Materials and Manufacturing Processes

ISSN: 1042-6914 (Print) 1532-2475 (Online) Journal homepage: http://www.tandfonline.com/loi/lmmp20

Experimental and Numerical Simulation of In-Situ

Tube Expansion for Deep Gas Wells

T. Pervez , S. Z. Qamar , Omar S. Al-Abri & R. Khan

To cite this article: T. Pervez , S. Z. Qamar , Omar S. Al-Abri & R. Khan (2012) Experimental
and Numerical Simulation of In-Situ Tube Expansion for Deep Gas Wells, Materials and
Manufacturing Processes, 27:7, 727-732, DOI: 10.1080/10426914.2011.648037

To link to this article: http://dx.doi.org/10.1080/10426914.2011.648037

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Mar 2012.

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 Materials and Manufacturing Processes, 27: 727–732, 2012
Copyright # Taylor & Francis Group, LLC
ISSN: 1042-6914 print=1532-2475 online
DOI: 10.1080/10426914.2011.648037

Experimental and Numerical Simulation of In-Situ

Tube Expansion for Deep Gas Wells
T. Pervez, S. Z. Qamar, Omar S. Al-Abri, and R. Khan

Department of Mechanical and Industrial Engineering, College of Engineering,

Sultan Qaboos University, Al Khod, Sultanate of Oman

Growing energy demand is forcing the petroleum industry to reevaluate resources found in unconventional gas formations and utilizing
low-production zones. Extracting oil and gas from these difficult and deep reservoirs require new knowledge which should lead to develop
solutions in lifting those reserves to the surface. Centuries-old manufacturing process of tube forming has found an interesting and extended
application in petroleum well drilling and delivery. The in-situ expansion of tube is aimed at expanding its diameter by pushing or pulling a
mandrel through it. The expansion process is strongly nonlinear due to material and contact nonlinearities. The goal is to achieve desired
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tube expansion smoothly as well as maintain minimum post expansion material and mechanical properties. The objective of this research is
to conduct experiments to expand the tube under simulated downhole conditions. Finite element analysis is also used to simulate the expan-
sion process, and the results are compared with experimental data. The force required for expanding the tube, thickness reduction in tube
wall thickness, and length shortening under fixed-free end condition are estimated. Good agreements were found between numerical and
experimental results. Thickness reduction greater than 12% lowers collapse strength by 50% making it unsuitable for deep wells.

Keywords Collapse; FEA; Forming; Gas-wells; Plasticity; Tube expansion.

INTRODUCTION reservoir, etc. [1–3]. The isolation of hydro-zones is done

Metal-forming processes cause changes in shape and
size of solid metal via plastic (permanent) deformations.
Metals deform very much like soft clay or wax. Even in
the solid state, permanent changes in shape can be
forced upon them by displacement of relative positions
between neighboring material particles. To enforce these
changes, external forces are applied. Tube expansion is a
metal forming process in which the diameter of a tube is
increased to a desired value by forcing a mandrel
through it. The notion of use of expandable tubing by
boiler manufacturers existed since the beginning of
twentieth century. At the end of the last decade, tube
expansion has found an interesting application in the
oil and gas industry due to three desirable features in
oil well drilling and completion: mono-diameter well,
increased success in deepwater applications and cost
effectiveness for many long outstanding, and far reach-
ing problems faced during construction and operation
of wells, a feature that allows flexible design. It has
gained momentum and attracted the attention of opera-
tors and researchers as a common element in enhancing
the economics and performance of both new and old
wells. For example, secondary oil recovery is often
impaired by zones of high permeability, i.e., fractures,
fault-related fracture corridors, karstied parts of the
Received November 14, 2011; Accepted November 23, 2011
Address correspondence to T. Pervez, Department of Mechanical
and Industrial Engineering, College of Engineering, Sultan Qaboos
University, P. O. Box 33, Al Khod 123, Sultanate of Oman; E-mail:
tasneem@squ.edu.om
using mechanical and chemical packers near the
wellbore-fracture intersection. These mechanical and
chemical methods had limited success due to increased
cost, difficulties in drilling, etc. [4]. An alternative
method of downhole closure of these fractures is based
on tube expansion process with or without inert or swell-
ing elastomer annular seals. This method resulted in up
to 40% reduction of unwanted fluids being pumped from
wells to surface. However, the recent use of this concept
in oil and gas well applications posed unparalleled chal-
lenges to the engineering community, and still lot of
research and laboratory experiments need to be done
before this technique is fully used for commercial appli-
cations [5–8]. The ease of use in downhole environment
will only be possible through properly conducting tube
expansion under such conditions, understanding
geometric and contact nonlinearities, dynamics of
components=system involved in the expansion process
and post-expansion material, and mechanical properties
of tube. Significant application-based research were
carried out by oil and gas fields operators and service
providers to find short term and problem specific solu-
tions without following a scientific approach. Their
prime objective is the drive to drill more barrels of oil.
Contrary to this approach, extensive research work
has been done to understand tube forming processes
such as sinking, expansion, or flaring. These processes
are generally conducted at low temperature and gov-
erned by similar equations of motion. George et al. [9]
did theoretical stress analysis of tube sinking and
showed that the sinking stress is a function of reduction
in the mean diameter. Hill [10] developed an analytical

727
 728
model under tension and compression for tube sinking.
For tube flaring process, Lu [11] developed an analytical
solution relating tube flaring ratio and tube end strain
rate to the tool stroke and velocity. Recently, Celentano
et al. [12] conducted thorough analysis of the mechanical
behavior of a steel tube during its sinking drawing.
Al-Hiddabi et al. [13] used the equilibrium conditions
and plasticity theories to develop analytical model for
tube expansion with a conical expansion tool under very
simplified conditions. The results showed the variation
in the force required to expand the tube with respect
to expansion ratio (ER), friction coefficient, mandrel
geometry, and the tube’s material yield strength. This
model was further extended by Karrech et al. [14] to
predict the stress field in the expansion zone and the
dissipation of energy from which an optimized mandrel
shape can be determined.
However, in case of an in-situ expansion (downhole
environment), there is no room to make mistakes and
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there is a need to lower expansion force, accurately pre-
dict thickness and length changes, and post-expansion
characterization of tube material. So far, in downhole
environment, tube can be expanded from 12% to 16%
without significantly lowering its collapse strength.
Particularly, the mechanical properties of the tube after
expansion become a critical factor in assuring its struc-
tural integrity after expansion.
Large ERs and post-expansion material properties
considerably affect the internal pressure rating of the
expanded tube. Analyzing the expansion effects for
ERs of 15% and above are still vague. The aim of this
study is to determine the dimensional and properties
change in the downhole expanded tube. A full scale test-
ing facility has been designed and developed to simulate
in-situ tube expansion processes for different tube sizes,
materials, end conditions, and downhole environment.
Expansion process was also simulated using finite
element method and compared with experimental results.
Material hardening, contact between tube and mandrel,
and geometrical nonlinearities were included in the finite
element model. Reasonably good agreement was
obtained between experimental and numerical results.
EXPANSION PROCESS
The tube expansion process consists of permanent
radial tube expansion through cold working mechanism
either mechanically by pulling a conical shaped mandrel
or hydraulically by pushing it through the tube. The
hydraulic force is applied by pumping through a work-
string connected to the mandrel, and the mechanical
force is applied by either raising or lowering the
work-string. The progress of the mandrel deforms the
tube to a certain desired ER leading to an increase in
the tube diameter, variation in the tube thickness and
length, and alteration of the material properties. The
tube deforms beyond its elastic limit into the plastic
region but remains below its ultimate tensile strength.
The term ER is defined using the mandrel and the
pre-expanded tube diameters [5]. The expanded tube
T. PERVEZ ET AL.
must be able to maintain hydraulic integrity to provide
sufficient resistance against burst and collapse during
service. It should have constant diameter and wall thick-
ness over the entire length of the expanded section and
should maintain its strength.
Since the tube as well as the mandrel experience high
interfacial stresses, as expansion proceeds, the selection
of the mandrel geometry and material is also crucial.
The shape of the mandrel also plays a critical role for
successful completion of the expansion process. Further-
more, critical data such as wall thickness, length changes,
post-expansion strength, ductility, burst, and collapse
strengths are needed for safe and reliable use.
TEST-RIG FOR EXPANSION
The experimental setup for expanding tubes with ERs
varying from 8% to 30% has been designed and com-
missioned in the Engineering Research Laboratory.
Tubes of up to 10 m length and 10 to 300 cm diameters
can be expanded under different boundary conditions.
Hydraulic expansion is done using a 2,000 bar pump
with a flow rate of 11 liters=min. For mechanical pull,
the expansion force can be varied from 10 to 140 metric
tons. Real-time test data such as strain, displacement,
expansion force, variation in tube thickness and length,
and speed and location of the mandrel during expansion
were recorded. Pre- and post-expansion properties of the
tube are determined using ASTM standard test methods
including hardness, Young’s modulus, yield, and ulti-
mate tensile strengths, ductility, and strain at fracture.
The experimental setup that is used to hydraulically
expand the tube consists of mandrel-launcher system,
the tube to be expanded, and a measurement system.
The mandrel-launcher system is welded to the tube. In
order to guarantee the alignment of the mandrel during
the expansion process, an aligner made of two discs
separated by a distance with diameters equal to the drift
diameter of the tube is used. This assembly is then
mounted on the test-rig for expansion. The high pressure
pump supplies the hydraulic fluid required to push the
mandrel forward. However, it is important to highlights
that the testing procedure is cumbersome and usually
requires careful selection of tools and its execution.
FINITE ELEMENT MODELING
The structural response of the tube was modeled using
ABAQUS, a finite element analysis software. A two-
dimensional (2D) axi-symmetric model, shown in Fig. 1,
was developed, and results are compared with the
three-dimensional (3D) model. Once converged, the 2D
axi-symmetric model is used for further simulation due
to cost and computational time considerations. The tube
was modelled as a deformable body with elastic-plastic
material behavior, whereas the mandrel was modelled
as a rigid body. The induced friction between the tube
and mandrel was modeled using the Coulomb friction
law. The coefficient of friction was set at 0.07 so that it
matches the actual test conditions. The mandrel cone
angle was set at 10 degrees to compare simulation results
 IN-SITU TUBE EXPANSION FOR DEEP GAS WELLS 729

FIGURE 2.—Thickness variations for 20% expansion ratio.

value was calculated for comparison with simulation

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FIGURE 1.—Two dimensional axi-symmetric finite element model of

tube-mandrel system (color figure available online). results. There is an excellent agreement in case of length
shortening, while the difference in thickness reduction is
approximately 10%.
with experimental data. The edges of the cone were Real-time measurements of mandrel position and
fillet of 6 mm radius. Force required for expansion, velocity are critical parameters to detect the mandrel
thickness and length changes, and excess deformation misalignment and occurrence of stick-slip phenomenon.
is reported in this work and compared with experi- Any saw tooth behavior in velocity profile is an indi-
mental data. The material behavior is governed by power cation of stick-slip phenomenon which mainly happens
law. The material properties of the tube were obtained due to the tube surface irregularities, lack of lubrication,
based on uni-axial tensile test conducted on specimens and the presence of connections. This phenomenon
following ASTM E8 standard. The material properties induces wall thickness imperfections due to local plastic
include: E ¼ 82 GPa, ry ¼ 615 MPa, rult ¼ 702 MPa, and deformation. In the current experiment, the mandrel
ef ¼ 0.197. To simulate the downhole expansion process, movement during the expansion was smooth. Once the
the lower end of the tube was held fixed, while the upper expansion pressure was built up, the mandrel moved at
end was kept free. a constant speed of 0.03 m=s until the expansion of
desired length is achieved. Additionally, a buttress
threaded connection between two tubes was tested for
RESULTS AND DISCUSSION ERs of 20% and 23.6%. The expansion forces required
A tube of 500 mm length, outer diameter of for 20% and 23.6% were 240 and 277 metric tons. The
193.675 mm, and thickness of 9.525 mm was used for expansion force is significantly higher in magnitude with
both experimental and simulation study. The ER was an increase of 15% for a welded connection and twofold
varied from 10% to 28% of the tube inner diameter. It for threaded connection.
was found that the expansion pressure=force required
for 20% ER obtained through simulation is in good
agreement with experimental results with an error of less
than 4%. In all cases, the expansion pressure=force
initially reached a peak value (representing the initial
upsetting process) and then drops down to an almost
steady-state value. For instance, in case of 10
mandrel
angle and 20% ER, the initial peak pressure was 340 bars
and then stabilized at 315 bars during the rest of the
expansion process. Small fluctuations in the expansion
pressure were observed during transient period, but over-
all the process is stable.
Figures 2 and 3 show the reduction in tube thickness
and length shortening for 20% ER. Tube thickness,
before and after expansion, were measured at ten differ-
ent locations, and an average value of thickness
reduction was calculated for comparison with simula-
tion results. Similarly, length shortening was measured
at the beginning and end of the tube, and the average FIGURE 3.—Length variations for 20% expansion ratio.
 730 T. PERVEZ ET AL.

TABLE 1.—Effect of expansion ratio on burst and collapse strengths

(fix-free boundary condition).

Expansion Thickness Burst pressure Collapse pressure

ratio (%) reduction (%) Di=t Do=t (MPa) (MPa)

0 0 18.3 20.3 52.950 38.557

16.36 6.40 22.8 24.8 47.238 21.669
20.00 10.30 24.5 26.5 43.898 16.782
23.64 13.16 26.1 28.1 41.248 12.722

Due to the springback phenomenon, the expansion

process will not yield the exact final diameters as needed
by design. The difference in tube final and desired inner
diameters when expressed in percentage of desired inner
diameter is termed as excess deformation [5]. It was
found that excess deformation is smaller in magnitude
as compared to length and thickness variations. How-
ever, it must be accounted in the final design to have
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the minimum required clearance between the production FIGURE 4.—Variation in expansion force with respect to expansion ratio.
line and the tube.
The most critical aspect of expanding a tube is the
effect of the expansion process on its burst and collapse elastic collapse is not sharp but covers a significant range
strengths. Table 1 shows the effect of ER on the tube’s of Do=t values. While for thin-to-thick wall tube, the
burst and collapse strengths after expansion. According collapse strength can be calculated using the empirical
to API standard, the burst pressure for thick-wall tube relation
can be established using Barlow’s equation [15]:
 
2t F1
PBr ¼ 0:875 rY ð1Þ PCr ¼ rY  F2  F3 ð3Þ
Do Do =t

where Do and t represent the outer diameter and the
thickness of the tube, respectively. The equation assumes
87.5% of the minimum yield strength (rY) of the tube. It
is important to note that the expansion process causes
increase in the tube diameter and decrease in wall thick-
ness, and hence this may convert the tube from being
thick-to-thin wall depending on Do=t ratio. For thin-wall
tube, the burst pressure can be determined using the
following relation:
2t
PBr ¼ 0:875 rY
Dt
where Di is the tube inner diameter. The post expansion
tube collapse strength is also very important to safe-
guard the well against formation collapse. To determine
collapse strength, API has used the theory of elastic
stability to determine collapse strength for thin-wall
tubes. The transition from yield-strength collapse to
where F’s are empirical coefficients depending on tube
material. For current study, F1 ¼ 3.071, F2 ¼ 0.0667,
and F3 ¼ 1955. The results for burst and collapse strength
for two tube sizes, different boundary conditions and
ERs are given in Table 2. The results showed that the
post-expansion burst and collapse resistance decreases
linearly, as the ER increases. Furthermore, the collapse
and the burst resistance lowers sharply when the tube is
restricted at one end. This is true regardless of the tube
size. The effect of the axial restraint is more severe on
collapse and burst strengths due to large thickness
ð2Þ reduction.
It is necessary for field engineers to estimate the expan-
sion requirements before proceeding with downhole
expansion in order to select appropriate expansion tools
and avoid any unexpected failure. Figures 4–6 show the
variation in the expansion force and length and thickness
variations as a function of ER. An increase in ER results
in an increase of expansion force, thickness reduction,

TABLE 2.—Effect of axial restraint on burst and collapse resistance of expandable tube.

Tube size Expansion Pre-expansion Thickness Post-expansion Burst Collapse

ratio End reduction pressure pressure
ID (mm) OD (mm) t (mm) (%) Di=t Do=t condition (%) Di=t Do=t (MPa) (MPa)

174.625 193.675 9.525 16.36 18.3 20.3 Fix-Free 6.4 22.8 24.8 47.238 21.669
Fix-Fix 8.55 23.3 25.3 46.153 20.164
182.88 203.2 10.16 19.4 18.0 20.0 Fix-Free 8.84 23.6 25.6 45.650 19.288
Fix-Fix 13.69 24.9 26.9 43.650 15.722
 IN-SITU TUBE EXPANSION FOR DEEP GAS WELLS
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FIGURE 5.—Variation in percent thickness reduction with respect to
expansion ratio.
FIGURE 6.—Variation in length shortening with respect to expansion ratio.
and length shortening. It is obvious form figures that the
experimental and the simulated results agree well with
each other. For ERs greater than 20%, the thickness
reduction is 12% or more. This results in lower collapse
strength, which may lead to premature failure of the
expanded tube during its service life. In other words, it
is the reduction in thickness which will limit the maximum
allowable expansion and not the expansion force.
CONCLUSIONS
Experiments were conducted to simulate tube-
expansion in downhole environment depicting an oil
well. ERs were varied from 12% to 28%. Finite element
analysis was used to simulate tube-expansion process.
731
Results were obtained for various boundary conditions
to study the effect of ER and friction coefficient on
expansion force=pressure, thickness and length changes,
and surplus deformation. Excellent to good agreements
were found between experimental and simulation results,
particularly for expansion force and length shortening. It
was found that the drawing force to expand a weld con-
nection was approximately 15% more than a normal
expansion. However, for typical API buttress threaded
connection, the increase in expansion force was twofold.
The wall thickness of expanded tube decreased linearly,
as the ER and friction coefficient were increased. Tube
length shortens under fixed-free end conditions and var-
ies linearly with ER. Large ERs to have wider wells are
limited by tube thickness reduction. ERs greater than
25% results in larger than 12% thickness reduction result-
ing in 50% reduction in collapse strength, hence making
it unsuitable for downhole applications due to excessive
formation pressure.
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