With the increasing wellbore repair in old wells, such as plugging perforated intervals, repair of casing leakage, and blockage of wellbore corrosion and perforation, classical expandable tubular technologies have emerged many drawbacks, for example low patching efficiency, small diameter with effect after patching, and inconvenience in not only running general completion tools after patching but secondary patching at the original patch. So, with thin wall, large diameter and stainless steel, a new expandable tubular technology was developed. In addition, its structural configuration, principle, process and supporting tools were analyzed in detail. Field applications show that (i) this expandable tubular patching technology is advantageous for low operation pressure, high patching efficiency, reliable performance, and easy operation, which may solve such problems as poor corrosion resistance and rust in traditional expandable tubular; and (ii) the casing with the internal diameter Ø124.26 mm becomes approximately Ø108 mm through traditional ways, but achieving Ø116 mm via this expandable tubular patching with thin wall and large diameter, and its resistance to internal pressure equivalent to that of traditional technologies. This performance allows for subsequent running of conventional downhole tools and realizes the restoration by large-diameter casing patching. This technology perfects the expandable tubular patching system and provides a novel option for large-diameter wellbore repair in the secondary development of old wells.
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