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Johnson 2013
Johnson 2013
This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 6–9 May 2013.
This paper was selected for presentation by an OTC 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 Offshore Technology Conference and are subject to correction by the author(s). The material does not necessarily reflect any position of the Offshore Technology Conference, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Offshore Technology Conference 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 OTC copyright.
Abstract
This document reviews challenges and solution to previously overwhelming issues regarding 14-in. liner placement in the
Gulf of Mexico. Necessity and considerable effort are required to deal with multiple mobile/active tar zones, associated with
fault zones throughout the sediment sections and below the base of salt. Deploying liners to the desired depth through such
hole sections have resulted in costly non-productive time (NPT). The large bore expandable liner hanger drilling/washing
capabilities provides a reliable method to assist the operator in reaching their targets.
Advancements in casing connection technology have provided enhanced torque capabilities for some time. Today, the
large-bore expandable liner hanger (LBELH) system provides the capability and reliability to deliver torque to the liner shoe.
This added rotation and reciprocation capability while circulating is at the heart of NPT reduction.
The running tools to deliver such a system have the capacity to provide 110K foot pounds of torque at top of liner (TOL).
Reaming/drilling attachments to the liner shoe have advanced to a point that allows operators to take advantage of the
technique to deliver the liner to its target depth.
This combination of equipment allowed a major Gulf of Mexico operator to wash and ream a 14-in. liner through tar and
shale, inside their 16-½-in. borehole. Two successful attempts totaling 7-½ hours of reaming resulted in gains of 335 feet.
The final effort was to wash and ream the liner down inside the 14-½-in. pilot hole. This was an additional 30 feet of “drilling
conditions” to total depth (TD), requiring an additional 45 minutes of torque and vibration.
The liner was cemented and the hanger was set and tested. The operator commented: “Excellent results”, [and that he
was]”Very pleased to get this critical and difficult section cased off”. (Benet, 2012)
Introduction
With proven expandable technology already in place due to problems experienced with traditional liner hangers in difficult
well-bore scenarios, the time had come to push toward large-bore expandable liner hangers (Cantu et al, 2004; Nida et al,
2004). The main components of the expandable liner system are an integral liner hanger/packer assembly combining an
upper tie-back receptacle with elastomeric elements, which are bonded directly to the body of the hanger.
Figure 1 shows the basic components of the original expandable liner hanger (ELH) system compared to a conventional
“casing hanger”. The bonded elastomeric elements compress against the internal diameter as the hanger expands which
virtually eliminates any leak paths between the liner, liner hanger, and previously run casing, maintaining the pressure
integrity of the well bore (Moore et al, 2002).
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This paper reviews the development and application of the 14-in. x 16-in. large-bore
expandable liner hanger system used as a liner within casing after the liner was drilled
into position, reaching the total depth of the well. (Shown in Figure 2) The large-bore
expandable liner hanger would provide flexibility in placement of the liner, offering
reliable support and proven redundant sealing technology.
Performance Benefits
Benefits of the LBELH include eliminating the need to land the 14-in. liner at a fixed
point in the well bore. With deviation playing the role of “spoiler” when attempting to get
the conventional casing hanger to the desired depth, the LBELH would be able to set at
the depth that would provide the best integrity to the string. The capability to rotate and
drill-into position, plus reciprocate during the cementing job proved beneficial with high
deviation at the liner shoe. Additionally, this hanger type provides liner anchor capability
bi-directionally that is in tension or compression at TOL. The hanger meets the challenge
to maintain anchor under compressive loading, whereas conventional systems either do
not or are challenged to maintain position.
Job Design
From the beginning, the well design called for a large bore expandable hanger to set a 14-in. 115 ppf semi-flush thread liner
across the 14-½-in. x 16-½-in. open hole section. As the section was drilled, it was discovered that the liner run would
involve tripping through multiple tar zones, and as a result, washing and reaming with a reamer shoe/bit would be necessary.
The open hole section was planned from 23,645 ft. MD (23,208 ft. true vertical depth (TVD)) to 26,116 ft. MD (25,540 ft.
TVD) with a 120 ft. pilot hole. Likewise, TOL was planned for 22,942 ft. MD (22,700 ft. TVD) with the 14-in. shoe to be
positioned at 25,959 ft. MD (25,400 ft. TVD). The synthetic based mud (SBM) was to range from 11.8 – 13.6 ppg for this
section (see Figures 3 and 4).
From top to bottom, the liner landing string consisted of the following 6-5/8-in: 57 ppf (V-150), 50 ppf (S-135), 40 ppf
(S-135), and 34 ppf (S-135) drill pipe, the ELH assembly, 14-in. 100 ppf semi-flush thread x 14-in. 115 ppf semi-flush thread
connection crossover, 68 joints of 14-in. 115 ppf semi-flush thread liner, a landing float collar, one joint of liner, a secondary
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float collar, three joints of liner, and a drillable reamer shoe/bit. Installed directly beneath the ELH was a dual liner wiping
plug set, which is common for most deepwater casing cementing jobs. Provided that the liner run would be a wash and ream
operation, the changes to the landing string were the removal of the non-rotating bow spring centralizers and the addition of a
drillable reamer bit/shoe located at the bottom of the string. Prior to running the liner, surge reduction tools were also
removed from the landing string along with the auto-float collar in the liner being converted to a closed position. This was to
mitigate the potential of tar entering into the liner and plugging the ELH assembly. In the absence of non-rotating
centralizers it, was approved by the operator that the liner be set in the 14-1/2-in. pilot hole for centralization during the
cement job.
Figure 4: Original Model Figure 5: Landing String for Wash & Ream Operation
Given that the wellbore is full of synthetic-based mud, friction factors chosen for this model were 0.19 for the cased hole
and 0.25 for the open hole. The difference for this particular model being that a factor of 0.50 was chosen to represent the tar
zones strung along the open hole section (see Figure 5). Due to the nature of tar, it was expected that there would be
unwanted weight on bit (WOB) while running in hole. This effect would be rather difficult to model, and as such, more
emphasis was placed on the modeling of torque distribution through the landing string, especially since washing and reaming
will work the liner to the bottom.
To better illustrate the behavior of downhole torque, all critical shoe depths were considered for minimum and maximum
torques. The critical shoe depths to be considered were located at:
16-in. casing shoe (23,645 ft. MD)
Top of known tar zones (24,400 ft. MD)
Middle of known tar zones (24,625 ft. MD)
End of known tar zones (24,850 ft. MD)
Open Hole TD (26,616 ft. MD)
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Installation
The drillable reamer shoe/bit was made up to the shoe track and was the first of the liner landing string to run into hole
(RIH). The float equipment was converted at 1,700 psi on surface and the 68 joints of liner were then RIH behind the shoe
track. The ELH assembly was made up to the liner and the landing string was deployed to the 16-in. casing shoe. A baseline
for circulation and torque was then taken; followed by pick-up (P/U) and slack-off (S/O) weights to judge the amount of drag
in the string before proceeding out into open hole. (Figures 8 and 9)
Figure 9: A Baseline Was Taken at the 16-in. Casing Shoe (23,645 ft MD)
The string began to ream down with 35-45 kips of WOB, and 700 psi of pipe pressure. To continue making hole, the
string was lifted 10 ft. to clear debris from around the bit shoe, and down forward to a depth of 24,660 ft. WOB of 28 kips
was applied and after two ft. of progress, it was increased to 40 kips, before breaking over to 15 kips after another 4 ft. To
clean the hole, the entire stand was lifted while rotating and circulating to move debris and tar from between the pipe and the
open hole. The amount of time spent washing and reaming at this point totaled 2 hours.
Conclusion
The objectives were achieved to place the 14-in. liner on depth as planned and within the wellbore coordinates consistent
with the original design. This resulted in retaining the 11-7/8-in. contingency liner option should further well-bore problems
be encountered below the tar zone prior to reaching total depth. This is a key deliverable and important criteria given that a
12-1/4-in. hole size is required at total depth to accommodate the well completion design.
Furthermore, options to bypass tar in the 16-1/2-in. hole were becoming limited due to the constraints at the 16-in. casing
shoe. Available open-hole section below the 16-in. shoe to conduct the bypass and still achieve original reservoir targets was
diminishing with each successive bypass.
The application was not only successful in reaching the planned liner setting depth, it also provided a means for future
application in potential unstable wellbore drilling conditions; such as but not limited to, sloughing shale, depleted zones,
formation creep, and wellbores with hole cleaning constraints or cuttings beds build-up.
The engineering effort and collaborative planning required to progress past these zones with multiple mobile/active tar
zones proved highly beneficial to both the operator and the service provider. Deploying liners to the desired depth through
such hole sections have significantly reduced exposure to non-productive time. The liner hanger’s capacity to enable rotation
and reciprocation to the liner, while circulating, is the fundamental basis of this successful installation.
With the utilization of this enabling design and strategy, the concept is now being added to the contingency planning for
subsequent similar well types. Using the design as outlined in this case study to meet the challenging well-bore conditions
due to tar and the requirements to maintain hole size on target with the 14-in. liner has established a key risk mitigation.
Acknowledgments
The authors wish to thank the management of Chevron DWEP for allowing Halliburton to use this hanger technology by
recognizing its advantages towards key risk mitigation in the deepwater arena and the management of Halliburton for their
encouragement and permission to publish this paper.
References
Benet, Paul, intercompany email, 2012.
Cantu, J., Smith, P., Nida, R.: “Expandable Liner Hanger Application in Arduous Well Conditions Improves Reliability: A Case History,”
paper SPE 88510 presented at the SPE Asia Pacific Oil and Gas Conference and Exhibition held in Perth, Australia, 18–20 October
2004.
Jimenez, C., Soto, S., Leon, A., Batocchio, M., Marval, P., Schoener-Scott, M.: “Case Histories ― Implementation of New Liner Hanger
Technology in South Central Venezuela Significantly Improves Operations in Complex Wells,” SPE 118387 presentation at the 2008
Abu Dhabi International Petroleum Exhibition and Conference held in Abu Dhabi, UAE, 3–6 November 2008.
Johnson, M., Ardoin, K., Bullard, B.: “Large-Bore Expandable Liner Hangers Significantly Improve Operational Cost in a Deepwater
Gulf-of-Mexico Well” paper OTC 21925 presented at the 2011 Offshore Technology Conference, Houston, Texas, 2-5 May 2011.
Mason, C.J., and Chen, D. C.-K., “Step Changes Needed To Modernize T&D Software,” Paper SPE 104609, SPE/IADC Drilling
Conference, Amsterdam, The Netherlands, 20-22 February 2007.
Moore, M. J., et al.: “Expandable Liner Hangers: Case Histories,” paper OTC 14313 presented at the 2002 Offshore Technology
Conference, Houston, Texas, U.S.A., 6-9 May 2002.
Nida, R. et al.: “Innovative Expandable Liner Hanger Application Saves Time on Pinedale Anticline Drilling Operations: Two Case
Studies,” paper SPE 90192 presented at the 2004 SPE Annual Technical Conference and Exhibition, Houston, Texas, 26-29
September.