.

@
.
.
,E
Society

lADC/SPE

39399

of Petroleum

EnglneerS

Rotary Liner Drilling for Depleted Reservoirs

L.A. Sinor,* Hughes Christensen
B.C. Wenande,-Consultant

Co.; P. Tybero and O. Eide,* Amoco Notway Oil Co.; and

*IADC Members
Copyright

1998, lADC/SPE

Drilling Conference

This papr was prepared for presentation

Dallas, Texas 3-S Msrch 1998.

at the Igge

lADC/SpE

Drilflg

cofere~a

penetrated and the hole cased as close as possible to the

depleted
chalk reservoir
to prevent
wellbore
stability
problems. A typical approach has been to drill to within 1623 ft (5-7 m) above the prognosed top of the depleted Tor and
run and cement the casing on bottom. Another approach has
been to drill until the bottom of the hole falls out and seal
off the losses with a gunk pill (diesel oil/bentonite LCM).
Then the gunk has to be dressed off to within 10-16 ft, (3-5 m)
above the bottom of the hole without washing away the pill
prior to running casing.

held i

This paper was selected for presentation

by an IADCISPE Prcgram Committee following
review of information conteined in an abstract aubmltted by the author(s), Contents of the
paper, as presanted, have not been reviewd
by the International kswiation
of Drilling
Contractors
or the Socla!y of Petroleum Engineers and are sub@t to correction by the
author(s), The material, as presented, does not necessarily reflact any ~sition of the IADC or
SPE, their officers, or members. Papers presentad at the IADCISPE meetings are aub~cf to
publication review by Editorial Committees of the IADC and SPE. Electronic reproduction,
distribution, or storage of any part of this paper for commercial purpses
Mthout the written
consent of the Smiety of Petroleum Engineers Is prohibited, Permission to reproduce in print
is restricted to an ebslract of not more than 3W werds; illustrations may not be copiad. The
abstract must contain conspicuous acknowledgment
of tiere
and by Morn the paper wss
presented. Write Librarian, SPE, P.O. Box 833s36, Richardson, TX 750S3-3S36, U. S. A., fax
01-972-952-9435.

Hole enlargement, poor cuttings transport in the open hole,

stuck pipe, and well control caused by gas influx are just a few
of the problems experienced with these methods since they do
not completely isolate the Lista formation. Longer term
concerns are the potential for loss in production resulting from
influxes of weighted mud, gunk squeezes, and cement to the
productive zone.

Abstract
This report summarizes the testing and field application of a
rotary liner drilling system. Liner drilling was first attempted
by Amoco Norway Oil Company (ANC)C) in 1993 and there
have since been eight additional wells drilled using rotary,
motor, and a combination rotary/motor liner drilling system.
This paper will focus on six of those wells drilled with a rotary
liner drilling system.
Key learnings
from these well
applications in the Norwegian sector of the North Sea are
reviewed.

Background
The Valhall field is located in the South Central Graben in the
North Sea. The reservoir contains black oil with a relatively
high solution gas-oil ratio. The Valhall field is operated by
Amoco Norway (28. 1%) on behalf of Enterprise Oil Norge
Ltd. (28. 1%), Amerada Hess Norge A/S (28. I %), and Elf
Petroleum Norge A/S (15.7%).

Introduction
A successful rotary liner drilling system can help overcome
challenges related to wellbore stability through sections which
are depleted, contain unconsolidated
or sheared debris, or
experience flow problems.
Interest in this technique has
increased as drilling operations begin to look for additional
reserves below depleted sands which cause differential
sticking problems, below salt domes containing sheared zones
which experience flow and wellbore stability problems, and in
reservoirs with weak matrix strength were there is significant
depletion around old producers.

Amoco Norway Oil Company (ANOC) first penetrated the

chalk in the Valhall area in 1969 with Well 2/1 1-1. Six years
of exploration were performed before drilling the discovery
well 2/8-6. Five additional exploration wells defined the
approximately 2.0 billion barrels of oil in place before the
field was deemed commercially attractive in 1977/1978.
The Valhall field averaged 84,500 BLPD production for the
first half of 1997 from 33 wells. To date a total of 90 wells
have been drilled of which 37 are currently completed. The
remaining 53 wells are abandoned sidetracks. Ten of the 20
wells. are horizontal producers.

ANOC has faced the latter challenge on several wells drilled

since 1990. Drilling into depleted portions of the Tor Chalk
reservoir in ANOCS offshore Valhall field is a major
challenge due to the 5-7 ppg equivalent reduction in pore
pressure that occurs instantaneously at the interface between
the shale overburden (Lista) and the chalk reservoir (Tor).
During

drilling

operations,

the shale overburden

Development drilling began in Valhall in late 1981. A threeplatform complex was installed which included process and
compression,
drilling, and living quarters. The drilling
platform was originally designed with 24 well slots. Six
additional slots were later added bringing the total number of
slots up to 30. The processing facility consists of two stages of

must be

879

L.A. SINOR, P. TYBERO,

lADC/SPE

O. ElDE, AND W. WENANDE

39399

Well 2/8A- I had been the most stable and prolific producer on
Valhall since it was first put on production
in 1982.
Production
history showed the well averaged
12,00016,000 BOPD from 1989-1993. The well was located in the
central crestal area of the field and had failed as a result of
casing collapse inside the overburden. The drilling objective
of Well 218A-1A was to sidetrack out of the 9-5/8 in. casing at
approximately
6,000 ft (1,830 m) and drill a vertical twin
approximately 250 ft (75 m) to the Northwest. The location
was selected to minimize risks related to fault proximity and
possible water flood effects.

primary three phase separation followed by six stages of

compression with an expander and NGL stabilizing system.
Maximum capacity is approximately 168 MBOPD of oil and
175 MMSCF/D of gas. Water handling capacity is designed to
be about 4,000 BBL/D. To further develop the field, a 19 slot
well head platform (WP) was installed Southwest of the
current installation in the spring of 1996. Production from this
platform started in June of 1996 and all new WP wells are
planned to be horizontal. Figure 1 shows the four platform
Valhall complex. The complex is located about 150 miles
Southeast of Stavanger, Norway.

ANTICIPATED STRATIGRAPHIC

WELL

COLUMN

218AIA

rVD BRT (m)

il 3

1431

wP\

: POINT

1825

Fig. 1: ANOC Valhall Complex

.

2180

Uncertainty related to subsidence and wave height resulted in

an additional 20 ft (6.1 m) of safety margin for air gap
clearance with the original complex. Continuous surveys of
platform
subsidence
performed
at Valhall indicates
a
subsidence rate around 9.8 in./yr (25 cm/yr). The total
platform subsidence is estimated to be around 9.02 ft (2.75 m)
which has been confirmed with bathymetry surveys.

ss8

,-68.6..,

: UMESTONE STRINGERS

.1

2418
2430
2.446
2467

The Valhall field is extreme in many respects. Porosity in

excess of 45% is not uncommon although the chalk has a low_
matrix permeability. The high porosity of the unconsolidated
chalk results in a relatively weak matrix which provides
reservoir
energy
through
pore compressibility.
Solids
production, compaction
of the reservoir, and subsidence
effects are features that challenge production.
Reservoir
compaction and depletion ,are the primary features that affect
drilling operations. Successful development of the Valhall
field is dependent on the ability to control solids production
without inhibiting the production of oil. Figure 2 shows the
general stratigraphic column for the Valhall field.

3 HOD

::::::::

2503
;:%

: VOLCANtC TUFF/CLAYSTONE
CtAYSTONE/LIMESTONE
CHALK51MESTONE

2563
2s81
2612
i ARGILLACEOUS LIMESTONE
I

Fig. 2: Stratigraphic

column for the Valhall Field

The required mud weight through the Lista shale on well

2/8A- 1 was 14.7 ppg at 8,040 ft (2,450 m) yet the pressure
inside the Tor formation was predicted to be 6.4-7.8 ppge. The
challenge to the drilling operations was to set a 7 in. liner
close to the Tor to prevent wellbore stability problems, yet
minimize well control risks associated with mud losses into
the depleted pay section.

Reservoir compaction and depletion are the primary features

that affect drilling operations as previously mentioned. During
drilling operations, the shale overburden (Lists) must be
penetrated and the hole drilled and cased as close as possible
to the Tor reservoir to prevent wellbore stability problems.
This is due to the high differential pressure between the Lista
and Tor formations. Well 2/8 A-l A is a good example of the
drilling challenges.

While

880

drilling

the

overburden,

the

Tor

formation

was

. . . . ..-..

IADCISPE 39399

ROTARY LINER DRILLING

FOR DEPLETED

RESERVOIRS

..
..

.
.

.
.

.
.
7/

penetrated 55 ft (16.8 m) higher than expected resulting in an

immediate loss of mud to the reservoir. Mud losses including
two 50 bbl gunk squeezes resulted in the loss of+ 1,000 bbl of
weighted oil base mud before the wellbore became stable. The
Chalk was eventually drilled and cased off with a 5 in. liner
but not without recording a considerable amount of trouble
time. The problems were primarily related to poor wellbore
stability caused by leaving a portion of the overburden
exposed. Hole enlargement, poor cuttings transport past the
washout at the shoe, stuck pipe, and high gas readings
(requiring well control) were just a few of the unscheduled
events.
Unscheduled events totaled 21 ~! for this
the liner section, which had a total cost
Time from spud of the 8-1/2 in. section
clean out of the 5 in. liner, excluding open
days.

.
..

well, 47% through

of $6.5 MM USD.
to completing the
hole logs, was 33.8

.
.

-.

.
.

.
..

.
_.
.. ..

.
.

//

Shale
:
M.W. 14.5 ppg:

Chalk/Limestone
P.P. = 6.4 to 7.8 ppge

Well 2/8A- 1A has since been completed with three separate

stimulations to improve the production which is currently
about 5,000 BOPD, although it had been producing at
12,000 BOPD immediately before it failed. This translates to a
loss of 7,000 BOPD or $140,000 USD/D at $20/bbl. A big
unknown is why the production from this well changed so
dramatically. Possible reasons are related to differences in
wellbore placement relative to fault proximity, differences in
completion performance which is limiting the amount of
drawdown pressure before solids are produced, or related to
the loss of weighted mud, gunk squeezes, and cement to the
pay section which could conceivably block the best fractures.

Fig. 3: Drilling stopped above depleted zone.

The use of a liner drilling systcm to penetrate and isolate the

Lists/Tor
in}erface could potentially
have reduced the
problems experienced on this well. Implementation
of this
concept would entail the use of a properly designed bit shoe
that could be drilled out easily, a method for isolating the
Lista from the Tor (isolation packers, cement, etc.), and a
rotating liner hanger. The system would be run just above the
depleted pay with approximately 25-30 ft (8-10 m) of higher
pressure overburden left to drill. Figures 3 and 4 depict one
process for running the liner drilling concept.

_
-

.
_
#k

1
I

I
I

I
I

Pressure Depleted Zone

.
.
-

.
_

&k

.
Shale

.
:M.W,
14.7
Ppg

-
-.
-------

_.
.

YE

Stabilizer

E-Pxer____-L
_

c
Stabilizer__
F

ANOC tested a portion of this concept in 1993 on Well 2/8AIA while drilling a 5 in. liner down with a conventional PDC
bit on bottom. The bit and liner combination reached total
depth after drilling 390 ft (119 m) of cement and fill. In 1994,
Hod well 2/1 1-A7 used an 11-3/4 in. liner coupled with a
downhole motor and underrcamer to drill 85 ft (25.9 m) of
shale until the casing could not be slid any further.

lPacker I
I
I

I
I

T;n;:yJ

I
I

I
t

Chalk/Limestone

PP. = 6.4to 7.8

I

__E

Pressure Depleted Zone

~ Bit
Fig. 4: Liner drilling into depleted zone followed by
zonal isolation with packers and cement.

Drilling with casing to overcome challenges related to

welibore stability through sections which are depleted,
unconsolidated,
contain sheared debris, or experience flow
problems is an interesting alternative to conventional drilling
operations. This report details the research and development
efforts used to successfully drill into depleted pay sections on
six wells, well 218A-A2, 218A-A8, 218A-3B, 2/8 F-6, 218A9A, and 2/8A-5B drilled by ANOC.

Laboratory Testing
Wells on the Valhall platform which cease to produce are
typically sidetracked inside of the 9-5/8 in. casing to minimize
the cost of slot reclamation and redrilling of the well. An 8-1/2
in. hole is drilled through the window which allows a 7 in.
liner to be run into the top of the production zone.

88

L.A. SINOR,

P. TYBERO,

O. ElDE,

AND W. WENANDE

lADC/SPE

39399

A series of 8-1/2 in. fixed cutter bits attached directly to 7 in.

casing were laboratory tested under pressure to evaluate the
drilling challenges. The successful bit would have to drill at
relatively low flow rates through shale and limestone stringers
without balling and it would have to be designed for trouble
free drillout.
Operating parameters for the laboratory testing were 120 rpm,
250 gpm (946 lpm), and a borehole pressure of 1,150 psi
(7930 kPa). Catoosa shale was used to evaluate balling
tendencies.
The liner shoe design required several iterations
to overcome
balling
and stability
limitations
before
application in the field. Figure 5 shows the design used on
well 218-A-2A, Fig. 6 shows the design used on well 218-A8A (T2), and Fig. 7 shows the current design used on wells
218A-3B, 2/8 F-6 ( 12- l/4 in. shown), 218A-9A, and 218A-5B
drilled by ANOC.
The flow tubes in each blade extend up
two feet (0.6m) inside of the casing body. The area between_
the blades and just to the top of the flow tubes are cemented to
isolate the flow inside the. !iner,...

Fig. 7: Fou~blad~~~4
in. liner shoe with % in (19
m_rn)P_DCcutters used on ANOC well 28 F6.
Figures 5-7
show the progression of liner shoe bit designs
based on key Iearnings from the laboratory and field drilling
results. The results of laboratory testing in shale with five
different liner bit designs showed blade standoff and proper
pressure drop through the nozzles were important to minimize
balling. Figure 8 is an example of severe balling experienced
in Catoosa shale with nozzles that were too large for the flow
rate of 250 gpm (946 lpm) used during the test. The bit
initially balled at a rate of penetration of 26 ft/hr (8 m/hr)
during the initial testing. With nozzle improvements, the rate
of penetration increased up to 93 ftir (28 m/hr) at 7,000 Ibs
WOE with minimal balling.

Fig. 5: Two bladed 8-1/2 in. liner shoe with% in. (19mm)
carbide cutters used on ANOC we[l 218-A-2A.

Fig. 8: Severe balling in Catoosa

pressure drop through the nozzles.

shale with poor

After laboratory testing the bits for balling tendencies, the bit
shown in Figure 5 was drilled out with a junk mill. The 6 in.
mill had four blades and four 1 in. diameter nozzles for flow.
The primary cutting elements were 0.4 in. (10 mm) carbide
cutters with a built-in chip breaker feature.
The main
limitation observed on the mill was the lack of clearance in the
junk slots for drilled debris to pass and the lack of ,cutter

Fig. 6: Two bladed 8-1/2 liner shoe with % in. (19mm)

PDC cutters used on ANOC well 2/8-A-8A (T2).

882

ROTARY LINER DRILLING

lADC/SPE

39399

stand-off
does not
operation
with solid

at the center. The lack of stand-off at the center

present a limitation for normal casing milling
but it could act as a bearing when milling materials
bodies.

FOR DEPLETED

RESERVOIRS

mud. It was essential not to risk penetrating the top of the Tor
with the directional assembly but at tle same time min~lze
the length to be drilled with the 7 in. liner.
The liner drilling assembly would use the liner shoe design

shown in Fig. 5 with two inflatable external casing packers for

formation and pressure isolation. The liner system would be
used to drill the last few meters of Lista shale and a couple of
meters inside the Tor. The two packers would then be inflated
with cement to seal off the differential pressure between the
Tor and Lista at the liner shoe. The liner top packer (TSP)
would then be set to seal the liner lap inside of the 9-5/8 in.
casing. The operations plan is summarized as follows:

The liner shoe in Fig. 5 was cemented inside of an existing 81/2 in. Carthage limestone rock sample prior to milling to
simulate the operating condition in the field. The milling test
was performed by first tagging the cement inside of the liner
with 60 rpm to seat the bit face. After drilling about one-third
of a foot (0.3m) the bit speed was increased up to 180 rpm.
Operation of the junk mill was much smoother at the higher
rotary speed. Sensor output from the rig showed the mill
rotating slightly off-center as it drilled. High frequency lateral
vibrations were aIso noted as th? mill tagged the steel blades
inside the liner shoe. The time from tagging the cement to
breaking through the blades was about 10 minutes. For the
field application, the mill would be modified to have larger
junk slots since it would have to drill a landing collar, cement,
float collar, and then the liner shoe. Figure 9 shows metal
shavings caught during the testing by bar magnets located on
the shale shakers.

. K.O. the 9-5/8 in. window at 7,218 ft (2,200 m)

. Directionally drill 8-1/2 in. hole to Lista shale

Run and drill 7 in. liner assembly into top Tor

Pump cement and inflate two packers

. Test casing shoe and liner lap

Drill out 7 in. casing shoe with a 6 in. mill

Well 218-A-2(T2) was first plugged and abandoned to allow
setting of a packstock in the 9-518 in. casing. A window was
then cut inside of the 9-5/8 in. casing at A7,220 ft (2,200m)
MD BRT and an 8-1/2 in. steerable assembly was used to drill
down to 10,354 ft (3, 156m) MD BRT inside the Lista
formation. Maximum inclination below the kickoff point was
57.7 at 8,038 ft (2,250m). The inclination was held constant
through a short tangent section before dropping the inclination
back to vertical towards the top of the Tor.
Lost circulation problems required extensive treatment of the
wellbore. Losses were believed to be related to poor cement at
the window cut inside the 9-5/8 in. casing and near total depth
of the well at 10,355 ft (3, 156m). Total losses of
approximately 1,200 bbls were reported during the three days
required to stabilize the wellbore.

4
ma
-.
..
Fig. 9: Bar magnet with metal shavings from liner bit.

ANOC Rotary Liner Drilling Field Results

This section focuses on the results of six wells drilled with a
rotary liner drilling system. A portion of this work was
obtained from Amoco internal reportsz~. Detailed analysis is
provided
for wells 218-A-2A and 218-A-8 A(T2) with
condensed
analysis
for wells 218-A-3B and 2/8 F-6.
Summaries only arc given for wells 218-A-9A and 218-A-5B.

After curing the losses, the liner drilling assembly was picked
up which included 84 joints of 7in. 29 ppf L-80. The total
liner length was 3,346 ft ( 1020m). The connections used
Hydril 521 threads to provide high torque capacity which
would be required while drilling.
The minimum makeup
torque of the threads is 8,300 ft-lbs with a minimum field
recommended makeup of 9,550 ft-lbs. Maximum yield torque
with L-80 material is 46,000 ft-lbs. The liner was made up
with the following equipment and order:

Well 218-A-2A Summary

Well 2/8-A-2A was planned as a vertical replacement of well
2/8-A-2 (T2), an offshore oil producer on the Valhall platform
suffering severe stability problems from production of chalk.
The well had ceased flowing shortly after a shutdown on
Valhall. The estimated costs for sidetracking, drilling, and
completion into the Hod I formation was $4,954,000 US.

The drilling plan called for using an 8-1/2 in. steerable

assemb[y to the top of the Tor chalk and then puiling it to run
the 7 in. rotary liner drilling system. The liner would help
isolate the high differential
pressure between the shale
overburden and chalk. Estimated Tor pressure at entry point
was 8.3 ppge and a complete loss of returns was expected
while drilling into the Tor with 14.7 ppg weighted oil base

883

8.5 in. x 3 ft Bit shoe, Hydril 521 box up

7in., 29 ppf float collar
7 in. 29 ppf landing collar
8 in. packers for 7in. casing, 20 ft element
7 in. 29 ppf L-80 casing, Hydril 521 connections
7 in. rotating liner hanger
7 in. TSP setting sleeve w/top packer& 15 ft PBR
Rotating liner hanger running tool, type R
5 stands of 5in. HWDP
5 in. S-135 drill pipe to surface

L.A, SINOR,

P. TVBERO,

O. ElDE,

Surge calculations
with a closed end displacement
gave
maximum
casing running speeds of around 36 ftimin
(1 I m/min) near the 9-5/8 in. window with an EMW of 15.2
ppg and speeds of 20 ftimin (6m/min) for an EMW of 15.0
ppg. Actual running speeds of 20 ft/min (6m/min) were used to
minimize losses. The pipe ran to bottom smoothly except for
the 9-5/8 in. window at *7,220 ft (2,200m) MD which was
tagged with 20,000 ibs. Slow rotation of the pipe was
eventually required to pass by the window.

IADCISPE

39399

drop, and torque response. Drilling was continued to a final

depth 10,405.5 ft (3,171.6 m).
The pump pressure had
dropped to261 psi (1823 kPa) at total depth.
Taraue.

ft-lbs

15

Torque simulations with 30/1 00 ft doglegs estimated a drilling

torque of 7,000 ft-lbs. Hydraulics
analysis estimated a
pressure drop of 480 psi at 140 gpm (530 Ipm). Torque and
pressure readings one stand above the window were recorded
as shown below.

AND W. WENANDE

Slight losses were recorded at the 140 gpm (530 lpm) reading.
The equivalent mud weight based on annular pressure losses
at 140 gpm (530 lpm) was 15.4 ppge. No additional losses
were recorded while tripping into the hole and breaking
circulation until 10,269 ft (3, 130m). Attempts to circulate and
work the pipe resulted in only 10% returns back to surface.
The liner running continued until total depth of the hole where
it picked up weight at 10,354 ft (3, 156m). The top of the ~or
formation was estimated at 10,398.6 ft (3, 169.5m). Hole drag
prior to drilling showed the up drag to be 275,00 lbs while the
down drag was 270,000 lbs. Drilling began with 225 gpm
(1, 100 psi/7684 kPa) with returns of only 10%,60 rpm, and O4,000 lbs measured weight. The rotating torque varied
between 10,000-15,000
ft-lbs.

21

24

<d

20 rpm/70 gpm (265 Ipm): 6,000 ft-lbs and 210 psi

40 rpm/140 gpm (530 lpm): 6,000 ft-lbs and 450 psi

18

&
.,----
A--

.--Torque

-RPM
3.162

Fig. 10: Liner drilling torque through a hard stringer

A total of51 ft ( 15.6 m) of formation were drilled in 3.2 hours
at an average rate of 16 ft/hr (4.9 m/hr). This included 24.9 ft
(7.6 m) of depleted Tor based on the actual top of Tor depth
picked from logs. While drilling with no returns, the annu[us
was kept full with 6.8 ppg base oil requiring 69 barrels at total
depth. Total losses of 14.6 ppg drilling mud were 1,350 bbls.

The rotary stalled at 14,000 ft-lbs after drilling 2.6 ft (0.8 m)

requiring the pipe to be worked up and down to free. Up and
down drag was measured to be 320,000 lbs and 200,000 Ibs
indicating tight hole problems from fill or cavings. There was
concern that any tight hole problems could damage the sealing
elements on the liner packers so extra care was taken to limit
harmful drilling conditions. Drilling was continued at a lower
flow rate of 140 gpm (530 lpm) and 700 psi (4827 kPa) and
approximately 5,000 lbs weight.

After reaching total depth, the liner hanger was set by

dropping a ball and shearing the ball seat at 2,200 psi (15169
kPa). The TSP packer was then tested unsuccessfully while
pressuring the annulus between the drill pipe and the casing. It
was later confirmed that the emergency release had sheared
while releasing from the hanger allowing communication
between the drill pipe and casing annulus. This prevented
positive testing of the hanger packer element.

The ROP slowed at 10,374 ft (3,162 m) in what was believed

to be a hard limestone stringer. The torque was also much
rougher from this point forward
indicating
a change
downhole. The rate of penetration was also reduced by half
although additional weight was required to keep drilling
ahead. Damage to the all carbide cutters most likely occurred
while drilling through the stringer which slowed the bit down
and eventually stopped drilling at total depth. Figure 10 is a
snapshot of the torque before and after encountering the hard
stringer.

The cement pumps were used to inflate the packers. Low

initial pressures gave indications
that the packers were
opening but this should not have been possible based on the
setting pressures of the packers. The pressure was taken up to
4,500 psi (3 i 432 kPa) where it leveled off with continued
pumping. The pressure was then released to zero and the
pumps were restarted to try and inflate the second packer. The
pressure was increased to 1,500 psi (10343 kPa) at 1.4 bpm
but leaked off quickly to 1,000 psi (6895 kPa) when the
pumps were shut down .

At 10,387 ft (3, 166 m) the pump pressure decreased 200 psi

(1380 kPa) and the rotary stalled at 10,397 ft (3,169 m) with.
20,500 ft-lbs torque. The top of the TOR was estimated to be
10,398.6 ft (3, 169.5 m) based on the annular losses, pressure

884

IADCISPE 39399

ROTARY LINER DRILLING

FOR DEPLETED

RESERVOIRS

floating junk bonnet and an undercut stinger (with no

emergency release sleeve). The drill pipe dart was standard
but the liner wiper plug was modified with extra fins to ensure
a good seal and latch in the landing collar. The total liner
length was 1,640 ft (500m). The operations
plan is
summarized as follows:

The well was then shut-in with 1,000 psi (6895 kPa) until the
cement samples on the surface became hard. Caution was
taken since the casing could not be tested at higher pressures
without losing pressure. There was reason to believe that the
wiper had not seated properly in the landing collar preventing
a positive seal. This was later confirmed by testing the casing
to 1,500 psi (10343 kPa) after allowing the cement to cure.

. K.O. the 9-5/8 in. window at 6,890 ft (2,100 m)

. Directionally drill an 8-1/2 in. hole to Lista shale

Run and drill 7 in. liner assembly into top Tor

. Pump cement and inflate one CTC packer
. Test casing shoe and liner lap

Drill out 7 in. casing shoe with a 6 in. mill

. Drill ahead with a 6 in: mill through Tor and HOD-4

The well was displaced to sea water and a 6 in. mill assembly
was picked up with 26 joints of 3- 1/2 in. HWDP and 91 joints
of 3-I/2 in. drill pipe. The assembly was run to bottom
without trouble and the sea water was displaced to 8.7 ppg
water based mud. Firm cement was drilled from 10,315 ft
(3, 144m) to the landing collar at 10,400 ft (3, 170m) with 75
rpm and 7,000 Ibs weight. The landing collar, float collar, and
bit shoe were drilled quickly in I hr 5 minutes with 120 rpm
and 2,000-12,000
lbs weight. The mill torqued up as it broke
through the bit shoe at 10,405.5 ft (3,17 1.6m) and was
averaging 33 ftihr (10 m/hr) just below the casing shoe.

Well 218-A-8 was first plugged and abandoned to allow

setting of a packstock in the 9-5/8 in. casing. A window was
then cut inside the 9-5/8 in. casing at A6,890 ft (2, 100m) MD
BRT. The casing window was then squeeze cemented as-part
of a key learning from well 2/8-A-2A to minimize lost
circulation
problems.
No tight hole or lost circulation
problems were experienced at the window.

The liner drilling approach cut the time from spud of the
S-l/in. section to completing the clean out of the 5 in. liner,
excluding logs, from 33.8 days (A-1A) to 15.6 days. The
unscheduled
events for the liner section was 55.6V0.
Savings
was estimated
at $1.82MM
US using a
conservative spread rate of $100,000 US/day (1995).

An 8-1/2 in. steerable assembly was used to drill down iiiiide

the Lista formation to a depth of 8,307 ft (2,532m) MD BRT,
26 ft (8m) into the Lista. The inclination was a maximum at
the casing window with a measured inclination of 12.9. From
the casing window, the inclination was dropped to vertical at
7,398 ft (2,255 m), built back up to 9.2 at 8044 (2,452m), and
dropped back to 5 near the top of the Tor formation at 8,307
ft (2,532 m). No lost circulation problems were experienced
while drilling with the steerable assembly. This is an
important improvement over the 1,200 bbls of mud and LCM
used in this section while drilling well 2/8A-2A.

Well 2/8-A-8A(T2) Summary

Improving upon the lessons learned in well 2/8-A-2A, a
modified 7 in. liner was run on well 2/8-A-8 A(T2) in 1996.
Estimated Tor pressure at entry point was 3,300 psi (22753
kPa), 7.8 ppge, and a complete loss of returns was expected
while drilling into the Tor with 14.7 ppg weighted oil base
mud.
Well 2/8-A-8A was planned as a vertical replacement of well
2/8-A-8, an offshore oil producer on the Valhall platform.
Careful drawdown schedules and choking back on the
production had kept the well alive since the last failure. Clay
from the overburden had been seen in the production from this
well indicating casing collapse was imminent. Estimated cost
for the sidetracking, drilling, and completion was $5,930,000.

When the steerable assembly was pulled, 23ft (7m) of Lista

shale was left to be drilled with the liner before entering the
Tor. The liner drilling assembly included 40 joints of 7 in. 29
ppf L-80 casing with Hydril 521 threads. Two rigid
centralizers were also run to help protect the packer from the
formation while drilling. The top centralizer was 8-3/8 in.
diameter and the bottom centralizer was 8-1 /4 in. diameter to
allow the bicenter design shoe to fit inside the 9-5/8 in. casing.
The liner was made up with the following:

The drilling plan for this well was almost identical to the one
used to drill well 2/8-A-2A with the addition of key learnings
generated during the post analysis. The drilling plan called for
squeeze cementing the window after sidetracking. The liner
drilling assembly would use a redesigned bit shoe (Fig. 6)
with one inflatable external casing packer for formation and
pressure
isolation. Major changes
included Anti-Whirl
features for bit stability, bicenter design for improved annular
clearance and hole cleaning, PDC vs. carbide cutters for
impact and wear resistance through the carbonate stringers,
and larger nozzles for LCM material.

The liner hanger would be run with a 15 ft (4.6m) PBR and a

redesigned TSP packer. The new TSP was more flush with the
steel body allowing better protection against wear generated
while drilling. The running tool was also a new design with a

7 in. x 9 in. x 3 ft Bit shoe, Hydril 521 box up

7in., 29 ppf float collar
7 in. 29 ppf landing collar
8 in. packer for 7 in. casing, 20 ft element
7 in. 29 ppf L-80 casing, Hydril 521 connections
7 in. MHR. rotating liner hanger
7 in. TSP setting sleeve w/top packer& 15 ft PBR
Rotating liner hanger running tool, type R
5 stands of 5 in. HWDP
5 in. S-135 drill pipe to surface

The 7 in. liner was run at 2 minutes per stand to the bottom of
the 9-5/8 in. window without any mud losses. The rotating
torque of the liner was measured to be 4,200 ft-lbs (120 amps)

885

L.A. SINOR, P. TYBERO, O. ElDE, AND W. WENANDE

lADC/SPE

39399

brought up to 280 gpm (1060 lpm) and the rotary was

increased to 50 rpm to seat the bit. The rate of penetration
slowed at 8,319 ft (2535.5 m) indicating a possible limestone
stringer. The weight was increased from 3,000 to 4,000 Ibs
and the rate of penetration jumped from 7.2 to 36 ft/hr (2.2 to
11m/hr).-At 8,3W ft12,53-8rn), the pressiire-dropped instantly
from 1,135 psi to 500 psi (7826 to 3448 kPa) with a
corresponding loss of returns. The mud was switched to 10
ppg mud down the drill pipe and base oil was used to keep the
annulus full. The pressure began to increase slowly from
8,330 ft (2539m) to the final depth of 8,341 ft (2542 .5m). The
pressure-at-total depth was 1,320 psi 9191 kPa).

just above the 9-5/8 in. casing window. The liner was then run
to bottom and the 14.7 ppg oil base mud was cut back to 14.5
ppg prior to drilling. Hydraulics estimated a pressure drop of
675 psi (4654 kPa) at 200 gpm (757 Iprn) vs. a measured 730
psi (5033 kPa). Additional simulations at 300 and 350 gpm
(II 36 and 1325 Ipm) gave pressure drops of 1,075 and 1,325
psi (7412 and 9 i 36 kPa), respectively.
New formation was drilled from 8,307 ft - 8,314 ft (25322534 m) at rates averaging 10-16 m/hr, The torque then
jumped to over 15,000 ft-lbs and the pressure increased
requiring the pumps to be slowed to prevent premature s&ttingof the liner hanger. At 270 gpm (1022 lpm) the pump pressure
was reading 1,400 psi (9653 kPa). The pipe was picked up off
bottom and worked slowly to bottom with erratic torque
readings. Fluid losses started requiring the flow rate to be
slowed to 175 gpm (662 lpm) to regain full returns.

A total of 28 ft (8.5m) were controlled drilled in 1.5 hrs at an

average rate of 18.7 ft/hr (5.7 m/hr). Average running weight
was 3,000 lbs except for the-last 5 ft (1 .5m). The estimated top
of the Tor was 8,330 ft (2,539 m). After reaching total depth,
the ball was dropped and the hanger was set with 2,800 psi
(19306 kPa) and released from the running tool. The
cementing lines were then hooked up and 30 bbl of 15.8 ppg
slurry was pumped and displaced with 10 ppg mud using the
rig pumps. The wiper plug sheared at 2,150 psi (14824 kPa)
and the landing colIar was tagged with 3,500 psi (14133 kPa).
Total losses while drilling and cementing were 700 bbls.

An overpuil of 35 klbs was measured when trying to pick up

off bottom requiring the pipe to be worked. After freeing the
pipe and regaining 100~ returns, a meeting was held to
review the drilling operation. Total mud losses were 240 bbls.
Based on the torque spike, pressure increase, and subsequent
lack of penetration rate, there was reason to believe that the bit
had been damaged and the liner would have to be pulled back
out of the hole. A 50 bbl LCM pill was spotted on bottom and
the liner was pulled out of the hole. The liner pulled tight at
7,628 ft (2,325 m) and the liner was washed up hole to 5,840
ft ( 1,780 m). An ovcrpull of 20,000 lbs was required to pull
the liner shoe past the 9-5/8 in. window. Damage to the packer
element was believed to be the cause of the overpull.

Pipe conveyed perforating guns were run to bottom on 3-1/2

in. drill pipe and the liner shoe was squeezed with cement in
one trip. A total of two 6 in. mills were used to mill out the bit
shoe and drill 361 ft ( 1IOm) of chalk to total depth. The first
mill tagged firm cement at 7,585ft (2,434m) and averaged 2033 ft/hr (6- 10m/hr). The mill drilled the landing collar float
shoe, and liner bit in 4 hours. Flat surface torque indicated the
mill was worn after drilling through the shoe and it was pulled
with 1A in. wear on the bit face with a groove cut near the
center. A second mill was picked up and run to total depth
inside the Hod formation with no hole problems.

All of the Hydril 52 I connections which had been torqued to

15,000 ft-lbs broke out with no signs of damage to the threads
except the shoe track which had been Baker Locked. Those
connections had to be cut with a torch. The stop collar used
with the top centralizer had slid and stretched to the point that
it was nearly past the lower box end of a connection.
Inspection of the packer showed the entire rubber element to
be missing and left in the hole. The blades on the bit shoe had
been sheared off clean with the face of the bit leaving the
bottom base plate intact.

The liner drilling approach cut the time from spud of the
8-1/2 in. section to completing the clean out of the 5 in.
liner, excluding logs, from 33.8 days (A-1A) to 12.1 days.
The unscheduled events for the liner section was 43.6%.
Savings was estimated at $2.17MM using a conservative
spread rate of $100k/day (1996). This reduction included
two days required to sidetrack around junk left by an
unsuccessful liner run which left parts of the liner bit and
packer rubber in the weIIbore.

Two days (47 hours) were required to go into the hole with a
junk mill and work the rubber element to bottom, spot a 30
bbl 15.8 ppg cement plug on bottom, and sidetrack around the
junk. The well was kicked off at 7,940 ft (2,420 m) and
stopped at 8,314 ft (2,534 m).

Well 2/8-A-3B Summary

Improving upon the lessons learned on well 2/8-A-8A(T2),
another 7 in. liner was run on well 2/8-A-3B in 1996. The liner
drilling assembly would use the liner shoe design shown in
Fig. 7 without the use of a packer. Total length of the liner
was 3,960 ft ( 1207m). The bit design improvements included:

The bit shoe was modified on the rig by adding additional

reinforcement behind the blades. Reinforcement was included
in the original design but later removed after lab testing
showed it helped initiate balling. The backup bit still had twothirds of the reinforcement in place which was strengthened
further by bracing the bltde toward the bit center. The liner
was then run back into the hole with the modified bit and no
centralizers or isolation packer.

The bottom was tagged at 8,314 ft (2534 m). The pumps were

886

Four blades vs. two blades to decrease the load to the

individual blades while drilling
Six 14/32 in. jets (two each on the primary blades, one
each on the secondary blades) vs. four jets
Cutter backrake angle of 30 vs. 10 to increase the cutter
robustness and to make the bit less sensitive to WOB

IADCISPE 39399

ROTARY LINER. DRILLING FOR.DEPLETED

Inner cone angle of ISn vs. 20 for easier milling

Rounded O.D. taper to minimize the potential for
while running into the hole
Conventional PDC design vs. bicenter design
Thinner 0.25 in. (6.4n1rn) cutters inside of the
allow ftister milling; thicker 0.52 in. (13mm)
placed at the drift diameter of the 7 in. casing out
Thicker steel platt t~f 0.75 in. vs. 0.50 in. with
edges to minimize stresses and improve strength

_____
____

annulus dropped to 13.0 ppg during this time, a reduction of

approximately
1,200 psi (8275 kPa) from the 15.6 ppg
equivalent circulating density. After spotting the gunk and
stopping the mud loss, the assembly was pumped out of the
hole to 8,953 ft (2729m) where circulation was attempted with
major losses. An increase in surface torque from 15,000 ft-lbs
to 24,000 ft-lbs and an increase in drill pipe pressure while
rotating indicated that the hole was trying to pack off near
bottom. The pipe was reciprocated and rotated while a 40 bbl
slug was pumped (600 bbl mud lost at this point). Pumping
out of the hole continued to 3,468 ft ( 1057m) before normal
tripping could resume.

hang-up

cone to
cutters
to gage.
rounded

Well 2/8-A-3A had been dead for approximately one month

due to solids intlux prior to the start of plug and abandonment.
After plugging the well, a window wtis cut inside of the 9-5/8
in. casing at 4,583 ft (1397m) and an 8- 1/2 in. steerable
assembly was used to drill to a depth of 8,414 ft (2564 .5m),
23 ft (7m) TVD above the prt]gnoscd top of TOR. The liner
drilling assembly was picked up which included the 8- 1/2 in.
bit shoe, 7 in. float colhrr, lending collar, 29 ppg N-80 casing
with Hydril 521 connections, r(.~ttiting liner hanger, TSP liner
packer, PBR, liner hanger running tool, and 5 in. drill pipe.

A rotary assembly was picked up after laying out the motor

and MWD tool. The assembly was run to a planned depth of
9,006 ft (2745m) to clean out the fill above the gunk squeeze.
Large cavings and chunks of formation were coming across
the shale shakers while the wellbore was being circulated. The
assembly was pumped out of the hole to 3,280 ft ( 1000m)
before normaI tripping was resumed.
The 9-5/8 in liner assembly was picked up which included the
12- l/4 in. bit shoe, 9-5/8 in. float collar, landing collar, four
joints 53.5 ppf C-95 catirrg with New Vam connections
full
opening cement (FO) collar, 53.5 ppf C-95 casing with New
Vam connections, rotating liner hanger, TSP liner packer,
liner hanger running tool, 2 stands of 8 in. drill collars, 11
stands of 5 in. HWDP, and 5 drill pipe to surface. Torque
reducing subs were installed every third joint for the 5 in.
HWDP and the 5 in. drill pipe. Circulation was broke every
985 ft (300m) while slowly raising the casing to minimize the
ECD on bottom. A total of 5 lbs/bbl of Lubra Glide fine beads
was put into the active mud-system while going to bottom. It
was hoped that the friction between the casing and the open
hole would be reduced if the beads were worked into the filter
cake while tripping to bottom.

The liner drilling was a success, drilling 31.2 ft (9.5rn) in 2

hours.
The unscheduled events for this section averaged
14.8%. The overage rate of penetration was generally good
except for the limestone stringers where the rate was slower
than normal because of the increased cutter back rake angle.
The overall rate of pcnctra.tion was controlled to limit bit
balling in the shale since the flow rate averaged 160- 210
gpm (606 -795 Ipm) in the 8- 1/2 in. bole. A total of 796 bbl
of 14.7 ppg oil baso mud were lost while drilling and setting
the 7 in. liner. This included 2 I bbl while running the liner to
bottom, 465 bbl lost while drilling the liner, 220 bbls lost
while pumping the liner hanger ball tind plug, and 90 bbls lost
behind the 7 in liner.
Well 2/8 F-6 Summary
Well 2/8 F-6 was a new well drilled from the WP platform on
Valhall in 1997. The drilling plan called for using a 12-1/4 in.
steerable system to the top of the Tor chalk and then pulling it
to run a 9-5/8 in. rotary liner drilling system. The 12- 1/4 in.
section was directionally drilled to an angle of 53 at a
measured depth c>f 9,029 ft (2752 m). The average dogleg
throughout the entire 12- I/4 hole was planned to be 2.3. The
9-5/8 liner drilling assembly would usc a 12- 1/4 in. shoe
design shown in Fig. 7 without the use of a packer. Total liner
length would be 4,469 ft ( 1362m).

The liner drilling system was washed down to the top of the
gunk pill at 9,06 ft (2745m) where mud losses were averaging
2 bpm. The liner required 24,000 ft-lbs to initiate rotation
(while reciprocating) before dropping down to 20,000 ft-lbs.
Washing and reaming continued to 9,029 ft (2752m) where
drilling was initiated with 250 gpm (946 Ipm), 800 psi (5516
kPa), 110 rpm, and 18,000-20,000
ft-lbs torque with no mud
returns. One meter of formation was drilled while pumping
275 bbl of 6.8 ppg base oil down the annulus. The drill string
stalled at 25,000 ft-lbs torque indicating that the hole was
caving around the liner shoe with the reduced EMW. Mud
returns up the annuhrs were lost but the annulus was staying
full without the pumps.

The drilling planned called for placing the bottom of the hole
10- 15 ft (3 - 5m) TVD from the prognosed top of TOR but
the Lista fortnation was 33 ft (10 rn) thinner than estimated.
Unknown at the time, the actual depth above the Tor was 1.5
ft (0.5m) which resulted in total mud losses with the steerable
assembly. The mud weight was 14.7 ppg with an equivalent
circulating density of 15.6 ppg at total depth.
During the losses, the
bbi of 6.9 ppg base
squeeze was pumped
while-drilling (MWD)

RESERVOIRS

Although the distance drilled was short, the liner drilling

system was successful. A total of 4,469 ft ( 1362m) of 9-5/8 in.
casing was rotated at inclinations up to 55 with average
doglegs of 2.3/100 ft. The system allowed 23 ft (7m) of gunk
to be reamed and 3 ft (1 m) of hole to be drilled into the
depleted Tor formation. Unscheduled events for this section
were 13.570.

annulus was kept full by pumping 206

oil down the hack side while a gunk
through the motor and rneasurcmenttool, The equivalent mud weight in the

887

10

L.A. SINOR, P. TYBERO,

IADCISPE

O. ElDE, AND W. WENANDE

39399

Table 1
I Year I Hole IL]ner I Elner ILength] Drill I
I Name ]
lAngle] Size ILength IDrilled I Time I
(ft)
(ft)
(hrs)
(deg) (in.)
5.00
568
899
29.0
1993
0
A-1A
5?35
1175
89
2.5
Hod A-7B * 1QQ~ 4n
.
.1 1995 I 7 I 7.001 33~

Well 2/8-A-9A and Well 2/8-A-5B Summary

ANOC wells 218-A-9A and 2/8-A-5B were drilled during the
latter part of Q4 1997. Final well reports are still pending for
these wells and only a brief summary of the liner drilling will
be given.

Well

Well A9, an oil producer on the Valhall Platform was to be

recompleted by well 2/8-A-9A.
The drilling plan called for
drilling 2,790 ft (850m) of 7-5/8 in. liner with an 8-1/2 in. bit
shoe (Fig. 7). The wellbore trajectory at the top of the Tor was
planned to be 10 where severe depletion around the old
wellbore would result in a 6.5 - 7.2 ppg equivalent mud
weight. The weight of the drilling mud at the depth of Tor
penetration would be 14.5 -14.7 ppg.

./

--,.-

,.

1 nnL

A-8A

<

177UI

..,-,-

7 Ml
J.w

---

1A,
1 du

L.J

2;
I .5
1996 I 5 I 7.00 1640
31
2.5
3960
1996I I
-41/. -00
3
1.0
1996 [ 60 I 9.63 4472
.nnl
,- 1 -l/*
.-99
64
12.0
I IYY/ I 14 I /.0.11L/(
66 I 2.5
I 1997 ] 60 I 7.631 4~~ I
I 19971
63
{u
. . ---- 60 ,. 9.63
.-., I 6890
--* Bit and underreamer. inner string motor, and casing spear
** Drilled in three attempts due to ;asing failure at wi~dow
** Baker liner drilling
systems using a motor and thruster

A-8A(T2)
A-3B
F-6
A-QAw~

The 7-5/8 in. liner had to be fished twice due to twist-offs in

the H-52 1 pin connection of the Q-125 casing, first after
drilling 49 ft ( 15m) and second after drilling 3 ft (1 m). Both
twist-offs occurred across the 9-5/8 in. window (across the
whipstock)
after approximately
12,000 - 14,000 pipe
revolutions. The liner drilling was a success on the third
attempt, drilling an additional 11.5 ft (3.5m) at an inclination
of 12. Post analysis of the drilling operation showed that a
hard stringer at 10138 ft (3090m) caused a single connection
to be exposed to a high number of revolutions at the window
in the sidetrack.
The tension at the failed connection was
55,000 Ibs. The theoretical dogleg across the whipstock was
(24/30m) where the liner failure occurred.

00

gwg40-

%%20.

3
.c lo-

3
~

0+
A-iA

A-2A

A-8A

A-3%

F6

Well

ANOC well 2/8-A-5B was drilled as a sidetrack to well 2/8-A5B which was producing at 1800 BOPD, far below its
potential of 8000 BOPD as a horizontal well. The drilling
plan called for drilling with a very short section of 7-5/8 in.
liner (433 ft/132m) into the Tor formation at an angle of 60.

Fig. 11: Unscheduled events reduction

wells drilled with the rotary liner system.

for ANOC

Acknowledgment
The authors would like to thank Amoco Norway Oil Company
and Amoco Production Company- Exploration and Production
Technology Group (EPTG) for permission to publish this
work. Special thanks to Phil Pattillo, Steve Morey, and Jim
Powers for
the tubular analysis and testing; Hydril for
supplying the pup joints used with the 7 in. and 7-5/8 in liner
drilling shoes; and Mike Murphy, publisher of THE BRIEF
for his assistance in obtaining archived information, Lastly,
we would like to thank Baker Oil Tools for supplying the 6 in.
mill used during the laboratory testing.

The liner drilling was a success, drilling 66 ft (20m) of

formation at an angle of 60. Average ROP was 30-65 ft/hr
(10-20 m/hr) at a rotary speed of 80 rpm and a flow rate of
190 gpm (720 Ipm).. The drilling included 28 ft (8,5m) of hole
after the Tor formation was penetrated.
ANOC Liner Drilling Summary
The ANOC drilling team has made significant progress in
overcoming the challenges presented by drilling into depleted
zones. The teamwork bet ween the drilling operations engineers
and the technology providers made it possible to reach another
milestone in the effort to cut costs through the application of
innovative technology.

References
1. Warren, T.M., and Armagost,

2.

Table 1 summarizes the wells drilled by ANOC with the liner

technology. Figure 11 shows the reduction in unscheduled
events up through well F6, The total time to drill wells A-2A
through F-6 represent a reduction of up to 50% compared to
the best Valhall well (A-IA) drilled into the depleted part of
the Tor chalk reservoir. By implementing the lessons learned
on each liner drilled well, the unscheduled events have
dropped nearly 7570.

-3.

4.
5.

888

W. K., Laboratory Drilling

Performance of PDC Bits> SPED (June 1988) 125- 135.Sinor, L,A., Liner Drilling for Depleted Pay, Amoco
Internal Report F94-P-86, Aug. 11, 1994.
Sinor, L.A., Innovative Drilling TechnologyRotary
Liner Drilling System for Depleted Reservoirs, Amoco
Internal Report F95-P- 110, Nov. 28, 1995.
Warren, T. M., Brett, J. F., and Sinor, L. A., Development
of a Whirl-Resistant Bit, SPEDE (Dec. 1990) 267-274.
Vogt, C., Makohl, F., Suwano, P., and Quitzau, B.,
Drilling Liner Technology for Depleted Reservoir,
SPE 36827 presented at the 1996 European Petroleum
Conference, Milan, Italy, Oct. 22-24, 1996.