OTC 7549

Debris Protection System for Liner Tops

George Telfer, NODECO Ltd., and Dave Sweeney, Enterprise Oil plc
Copyright 1994, Offshore Technology Conference
This paper was presented at the 26th Annual OTC in Houston, Texas, U.S.A., Z-5 MaY 1994.
This paper was selected for presentation by the OTC Program Commkt%e following review of information contained In an abstract submitied by the author(s). Contents of the PaPer,
as prescmted, have ot been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The Material, ?.Spresented, d~$ not necessarily reflect
ay position of the Offshore Technology Conference or its officers. Permission to copy is restricted to an abstract of not more than S00 words. Illustrations maY not be ~pled. The *stract
should contain conspicuous acknowledgment of where and by whom the PaPer is presented.

DEBRIS PROTECTION SYSTEM FOR

LINER TOPS
GEORGETELFER, NODECO LTD.
DAVE SWEENEY, ENTERPRISE OIL PLC.
ABSTRACT__
.This paper will introduce a new design of debris protection

evident that there had been a significant risk of cementing the

liner running string into the liner top P.B.R.
In all cases, the well debris entering the liner top P.B.R.
consisted of fine cavings of shale originating from the base of
the Balder formation (see fig. 1). The setting depth of the
9.5/8 casing strings on Nelson development wells is
governed by two factors, these being :

system for liner tops. The system has been used extensively
in the North Sea and has solved the problem of well debris
(e.g. formation cuttings/fines, mud solids, cement solids,
foreign bodies etc.) entering the liner top P.B.R. and sticking
the setting tools.

INTRODUCTION

The Eocene formation must be cased off prior to

drilling the Forties formation

(ii)

Casing must be set prior to drilling into a loss zone.

85 feet TVD below the top of the Balder formation.

The Eocene formation consists of highly reactive and overpressured shales which become unstable if drilled with mud
weights less than 14.0 ppg, ~d the Forties fo~tion
is
normally pressured sandstone in which differential sticking
may occur if drilled with mud weights above 10.0 ppg.
Therefore, to allow the Forties sandstone to be successfully
drilled without inducing borehole collapse in the Eocene, the
9.5/8 casing string is set in the Balder formation. In
addition, the Balder also contains a known loss xone when
drilling with 14.0 ppg mud, above which the 9.5/8 casing
must be set. These criteria dictate the setting depth of the
9.5/8 casing shoe. Having mn and cemented the 9.5/8
casing string, the 14.0 ppg mud used to drill the 12. 1/4 hole
section is displaced to 10.0 ppg mud prior to drilIing the
8.1/2 hole section. However, this mud weight can induce
borehole instability in the Balder as, ideally, this formation
should be drilled with 12.0 ppg mud. TO bt% drilling the
Balder with 10.0 ppg and has led to the production of a small
volume of fine shale cavings which have, as yet, caused no

Well debris entering liner top polished bore receptacles

(P. B. R.s) during cementing operations has been a notorious
problem for many years, and in some cases has led to liner
banger setting tools becoming stuck in the liner top P.B.R.
This can lead to the setting tool being cemented in place and
result in an expensive fishing job or side-track. This paper
will describe how Enterprise Oil experienced severe problems
with well debris entering the liner top P.B.R. and sticking
the liner hanger setting tool, In addition, it will describe
how a prototype debris protection system was developed and
tested prior to offshore application, and the subsequent
successful use of the tool on Nelson development wells.

DESCRIPTION OF PROBLEM
During drilling of the early Nelson development wells in the
UK North Sea, severe problems were experienced with well
debris entering the Iiner top P.B.R. As a result, difficulties
occurred retrieving the liner hanger setting tool. Although in
all cases the setting tools were successfully raovered,

(i)

it was
377

DEBRIS PROTECTION SYSTEM FOR LINER TOPS

problems during drilling operations or while running the
production liner. However, severe problems have occurred
following cementing operations, when attempting to release
the liner hanger setting tool from the liner top P.B.R.
On each occasion when difficulties were experienced
releasing from the liner hanger, Balder shales were found
compacted around the setting tool. During cementing
operations, shale cavings were circulated up the 9.5/8 x 7
armulus by the wellbore fluids and deposited on top of the
liner top P.B.R. This is where the cuttings transport
efficiency drops significantly due to the increase in annular
volume (see fig. 2). Typical displacement rates for the 7/
5 tapered liner cement job wem 10 barrels per minute
(bpm), and this pump rate provided an annular velocity of
432 feet per minute (fPm) in the 9.5/8 x 7 ammlus.
However, when fluids passed the liner top P.B.R. and
entered the 9.5/8 x 5 drillpipe armulus of the liner running
string, the annular velocity dropped to 215 fpm. This drop
in the annular velocity led to some cavings dropping onto,
and then into the liner top P.B. R. and becoming compacted
around the setting tool.

OTC 7549

P.B.R. and the O.D. of the setting tool extension. These

devices have beam reasonably effective in normal
circumstances, but in situations where the debris or clay fines
accumulations are severe they do not prevent entry into the
P.B.R. The major limitation of existing designs is that they
must not form a pressure seal between the I.D. of the P.B.R.
and the setting tool extension. Should this occur, tie P. B.R.
could collapse due to the inability to allow hydrostatic
pressure equalisation, or the setting tool could become stuck
due to fluid locking.

INDUS TRY EXPERIENCE

Experiencing overpull when releasing setting tools from liner
tops has been an industry problem for many years. In some
cases, the liner is pulled back up the well before dropping
offI or pulled to surface if the problem is serious enough.
Filling the P.B.R. with a highly viscous medium prior to
running in the well is often done but is not particularly
effective.

THE SOLUTION TO THE PROBLEM

Adjustments were made to the 9.5/8 casing setting depth,
however, these failed to prevent the production of shale
Various methods, such as filling the P.B.R. with
cavings.
cross-linked t%cture material proppant, were also tried in an
effort to keep the cavings away from the setting tool,
however, these also proved to be unsuccessful. It was
therefore decided that the only solution was to mechanically
isolate the setting tool from the wellbore fluids, a decision
which led to the design, testing and introduction of the
floating junk bonnet.

Fig. 5 illustrates the Floating Junk Bon@ (FJB) which has

been used successfully in the Nelson Field and elsewhere.
This system is considered to be an improvement on other
currently available junk bonnets, offering the following
advantages :1.
2.
3.

~
WHY
D
LINER TOPS?

M LATE AT

The junk basket principle as a means of collecting loose items

of junk from the bottom of a well is well known (see fig.3).
Simply stated, the high annular velocity around the larger
O.D. part of the tool lifts the debris and when the annular
velocity is reduced at a smaller O. D., the debris drops out of
the fluid into the basket or catcher. As mentioned above,
the annular velocity in the 9.5/8 x 7 anmdus is 432 fpm
while circulating at 10 bpm. On conventional liner systems,
the maximum O.D. usually occurs at the P. B. Il. (e.g. 8.25
O.D. inside 9.5/8 casing) and, in this exacerbated situation
annular velocitiw can drop from 2100 fpm to 215 fpm while
This phenomenon has dictated the
circulating at 10 bpm.
use of some form of junk bomet at the liner top to prevent
debris entering the P.B.R. and fouling the liner setting tool.

WHAT ISA JUNK BONNET2

Fig. 4 illustrates a typical junk bonnet design, consisting of a
metal cap used to bridge the gap between the I.D. of the

4.

5.
6.

Forms a seal at the P.B.R. top and thereby prevents

entry of w debris into the liner top.
Does not move when the drill pipe/setting tool is
stroked up or down.
Back reaming blades allow easier removal of packed off
cuttings/debris when rotation is applied.
The emergency release sleeve rdlows the fluid lock to
be broken, even with severe accumulations of
cuttings/ debris.
Circulation through the emergency release sleeve port
can be used to clear debris from the liner top.
Smaller O.D. than conventional junk bonnets and is
therefore less likely to be fouled when pulling away
from liner tops.

DESIGN DESCRIPTION
Prior to running the liner hanger, the FJE3system is prepared
on the rig floor by filling the inside of the P.B. R. with water
through the water irdet (see fig.5 for the location of the water
inlet). When water is expelled through the air outlet the
P.B.R. is full (see fig.5 for the location of the air outlet).
The water inlet and air outlet are then plugged off, allowing
the junk bonnet to forma seal between the setting tool
extension and the inside of the P. B. R.. Due to fluid
locking, the FJB cannot be pushed further into, or pulled
out of the P .B. R. As the liner is run in the well, the gradual
increase in hydrostatic pressure forces the junk bonnet

OTC 7549

GEORGE TELFER, DAVE SWEENEY

downwards, thereby pressuring up the water volume in the

P.B.R. until the pressur= above and within the P.B.R. are
equalised. This downward movement of the FJB will be
partially offset by the thermal expansion of the water trapped
inside the P .B .R., with the net effect calculated to be 1 to
2 of downward movement. Prior to cementing the liner in
place, the running tool is released by right hand rotation of
the drill pipe and then picked up a few feet to chtzk for
proper release. This action is considered partly responsible
for cuttingsldebtis entering the P.B.R. when using
conventional junk bonnets. However, the FJB will stay in
place because the diameter of the setting tool extension is the
same as the stinger pulled through the internal seals of the
RSM pack-off which is locked in place.
(The RSM pack-off is a retrievable bushing which is used to
effect a seal between the drill pipe running string and the
liner. This type of sealing arrangement, or the commonly
used slick stinger with drillable pack-off, must be used to
allow the use of this junk bonnet). In other words, the
volume within the P.B.R. remains the same and in this way
cuttings/debris are prevented from entering the P. B. R. and
interfering with the functioning of the setting tool. The junk
bonnet is pulled out of the P.B.R. once sufficient distance
has been pulled back to allow the by-pass slots to pass under
the internal O ring seals in the junk bonnet and thereby
allow the necessary fluid to enter the P.B.R. (see fig. 6).
Continual upward movement will pull the junk bonnet clear
of the P. B.R. In the event that a severe accumulation of
cuttings/debris has occurred at the liner top, and the by-pass
slots plug, then a combination of pulling and drill pipe
rotation will allow the rotation lugs to engage corresponding
slots in thejunk bonnet, providing a means of rotating the
junk bonnet, and assisting the removal of the debris. If the
junk bonnet should remain stuck in the P.B.R. then
continued upward pull of the drill pipe will allow the
emergency release sleeve to be sheared at a predeterminedpre-set overpull and allow fluid to enter through
the port, breaking the fluid lock (see fig. 6). Additionally,
circulation through this port will enhance recovery of the
setting tools from the well.

TEST PROCEDURE AND OBSERVATIONS

Testing was performed, and observations recorded on the
prototype FJB following the procedural steps below:-

To function test the FJB a special test fixture (see fig. 7) was
constructed. The purpose of the test was to demonstrate that
an FJB for a 7 liner top, which forms a seal between the
7.5 I.D. of the P.B.R. and the 100MM. O.D. setting tool
extension will :A.

Move in a downward direction as a simulated

hydrostatic pressure of 5,000 PSI is applied above
the P. B. R..

B.

Allow normaI timction of the liner setting ted.

c.

Stay in place as the setting tool is reIeased then

moved in an upward and downward direction.

D.

Not be removable unless fluid is allowed to enter

the P.B.R

379

1.

The junk bonnet was pressure tested internally to

750 PSI, proving the integrity of the inner O rings
which seal around the setting tool extension and the
outer O rings which seal on the inside of the PBR.

2.

Area X (see fig.7) was filled with cold water and

pressure tested to 2,000 PSI through line 1 to prove
the integrity of all the threaded connections on the
liner setting tool assembly.

3.

Area Z (see fig.7 ) was filled with cold water, the

fill line through the junk bonnet plugged off, and the
assembly placed inside the test fixture.

4.

Area Y (see fig. 7) was filled with cold water.

5.

Pressure was applied through lines 1 and 2

simultaneously. The idlcator rod (tell-tale pipe)
connected to the junk bonnet moved inwards
approximately 4 before pressure started to build
due to air in the system. Continued to apply
pressure in 1,000 PSI increments to 5,000 PSI and
noted approximately 1. 1/4 of inward movement of
the indicator rod. This movement was close to the
calculated 1 of movement required to pressurise the
fluid volume in area Z to 5,000 PSI. The gauge
attached to the indicator rod read approximately
4,850 PSI, with 5,000 PSI applied above the junk
bonnet. As, both gauges had read 5,000 PSI when
connected to each other during a test prior to test
fixture
assembly, this 150 pSI discrepancy is
attributed to the frictional resistance of the O rings
on the junk bonnet. Bled pressure off to zero and
the indicator rod returned 3. The net effect of
these movements was that the junk bonnet had
remained 2.1 /4 lower than the initial position,
which was assumed to be due to air in the system
remaining partly compressed.

6.

Step 5 was repeated with similar results.

7.

The liner setting tool was backed off.

8.

Stroked the liner setting tool 18 and observed that

the indicator rod remained statiomry, made
possible because the O.D. of the setting tool
extension has the same O. D. as the stinger through
the RSM pack off.

9.

pulled the liner setting tool back until contact was

made with the junk bonnet (see fig. 8). A
substantial pull was then applied and the indicator
rod did not move.

OTC 7549

DEBRIS PROTECTION SYSTEM FOR LINER TOPS

10.

Removed the pressure gauge from the indicator rod

to allow air into area Z.

11.

Re-applied pull on the liner setting tool and

observed the indicator rod moving outwards,
indicating the junk bonnet being pulled clear of the
PBR.

12.

Removed the running tool from the test fixture and

examined for damage. No damage was observed.

When using the FJB, no overpulls have occurred while

checking for release of the setting tools. In addition, the junk
bonnets have stayed in place, as verified by the predetermkdpre-set
overpulls at the anticipated pull back
distance. On recovering the liner hanger running tools to
surface, it has been observed that the emergency release
sleeve has sheared on approximately 80 per cent of occasions
and that the by-pass slots are often packed with
cuttings/debris and/or cement.

CONCLUSIONS
TheFloatingJunk Bonnet is a radically new design of junk

TEST CONCLUSIONS
The conclusions drawn from the test observations may be
summarised as:
A.

The FJB will move downwards at approximately

1/4 per 1,000 PSI of simulated applied hydrostatic
pressure.

bonnet and has proved to be completely effective at

preventing well debris entering liner tops. This system will
practically guarantee the recovery of liner setting tools
(without the liner !) from the well no matter how severe the
debris problem is.

B.

The functioning of the liner setting tool is not

affected by the presence of the FJB.

ACKNOWLEDGEME~S
The authors would like to thank Graham Ross, Bob Lyons,

c.

The FJB will not move while the tool is stroked to

Andrew Paterson and Glenn Harris of Enterprise OiI for their

co-operation and encouragement, and also Mark Carmichael
of SPS for his input.

check for release.

D.

Air, or fluid, must be allowed to enter area Z to

break the fluid lock and allow removal of the FJB
from the PBR.

JUNK BASKET PRINCIPLE

The test was considered successful and a production model

based on the design shown in fig. 5 was manufactured for
downhole use.

OPERATING HI STORY
TheFJBwasfirstusedby Enterprise Oil in September 1992
on their Nelson Field in the North Sea, and since then has
been used successfully on31 occasions by the following
operators: OPERATOR
Amerada Hess
Amoco
Amoco
B.P.
B.P.
Conoco
Enterprise
Maersk
Mobil
P.D.O.
Texaco
Total

All&$
U.K. North Sea
Norwegian North Sea
U.K. North Sea
U.K. Land
U.K. North Sea
U.K. North Sea
U.K. North Sea
Danish North Sea
U.K. North Sea

oman
U.K. North Sea
U.K. North Sea

NO. OF RUNS
3
3
1
2
1
4
3
1
7
1
1
~
&l

BASIC JUNK BONNET

SEITING

TOOL

EXTENSION

CASING

FIXING

CAP

SCREW
JUNK BONNET
(SPLIT TVPE)

PBR

380

BY-PASS
SLOT

FIG. 4

------------5 -----

-----

-----

ij
m

----J __ -.

381

I
GEORGE TELFER, DAVE SWEENEY

OTC 7549

DOWNHOLE

DOWNHOLE

HOOK-UP

DRILL PIPE

::.

SElllNQ TOOL
EXTENSION
BACK REAMINQ
LU13

E
.i
:,:
::

HOOK-UP

WATER lNLET/AIR
OUTLET

.:.

FLOATING JUNK BONNET

.5

i
$--

IL

EMERGENCY
RELEASE SLEEVE
(SHEARED)

O RINGS
ROTATION SLOT

PBR

9 5/8 CASING
LINER SETTING TOOL
(RELEASED)

<

BY-PASS SLOT

][~
r

ROTATION LUG

r-

SHEAR SCREWS

EMERGENCY
RELEASE SLEEVE

l--

LINER SElllNG
(AITACHED)

TOOL

(REiREIVABLE
SEAL MANDREL)
PACK-OFF

STINGER

FIG. 6

FIG.

382

OTC 7549

DEBRIS PROTECTION SYSTEM FOR LINER TOPS

PROTOTYPE JUNK BONNET

TEST FIXTURE

PROTOTYPE JUNK BONNET

TEST FIXTURE

LINE #1

FRopup
LINE

E
:.,

#2

FROM PUMP

LINE #2
SETllNCi TOOL
EXTENSION

PRESSURE GAUGE

TELL-TALE

?
PIPE

SEALING FLANGE

AREA

AREA X

AREA i

AREA f

PRoTOTVPEJUNK
BONNET
AREA Z

O RINGS

AREAZ

PBR(POLISHED
BORE
RECEPTACLE)
7.51DX6LONG
LINERSErnNGTOOL
(RELEASED)
LINERSETIING
(AITACl+ED)

TOOL

LINER SETRNG SLEEVE

RSM (RETRIEVABLE
SEAL MANDREL)
PACK-OFF

RSM NIPPLE

o RINGS

SEALING SUB
100mmODSllNGER

PLUG

FIG.

FIG.

383