Tubular expansion in irregularly shaped boreholes - Computer simulation and field measurement

Recently, field engineers have tried to use a new technique using expandable tubular with elastomers to seal the annulus. Ultrasonic down-hole measurements carried out for evaluation of zonal isolation revealed that the tubular expanded to an oval x-section instead of the desired circular x-section at certain locations. This is a phenomenon previously unknown. It is believed to occur due to expansion in irregularly shaped boreholes. The ovalization of expanded tubular was studied to avoid such problems in future. The finite element method was used to predict tubular ovality and compare it to measured values. Results were then used to develop ready-to-use design curves in making decisions for running a completion tool in expanded tubular.