IADC/SPE 72295

Isolation Of Problematic Zones Using a Cemented Expandable Slotted Liner

Stephen Kent, Weatherford Completion Systems Inc. - Roger van Noort, Shell International Exploration and Production.
Copyright 2000, IADC/SPE Middle East Drilling Technology
This paper was prepared for presentation at the IADC/SPE Middle East Drilling Technology
held in Bahrain, 22-24 October 2001.
This paper was selected for presentation by an IADC/SPE Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the International Association of Drilling
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which could make the difference between the well being

commercially viable or not.
In conclusion, there is now a viable alternative to setting
contingency casing strings along with a mechanism for
operators to consider reducing the number of casing
strings that need to be installed to reach target
reservoirs. The case histories that will be discussed
were completely successful and support the use of the
cemented expandable slotted liner in both contingency
and planned scenarios.

Abstract

The Problem

This paper is based on recent job case histories for an

operator based in Oman, leading to a case for change.

Drilling in the Fahud field in Oman is extremely

challenging and complex. In certain wells in the Fahud
field the build up section of the well is drilled through the
Natih A, C and E hydrocarbon bearing zones (FIG. 1
Well Schematic). As the field is partially depleted losses
may occur through these zones.

Operators throughout the Middle East regularly have no

option but plan to set casing strings earlier or higher than
desired due to problematic geological zones.
Unstable formations can also cause casing runs not to
reach depth, resulting in contingency casing strings to be
used.
In both of the mentioned scenarios, as a result of being
forced to run an additional casing string, the diameter of
the well bore through the reservoir could be
compromised resulting in a well that is unable to meet
production expectations or even reach the planned
depths.
The cemented expandable slotted liner is a solution to
overcome the issues previously mentioned. For
example, if a 9 5/8 in. casing string with an internal
diameter of 8.681 in. is set higher than planned due to
not being able to get to depth, the cemented expandable
cemented slotted liner can be installed below this casing
string isolating the problem zone but retaining a through
bore of 8.681 in. or larger.
As a result of this technology, operators are able to
retain hole size through the next section of the well

Below the Natih A and C hydrocarbon zones is the D5

shale. The D5 shale has to be drilled with a mud
gradient of 12.5 kPa/m (0.55 psi/ft) to maintain hole
stability. After the D5 has been drilled losses may occur
in any of the Natih zones above or below before
reaching the 7 in. horizontal casing point in the target
reservoir.
Inevitably, losses do occur and a reduction in mud
weight or displacement of the well to water (in cases of
total losses) has to be undertaken. The lowering of the
mud weight or the displacement to water has the effect
of causing the D5 shale to collapse resulting in stuck
pipe or loss of hole.
As a result of the described situation drilling the
problematic D5 shale section (D5 shown in FIG. 1) has
historically been proven very difficult.
The D5 shale is located 270 meters from the previous (9
5/8 in.) casing shoe, is 15 meters in length (MD) and is
drilled through at an angle of 45 degrees (FIG. 1)

STEPHEN KENT, ROGER VAN NOORT

SPE 72295

The most practical initial solution was to run an extra

casing string to isolate the D5 shale but to retain the
same hole size through the reservoir section of the well,
the casing design would have to be sized up. This
would result in replacing the current 8.50 in. open hole
through the Natih A, Natih C and D5 shale with a 12.25
in. This would have a significant impact on the overall
well costs through increased rig time and additional
hardware expenditure.

Once the cemented expandable slotted liner is in place

over the D5 shale the mud weight would be lowered
from 12.25Kpa/M to 11.2 Kpa/M as the D5 shale section
is now isolated from the drilling fluid.

In addition to the increased costs associated with sizing

up the wells design there is an increased HSE risk
associated with a larger casing design.

The cone shaped mandrel (FIG 2.) is made up of a

8.180 in. lead cone and a 8.500 in. back up cone
(suitable for this application) resulting in an expanded
outside diameter of 10.200 in. and an internal diameter
of 8.700 in.

The risk of having complete losses while drilling the

Natih A and Natih C is high and, to continue drilling,
water is used to maintain well control. Having a larger
casing means that more water is needed to keep the
well full if the water supply is not quick enough there is
an increased risk of taking a gas kick from one of the
Natih zones.

The cementable expandable slotted liner in these cases

is a 6 5/8 in. (nominal) diameter slotted tube (FIG.2)
which is expanded by pushing a cone shaped
mandrel(FIG. 2) through the inside of the slotted pipe.

System Component Overview

Figure 2 shows the components that make up the
system.
Expandable/Drillable Anchor shoe:

Having an increased water supply (250 m per hour)

available at the rig site is a major challenge in the Fahud
area of Oman. Additional water supply lines, pumps and
storage basins would have to be supplied in order to drill
the wells safely. This would also add to the total well
cost.
Due to the HSE risk, the cost involved to reduce the risk
and cost involved in increasing the casing sizes
alternative solutions were considered.
The Solution
The goal was to maintain a minimum 6.125 in. hole size
through the reservoir section whilst isolating the D5
shale without increasing the casing sizes.
In order to meet this target it was decided to isolate the
D5 shale with a cemented expandable slotted liner. After
installation this liner would have an internal diameter that
matches or is greater than the internal diameter of the
previous casing. This would allow the planned bit size to
be use to section depth of the well. The direction in
which the cemented expandable slotted liner expands is
from top to bottom.
From experience only months earlier, the operator had
already proven, to the asset team involved, that an
cemented expandable slotted liner could be set to
consolidate the hole below a (stuck) casing shoe. The
challenge was to set the cemented expandable slotted
liner some 270 m away from the shoe at a 45 degree
hole angle.

This shoe anchors the liner in the hole, preventing it from

being dragged back up after expansion.
The shoe confirms the position of the expansion mandrel
at the base of the liner on completion of the expansion
process. It is easily drillable and allows support of the
compressive loads exerted through it during liner
expansion.
Expandable Bottom Connector:
The Expandable Bottom Connector allows the
connection of the Anchor Shoe to the Expandable Joints.
Expandable Liner Joints:
The Expandable Liner Joints comprise the main body of
the system. These joints are available in 40 ft. sections
as well as various pup joint lengths in order to achieve
correct space out of the assembly.
Expandable Centralizes:
Expandable centralizes help centralization of the pipe
both before and after expansion. They ensure the
presence of a cement sheath around the liner and
minimize the effect of liner buckling during expansion.
Expandable Top Connector:
The Expandable Top Connector allows the connection of
the Expandable Liner Joints to the integral running
tool/expansion mandrel. After expansion the expandable
top connector provides a fluted guide for the drill out
assembly.

SPE 72295

ISOLATION OF PROBLEMATIC ZONES USING A CEMENTED EXPANDABLE SLOTTED LINER

The Integral Running Tool/Expansion Mandrel:

Installation Design & Procedures

The integral running tool/expansion mandrel is field

dressable allowing the expansion mandrel size to be
changed on-site according to suit job parameters. The
running tool incorporates a simple shear release
mechanism that is used to attach the expandable top
connector to the running tool and provide a positive
indication that expansion is about to start once sheared.

The 8.50 in. hole was drilled through the Natih A, Natih
C and through the problematic D5 shale and terminated
3 meters into the zone below (the E1 Sandstone) at 45
degrees (FIG. 1).

As weight is set down on the Expansion Mandrel (Cone)

the Cone is pushed through the internal diameter of the
Cementable Expandable Slotted Liner causing the
internal and external diameters to change.
The expandable liner joints have an internal coating
which allows mud and cement to be circulated through
the liner, avoiding leakage of the fluid through the slots.
The coating can withstand a pressure differential of
approximately 150psi before being extruded through the
slots. The coating has been designed to remain attached
to the metal surface of the liner preventing removal
during expansion.
Risk Analysis
Typical solutions provided by the cemented expandable
slotted liner have, in the past, been designed so that the
top of the expandable slotted liner is as close as
possible to the previous casing shoe. This is to minimize
the risk of the expandable slotted liner drill out assembly
kicking off above the top of the expandable slotted liner.
With a well designed drill out assembly and the top of
the cemented expandable slotted liner within a few feet
of the previous casing the risks of not getting back inside
the expanded liner have been greatly reduced.
In the Fahud application it was required that the top of
the cemented expandable slotted liner be located 270
meters from the previous (9 5/8 in.) casing shoe, and in
an angle of 45 degrees (FIG. 1).
This had previously not been tried as many operators
had deemed that there was too much risk involved in this
particular application and the drill out assembly was
likely to kick off the top of the expanded liner and not
being able to get back inside it.
It was decided that due to the nature of the problem
facing the operator and the potential gains a successful
installation would bring them that a trial would go ahead.
Special attention was paid to the centralization and
tapering of the drill out assembly to maximize the
chances of successful installation, cementation and drill
out.

(This would allow the cemented expandable slotted liner

to overlap the D5 shale enough to isolate it from the
wellbore fluids and the drilling assembly).
The 8.50 in. open hole was then under-reamed to 12.25
in. in the section where the cemented expandable
slotted liner would be installed. The under-ream bottom
hole assembly consisted of :
12.25 in. Ream-master
4.75 in. Bit Sub
5 in. Drill Pipe (1 joint)
MCBPV
6.750 in. Float Sub
5 in. HWDP (12 joints)
6.875 in. Slick Crossover
6.750 in., H.E. Drilling Jar
Slick Crossover
5.50 in. HWDP (19 joints)
5 in. Drill Pipe to surface
The under-reamed section did not terminate at TD but
would be designed so that there was a minimum 2 feet
and maximum of 4 feet of previously drilled 8.50in.
rathole. This rathole would enable the setting of the
Anchor Shoe (see previous paragraph System
Component Overview).
The open hole section was then measured with a 6 arm
caliper to ensure suitability of the hole condition and to
obtain accurate cement volume measurements.
The expandable slotted liner was then picked up and run
in place using a combination of heavy weight drill pipe
and drill pipe. The cementable expandable slotted liner
bottom hole assembly consisted of:
Partially Slotted Anchor Shoe
Slotted Bottom Connector
6.625 in. Slotted Pipe
6.625 in. Slotted Top Connector
6.625 in. Running/Expansion Tool
Crossover
5 in. Drill Pipe (18 joints)
Float sub
5 in. Heavy Weight Drill Pipe
On reaching the total depth of the well the assembly was
tagged against the bottom of the well and weight
continued to be set down until the shear pins that attach

STEPHEN KENT, ROGER VAN NOORT

the running tool/expansion mandrel to the expandable

top connector sheared. Expansion was initiated by the
fixed outside diameter of the expansion cone being
pushed through the expandable slotted pipe. Downward
movement was continued and the remaining expandable
slotted pipe expanded. As the expansion cone tagged
the top of the Anchor Shoe there is an indication at
surface that the expansion has been completed.
Indications at surface showed that to shear the Running
Tool/Expansion Mandrel took 16 daN and the continual
expansion of the Cementable Expandable Slotted Liner
took 6 daN set down weight at a rate of 10 feet per
minute. Once the expansion had taken place the Anchor
Shoe was tagged with 7 daN to show expansion had
finished. This was confirmed with the pipe tally.
Cementation took place through the drill string and
running assembly. A balanced cement plug was placed
through the anchor shoe and due to the expanded pipe
having an inflow area of around 30% cement is able to
be placed inside and outside of the cementable
expandable slotted pipe.
Cementation design is undertaken jointly by the
Operator and Service Companies involved.
The cement design used is as follows:
Wellsite Water - 6.4 M
Halad-322 116 KG
HR-5 14.5 KG
NF-3 3.6 lt
Fibres 145 KG
Once cementation is completed the running tool is slowly
pulled to the top of the cemented expandable slotted
liner, excess cement reverse circulated to surface and
then pulled out of hole.
A centralized and tapered drill out assembly was then
run to drill through the cement and through the top of the
cemented expandable slotted liner. This assembly was
designed to enable the best chance of re-entering the
cemented expandable Slotted Liner without kicking off
over the top causing a side track. This assembly
comprised of:
6.125 in. Bit
4.6875 in. Bit sub
5.9375 in. Crossover
8.50 in. Stringmill
6.25 in. Float-sub
6.50 in. Crossover
5 in. Heavy Weight Drill Pipe
5 in. Drill Pipe

SPE 72295

Once confirmed that the pilot drill out assembly

back inside the cemented expandable slotted liner it
pulled to surface and a full size drilling assembly
used to drill out the anchor shoe and normal drilling
resumed.

was
was
was
was

The full size drilling assembly consisted of the following:

8.50 in. Bit
Crossover
6.125 in. Float Sub
Crossover
8.50 in. Stabilizer
5 in. Heavy Weight Drill Pipe (7 joints)
6.50 in. Jar
5 in. Heavy Weight Drill Pipe (23 joints)
5 in. Drill Pipe
CONCLUSIONS
In the Middle East Expandable Liners are becoming a
readily available alternative to casing where the use of
conventional casing will result in a compromised
wellbore.
Although the system has been used very successfully in
the past where the top of the liner was within a few feet
of the previous casing shoe in this particular application
the top of the expandable liner was 270 M from the
previous casing shoe and set at 45 degrees.
With proper prior planning the operating boundaries of
the system can be widened with great success.
ACKNOWLEDGEMENTS
The Authors would like to give special thanks to Mr.
Terence Humphries Petroleum Development Oman,
Mr. Hatif Hatmi Petroleum Development Oman and Mr.
Bill Hetherington Weatherford Completion Systems
Inc. for their belief in the system described and the hard
work and determination that resulted in our successful
installations.

SPE 72295

ISOLATION OF PROBLEMATIC ZONES USING A CEMENTED EXPANDABLE SLOTTED LINER

FIGURE 1 WELLBORE SCHEMATIC

Note all depths rotary

table along hole

Proposal for first ABL trial in deviated 8 1/2 hole

Fahud 25-95-28

13 3/8 casing shoe vertical

UER formation

Fiqua formation top @ 211 mahd - Shales

Natih A formation top @ 436mahd - High risk of losses - carbonate

Natih B formation top @ 501mahd - carbonate
9 5/8 casing shoe @ 436mahd - 17 deg

Natih C formation top @ 587mahd -carbonate

Natih D5 shale formation top 691mahd (note shale interval @ 15mahd)

ABL set in 8 1/2
hole and under
reamed to 12 1/4 at
a tangent angle of 44
deg. To be set over
the shale interval.
ABL length @
28.71m.

Natih E1 formation top 706mahd (meters along hole depth)

Natih E2 formation top 735mahd- TOTAL LOSSES EXPECTED
Natih E3 formation top 757 mahd

7 casing shoe @ 1069mahd

6 1/8 horizontal open

hole - RESERVOIR

STEPHEN KENT, ROGER VAN NOORT

FIGURE 2. SYSTEM DESCRIPTION

Running tool and

Expansion mandrel

Inter-changeable
expansion cone
(cone shaped mandrel)

Expandable top connector

40ft Expandable liner

joints
Expandable centralizes

Expandable bottom
connector

Expandable / Drillable
Shoe

SPE 72295