SPE-187924-MS

Design of 5 Liner Drilling System for Directional Drilling

A. R. Agishev, LLC TMK-Premium Service; M. Ya. Gelfgat, Gubkin Russian State University Of Oil And Gas,
National Research University

Copyright 2017, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Russian Petroleum Technology Conference held in Moscow, Russia, 16-18 October 2017.

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
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Abstract
The application of classical field development systems in the modern world is becoming more and more
complicated. The global portfolio of oil and gas fields virtually ran short of reservoirs located in favorable
conditions for geologists and drilling & completion engineers. New fields are either located in adverse
climatic conditions (e.g., Arctic projects) or are faced with various problems related to unconventional
reservoirs, complex geological structure, high pressures and temperatures.
One of those problems, which has become a particularly pressing issue in recent years, is the problem
of incompatibility of borehole pressures, which causes complications in the well construction: borehole
wall collapses, fluid losses and sticking of drilling tools. For the well construction process this means an
increased non-productive time (NPT) and extra costs. One of the solutions to such challenges is a liner
drilling technology, which is actively used as a means to lower NPT and operational risks.
Liner drilling systems, including those for directional drilling, are available, but for strings 178 mm
(7″) and more in diameter. Smaller diameter liner drilling is carried out using directionally-uncontrollable
systems, which restricts the application of the technology. In this regard the authors are offering the
technology of directional drilling with a 127 mm (5″) liner, which would reduce the rig time and address
the above technical problems.
The task is completed by the use of a disposable bottom-hole directional assembly - a drilling bit and
a bent-housing positive displacement motor (PDM with adjustable bent sub) and a retrievable telemetry
system. The coil tubing (CT) can be used to extract the retrievable telemetry system. All the system elements
are available on the market, the article describes the calculation results that demonstrate the possibility of
the use of such a system in drilling of deep directional and horizontal wells.

Introduction
Producing formations of currently developed fields are located progressively deeper and in increasingly
complex geological conditions. During the well construction at such fields engineers are faced with the
problems of pressure incompatibility, unstable rock zones and fluid losses. As early as 25 years ago drilling
in such wells was considered impossible. In these circumstances it is necessary to seek new approaches
to the drilling process, one of which is the Liner Drilling Technology. The Liner Drilling Technology is
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certainly based on the principles of Drilling with Casing (DwC), however, further, works shall be planned
taking into account the design and operational features of the liner hanger system. This allows to eliminate
potential risks when drilling.
The first pilot job on the liner drilling was carried out in 1993 at Valhall filed in the North Sea. Occasion
was given by accidents associated with stuck bottomhole assemblies due to a virtually instant, change in the
equivalent circulation density (from 16 ppg = 1,916 kg/m3 to 10 ppg = 1,200 kg/m3)[1]. The first commercial
attempts of the liner drilling were successful, which, ultimately, shaped a way to a rapid development of
this technology. The drilling was performed using rotary method: by rotating drill pipes driven from the
surface. Thus, the first assemblies were non-oriented, but allowed to achieve the main objective – drilling
through depleted reservoirs accompanied by a sharp pressure change.
The advantage of this system was its simplicity and its main constraints were the torque loads on the
running tools and threaded connections of casing strings. In addition, there was no possibility to control a
well path. However, just 4 years later the assembly, which allowed to control the well path, was tested at
the same field: it consisted of a downhole motor with MWD (measurement while drilling) system, which
were retrieved after the achievement of a target depth. An example of such an assembly is shown in Fig.
1. (used at Arun field, Indonesia).

Figure 1—Directional liner drilling assembly [4]

A large number of new equipment, which allowed to reduce the technology risks and to enable a managed
pressure and controlled borehole path drilling, has been designed and implemented over the past 24 years.
However, a size standard available on the market does not offer the possibility of the borehole controlled
path liner drilling for the size of 127 mm. The development of a cost-effective liner drilling technology with
the borehole path control and without extra tripping operations for the well cementing has become relevant
in view of financial constraints in the industry as well as due to the complication of geological conditions
in the development of new fields. The authors of this paper are offering a solution, which would allow
applying the technology for a directional drilling with 127-mm (5″) liner with MWD retrievable system.
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Components of Directional Drilling System with a 127 mm Liner

The developed system consists of a drilling bit, downhole motor, telemetry system, liner string, running
tools and liner hanger itself (Fig. 2).

Figure 2—Diagram of drilling system with 127 mm liner

A bit of 155.6 mm is considered for the assembly. The bit design: PDC or a roller-cone, the type of which
is selected individually depending on the geological features in a drilling interval.
Downhole motors with typical size of 120.65 mm or 127 mm (4-3/4, or 5″) fit to this design. For the
project cost-cutting the authors are offering to use a motor and a bit with virtually spent operating life, as
the bit and the motor are left in a well upon completion of drilling a liner interval.
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For cementing operations the assembly includes a sleeve with check valve (a float collar), therefore, the
use of the overflow valve is not required. Thus, the float collar prevents backflow of a drilling fluid and
ingress of drill cuttings into the motor, thereby preventing damage to the stator and plugging of the bit.
Further, upward of the float collar, at a distance of 20 m (2 casing pipes), a landing collar with ball seat
is located. This equipment is required for the activation of hydraulic components of the liner system, as
well as for precise determination of plug landing and completion of the cementing process. To prevent the
erosion of the seat it is recommended to use the seats made of ceramics.
Upwards there are two non-magnetic drill collars, which contain MWD system inside.
The basic requirements for the downhole part of the telemetry system:

• The tool ("electronics") shall be fully retrievable;

• The tool shall be of a light weight;

• The tool shall have dimensions that allow to pass through the critical internal diameters of the
system;
• The tool shall use a hydraulic communication channel.

Retrievable MWD available on the market are attached to non-magnetic drill collars using a collet type
mechanism. The vibrations, which occur when drilling, are compensated by the rubber centralizers, which
in addition to the damping function provide centering and locking of the system along the axis of the non-
magnetic drill collar. Emergency works associated with the retrieval of telemetry systems from conventional
assemblies, as they are the most expensive components in directional drilling, are carried out every year all
over the world. According to the experience gained, to unseat the telemetry tool with one centralizer a force
of 10 kN shall be applied. The maximum number of centralizers that can potentially be used is two. For the
successful retrieval of the system it is recommended to use centralizers with three ribs (Fig. 3).

Figure 3—Telemetry system diagram

According to published articles [2] the maximum outside diameter of the retrievable telemetry system
is 2 inches (51 mm), the length is 7 m. The tool with such geometric parameters can be retrieved from the
drill pipes with an internal diameter of 57.15 mm and more. The retrievable telemetry system has a special
arrowhead for a connection with an overshot.
Right after the non-magnetic drill collar there is a shearing sub, the main function of which is to shear
the rubber centralizers up to the maximum actual diameter of the telemetry system (Fig. 4). This is required
to ensure the passing of all telemetry system elements through the running equipment of the liner top when
retrieving.
SPE-187924-MS 5

Figure 4—Diagram of centralizers shearing by sub

Next is a liner string and a liner hanger system itself with hydraulic activation components. Due to the
high internal pressures when drilling it is necessary to provide for the application of the liner hanger system
with two activation cylinders. The presence of two cylinders allows preventing a premature activation of
the liner hanger. Symmetric cylinder layout allows having a differential pressure of zero when drilling (Fig.
5) [3]. It is recommended that the thread connection for 127 mm liner string have the following parameters
(Table 1):

Figure 5—Diagram of operation of hydraulic cylinders of liner top during drilling

Table 1

Rated outside diameter 127 mm

Tension efficiency 100%

Compression efficiency 80% and more

Operational torque 19 kN-m and more

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The operational torque value varies on a case-by-case basis. In our example, we have considered a liner
127×9.19 P-110; drill pipes 101.6 × 12.7 S-135 (4,″ 15.7 ppf,S). As we are considering the option of drilling
of a horizontal section, docking and retrieval of the telemetry system will require CT and overshot at the rig.

Basic Drilling Technology Procedures

The technology of drilling with a liner sized 127 × 9.19 P-110 is considered. The well has a J-shaped path
(Fig. 6). The drilling begins at a measured depth of 3,600 m. The drilled section length is 650 m (horizontal
interval - 500 m). The build-up intensity is 60/30 m. The final measured depth is 4,450 m.

Figure 6—Well path

Operating parameters are presented in Table 2

Table 2

Weight on bit 2-5 tonnes

Rotations per minute 60 rpm

Maximum torque at wellhead 25 kN-m

Flow rate 380 - 1,140 l/min

Mud density 1,120 kg/m3

The operating sequence is shown in Fig. 7. Upon reaching the borehole target and flushing in accordance
with the drilling program, the overshot shall be run in the borehole on CT for docking with the telemetry
system and its retrieval. In doing so the engineer shall pre-specify the CT tension force required to retrieve
the system. During the telemetry through the running tool it is recommended to reduce the speed to 0.1 m/s.
SPE-187924-MS 7

Figure 7—Sequence of operations when drilling

Upon retrieval of the telemetry system, the standard operation of the liner hanger activation and running
tool disengagement shall be carried out in accordance with the manufacturer's procedures. In our example,
the ball is dropped from the surface and pumped down until the seat is reached. After the liner top activation
and running tool disengagement the cement slurry is injected and the plug is dropped. It also should be
noted, that the string can be rotated during the cementing.

Engineering Support
To develop all the requirements and recommendations for the drilling of this section, the process was
modeled using the Well plan Landmark software package. The following friction coefficients were used
in the calculation:

Mechanical Calculations
To determine the mechanical operation capacity of the developed system the calculations were made in the
Torque&Drag module.
One of the main tasks was to determine the maximum torque at the wellhead and in the area of the liner
hanger. This is necessary to select the optimal design of the liner: type of thread connections for the drill
and casing string.
As can be seen in the shown chart, the torque loads for the selected drilling conditions are low, so the
use of high-torque connections is not required in this case.
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During the rotary drilling the maximum toque at the wellhead is 22 kN-m, which is perceived by the drill
pipe connections (Fig. 8). The torque in the area of the liner hanger is 12 kN-m.

Figure 8—Allocation of torque during drilling

Also, to select the correct liner assembly, it is necessary to simulate the stability loss (buckling behavior)
of the string during drilling and after disconnection from the liner. Fig. 9 shows the diagram describing the
basic intervals of the possible loss of the string stability during drilling. Neither during rotary drilling, nor
during drilling with downhole motor there are no zones of buckling (where the string losses its stability)
at the axial load on the bit of 5 tons.

Figure 9—Allocation of axial stresses during drilling

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Hydraulic Calculations
The result of the modeling in the Well plan Hydraulics software package is the determination of the optimal
flow rate for the drilling. The flow rate selection directly affects ECD (equivalent circulation density).
At the mud density of 1,120 kg/m3, ECD in the open interval area reaches 1,350 kg/m3 (Fig. 10) at the
measured depth of 4,792 m. Reducing the performance of pumps can be used to monitor ECD in the well.
In our example we assumed the flow rate of 8.3 l/sec to determine the equivalent circulation density, as well
as to allocate pressures over the well bore.

Figure 10—Allocation of equivalent circulation density

Maximum internal pressure in the liner top area reaches 43 MPa. It is therefore necessary to choose the
liner top with two activation cylinders (Fig. 11).
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Figure 11—Allocation of internal and external pressure

Conclusion
The liner drilling technology continues to develop and is primarily aimed at addressing the challenges related
to the pressure incompatibility when drilling. The developed system will allow for the drilling with the 127
mm production string liner and simultaneous casing. In this paper we discussed the basic system components
and procedure for the liner top activation and provided the calculations required for the implementation of
the process.

References
1. Sinor, L.A. TyberoP., Eide;O. Wenande.B.C. IADC/SPE 39399: Rotary liner drilling for depleted
reservoirs. 1998.
2. Henderson.B. SPE/IADC 16058: New MWD applications using a slimline fully retrievable
MWD tool, 1987.
3. Jim Kunning and Yafei Wu, Ian J. Thomson, Larry Marshall, Drrick Daigle, Henry J. Mata,
Robert Pena, Matt Hensgens, Billy Eppley, SPE124854 Nonretrievablelinerdrillingsystem
successfully deployed to overcome challenging highly stressed rubble zone in a GOM Ultra-
deepwater sub-salt application. 2011.
4. Vong, C. MakohiF., Suwarno, P. and Quitzau, B. SPE 36827: Drilling liner technology for
depleted reservoir, 1996.