling metal-to-metal connections that provide high axial load and pressure containment.■ Typically a casing joint or stinger is morphed into a grooved receptacle to engage

and seal, forming a permanent connection. ■ The two tubular components are connected using pressure delivered via

a setting tool operating at high pressure at the connection interface. ■ A low pressure is applied at surface, and downhole intensifiers

increase the pressure to the level required at the tool.

Advantages of using Metalmorphology technology ■ Contains no moving parts ■ �Conforms to the tubular ID, capable of performing within API, tolerance, and ovality ■ Does not use cone expansion techniques and is not limited to single weight range increments ■ Maintains material properties after morphing ■ Creates a high-axial-load metal-to-metal, gas-tight connection between two casing strings

Cutaway of a casing joint morphed into a receptacle. Compression blocks are seen in the crushed state because of the morphing of the tubular into the receptacle.

A typical morph pressure curve shows the material plastic expansion and final morph pressure.

FEA study shows stresses of casing tubular morphed into receptacle.

�Downhole mechanics ■ Landing edges of the casing stub and the receptacle have high residual contact pressure

profile, ensuring a metal-to-metal seal. ■ �Plastic strains in outer and inner tubular remain within specified material properties. ■ Burst, collapse, and bidirectional load capabilities can be predicted by using finite element

analysis (FEA) and are verified with qualification testing.

Example 95/8-in morph

Pres

sure

, psi

Time, hh:mm:ss

35,000

30,000

25,000

20,000

15,000

10,000

5,000

007:26:24 07:33:36 07:40:48 07:48:00 07:55:12 08:02:24 08:09:36 08:16:48

Final morph pressure

Casing contact with receptacle

Casing yield

Seal, psi Morph, psi

Load Anchor The load anchor system provides full metal-to-metal anchoring of downhole equipment. It is an effective anchor for high-axial-load applications where sealing is not required.

Casing Reconnect The Casing Reconnect* metal-to-metal, gas-tight casing repair system provides an in situ means of restoring a downhole casing connection.

Liner TiebackThe metal-to-metal, gas-tight liner tieback systems tie a liner system to surface with a full metal-to-metal connection created downhole. The latest offering provides ream-down capabilities and therefore the benefit of having a full casing string to surface.

Metal-to-metal, gas-tight solutionsCasing and liner systems based on Metalmorphology technology

Casing ReconnectMetal-to-metal, gas-tight casing repair system

Restore casing integrity with expansion technology The Casing Reconnect metal-to-metal, gas-tight casing repair system creates a gas-tight metal-to-metal seal connection downhole by using the patented morphing technology to morph the existing customer casing into a receptacle. The pressures required to achieve morphing depend on the specific casing in the well and the desired test pressures. On surface, the pressure required is typical to standard operations, and these are multiplied downhole by an intensifier. All of the pressure is contained within the setting tool and the area of the casing being morphed.

The end result is a fullbore, high-tensile-strength, gas-tight, V0-rated connection. No elastomers are required for the connection.

Available sizes

APPLICATIONS ■ Stuck casing ■ �Wellhead replacement ■ Reestablishment of integrity for plug

and abandon (P&A) operations ■ Casing repair ■ �Well change of use ■ Connection of subsea wellhead

to surface

BENEFITS ■ Seamlessly replaces stuck

or damaged casing ■ Keeps drilling programs on schedule ■ Eliminates the need for costly fishing

operations or sidetracks ■ Secures well integrity for P&A activities ■ Provides robust seal for the life of the well ■ Allows fullbore access after installation

FEATURES ■ Metal-to-metal, gas-tight sealing

and anchoring technology ■ �ISO 14310 V0 rating ■ Installation depth not limited by casing

reconnect system ■ High axial-load-bearing capability in excess

of 1,500,000 lbf ■ Compatibility with NACE MR0175 standard

for sour service

Rated up to 1,485,000 lbf [661,000 daN]

Rated up to 8,000 psi [55 MPa]

Rated up to 160 degC [320 degF]

Sample Casing Reconnect System Specifications

Nominal casing size, in 95/8 135/8

Nominal ID, in [mm] 8.535 [224.4] 12.347 [313.6]

Casing drift, in [mm] 8.500 [215.9] 12.191 [309.7]

Casing weight, lbm/ft [kg/m] 53.5 [79.6] 72 [107.1]

Casing grade C110 P110

Internal pressure, psi [MPa] 7,985 [55] 5,000 [35]

External pressure, psi [MPa] 7,930 [55] 2,880 [20]

Axial compression, lbf [daN] 681,000 [303,000] 1,485,000 [661,000]

Axial tension, lbf [daN] 1,147,000 [510,000] 880,000 [391,000]

7 in

95/8 in

97/8 in

133/8 in

135/8 in

14 in

Typical applications Casing Reconnect System Saves Customer USD 3 MillionCase StudyChallenge While running the 133/8-in Q125 casing section in a new-drill water injector, a customer was unable to land and set in the hanger, so the casing was cemented high. The customer then needed to reconnect the casing to the subsea wellhead with a tight gas seal to avoid a time-consuming sidetrack and an estimated cost of USD 3 million.

Solution Using the Casing Reconnect system, the operator reinstated the 133/8-in Q125 casing with full integrity and no reduction in ID, avoiding running a whipstock and sidetrack.

Results Within 2 days, the Casing Reconnect system achieved a permanent metal-to-metal, gas-tight, axial-load-bearing connection with full integrity and ID, enabling drilling to continue as planned.

Basic operational sequence1. Casing cut and dressed. Casing Reconnect

system spaced out with new casing, whichis set in a surface hanger.

2. Setting tool positioned on depth usingthe integrated latch mechanism.

3. Hydraulic pressure applied, monitored,and controlled from surface.

4. Setting tool recovered to surface,leaving a morphed metal-to-metal,gas-tight connection.

1 2 3 4

Ratings represent qualification achieved based on specific requirements and do not represent maximum achievable rating on the connection. Additional qualification testing can be conducted in casing in which higher ratings are required.

Stuck CasingCasing stuck high;hanger not landed

on wellhead

Casing cut; Casing Reconnect system used to land hanger

in place

Damaged or Corroded Casing

Holed, corroded, or damaged casing

Casing cut; Casing Reconnect system used to install new casing

Liner TiebackMetal-to-metal, gas-tight liner tieback system

Reach desired depth in challenging wellsThe liner tieback system is a V0 ISO 14310–certified, high-axial-load-bearing system that enables operators to connect liners to a tieback string through a permanent and durable metal-to-metal seal. Its high load-bearing capabilities and sealing functionality without elastomers enable this technology to maintain functionality for the life of the well.

The standard liner tieback system is used in situations in which a single production string cannot be run from surface, such as when the production string is heavier than the rig can handle. A ream-down option is available for use in highly deviated wells or challenging environments where there is an expectation of difficulty in reaching TD.

A receptacle for the system is run with the liner on the initial run and landed in place. The tieback casing is then run above a tieback stinger, which is positioned across the receptacle and then morphed into position with a running tool.

The liner tieback system can be configured for installation as part of a liner or casing string.

Available sizes

APPLICATIONS ■ �Extended-reach drilling ■ Deviated wells ■ Deepwater wells with heavy

production strings ■ Wells with architecture or conditions

that make it challenging to run long casing strings

BENEFITS ■ Connects liners to a tieback string with

a durable, permanent metal-to-metal seal ■ Provides flexibility in landing casing

and liner space-out ■ Eliminates need for polished bore

receptacle (PBR) elastomeric sealing ■ Enables planning for well integrity

over the field’s lifetime ■ �Has the capabilities of a ream-down

liner system with the integrity of a full casing string

FEATURES ■ ISO 14310 V0 rating ■ �Installation depth not limited by liner

tieback technology ■ High axial-load-bearing capability ■ Effectiveness for the life of the well ■ Compatibility with NACE MR0175 standard

for sour service

7 in

75/8 in

95/8 in

97/8 in

Sample Liner Tieback System Technical Specifications

Nominal casing size, in 7 95/8

Nominal ID, in [mm] 6.184 [157.1] 8.535 [216.8]

Casing drift, in [mm] 6.059 [153.9] 8.500 [215.9]

Casing weight, lbm/ft [kg/m] 29 [43.2] 53.5 [79.6]

Casing grade C95 C110

Internal pressure, psi [MPa] 5,000 [34.5] 7,985 [55.1]

External pressure, psi [MPa] 4,250 [29.3] 7,930 [54.7]

Axial compression, lbf [daN] 300,000 [133,000] 681,000 [303,000]

Axial tension, lbf [daN] 300,000 [133,000] 1,147,000 [510,000]

Typical applications

Liner Tieback System Saves Time and Cost in High-Risk Wells Case StudyChallenge An operator in the North Sea wanted to install a 95/8-in liner and tieback system designed for the life of the well. The tieback system was to be cemented. Although engineers were aware of the challenges of running the liner string to TD because of the reservoir characteristics and well trajectory, the customer wanted to gain the benefits of having a continuous casing string from TD to surface.

Solution The liner tieback system with ream-down option was used successfully. The liner was run to TD with the robust setting adapter enabling ream-down running with high torque, high tensile strength, and high pumpthrough capacity. The liner hanger was landed and cemented in place. The tieback string was then deployed and morphed at the receptacle into the existing liner string.

Results The liner tieback system was successfully used to create a continuous, full metal-to-metal production string from TD to surface. The solution enabled ream-down running for the liner system and maintained the integrity of a full casing string. This eliminated the challenge of running the entire production string in a single run.

Basic operational sequence1. Liner tieback system is postioned below

or above the liner hanger.

2. Tieback casing is run into the liner tieback system.

3. Setting tool is positioned.

4. Hydraulic pressure is applied, monitored, and controlled from surface.

5. Setting tool is recovered, leaving a morphed, metal-to-metal, gas-tight connection.

Ream-down liner tieback system The ream-down liner tieback system integrates the conventional liner tieback system with the setting adapter from the field-proven COLOSSUS* liner hanger systems. This optional combination enables reliable high-torque deployment for liners in challenging environments. The system can be used with or without packers and hangers, depending on the application.†

Ream-down system features ■ �Liner can be cemented or uncemented. ■ �In the hangerless ream-down option,

the liner assembly has a slick OD with no moving parts, slips, gauge rings, or elements.

■ The assembly diameter is maintained at connection OD to prevent increases in equivalent circulating density (ECD).

■ Liner hanger is optional and can be used when the liner casing must be in tension.

■ High torque—up to 60,000 ft.lbm— is available while reaming down at the interface btween the running tool and the setting adapter.

■ After morphing, a full-ID, metal-to-metal, gas-tight connection exists from TD to the wellhead.

■ A full system recovery option is available for this method.

Ream-down system operation summary ■ Run liner. ■ Install liner tieback system with or without

hanger.† ■ �Run into the well on drillpipe. ■ Wash or ream as required to TD.

■ Drop ball and either release running tool or, if hanger is used, set hanger and release running tool.

■ Cement liner, ensuring cement does not completely cover the liner top.‡

■ Pull running tools out of the well. ■ Run into the well with expandable stinger

and space out correctly for casing hanger. ■ When casing hanger is landed, run into the

well with morphing tool, position in stinger, and complete morph operation.

■ Pull out of the well. ■ A full recovery option is also available.‡

Rated up to 2,500,000 lbf [1,112,000 daN]

Rated up to 8,000 psi [55 MPa]

Rated up to 160 degC [320 degF]

1 2 3 4 5

Ratings represent qualification achieved based on specific requirements and do not represent maximum achievable rating on the connection. Additional qualification testing can be conducted in casing in which higher ratings are required.

†The liner tieback system can be run with the Schlumberger integrated liner hanger running tool to form a ream-down system. It is also compatible with other industry liner hanger and packer equipment.

‡Cement must be positioned below the liner top to facilitate recovery.

Conventional tieback with elastomeric

element

Liner tieback with metal-to-metal

sealing

Liner Tieback

Conventional tieback with elastomeric

element (low load capability)

Liner tieback with metal-to-metal

sealing (high load capability)

Deepwater Casing Tieback Ream-Down Liner Tieback

Hole problems that preclude running

casing to TD

Liner reamed to TD and cemented; tieback

installed, recreating full casing string

14 in

Load AnchorMetal-to-metal anchor for tieback casing

Well integrity assurance The load anchor is set against the outer casing above the hanger to remove excessive compression loading from the hanger and tieback seal. The load anchor can also be used to prevent movement of the tieback casing to help maintain the integrity of traditional seal stacks and PBR systems.

APPLICATIONS ■ Anchor casing, tieback, and hanger

to enable higher load capacity ■ Lock uncemented tieback strings

in place without space-out issues

BENEFITS ■ Reduces the effect of thermal expansion

while anchoring extended-reach drilling completion strings

■ Enables use of conventional liner hanger equipment that would otherwise be unable to support heavy axial loads

FEATURES ■ Cost-effective, nonsealing, robust

metal-to-metal load anchor system ■ Bidirectional high axial-load-

bearing capability ■ Effectiveness for the life of the well ■ Applicablity for fully anchored

uncemented tieback ■ Compatibility with NACE MR0175

standard for sour service

Available sizes

75/8 in 117/8 in

103/4 in 135/8 in

×

×

Sample Load Anchor Technical Specifications

Anchor size, in 75/8 × 117/8 103/4 × 135/8

OD, in [mm] 5.750 [146.1] 12.125 [308.0]

Nominal ID, in [mm] 6.375 [161.9] 9.600 [243.8]

Internal pressure, psi [MPa]

11,000 [76] 9,760 [67]

External pressure, psi [MPa]

13,400 [92] 5,880 [41]

Axial compression, lbf [daN]

1,300,000 [578,000] 1,000,000 [445,000]

Setting tool OD, in [mm] 6.0 [152.4] 9.5 [241.3]

Typical applications

Rated up to 1,300,000 lbf [578,000 daN]

Rated up to 160 degC [320 degF]

Ratings represent qualification achieved based on specific requirements and do not represent maximum achievable rating on the connection. Additional qualification testing can be conducted in casing in which higher ratings are required. Also, additional sizes may be available on request.

Conventional liner systemAssisting Liner Hanger

Load anchor takes excess load

Supporting Tieback LoadConventional tieback load on liner system

Load anchor supports entire tieback load

Assisting Supplemental Hanger SystemConventional supplemental

hanger systemLoad anchor

supports excess load

Basic operational sequence1. The liner hanger is cemented and set.

The load anchor and casing tieback are deployed to depth.

2. The morphing tool is pulled up to locate across the load anchor on the tieback string (above the liner hanger).

3. Pressure is applied down the drillpipe to actuate the sealing elements of the morphing tool against the load anchor.

4. The load anchor is morphed into the previous casing string, anchoring the tieback to absorb the full load of the string.

5. The morphing tool is depressurized and then pulled out of the well, leaving a load-bearing, nonsealing anchor.

1 2 3 4 5

Challenge An operator in the Gulf of Mexico wanted to install a 75/8-in liner and tieback system designed for the life of the well. A Schlumberger liner tieback system was to be installed and left uncemented below the conventional hanger system, eliminating conventional liner tieback seals. However, because the uncemented 75/8-in tieback string’s worst-case discharge (WCD) loads were well beyond the conventional hanger slip load design, it was necessary to develop a bidirectional casing load anchor that could engage the host casing string without pipe movement and keep the liner in place without transmitting the loads to the liner hanger.

Solution The load anchor needed high bidirectional load-bearing capability so that the drilling and completion operations could proceed as planned. Using Metalmorphology technology, Schlumberger created a bidirectional casing load anchor without conventional slips or hydraulic cylinders and which would not require pipe movement to engage the host casing. The capability was successfully demonstrated and qualified in a test well.

Results The test demonstrated the technology’s extremely high bidirectional load-bearing capability; metal-to-metal contact with no moving parts, setting cylinder, or seals; full internal pressure integrity; no internal restrictions; life of well connection; and functionality without cementing.

Load Anchor Proves Viable to Ensure Life-of-Well Connection Test Deployment

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