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SPE

Society of Petroleum Engineers

SPE 17523

Installation of Retrievable Liners


by D.O. Manley, Manley Consulting
SPE Member

Copyright 1988 Society of Petroleum Engineers


This paper was prepared for presentation at the SPE Rocky Mountain Regional Meeting, held in Casper, WY, May 11-13, 1988.
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 ~f the paper, as presented, have no~ been reviewed ~~the Society ?f Petroleum Engineers and are subject to correction by the
author(s). The matenal, .as presente~, does not ~ec~ssanly. reflect any P?Sitlon of ~he Soc1ety of Petroleum Engineers, its officers, or members. Papers
pres~nted at SPE meet1ngs are subject to publ1cat1on rev1ew .bY Ed1tonal Commltt.ees of the Society of Petroleum Engineers. Permission to copy is
restncted to an abstract of no~ more than 300 .words ..111u~trat1ons may not be cop1ed. The abstract should contain conspicuous acknowledgment of
where and by whom the paper IS presented. Wnte Publications Manager, SPE, P.O. Box 833836, Richardson, TX 75083-3836. Telex, 730989 SPEDAL.

INTRODUCTION

active production or injection zone from foreign


fluid
invasion
and
when needed,
allows
the
installation of special alloy liner equipment to
protect
against
hydrogen
sulfide
and
carbon
dioxide environments.

In today' s oil and gas economic environment,


oil and gas wellbores must remain competent for
long-term production and injection use.
Secondary
recovery, waterflooding,
and tertiary recovery
methods of polymer and carbon dioxide injection
have given new 1 ife to old wells, reqUJ.r~ng even
longer use
of existing wellbores.
Wellbore
integrity tests required by state and federal
regulations, are designed to protect fresh water
zones, prevent hydrocarbon migration into unwanted
zones of porosity and insure that wellbores are
not in communication with the strata behind the
pipe.
These integrity tests and the longer more
demanding use of wellbores have contributed to oil
and
gas
operators
discovering
that
lengthy
sections of the original
casing string have
disintegrated.
Contributing factors of casing
failures are external corrosion, electrolysis, and
internal metal loss, due to hydrogen sulfide and
carbon dioxide. "Retrievable" liner installations
provide
a method of ameliorating the casing
problems,
and restoring
the
old wellbore to
service.
Through the use of
a gelatinous,
thixotropic oil-base packer grease, instead of
cement, placed in the annular area between the
newly installed liner and the original casing
string
the
1 iner become
retrievable.
When
initially mixed the oil-base packer fluid is
1 iquescent enough ta be pumped into the annul us.
In a quiescent state it develops the consistency
of a stiff grease. Upon agitation, the packer
fluid will alter to a consistency capable of being
pumped, thus allowing the liner to be recovered.

When the hydrocarbon reserve base is not large


enough to justify the drilling of a replacement
well, a retrievable liner offers a lower cost
opportunity for continued long-term service of the
original wellbore.
By adding years
to the
productive
and
useful
life
of
a
wellbore,
premature
abandonment
can be
avoided
and
a
significant increase in the recovery of reserves
can result.
THE PROBLEM

In several geological basins throughout the


Rocky
Mountains,
and
in
particular
in
the
Williston Basin, the productive horizons of the
Madison, Devonian, Silurian, and Ordovician are
overlain by brackish, corrosive water zones in the
Minnelusa,
Minnekahta,
Dakota
and
Greenhorn
Formations.
In the Powder River Basin, the
productive Minnelusa is overlain by corrosive
waters
in
the
Dakota
Formation.
These
water-bearing zones tend to provide corrosion
problems over long intervals when not protected by
an adequate primary cement job or an active
cathodic protection system.
Entire sections of
casing several thousand feet thick have decayed
in a matter of years to the hostile water-bearing
formations.
The resulting
deteriorated casing
interval emanates water infiltration. This influx
of brackish water may cause dump flooding of the
producing horizon or a high water-oil ratio, thus
creating premature abandonment of the well.

The retrievable liner provides an alternative


to squeeze cementing where the deteriorated casing
length is too long to provide for adequate cement
fill.
The liner offers a method to protect the

409

INSTALLATION OF RETRIEVABLE CASING LINERS

Many times the length of the weakened casing


section is too long to be covered adequately by
squeeze
cementing.
Problems
with
formation
sloughing,
decentralized
casing,
or
lost
circulation may prevent squeeze cementing from
providing good fill and protection over the entire
extent of the deteriorated casing interval.
This
leaves a liner installation as the only remedial
means of corrective measure.

SPE 17523

INSTALLATION
This paper presents three methods used to
determine the amount of metal loss, and the length
of the deteriorated casing interval.
From these
determinations, two methods of liner installations
are presented.
The placement and installation
technique
of
setting
a
permanent
packer,
installing a packer plug, running the liner, along
with mixing of the proper packer fluid components,
and
the
proper
displacement
procedure
are
presented below.

Water injection wells or water disposal wells


are
often
times
lost
from service when the
wellbore integrity test requirements cannot be
met. This results in reducing the reservoir sweep
efficiency
and
creates
loss
of
recoverable
reserves.
If a water disposal well is lost from
service it may result in shutting down the entire
field
until
another
disposal
source
can be
generated.

The
retrievable
liner
installation
first
involves determining the length of deteriorated
casing that needs to be covered.
This can be
accomplished by any one of the three methods
below:

In addition to the external casing corrosion


problem, there can be internal corrosion from both
hydrogen
sulfide
and
carbon
dioxide
in
the
produced fluid str:eams.
This type of corrosion
attack induced from the corrosive gases of the
produced well fluids, can also render an entire
span of production casing useless where excessive
metal loss has occurred. The high concentration of
iron sulfide build-up along the surface area of
the casing and tubular products will enter the
bottom hole
pump
intake
of
those wells
on
artifical lift causing an unusually high degree of
bottomhole pump failure problems, frequent pulling
jobs and high lease operating expenses.

1.

Running
a
casing
inspection
survey to
determine the degree of metal loss and to
ascertain
remaining
of the
the
thickness
casing.
This cased hole log is best used
where
casing
external
corrosion
or
electrolysis is the main cause of the casing
failure.

2.

Running an internal casing caliper log to


determine the amount of metal loss from the
internal diameter or to locate holes in the
casing created by corrosion.

3.

A retrievable packer and bridge plug can be


used to mechanically locate suspected holes in
the original production casing.
This method
can only be used when the casing metal loss is
severe enough to have created holes somewhere
in the string. Using the tubing,
and by
running a combination retrievable bridge plug
and packer, or by running only a retrievable
packer the holes can be isolated and the depth
of the degenerated casing determined.

SOLUTION
The
prevention
of
lengthy
intervals
of
external metal loss lies primarily in the design,
installation, and execution of the primary cement
job. The proper use of stage tools, and light and
foamed cements can help insure that zones creating
casing corrosion problems are covered with cement.
In addition, the use of special alloy casing,
corrosion
inhibition
programs,
and
cathodic
protection
systems
can
help
mitigate
casing
problems.
However, there are cases that arise
when such methods are not completely successful.
The use of a retrievable casing liner, where an
oil base fluid is placed in the annular area
instead of cement, can be effective installed to
correct the degraded casing condition. This style
of liner installation provides a remedial means of
adding years to the productive life and may help
add to the recovery of many thousands of extra
barrels of reserves.

Using only a retrievable packer, the holes can


be isolated by setting the packer and pumping
down the tubing-casing annulus. By this means
the severe casing leaks can be located.
In
addition, a pump-in rate or fluid loss rate to
the formation can be determined.
If formation
pressure information is needed, this would
allow that data to be determined.
Once the necessary length of deteriorated
casing is determined, a decision as to the most
cost effective installation will need to be made.
Two possible methods of installation are feasible:

When the reserve base is not large enough to


justify the drilling of a replacement well, a
retrievable
liner
offers
the
opportunity for
long- term service of the original well bore.
The
oil-base packer fluid placed between the liner and
the original casing allows for the recovery of the
1 iner should economics later dictate abandonment.
The gelatinous, thixotropic nature of the oil-base
packer fluid acts to protect and upon agitation
will deform to a consistency to be pumped to allow
recovery of the liner.

410

1.

Install the liner from below the lowest zone


to be protected, all the way to the surface
and hang off in the casinghead (See Schematic
No. 1).

2.

Install the liner top with a liner hanger


installation above the top zone of casing
degradation (See Schematic No. 2).

SPE 17523

D. DAN MANLEY, P.E.

The proper grade, size, and footage of liner


must be determined to be compatable with those
sizes currently existing in the wellbore.
A
casing scraper should be run prior to proceeding
with the installation of any downhole equipment to
be sure all mud, metal, formation pieces, or other
debris that has adhered to the walls of the casing
are removed.

No. 5 and No. 6 fuel oil from a refinery.


Low
gravity asphalt base crude oils in the 10-25
degree range have been used, if available.
A hot
oil unit can be used to heat the crude to around
140 degrees Fahrenheit or the crude can be thinned
with other crude mixtures or refined fuel oil to
provide ease in pumping and mixing operations.

A permanent full opening packer should be


installed
50-125
feet
above
the
existing
perforations, leaving room above the perforations
to run any tracer,
differential
temperature,
perforating guns or other cased hole logging
tools. Installing a temporary retrievable plug
that fits in the permanent packer bore that can be
retrieved with the sand line or tubing will
protect the producing zone from contamination or
invasion of fluids during the installation of the
1 iner.
Once
the
liner
is
installed
this
retrievable plug can be removed.

The components include a modified fatty acid,


dispersed in an oil media and contain a unique
oil-absorptive filler that contributes to ultimate
gellation.
The final
component is quicklime
(Ca02) to form a calcium soap.
These complex
soaps form a lattice within the asphaltic oil
environment, producing the thixotropic grease.

The packer fluid is mixed by adding the liquid


concentrate of fatty acid chemical to a suitable
mixing oil and agitating vigorously to blend the
materials. Weighting materials should be added at
the wellsite just prior to pumping in the hole to
insure complete dispersion.
Adequate time should
be allowed for entrained air to break out before
being pumped in the well. The quicklime is added
to the blended fluid as it is being pumped into
the wellbore.
Gelation does not occur until after
the quicklime is added and pumping is stopped.
The fluid will reach 30-40 percent of its gel
strength in three hours.

The liner is run with a small diameter packoff


assembly on the bottom which allows the packer
fluid to be pumped by the packer rubbers without
washing out around the sealing rubbers. This
packer should have an increased by-pass area for
free
circulation
during
packer-fluid
pumping
operations.
THE PACKER FLUID
Application

Displacement

The packer fluid mixture is an oil-base type


fluid.
It can be a newly prepared mixture or be
prepared by converting an oil-base drilling fluid.
It is mixed as per the volume requirement needed
to fill the annular space between the liner and
existing casing.
The consistency, temperature,
fluid
viscosity,
and
density
should
all
be
determined prior to placement.

Procedur~~

If a newly prepared packer fluid or if an oil


base drilling fluid is converted, the fluid should
be
clean,
stable,
and
the
oil
tested
for
properties of gelation and pumpability.
The
packer fluid should be circulated in the wellbore
in order to tighten the emulsion and make it a
homogeneous
fluid.
There
will
be
some
intermingling between the displacing fluid and the
dis placed fluid, resulting in high viscosity and
gel strengths.
A diesel spacer should be run to
minimize any problems.

The oil-base packer fluid must provide all the


qualities of chemical and physical stability.
It
must provide protection against corrosion and
bacterial attack, and it can not be temperature
degradable.
The packer fluid must also be
non-conductive, and able to support barite or
other weighting material.

If a diesel oil spacer is inadequate, or


commingling is a
problem where viscosity or
pumpability is of concern, a 25 barrel packer
fluid mixture may be prepared with the yield point
adjusted to exceed the yield point of the fluid to
be displaced by a minimum of 10 lb/100 sq. ft.
The high yield point spacer fluid has good hole
cleaning
abilities
and
will
minLm1ze
the
possibility of channeling through the displacing
fluid.

Packer fluids used for the liner installations


are
a
gelatinous,
thixotropic
grease.
When
initially mixed it is fluid enough to be pumped
into the annulus.
In a quiescent state, it
develops the consistency of a stiff grease.
The
degree of gelation and shear strength can be
varied.
Upon agitation, the packer fluid will
deform to a consistency capable of being pumped.
The
gel
strength
provides
a
natural
weight
suspension ability.
The proper weight of packer
fluid needs to be installed, to prohibit fluid
flow from the wellbore to the formation,
or
crossflow from the formation to the wellbore.

The spacer fluid should be followed by the


prepared packer fluid and the pump rates held slow
and constant. Rotating or reciprocating the liner
may be desirable while pumping and will help in
the removal of the displaced fluid, but may not be
possible due to the hardware of the liner hanger
equipment.

Components
The most common oil used for packer fluids are

411

SPE 17523

INSTALLATION OF RETRIEVABLE CASING LINERS

The spacer fluid should be discarded when it


reaches the surface.
The packer fluid should be
circulated at least once to prepare it for final
treatment.
The fluid should be analyzed and the
amount of contamination determined prior to the
final displacement process.

Retrievable
liners
offer
a
lower cost
opportunity for continued long-term service of
the original wellbore when the hydrocarbon
reserve base is not large enough to justify
the drilling of a replacement well.
EQUIPMENT

FINAL LINER INSTALLATION PRACTICES


The packer is then set by a setting tool where
the setting dogs are raised above the packer
setting sleeve,
then applying weight
to the
packer.
Make sure the fluid temperature is in
equilibrium to allow for expansion of the pipe and
fluid before setting the pipe in the slips and
closing the annular space.

1.

Packer hanger

2.

Oil-Base Packer Fluid

3.

Casing Liner
a.
b.
c.

The temporary plug can then be pulled from the


permanent packer with the sand line or with the
tubing once the liner installation is completed.
4.
Tubing can be run in the well and stung into
the packer with a seal assembly for use in an
injection or flowing well.
If the well is on a
beam pump, a crossover can be installed to allow
fluid flow to enter the tubing-casing annulus
above the packer then into the pump intake.
The
crossover can also be used as a downhole gas
separator
for
effective
separation
of
the
entrained gas.

b.

Oil-base
packer fluids make an excellent
alternative
to
using
cement
for
the
installation of liners and can be used where:
Retrievability of the liner equipment
may be desirable.

2.

Low formation pore pressure or low


fracture gradients make cementing a
liner impossible.

3.

A non-conductive fluid to protect


against
corrosion
and
bacterial
attack is needed in the liner-casing
annular area.

4.

Retrievable Packer Plug


Anchor tubing seal assembly
pump production operations)

(for beam

Liner Hanger Assembly


a.

CONCLUSIONS

1.

Retainer Type Permanent Production Packer


a.
b.

5.

Size and dimensions:


(OD-ID-Cplg Size
and Wt/Ft)
Strength:
(Burst-Collaspe-Tension)
Length

for
Packoff and hang at wellhead
injection, flowing, or producing with
artifical lift.
Hang liner off at the top of the
deteriorated casing to reduce length
of the liner and reduce cost.

*************************************************
Acknowledgements:
The
author
wishes
to
acknowledge the present and past personnel of the
Amerada Hess Corporation for the introduction to
the methodology used in the liner installation
presented in this paper and to Mr. Donald E.
Bailey,
P.E.,
Halliburton
Services,
for
his
assistance in editing.

References:

Gray,
George
R.
and
Darley,
H.C.H.:
"Composition and Properties of Oil Well Drilling
Fluids", fourth edition, Gulf Publishing Company,
Houston, Texas; (1980), pp. 512-522.

The hazard of cement loss or damage


to the producing horizon needs to be
eliminated.

Retrievable liners can be used in wells where


long sections up to several thousand feet
thick
have
deteriorated
making
squeeze
cementing impractical.

"Applied
Mud
Technology";
fifth
edition,
(1974);
IMCO
Services,
Responsive
Printing
Company; Houston, Texas, Section 3, Chapter 13,
14, 15; pp. 85-102G.

Retrievable liners
can
be
installed in
inject ion wells where casing integrity tests
are not being met for state and federal
regulatory requirements.

Brown-Hughes,
A Divis ion
of
Company, 1984 Catalog; pp. 33-41.
Brown-Hughes,
Operators
Hangers; pp. 501-507.

Retrievable liners permit the installation of


special alloy pipe to help mitigate corrosion
severity due to hydrogen sulfide and carbon
dioxide.

Data

Hughes

Sheet,

Tool

Liner

**************************************************

412

SCHEMATIC No.1

FULL LINER INSTALLATION


LINER HUNG OFF
AT THE WELLHEAD

ZONE OF SEVERE
CASING CORROSION

--TUBING

ZONE OF SEVERE
CASING CORROSION
(BRACKISH WATER)
TOP OF CEMENT
..,~--LINER

OIL BASE PACKER FLUID

PERFORATIONS

SPi 17523
413

SCHEMATIC No.2

PARTIAL LINER INSTALLATION


LINER HANGER USED TO
REDUCE LINER LENGTH
TIE BACK SLEEVE

TUBING

ZONE OF SEVERE
CASING CORROSION
(BRACKISH WATER)

ZONE OF SEVERE
CASING CORROSION
TOP OF CEMENT
I'.AJ.k~-

L I NE R
OIL BASE PACKER FLUID

~,____CASING

PERMANENT PRODUCTION
PACKER
PERFORATIONS
~---CASING

T. D.

--------~T.D.

414

~YE 17 5 23

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