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Expandable Threadless Coupling Development

In recent years, the oil and gas industry has embraced expandable casing and expandable sandscreen technology. Significant research has been done on the expansion process, but there are still limitations with the connection, which often disconnects when being expanded. Additionally, there are issues with achieving a gas-tight expandable connection. The number of intelligent wells, which include intelligent sandscreens, is growing. The proposed technology addresses these limitations and provides a cost-effective means of connecting joints of tubing that can be expanded while maintaining gas-tight integrity. Furthermore, when applied to intelligent sandscreens, capillary tubes can be easily oriented so that intelligent slickline (incorporating fiber optic monitoring capability) can be injected into the capillary tube, enabling permanent reservoir monitoring. With around 40,000 gas wells drilled annually in the US and sandscreen wells representing 10% of global completions, this technology addresses a significant market segment. Objectives include the design, manufacture, and testing of various coupling types and the optimization of a hydraulic assembly tool. Commercial innovations include faster jointing times using the novel connector compared to current solutions, a hydraulic-powered tool ensuring rapid, safe, and reliable assembly on the rig floor, and a fast and foolproof assembly process. Technical innovations include a stronger connector that provides a better seal than current solutions, with options for flush inner diameter (ID), outer diameter (OD), or both. The casing can be rotated both clockwise (CW) and counterclockwise (ACW) and expanded without risk of separation. The new connectors allow jointed pipe to have higher tensile strength than virgin pipe.

Feedback Overview:

The proposed expandable threadless coupling technology addresses significant limitations in current solutions and offers substantial commercial and technical innovations. To increase market adoption, it would be beneficial to conduct extensive field trials and gather data to demonstrate the technology's reliability and efficiency in various conditions. Additionally, forming strategic partnerships with major oil and gas companies could accelerate market penetration.

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CTO

Expert in oilfield technology innovations and implementation strategies.

How feasible is the implementation of this new coupling technology in existing oil and gas infrastructure?

The implementation is feasible with some modifications to existing infrastructure. The technology's compatibility with current systems and its ease of integration will be key factors in its adoption.

What are the potential technical challenges in ensuring gas-tight integrity during expansion?

Potential challenges include maintaining uniform expansion and ensuring the material properties of the coupling can withstand the operational pressures and temperatures without compromising the seal.

How can we ensure the scalability of this technology for widespread use in the industry?

Scalability can be ensured by standardizing the manufacturing process, conducting extensive field tests, and obtaining certifications from industry regulatory bodies.

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