Tapered Liner System

for Zonal Isolation and

Hydraulic Fracturing: An
Application in the
Kirthar Fold Belt Region
Presenters:
Syed Asad Abid
Polish Oil and Gas Company –
ORLEN S.A. - Pakistan

Annual Technical Conference – 7th & 8th November 2023

Exploring the Unexplored: High Risk Plays and Economic Challenges
Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Introduction:

• Most Kirthar concession wells are characterized as “Tight Gas” wells (reservoir
permeability < 1mD) 1.
• The reservoir formation “Pab” needs stimulation through hydraulic fracturing to enable
the well to flow at commercial rates.

• Located in the Fold and Thrust Belt region with a strike-slip component.
o Borehole instability due to in-situ stress induced complexities such as weak bedding planes, rubble zones,
and fracture through shales i.e. Laki and Ranikot Shale formations.
o Shale formations are drilled in the 12-1/4” intermediate hole section with high MWs (15.0 – 16.5 ppg MW
ranges) for wellbore stability*.

• Pab sandstone drilled in the 8-1/2” production hole section.

o MW range of 11.0 – 12.5 ppg and cased off with a 7” Liner and subsequently Hydraulically Fractured and
completed.
o Potential lost circulation and differential sticking challenges – drilled separately from the high MW requiring
Laki Shale, and Ranikot formations.
*Based on geo-mechanical model.

Conventional Kirthar Well Schematic

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Well A and Side Tracks:

• Well A:
o Observed severe wellbore stability challenges in 12-1/4” section particularly the Ranikot formation with excessive reaming, well
conditioning, and pack off events.
o 8-1/2” production drilled through the Pab Formation with a Mud Weight of 12.5 ppg.
o Partial to complete losses were observed during drilling and string stuck during wiper trip after TD. Unsuccessful fishing attempts and the
open hole was lost.

• Well A ST-1 and ST-2:

o Two subsequent sidetracks (A-ST1 & A-ST2) were unsuccessfully drilled with string stuck in each successive sidetracks (MW > 15.0 ppg) –
Ranikot and Pab attempted to be drilled in the same hole section.
o Losses and differential sticking in the Pab formation worsened by high MWs required to stabilize Ranikot.

• Temporary suspension:
Well Temporarily suspended until following challenges were addressed:
1. Perform cased hole exit in the 9-5/8” casing and drill Ranikot formation in the 8-1/2” hole section.
2. Drill the Pab reservoir in a separate 6” hole section and to case it off using a liner system rated for high bottom hole pressures during the
frac operations while allowing a through bore ID for successful perforations and wellbore interventions, and allowing for a tie-back
completion option.

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Well A ST3 - Re-design:

N a m e : N u m e r; P ro d u
b c tlin e : C a
lo u t ;S u b

• Following tapered liner string evaluated: Uppe r PBR

1. A 9-5/8” x 7” dual direction slip type Hanger segment, with a 7” liner

Line r To p Pac ke r
top packer along with a Polished Bore Receptacle.
2. A lower PBR with a seal bore ID of 4.75” to be run above the 4-1/2”
liner joints. The burst rating of the lower PBR over 30K Psi – thus
Line r Hang e r
sustaining Frac loads generating bottom hole pressure of 16,000 psi C

or above. # N a m e : N u m e r; P ro d u
b c tlin e : C a
lo u t ;S u b

3. A V0 rated Seal Stem Assembly consisting of FFKM material 7" Line r Jo ints

elastomer seals for stinging into the 4-3/4” seal bore ID lower PBR
allowing for production through a tie-back mono bore completion. Lo we r PBR

7" X 4-1/2" X-o v e r

4-1/2" Line r Jo ints

4-1/2" Landing Co llar

# N a m e : N u m e r; P ro d u
b c tlin e : C a
lo u t ;S u b

4-1/2" Flo at c o llar

N a m e : N u m e r; P ro d u
b c tlin e : C a
lo u t ;S u b

Re ame r S ho e

Schematic of 9-5/8” x 7” x 4-1/2” Tapered Liner

String
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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region
Well A ST3 - Re-
design (continued):

o Critical to have liner

rotation for reaming
potential obstructions and
during cement job to
ensure good quality
cement and bond long.
o Torque and Drag simulated
along with centralization
placement to achieve at
least 80% standoff.

o Hydraulics calculations performed

ensuring circulation at a rate of 4-
6 bpm was possible within
permissible pressure values while
reaming with the liner string.
o ECDs and circulation pressures
were found to be within
acceptable ranges during cement
job simulation.

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Operations:
9-5/8” Casing
• Drilling and Casing off:
o Ranikot formation drilled successfully in the 8-
1/2” hole section and cased off with a 7” Liner
with a MW of 15.0 ppg.
Second 7" Liner Hanger
o Pab reservoir drilled in 6” hole section to well
3 x 7” Liner Joints for subsequent DST/Frac
TD at 2844 m MD with MW of of 12.6 ppg. Operations
o 9-5/8” x 7” x 4-1/2” Liner string run. Liner wiper 7” x 4-1/2” Inline PBR
plug placed across the 4-1/2” Liner joints below
lower PBR using 2-7/8” tail pipe assembly First 7" Liner Hanger
connected to running tool.
o Tapered liner string run in hole to setting depth
and liner hanger set successfully.
o Successful cementing operations conducted –
16.0 ppg Flexible Expandable cement slurry
pumped.
o Liner rotated while cementing – achieved
8.5” hole
excellent bond logs.
o The use of 3 x 7” Liner Joints were used in
between second 7” Hanger and Inner PBR for
subsequent DST/Frac/Completion Operations. 4-1/2" Liner Shoe
6” hole

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 Second Presenter

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Conventional design during Hydraulic Fracturing:

o Well is completed in 8.5” hole with 7” Production Liner

o 15K Frac / DST Packer set inside 7” Liner followed by perforations
o Hydraulic Frac Treatment as follows:
o Breakdown Test
o Step Rate Test (Step-up & Step-down)
o Calibration Test (Min Frac)
o Main Treatment

o Surface Pumping Parameters during HF treatment:

o Surface pumping Pressure: 12,500 psi
o Pumping Rate: 20 – 22 BPM
o Slurry Types: KCl Brine, Liner Gel, X-Linked Gel
o Slurry Density: 10 – 12 ppg (up to 10 PPA Proppants Slurry)

o After pumping the frac treatment, string is pulled back to surface followed by well
completion operations

Perforation
Perforation
Interval
Interval

Well Schematic conventional (Left)

Conventional completion schematic (Right)
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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application in the
Kirthar Fold Belt Region

Possible Options for 6” hole section for Hydraulic Fracturing:

o Conventional 15K Liner Hanger System

• 4.5” Liner Top is exposed during Hydraulic Fracturing – Potential Weak Path in case of poor cementing and/or issues
with Liner Top Packer, No Contingency

o Use of Tie-Back Seals to isolate Liner Top at bottom of Frac String

• Potential Risk of Tie-Back Seals Pop-Out during injection as per tube move calculations and limited length of liner top
PBRs

o Use of Mechanical Packer / Hold-down subs along with Tie-Back Seals to restrict seals movement
• Hydraulic Isolation chamber between PBR & Packer annulus area, Potential risk of hydraulic lock scenario while
unsetting Packer and Tie-Back Seals

o Use of DST/Frac Packer inside 4.5” Liner

• Minimum ID of DST/Frac String (~”) causing extra pressure drops – Compromise on the overall fracture design and
geometry

o Use of Inline PBR / Taper Liner Hanger System

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region
Lower PBR / Taper Liner Hanger System
 Well integrity wise fewer potential leak paths
32" Conductor Shoe

 No Minimum ID restraints – hence no compromise on the HF job design

 No Hydraulic Isolation Chamber Issues – allows installation of conventional 7” DST/Frac 24-1/2" Csg Shoe

Packer
18-5/8" Csg Shoe

13-3/8" Csg Shoe

o The system consists of Inline Tapered PBR with bottom connections compatible to 4.5” Liner and Second 7" Liner Top

Top Connections compatible to 7” Liner

DST/Frac
Production
String
Packer
Packer

o Provides inner polish bore with Burst Pressures over 30K Psi
o Allows to use standard 7” DST / Frac Strings with no weak component exposed
o The effective length of inner PBR may range up to 30 ft to accommodate for tube movement
Inline PBR

o The use of inline PBR allows to use lower rating of top liner hanger system.
First 7" Liner Top

4.5" Liner Top

o Frac packer would be set inside the 7” liner joints of the string, with the liner top (9-5/8” x 7”) 7" Liner top

9-5/8" Casing Shoe

located above the Frac packer and not exposed to Frac loads – negating possible leak path. 7" Liner Shoe

Perforation
Interval

PBTD
(Landing Collar)
4.5" Liner Shoe
Well TD

DST / Frac string with Tapered Liner string (Right)

Completion String with the Tapered Liner String (Left)
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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region
Integrity Testing of inline PBR / Tie-Back Seal Stem:
o The integrity testing of PBR seals were carried out during the Flex-Trip
operations.
o The lower assembly of the Flex Trip run was connected to Tie-Back seals and
integrity test was initiated after completing the Flexing Operation.
o The test was carried out at 8,500 psi surface pressure using higher M.W fluid
(to simulate similar downhole Frac Loads). Integrity test was successfully
carried out and tube movement calculations verified by correlating with
hook-load against pressure.
o The seal assembly was successfully retrieved to surface and physically
inspected. The surface condition was found satisfactory. Hookload corresponding to the applied surface pressure during the flex trip
o The DST & Frac operations were carried out by setting the packer inside 7”
liner joints (above lower PBR).
o During the hydraulic fracturing operations, the lower PBR was also exposed
to high burst pressures and overall system integrity was found satisfactory.
o The PBR seals were also connected at the bottom of Permanent Completion
Packer to provide a mono-bore design for ease in future well interventions.

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Tapered Liner System for Zonal Isolation and Hydraulic Fracturing: An Application
in the Kirthar Fold Belt Region

Results and Conclusions:

• 9-5/8” x 7” x 4-1/2” Tapered liner assembly allowed for Pab formation to be drilled separately in the 6” hole section .
• The tapered liner string with a lower PBR was demonstrated to be a successful liner system – enabling wellbore
isolation, hydraulic fracturing, and a monobore completion.
• Allows for a contingency hole section to be drilled mitigating risks.
• Addition of 6” hole section allows for drilling Laki shale and Ranikot separately as well – with Laki shale drilled in the
12-1/4” hole section and Ranikot drilled in the 8-1/2” hole section.
• Future applications can include option of conducting Frac using seal bore steam assembly stung inside Lower PBR.

• Few challenges are also involved related to inline PBR & slim hole section:
o The length of inner string during cementing operations is limited to 30 m, as practiced and recommended by vendor.
o Clean-out operations in the slim-hole pose extra challenge in terms of string torque & tensile strength.
o Conventional Wireline BHA can’t pass through clean-out BHA – slim wireline tools are required
o Perforations gun size limitations due to slim hole
o No standard provision for downhole memory gauges setting during well testing operations due to Mono-bore completion design.

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