Expandable

Technology

ALTERNATIVE BOREHOLE LINER (ABL®)

OVERVIEW AND BENEFITS

ABL (Alternative Borehole Liner) is a slotted expandable steel tubular. It has been designed to
temporarily isolate sections of wellbore with no loss of hole size. Unlike conventional casing and
liner, ABL® is designed to be run through the previous casing then expanded across the problem
zone. Once the ABL® has been expanded, cemented and drilled out the problem zone will be
isolated with a cement sheath, therefore normal drilling may resume with no loss of hole size.

After ABL® deployment the hole section is isolated by steel reinforced by fibre cement where steel
covers approx. the 60% of the area.

Typical applications for the ABL® are the selective isolation of problem zones which would
otherwise dictate the setting of a casing or liner:

• Unstable holes
• Rubble zones
• Sloughing shales
• Loss zones
• Faults
• Over-pressured formations
• Depleted formations
• Incomplete casing runs

By solving the above-mentioned problems with an additional string of casing in some instances the
associated telescoping could result in an unworkable hole size or prevent the well being completed
with the optimum completion.

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CONVENTIONAL ABL® SOLUTION

SOLUTION

Problem Zones Benefits

• Unstable Hole • Casing contingency
• Sloughing Shale without loss of hole size
• Loss Zone • Isolates the problem
• Overpressured/ depleted • Eliminates well
formations telescoping
• Incomplete casing run • Maximises final hole size
• Large potential well cost
savings

Larger hole diameter

through the reservoir

The ABL® is currently available in three different sizes:- 4 ½”, 6 5/8” AND 8 5/8”.

4 ½” ABL® expands to 7” casing size

6 5/8” ABL® expands to 9 5/8” and 10 ¾” casing size
8 5/8” ABL® expands to 11 ¾” and 13 3/8” casing size

There are essentially two ways of using an ABL®.

1. It can be a planned operation, therefore included in the Drilling Program (preferred method).
2. It can be also be used to solve an unexpected drilling problem.

Only when the ABL® is a planned operation it is possible to tieback the ABL® into the casing above.
In fact, if the casing has been run with a Weatherford oversize shoe it is possible to set the top of
the ABL® inside the shoe joint and still retain the same ID. of the casing after expansion.

1. Cased Hole “Tied Back” Method 2. Open Hole Method

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ABL® DEPLOYMENT
Hole Requirements/ Run in hole

In order to deploy an ABL® and still retain the same ID. of the casing above it is necessary to have
an over-gauge hole section. In the case that casing is set high, the hole section below the shoe is
over-gauge already. In the more common application, casing has been set at the correct depth and
at some deeper point a problem zone is found, then the hole size through that zone needs to be
opened up with a Bi-center bit, a bit+hole opener, or an under-reamer, depending on the formation.

Depending on the ABL® size to be deployed and the type of application, the over-gauge required
ranges from 1 1/2 to 4 inches.

Alternatively, if the hole is not overgauge, it is still possible to expand an ABL® but this will create a
1” to 2" restriction across the problem zone.

The ABL® string is run with a “conventional” drilling BHA which should include enough drill collars
and heavy weight drill pipe to shear the pins on the running tool (typically, pins are set to 30-60,000
lbs.).

The ABL® needs to be run to the bottom of the hole. This is because the pins on the running tool
are sheared by slacking-off weight against the bottom of the hole. Should it be necessary to set an
ABL® in the upper part of a hole, a cement plug must be set, to provide a base, prior to running an
ABL®.

The ABL must be fully cemented in place prior to drilling through it. It also must ultimately be cased
off as the integrity of the cement sheath cannot be guaranteed over time.

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ABL® EXPANSION

Weight from above drives a tungsten carbide cone through the ABL® pipe from top expanding the
ABL®. During expansion, two drift cones verify the inside diameter of the expanded ABL® is greater
than the outside diameter of the next drill bit.

An important phenomenon occurs when an ABL® is expanded. “Surplus expansion” is caused as

the steel naturally “flows” over the expansion cone, similar to waves created in the water by a
moving object. The result of this spontaneous behaviour is that the i.d. of the expanded ABL® is
approximately 4-6% larger than the o.d. of the expansion cone. This is a key feature in achieving
the same inside diameter of the last casing and prevents hanging up the running tool as it is
retrieved through the expanded ABL®.

After the running tool pins are sheared at approximately 30 – 60,000 pounds, then, depending on
the size of the ABL®, 10-25,000 lbs. of weight is necessary to expand. Typical expansion speed is
600 ft./hr. (10 ft./min.).

A single run is required to run, expand and cement the ABL®.

After the cement sets, an undersize bit/melon mill is used to re-enter the top of the ABL. A full
gauge bit is run to drill out the remainder of the cement inside of the ABL® and the ABL® shoe.
Drilling then continues below the ABL® with no loss of hole size.

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ABL® CEMENT JOB

An ABL® cement job is equivalent to setting a balanced cement plug across the ABL® (inside
and outside) as per normal good oil field practices.

Slurry recipe: to be similar to a conventional cement plug with an addition of 0.25 % fibers.
The Cementing Company in co-operation with WCS performs the preliminary design, this is
further optimised and tailored to the actual hole condition with specific reference to BHST, mud
proprieties, lost circulation and formation pressure.
Slurry and spacers weight: to be based on maximum ECD and mud weight.
Slurry and Spacers Volume: slurry volume to be based on open hole caliper log plus excess
(minimum 20% recommended). Volume of the spacer ahead to be 35 bbls minimum and
required volume for the spacer behind to balance and separate mud from cement.
Outline Operation sequence:
• Prepare fibre cement in a batch mixer to insure uniform distribution of fibres.
• Sting into ABL shoe with R/T nose and prepare for cement job. Connect lines to the
cement unit and test.
• Pump slurry and spacers and displace with mud at maximum possible rates. Slow down
at a rate of 1-2 bpm before end of calculated displacement. Stop pumps.
• Pull the R/T slowly (20-30 ft/min) inside previous casing at least 150ft above the casing
shoe.
• Circulate bottoms-up until mud is coming back clean.
• POOH and WAIT ON CEMENT

To cement the ABL® WCS has field proven and recommends the combination of regular cement
with the addition of 0.25% of fibres (nylon or polypropylene). Fibre cement provides improved
impact strength and durability when compared to regular cement alone. The fibres also help
maintain the mechanical integrity of the cement job while drilling ahead and tripping pipe.

Specially designed expandable centralisers also play an important role in achieving a good cement
job. They are necessary when the ABL® application is attempting to isolate an over-pressured or a
depleted formation. Image logs taken in the field have shown excellent centralisation of the ABL®
and have proven the effectiveness of the product. (See ABL® Components paragraph for more
information on centralisers).

The major cementing contractors are abreast of the WCS technology. Experience has
demonstrated an ability to work together and draw upon each other’s expertise in order to achieve
the best possible result for the well.

Note: The collapse and burst resistance of the ABL+Cement is determined by PECAP,
“Pressure Evaluation and Cement Analysis Programme”. The programme uses the
Winderburgs formula to calculate the Collapse resistance of the Cement. When we calculate
the resistance of the ABL we work on the conservative side and ignore the presence of the
steel. We assume that the steel is only providing a guide for the bit to drill through the hard
cement plug. Therefore we calculate the ABL resistance as if it were a cylinder made of
cement. This formula, which is approximately 12% more conservative than the API formula, is
a function of the mechanical characteristics of the cement (Wall Thickness, Shear Modulus,
Poisson Ratio, Young's Modulus, Tensile Strength). The burst resistance is calculated as a
function of the cement properties as well as the pore and fracture pressure gradient of the
formation.

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DRILL OUT CEMENT INSIDE ABL

It is recommended to drill out the ABL top with a “tapered” drill out assembly. This assembly will aid
re-entry into the ABL top connector, even if a tie back shoe has been run.

An under-sized Tri-cone Rock Bit in combination with a full gauge string/melon mill must be used to
dress the top of the ABL and simultaneously drill out the cement inside the ABL. The bit/mill
assembly should be used to drill 5m into the ABL. Then a full gauge Tri-cone rock bit should be run
with the next BHA to continue drilling out the cement and the ABL shoe.

These are the suggested drill out assemblies for different ABL i.d.’s:

ABL Size ABL ID Post Expansion Tapered dressing/drill out assembly

8 5/8” 12 ¼ ” 8 ½ ” Tri Cone Rock Bit + 12 ¼ ” STRING MILL
6 5/8” 8½” 6” Tri Cone Rock Bit+ 8 ½ ” STRING MILL
4 ½” 6” 4 1/8 ” Tri Cone Rock Bit + 6” STRING MILL

The drilling bit required to drill the remainder of the ABL after the mill run must be of the same size
or smaller than the secondary cone used to drift the ABL. A full gauge tri-cone rock bit should be
used. The BHA should never be stiff if the ABL has been set in a bent or build up section of the
hole.

During drilling out of the cement, R.O.P. should never exceed 15-20 meters/hour. Drill out the shoe
and continue drilling below the ABL until BHA change is required.

Always take extreme caution when running into the top and bottom of the ABL with future BHA’s.

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ABL® COMPONENTS

Running Tool
The top part accommodates the expansion cone and two drift cones, all of which are
provided with tungsten carbide interchangeable parts. The top connection of the
Running Tool is a standard BOX type The bottom part contains the shearing device
with the adjustable shear pins and the pin thread onto which the ETC is made-up.

Top Connector (ETC)

Is the interface between the running tool and the ABL string and contains the locations
for the shear pins. Two different Top Connectors are available for open hole and cased
hole applications with the main difference that the open hole type achieves a sort of
“flute shape” post expansion, due to the particular slotted pattern design. This has the
purpose of facilitating the entrance of the next drilling assemblies.

Joints
ABL® is tubular steel slotted to an exact pattern specification using an automated
abrasive high-pressure water jet slotting system. The ABL® incorporates a specially
designed expandable connection, which enables the joints to be handled easily and
made up quickly. Supplied in 40 ft lengths and also available in pup joints of different
lengths. The joints are internally coated with a polyurethane plastic sealant compatible
with the commonly used drilling fluids (oil or water based, salt saturated mud etc.) and
only sensitive to temperature.

Centralisers
1 or 2 Centralisers can be installed per each ABL® joint. When the ABL® is expanded
they split apart in two segments which are pushed against the wellbore as the cone
passes by. This action causes an increase of the restoring force that is acting on the
ABL® from the 2 opposite sides and naturally guides the ABL® to its point of equilibrium
that is the centre of the hole. This centralisation is important in providing an even all-
round cement sheath around the ABL®.

Bottom Connector
This is the interface between the shoe and the ABL® string.

Anchor Shoe
The shoe is made of drillable aluminium/composite. It has been designed with the
purpose of ensuring full expansion of the last ABL® joint (Bottom Connector). The
upper part of the shoe is slotted and follows the expansion of the Bottom Connector.
The lowest part remains unexpanded and provides a no-go for the R/T. The shoe also
provides an anchoring grip on the formation, since it is equipped with dogs that come
out when the nose of the R/T enters the top of the shoe, at the end of the expansion
process. This is an extra precaution for deployment in highly deviated wells to insure
that the drag of the running tool on the ABL®, when pulling out, does not cause any
upwards movement of the string. The anchor shoe is positioned inside the rat-hole
below the under-reamed section.

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ABL DEPLOYMENT SEQUENCE

Open Hole Option

Wait on
Drill Pilot Shear
POOH to cement,
Hole, Under- Running
Spot ABL top, drillout
ream Run ABL and tool,
balanced circulate cement
problem sit on bottom expand
cement plug out excess inside ABL
zone and run ABL to the
cement and shoe,
caliper log bottom
drill ahead

Cased Hole Oversize Tieback Shoe Option

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CASE HISTORIES

Unstable zone An unstable zone right below a 7” liner was dictating the setting of a 5” liner
to enable drilling the reservoir with light mud weight. The resulting diameter
across the reservoir was not compatible to the type of completion the well
required. The hole was under-reamed to 8.5” and 776 ft. of 4.5” ABL® was
successfully expanded to a 6” I.D. to cover the unstable zone. A 3 ft gap
was left between the shoe and the ABL® top. The section was a build-up
from 48 to 68 degrees at ABL® depth.
Salt formation Drilling became difficult when a salt dome was encountered in the 8.5” hole.
It became obvious that the 7” liner could not be run through the salt to its
planned setting depth and drilling was stopped at the salt base. The salt
section was under-reamed to 12.5” (the caliper showed a 10.5” hole due to
the squeezing tendency of the salt) and 187 ft. of ABL® was successfully
cemented and expanded to 8.5”.
Overpressured Whilst drilling 8.5” hole at 9,000 ft. with 14.5 ppg mud, a 16.6 ppg kick was
zone/ kick taken. The zone required 17.1 ppg mud to regain well control. The
formation below the over-pressured zone required mud cut-back to avoid
heavy losses so that a 7” liner was required at this point. Hole was under-
reamed to 11” and 286 ft. of 6 5/8” ABL® was deployed across the
overpressure zone and cemented with fibre cement + gas block. UBI/CBL
log showed perfect expansion of ABL® and good cement job. Mud weight
was reduced to 14.5 ppg and drilling continued with 8.5” bit to the 7” point
without recording any gas influx.
Loss zone Losses were experienced when drilling 8.5 hole at 11,500 ft. LCM and a
cement plug were able to cure losses but when the bit drilled through the
cement plug losses were re-initiated. Hole was under-reamed to 10 ¼” and
150 ft. of 6 5/8” ABL was successfully deployed across the loss zone and
cemented with combined LCM and fibre cement. Drilling continued below
the ABL® with 8.5 bit and no loss record.

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