SPE-182814-MS

First Successful Installation of a 4-1/2 Pre-Perforated Liner through a 5-1/2

Solid Expandable Liner

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Mohammed Murif Al Rubaii, Hasan H. Shehri, and Cosmas N. Nwachukwu, Saudi Aramco; Stacey Andrews and
Yasser Atallah, Enventure Global Technology

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Kingdom of Saudi Arabia Annual Technical Symposium and Exhibition held in Dammam, Saudi Arabia, 25–28
April 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Sustaining field proven technologies in mature fields and maximizing Return of Investment (ROI) is a
priority for operators worldwide. Financial constraints such as oil and gas prices, drilling cost, and any
intangibles must not burden the success of pushing limits to open new horizons, not just for the present
time but also for future generations. Parallel to reaching new limits, we must keep an eye on the safety
and engineering behind any step taken toward the limit to push the envelope successfully. Drilling team
recently used a a vendor product to maximize production, isolate a loss circulation zone, and push the
operating envelop by installing the first 4-1/2⬙ open hole completion (Pre-perforated liner) with inflatable
open hole isolation packers through a 5-1/2⬙ ⫻ 7⬙ open hole liner (OHL). The vendor product enabled
Saudi Aramco to install 5-1/2⬙ ⫻ 7⬙ solid expandable liner installation. The 5-½⬙ 18.24 lb/ft solid
expandable systems was utilized to isolate a loss zone and reactive shale section, sealing off the
problematic interval and allowing an extended lateral section to be drilled through the reservoir. The
expandable liner was run through a window cut through 7⬙ 26 lb/ft casing and subsequently installed
across part of the curve section to isolate the lost circulation zone. The use of the expandable liner enables
the ability to drill the remaining build section and horizontal section together with full circulation. This
paper describes the challenge and application.

Introduction
Maturing fields are a common challenge for drilling and workover operators around the world. Wells that
produce for long periods usually experience a variety of problems, which will ultimately require
workover. These workovers become essential to extending well life.
Four offshore areas have ongoing drilling and workover campaigns to maximize production. All four
areas show the same geologic structure and geological challenges. The casing design used is also identical,
which helps in unifying the solution and best practices. In these fields, severe losses typically occur in the
6-1/8 in. hole section, when drilling the buildup section and the horizontal section use high over-balanced
mud, due to limited hole size options. The losses cause difficulties running in hole to Total Depth (TD)
and are a major source of nonproductive time during both operations drilling and completion. Differential
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stickings across the horizontal section is one major problem encountered and is a challenge because of
high overbalance.

Case Study
In one recent case, the Drilling Team planned to sidetrack a workover well below a known lost circulation
zone, drill the 6 1/8⬙ hole section and run a ICD completion. Because of the heavily corroded 7 in. casing,
the sidetrack whipstock was set just below the lost zone. The drilling team faced a challenge while drilling
to isolate the loss circulation zone, and maintain a hole size to run with a conventional 4-1/2 in. liner

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completion to the total depth. This needed a solution to isolate the loss circulation zone, to be able to have
a full circulation column while drilling the reservoir section.
Drilling engineers suggested using a 5-1/2 ⫻ 7 in. expandable open hole liner (OHL), to isolate the loss
circulation zone before drilling the next reservoir section running 4-1/2 in. Pre-Perforated liner below the
5-1/2 ⫻ 7 in. OHL. The application was a first in Saudi Aramco and presented a challenge.
The unique application required multiple peer reviews and engineering confirmation to ensure a
successful installation. Extra attention was required due to the challenges the expandable liner would
encounter, including a differential sticking tendencies and anchoring the expandable liner. Prior to
installation, the installation team conducted a full Expanding SET on Paper (ESOP) meeting, to ensure the
design was optimal. The approach was to set the expandable liner shoe at the bottom of the loss zone, and
link it with the top anchor hanger above the cut window in the 7-in. casing. In doing so, the open hole
section was covered by expandable pipe, to provide zonal isolation to prevent communication between the
next section and liner. The success of the application allowed the well to return to a full fluid column, and
provide a new option for extending well life in this field, and in similar drilling and workover applications
in mature fields around the world.
The typical application for this type of expandable liner system is to cover loss zones. Many of the
aging wells in the field have loss zones due to many years of production. Installation of an expandable
liner seals off the loss zone with minimal ID restriction, to allow for maximum pass through.

Technology and Application Details

The vendor technology is a significant advancement first utilized 18 years ago. It has been used in a
number of installations and expandable liner of different sizes have been installed in a number of fields.
The 5-1/2 ⫻ 7 in. expandable system is an expandable solution primarily designed for well construc-
tion, intervention and workover sidetracks. The expandable joints utilize bonded elastomeric seals that
once expanded, anchor the system and provide sealing capabilities for zonal isolation.
Section preparation
Well Data The subject production well in the offshore oil field has 7-in. 26 lb/ft J55 base casing. A 75
pcf water based mud fluid was in the hole. The setting depth was 5454 ft to 6,570 ft. and hole inclination
was 56 degrees.
The buildup section was drilled using a 6-1/8-in. PDC bit and opened to 7-3/8-in. with an underreamer.
A six-arm calliper was then run to ensure hole size is in gauge. A dummy run was made with a 6-1/8-in.
tandem mill to simulate the running of the liner and to ensure that the 7-in. window is properly cut.
Running the liner The 1,170 ft expandable liner (OHL) consisted of the launcher, 31 joints of 5-1/2-in.,
18.4 lb/ft expandable casing, the anchor hanger, and tapered guide. The expansion assembly and
expansion cone are pre-installed in the launcher before running the OHL; the top of the expansion
assembly facing up is a lower safety sub. The complete system was made up and hung in the rotary table
on the rig floor by the casing slips. A false rotary table was placed over the casing stub on the rig floor,
and a 5-in. drill pipe inner string with upper expansion assembly components were run inside the
expandable liner, until the lower safety sub was tagged by the upper safety sub on the bottom of the inner
SPE-182814-MS 3

string drill pipe. The safety subs were connected and the drill pipe picked up to pull the slips on the liner.
The liner was run to the bottom of the 7-3/8-in. open hole section.
Cementing the liner A cement job was conducted to set the expandable liner on bottom. The job
consisted of pumping 125 bbl of 118 pcf slurry with thickening time of at least 10 hours. Following the
cement job, the expansion initiation dart was dropped to displace the cement from the drillpipe. The dart
landed in the launcher with 85 bbl displacement as calculated.
Expanding the liner After landing the dart, the drillpipe was pressured-up to break the rupture disc. The

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rupture disc is part of the expansion assembly and is located in the lower part of the launcher, between
the expansion cone and dart-landing seat. When the disc ruptured, pressure acts across the lower surface
area of the cone generating sufficient force to drive the cone upward to expand the pipe. After the disc
was ruptured, the expansion was initiated at 5500 psi. The expansion commenced in 90 ft increments, as
it was expanded out by stands of drillpipe. The average expansion pressure was 3500 psi.
As each stand was expanded, the pressure was released, top drive disconnected, stand was racked back,
and the top drive was lowered and reconnected at the rig floor. Once reconnected, the drillpipe was
pressured up again and the resulting upward force on the bottom surface area of the cone drove the cone
upward to expand the entire 5-1/2-in. casing. This process was continued until the cone was driven
through the anchor hanger of the system. The anchor hanger has five elastomer bands that are compressed
into the ID of the 7-in. casing when the cone is driven through it. As these bands are compressed, they
hang the system in the 7-in. casing and form a seal at the top of the liner. The expansion process is
completed when the cone is driven out the top of the expandable liner through the tapered guide at the top
of the liner. Total expansion time was 3.5 hours. The expansion tools and the cone assembly were then
pulled and laid out of the hole.
Drilling out the OHL and the following 5-1/2-in. section
A 5-1/2-in. PDC bit was used to drill the shoe of the expandable liner. Prior to drilling the liner shoe, the
liner was tested to 1500 psi for 10 minutes. The shoe was drilled and the following section was drilled
with the reduced mud weight to the planned TD. The 5,846 ft of 4-1/2-in. liner was they set on bottom
as per design.
Well Schematic
Below (Fig.1) shows the schematic of the well after the 4-1/2 in. pre-perforated liner was run and
cemented through the 5-1/2 ⫻ 7 in. expandable open hole liner

Figure 1—Schematic of the 4-1/2 Pre-Perforated Liner Installed below the 5-1/2 ⴛ 7 in. Expandable Liner
4 SPE-182814-MS

Equipment Details
Liner Data
The specifications for the expandable liner used in the well is described in the following set of tables:
Solid Expandable Tubular Data

Pre-Expansion Specifications Post-Expansion Specifications

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Grade EX-80 Expansion Ratio 15.1 %
Collapse 7,450 psi Collapse 3,900 psi
Nominal Weight 18.24 lb/ft Nominal Weight 19.48 lb/ft
Nominal OD 5.5 in. Nominal OD 6.195 in.
Nominal ID 4.840 in. Nominal ID 5.570 in.
Drift ID 4.715 in. Drift ID 5.511 in.
Wall 0.330 in. Wall 0.313 in.
Internal Yield 8,640 psi Internal Yield 7,260 psi
Launcher OD 6.151 in. Estimated Shrinkage 4.23 %

Expandable Connection Torque Data – XPC Connection Type - GIIC

Min Makeup Torque 4,500 ft-lb Yield Torque 7,900 ft-lb

Max Makeup Torque 5,700 ft-lb Maximum Initial Shoulder Torque (30% Minimum Makeup Torque) 1,350 ft-lb

Base Casing Data

Nominal OD 7.000 in. Minimum ID 6.276 in.

Nominal ID 6.276 in. Pin Bore ID 6.276 in.
Drift ID 6.151 in. Special Drift N/A in.

Open Hole Section

Hole size 7-3/8 in. Section Drilled Build Section

Pilot Hole size 6-1/8 in. Max Build Rate 3.0 deg/100ft
Pilot Hole length 5 Max Inclination 71 to 90 deg

Set Running Limitations

Max Set down Weight 31,200 lbs Maximum Overpull on 50,000 lbs
in Open hole for ledge Drillpipe before Mechanical
or unstable wall; 80% Expansion; 80% of Launcher
of Guide nose initiation force
Compression Rating
Max Set down Weight 217,600 lbs Max Circulation Pressure; 80% 2,400 psi
in Open hole with of Rupture Disc Rating
Differential sticking; Max Set down Weight in 10,000 lbs
80% Connection Cased Hole or in Window
Minimum Parting Load
SPE-182814-MS 5

Workstring Data

Workstring Components Strengths and Limitations

Component Tensile (lb) Torque (ft-lb) Compression (lb)

Debris Catcher 206,000 7,100 206,000

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● Includes 20% Safety Factor

Circulation Flow Rate Cementing

Dart Seat ID Unlimited Time Up to 10 hrs Up to 1 hr Up to 3 hrs

(in.) ⬍25 ft/sec ⬍50 ft/sec ⬍75 ft/sec
1.624 4 bpm 8 bpm 12 bpm 5 bpm

Case Study Summary

The job was performed successfully without any incidents and in accordance with Saudi Aramco
specifications and standards. The extra attention to ensure that the base casing is free of any cement or
debris, was critical to the job’s success. All personnel and service company representatives were
knowledgeable about their equipment, and there were no problems with any personnel or equipment used
on the job. The attention paid to planning and communicating effectively are the primary reasons this
installation was a success.
Value
The solid expandable tubular allowed Saudi Aramco to minimize formation damage if bridging materials
were used to isolate the loss circulation zone. The expandable tubular greatly reduced the cost by not
having to use an off bottom cemented liner and its associated risks. The expandable liner also isolated the
loss circulation zone minimizing potential problems to run the 4-1/2 in. pre-perforated liner.
Conclusions
Differentially stuck open hole liners in a loss circulation zones are a common problem in mature oil and
gas fields, and especially with horizontal re-entry wells. This successful installation to mitigate a
differentially stuck conventional liner shows the viability and cost-effectiveness of solid expandable
tubular technology in resolving the wide-spread, long-standing challenge.

Acknowledgements
The authors thank the management of Saudi Aramco for their support and approval to publish this paper

References
1. Dupal, K., Shell Deepwater Development, Inc.; Campo, D., Shell Exploration & Production Technology; Lofton, J.,
Chevron Petroleum Technology Company; Weisinger, D., BP; Cook, R., Bullock, M., Grant, T., and York, P.,
Enventure Global Technology, L.L.C., ⬙Solid Expandable Tubular Technology – A Year of Case Histories in the
Drilling Environment,⬙ at 2001 SPE/IADC Drilling Conference, Amsterdam, 27 February – 1 March.
2. Steven W. Sparling, Kerr-McGee Oil & Gas Corporation; Greg Noel, Enventure Global Technology; ⬙Expanding Oil
Field Tubulars Through a Window Demonstrates Value and Provides New Well Construction Option⬙ at 2004 SPE
Annual technical symposium & Exhibition, Dammam, April 25–28, 2016.