Chapter 8

SAUDI ARAMCO WORKOVER MANUAL
Drilling Technical Department September 2013
CHAPTER 8 RE-ENTRY SIDETRACKS
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RE-ENTRY SIDETRACKS
1.0 INTRODUCTION
Back
2.0 DEFINITIONS
3.0 WELLBORE CLEAN OUT
4.0 CASING EXIT EQUIPMENT & OPERATIONS
4.1 Open Hole Sidetracking

4.2 Cased Hole Sidetracking
4.2.1 Casing Sectioning
4.2.2 Window Milling
5.0 DESCRIPTION OF DIRECTIONAL DRILLING
5.1 Short Radius Re-Entries

5.2 Medium Radius Re-Entries
5.3 Long Radius Re-Entries
6.0 FEATURES OF A DIRECTIONAL WELL PROFILE

7.0 CURVE SECTION ISOLATION
8.0 SHORT RADIUS SIDETRACKS IN GHAWAR FIELD
9.0 ARAB C & D COMBINED SIDETRACK PROCEDURE IN GHAWAR FIELD
10.0 5-1/2” SOLID EXPANDABLE LINER SYSTEM
11.0 EXPANDABLE OPEN HOLE LINER
11.1 Specifications
11.2 MetalSkin® Open-Hole Liner Installation Procedure
11.3 Expand MetalSkin® Open- Hole Liner
11.4 MetalSkin® Open-Hole Liner Float Shoe Milling Procedures
12.0 HOLE PROBLEMS

12.1 Long Radius Sidetracks
12.2 Short Radius Sidetracks
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RE-ENTRY SIDETRACKS
1.0 INTRODUCTION
The concept of re-entry drilling is not actually new, however, the old supporting
technologies made it one of the last options an operator most likely would perform.
A recent burst of technical inspiration has produced a plenty of new ways to
revitalize old fields and tap bypassed pockets of oil and gas. However, identifying
the best solutions requires a team of experts with a broad range of skills that cross
the traditional boundaries of drilling engineering disciplines.
Over the last 10 years, new technologies and field strategies have converged,
enabling operators to give new life to old wells. Now, reviving production from
declining fields has become a major goal for oil and gas companies, and one that
requires more support to identify the right technical solutions. With improved
capabilities from new drilling technologies, a growing number of wells are
candidates for re-entry drilling.
Listed below are some of the basic reasons for re-entry wells (vertical,
directional or horizontal):
• Can accomplish what new wells can do, but usually at a much lower
cost. Cost reductions of 40% to 60% and higher versus a new well have
been achieved in several areas. This benefit must be reviewed on a
case by case basis. It depends on target depth and, in some
areas, regulatory requirements. For shallow fields, a new well could be
cheaper, depending on the physical status of the existing well and
operational requirements. As the reservoir gets deeper, the potential
benefit of a re-entry well improves. However, in environmentally
sensitive or populated areas, it may be impossible to get permission to drill
a new well so that a re-entry is the only option, regardless of the cost.
• Allows the use of existing location and surface facilities. This can be a
significant cost saving for marginally economical areas.
• Reduces the environmental impact of drilling operations by eliminating

the need to build a new road and location and lay new flowline. This may
be the primary reason for using an existing well in some areas.
• The geology is known. Log, sample, and production data are

available, which can reduce the geologic uncertainties. In effect, there
is an existing "probe" hole.
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• Maintain or extend the operating life of the field.
• Produce reserves that otherwise could not be recovered economically

(attic oil, edge oil in, etc.).
• Increase production, especially if the well is sidetracked horizontally (2 to 5

times higher).
• Maximize ultimate recovery, especially if the well is sidetracked horizontally

(reduce coning).
• A smaller rig may be required for a re-entry than for a new well. This can
significantly reduce costs.
Controlled directional drilling is the science and art of deviating a wellbore along a
planned course from a starting location to a target location, both defined with a
given coordinate system.
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2.0 DEFINITIONS
Re-entry Drilling
A term for the operations of entering into an existing wellbore, exiting from it, and
constructing a new wellbore using various technologies, to exploit either known
reserves or explore new horizons, for the purpose of increasing productivity,
ultimate recovery, and enhancing value of the asset.
Tie In Point
The tie in point is the reference point of any well plan.
Kickoff Point (KOP)

The Kick-off point is defined as a point in the wellbore at a given vertical depth
below the surface location where the well is to be deviated away from vertical in a
given direction up to a given inclination at a given build rate. The selection of the
Kick-off point is made by considering the geometrical well-path and the geological
characteristics. In openhole sidetracks, it is usually called Branch-out Point.
Buildup Rate (BUR)

The buildup rate is the change of inclination of a wellbore where the angle is
increased. The rate is usually expressed in degrees per 100 ft or angular increase
per 30 m of the measured depth.
Curve Section
Is the section of the new wellbore required to build angle from the initial kick-off
point to the final landing angle at the end of curve or target entry.
Well Inclination
The well inclination is the angle by which the wellbore deviates from the vertical.
End of Buildup (EOB)

The end of buildup is the location where the wellbore has finished increasing
inclination.
Hold Angle
The hold angle occurs where the inclination of the borehole is held constant.
Tangent Section
The tangent section (hold section) occurs after a buildup where the inclination of
the borehole is held constant for a certain distance. There could be an additional
build or drop before reaching the target.
Start of Drop
The start of drop is the location where the wellbore starts dropping inclination.
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End of Drop (EOD)

The end of drop is the location where the wellbore finishes dropping inclination.
Target Displacement
The target displacement is the lateral distance from the surface location to the
target.
Target Location
The target location is a point defined in space by geographical coordinates at a
given true vertical depth. A well profile could have multiple targets.
Drop Off Rate (DOR)

The drop off rate is the rate at which the inclination decreases. The rate is usually
expressed in degrees per 100 ft or degrees per 30 m of the course length.
Turn Rate
The turn rate determines the rate a well profile turns in azimuth direction, usually
expressed in degrees per 100 ft or degrees per 30 m.
True Vertical Depth (TVD)

The true vertical depth of any point or station along a wellbore is the vertical
distance from the well surface reference point to the station of interest.
Measured Depth (MD)

The measured depth of any point or station along a wellbore is the distance from
the well surface reference point to the station of interest along the actual well path.
Horizontal Displacement (HD)

The horizontal displacement is the distance between any two points along a
wellbore projected onto a horizontal plane or plan view.
Vertical Section (VS)

The vertical section is the distance between any two points along a wellbore
projection onto a vertical section plane.
Azimuth
The azimuth is the angle in the horizontal plane measured from a fixed reference
direction (such as True North), usually measured clockwise.
Dogleg
Dogleg is the measurement of deviation of the wellbore, it is a uniform
measurement regardless of inclination or direction. DL has positive value only.
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Dogleg Severity
Dogleg severity is a measure of the amount of change of inclination and/or
direction of a borehole. It is usually expressed in degrees per 100 feet or degrees
per 10 or 30 metres of course length.
3.0 WELLBORE CLEAN OUT
The two keys of successful sidetracks are getting the Whipstock to the required
depth and orienting it to the proper direction. Any junk or scale in the hole as well
as corrosion in the casing could hinder the planned sidetracking operation and
could cause excessive lost time especially if the Whipstock was prematurely set. A
detailed and careful clean out trip must be made prior to running the Whipstock.
Continuous circulation and frequent sweeps must be pumped to ensure the hole is
free of any debris. Then the Whipstock is run in hole at a controlled speed under
the supervision of its operator. Whipstocks are not made to clean out debris or
work through casing restrictions.
The use of tandem Lo Vis / Hi Vis pills to clean out the debris of the well is also
important as we are clean the wellbore with the Clean Out BHA’s.
Casing String Junk String Near bit Bit /

Scrapper Magnet Trapper Mill Centralizer Mill
Full Wellbore Clean out BHA
4.0 CASING EXIT EQUIPMENT & OPERATIONS
Depending on the status of the candidate well and the target requirements, several
kick-off methods are available.
The first method is applied in the openhole, which is usually in a new well, but it
can be applied to re-entry wells where there is no casing to penetrate. It
can be done "On bottom", "Off bottom", or off a cement plug.
The second method is applied in casing, which is usually in an existing well.

Access to the formation is obtained by either sectioning out the casing or by using
a whipstock and cutting a window.
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4.1 Openhole Sidetracking
In this method, the well is drilled down to the desired kick-off point and
then an angle-build motor is run.
The motor run is designed to build angle at a specific rate. This is

achieved by using various sizes and configurations of bent housings, bent
subs, and kick pads that force the bit sideways in the hole. This side-
loading is what allow the assembly to build angle. On-bottom sidetracking
may be applied in the case where the production casing was recovered
to allow for a larger hole size re-entry.
For off-bottom sidetracking, a different method is required. A similar motor

configuration is run in the hole, however it is oriented then reciprocated
across an interval to cut a deep groove into the formation. The assembly is
reciprocated until a deep enough groove is cut too allow the bit to exit the
existing wellbore. This technique is normally used for a second kick-off
in a multi-lateral operation where there is a risk in using other deflection
methods (whipstocks).
4.2 Cased Hole Sidetracking
This is the most common method for re-entries. Two methods are normally
used. The first involves cutting out a length of casing or "Casing Sectioning"
and the second involves cutting a window in the casings or “Window Milling”.
Most of the cased hole sidetracks in Saudi Aramco are performed using
window milling method.
4.2.1 Casing Sectioning
This involves removing the entire casing section about the area of the
kick-off depth. This is done with a section milling assembly.
The basic procedure is to:
a) Set a packer or bridge plug below the area to be sectioned and the
section out the casing with the section mill. It is best to ream to
new formation.
b) Fill the sectioned interval with cement.
c) Drill out to the kick-off depth. Continue drilling as in an openhole

kick-off.
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4.2.2 Window Milling
Window milling uses a whipstock tool to provide a deflection for the

milling/drilling assembly. It is often used in areas where there is some
concern about the success of building sufficient angle when using the
casing section method. This can occur in areas where the formation is
either much harder or much softer than the cement used to sidetrack
off. However, it is often based solely on the previous experience of the
"Operator" and the track record of the directional drillers.
There are two types of whipstocks. The retrievable-type whipstock is

used in wells where access to the lower portion of the well is desired at
a future date and the permanent-type is used where the lower section
is to be abandoned.
Weatherford Permanent Whipstock
Weatherford Retrievable Whipstock
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The basic procedure is as follows:
a) If the Whipstock is a mechanical type, where a solid bed is

required, place the cement plug with inner string or set packer on
workstring. Space out as needed in well. Position the hard bed so
that the window is not milled through a casing coupling. A casing
collar locator log is normally run to ensure the window is not cut
across a casing coupling.
b) Make up Whipstock along with its tri-mills and run with the required
orientation guide, MWD for wells with existing deviation or Gyro for
vertical wells.
c) Tag bed, if a mechanical Whipstock is run; pick to seat same

above casing collar. Orient the Whipstock accordingly.
d) Set the Whipstock by applying weight for the mechanical type or

pressure up to set the hydraulic type.
e) Over pull to shear mills from the whipface.
f) Slide down whipface and start cutting the required window.
g) Continue milling out the required rat hole to allow the directional
BHA to pass through smoothly.
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Basic Procedure of Casing Exit
5.0 DESCRIPTION OF DIRECTIONAL DRILLING
Drilling a directional well basically involves drilling a hole from one point in space
(the surface location) to another point in space (the target) in such a way that the
hole can then be used for its intended purpose. A typical directional well starts off
with a vertical hole, then kicks off so that the bottom hole location may end up
hundreds or thousands of feet or meters away from its starting point.
5.1 Short Radius Re-entries
These are the re-entries in which the BUR or DLS are ranging from 30 to 70
degrees/100 ft. This type is the shortest radius range between the original
wellbore and the T.E. The equivalent radius range is from 45-200 feet. They
are used to isolate higher-/lower-pressured production zones or water sands
without setting and cementing a liner. This type of drilling is desirable when
kicking off below a problem formation.
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In Saudi Aramco, short radius re-entries have been used to sidetrack wells in
Ghawar Field especially in Uthmaniyah, Hawiyah and Haradh areas. Refer to
Section 8.0 for details.
BHA for curve section in a BHA for horizontal section in

Short Radius Well a Short Radius Well
5.2 Medium Radius Re-entries
degrees/100 ft. This type is the middle radius range between the original
wellbore and the T.E. They have curves with a 200-500 ft (61-152 m) radius
that can be drilled with conventional motors. This type of re-entries is not very
common in Saudi Aramco.
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5.3 Long Radius Re-entries
degrees/100 ft. This type is the largest radius range between the original
wellbore and the T.E. They have curves with a 750 ft (229 m) radius or larger
that can also be drilled with conventional motors.
Most of the re-entries in Saudi Aramco are of this type.
BHA for curve section in a BHA for horizontal section in

Long Radius Well a Long Radius Well
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6.0 FEATURES OF A DIRECTIONAL WELL PROFILE
A directional well profile is the planned well trajectory from the surface to the final
drilling depth by projecting the wellbore onto two plotted planes. In order to
determine the best geometric well profile from the surface to the bottom hole
target, the following information must be known:
• the position of the surface location,

• the position of the target location, and
• the true vertical depth (TVD).
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7.0 CURVE SECTION ISOLATION
One of the benefits of the short radius re-entries is to avoid isolating the curve
section as the whole section is made into a non-porous and non-permeable zone.
However on the long radius re-entries with open reservoirs, the curve section must
be isolated through different means. Refer to Chapter 4-H for the curve section
isolation means.
8.0 SHORT RADIUS SIDETRACKS IN GHAWAR FIELD
Saudi Aramco has been drilling short radius re-entry horizontal sidetracks since
1994 to revive dead vertical wells in Ghawar field and recover upswept oil at the
top of Arab-D producing limestone reservoir.
Arab-D reservoir in GHWR and ABQQ fields is capped with anhydrite layer that
separates it from the abnormally pressured Arab-C formation. The differential
pressure between Arab-C and Arab-D varies across the fields and can be as high
as 2000 psi. Earlier short radius sidetracks especially in ABQQ field were drilled
with buildup rates as high as120 deg/100’. The short thickness of the anhydrite cap
rock required such high build up rates. With such high build up rate it was not
possible to rotate the string while drilling the horizontal section which resulted in
several operation difficulties. Recent short radius re-entries are performed only in
the parts of GHWR field where the anhydrite cap rock thickness is enough to allow
a build up rate less than ± 60 deg/100’. This build up rate will allow rotating the drill
string while drilling the horizontal section, geo-steering with full LWD suite, and will
also allow running completion optimization equipment like ICDs (Inflow Control
Devices) and fracture isolation systems to optimize production, increase recovery
and prolong the life of the well.
The re-entry process involves cutting a window using a whipstock in 7” casing/liner

(5-20 ft below the base of the high pressure Arab-C water bearing formation). The
window isolation is confirmed before starting to drill by positive testing the window
to 1000-1500 psi and negative testing to 2000 psi relative to the Arab-C pressure.
The relatively high under-balance negative test is performed to ensure isolation not
only while drilling but also during the production life of the well. After window
isolation is confirmed, the 6-1/8” short radius curve section is drilled through the
cap rock. Finally, the 6-1/8” horizontal section is drilled and geo-steered across the
remaining thin oil column left at the top of the Arab-D reservoir. The practice is to
complete the short radius wells as a bare foot if no fractures are encountered while
drilling. On the other hand, wells are completed with ICDs and/or fracture isolation
systems when fractures are encountered. Figure below depict the details of the
short radius sidetrack.
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9.0 ARAB C & D COMBINED SIDETRACK PROCEDURE IN GHAWAR FIELD
After locating a good depth based on casing condition and formation to start
(usually is +/- 300 ft below top of Sulaiy formation), the window is opened in the 7”
23-26 lbs/ft casing and a rat hole of 10 to 15 ft is drilled to the KOP.
The 6-1/8” Directional Drilling assembly is run in hole to KOP and drilling starts at
low ROP with mud to achieve the buildup rate needed to separate the new hole
from the old casing track. After this separation is achieved, minimum of 100 ft, the
wellbore is displaced to water & gel slips to drill through Hith and Arab formations
in an identical manner as for the newly drilled wells.
After drilling 50' into Arab-C reservoir, the well is observed for flow. If well does not
flow, drilling operations continue with water & gel slips. If it flows, displace the hole
to calculated kill mud weight and continue drilling to 5’ TVD above PADS. When
well flows from Arab-C, measure stabilized SIWHP and kill the well with 2 pcf
above balance mud weight.
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At any stage, Arab-D reservoir must be drilled with mud that provides at least 200
psi over balance. If Arab-C mud weight was found to be higher than Arab-D, then
this is the mud weight to be used. This is why it is extremely important to know the
exact Arab-C pressure to minimize the overbalance across the lowest pressure
reservoir.
After the Target entry is achieved, the Drilling BHA has to be changed to pick up
the LWD tools to log and steer the lateral within the payzone.
Drilling continues in the reservoir payzone with mud until target depth is reached.
Several cleaning pills are pump through the entire drilling to get a good hole
cleaning minimizing the problems in the hole during and after the drilling phase.
Figures below depict the details of the combined sidetrack and the completions.
SULAIY
HITH
ARAB- A
ARAB- B
e
hol
Abandon hole Abandoned hole
ARAB- C
/8”
Oil/Water
6-1
Bearing
BASE
ARAB- C
ARAB-D (our target)
The mono-bore concept of Arab-C/D combined drilling technique from Sulaiy formation
down to Arab-D reservoir without isolating the curve section.
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Combine Drilling Arab-C SULAIY
and Arab-D Reservoirs

HITH
ARAB- A
ole
ARAB- B
Abandoned hole
/8”
ARAB- C
6-1
BASE
ARAB- C
ARAB-D (our target)
The technique of drilling a mono-bore hole allows all completion options such as ICD’s
and Off-bottom Cemented Liner for the curve section.
10.0 5-1/2” SOLID EXPANDABLE LINER SYSTEM
Solid expandable liners have typically been installed as drilling liners or repair
sections. Saudi Aramco has taken the application of this technology to the next
level through their use as qualified production liners. Over the last several years
the company has embarked on a technology-driven workover strategy to maximize
well productivity and total oil recovery by converting existing weak horizontal
producers to maximum reservoir contact (MRC) wells, many of which, if required
by reservoir management, were installed with downhole smart systems to control
flow from each lateral. This strategy has also been applied to convert dead vertical
wells to single horizontal producers or power water injectors.
A 5½ in. solid expandable liner cemented in place is one of the key drivers that
enable zonal isolation and provide a conduit for smart completion in the reservoir if
required. Numerous applications of expandable liners have been implemented in
the Saudi Aramco operated fields with successful results. The primary application
areas are:
(a) Providing cemented zonal isolation for build-up section from usually vertical
to near horizontal (as shown in below Figure).
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(b) Providing 7 in. liner extension and allowing multiple lateral window exits for
re-entry MRC well (as shown in below Figure), yet at the same time after
expanding the tubular in-situ, enable continued drilling with 5-1/2” optimal
reservoir hole size.
(c) Providing an effective contingency zonal isolation solution in the case that the
7 in. production liner gets stuck and it is necessary to cement off bottom.
TOW
Typical re-entry / workover well
whipstock
Drill 6-1/8" curve section and under-ream to 7-1/4" hole
5-1/2" expandable liner shoe

top of Arab-D 7" liner @ top of reservoir
Residual Oil
drill 5-1/2" horizontal hole
Water
4-1/2" liner
Figure: Typical cross-section of expandable liner in re-entry / workover well in Ghawar

Field.
Figure: Typical cross-section after workover well in the Shaybah Field.
Although there have been many demonstrated benefits of utilizing this technology
as listed above, extensive applications have had exposed some of the major
technology limitations and challenges.
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Having realized the limitations of the solid expandable technology and the real
values and advantages it could offer, a risk mitigating strategy was gradually
adopted to ensure that each field application managed risk and had a higher
chance of success.
For application in a curved section like in Ghawar and Abiqiaq fields, the key
elements of success include the following steps:
• Plan and design smooth build-up section with careful monitoring during
drilling operation (control actual dogleg < 10 deg/100 ft).
• Use a long whipface to cut window in 7” casing to reduce mechanical dogleg
across the window.
• Run junk trapper and master magnet while milling window and utilize ditch
magnets to maximize cutting removal.
• Dress window repeatedly to ensure a smooth window exit during a dummy
drift run.
•
• Drill with regular 6-1/8” bit on directional assembly, then open hole up to 7-
1/4” by under-reamer.
• Run multi-arm caliper log to both verify under-reamed hole size and cement
volume calculation.
• Spot a large hi-vis pill in open hole at end of a dummy drift run to ensure a
slick hole condition just before running expandable liner.
• Carefully supervise expandable tubular joint make-up.
• Use freshly made low solid and lubricant mud to fill the expandable liner and
to displace the dart.
For application in a horizontal section like in the Shaybah Field, the key elements
of success include the following steps:
• Thoroughly clean out existing 7” casing with casing clean-out tools.

• Run multi-arm caliper log to both verify under-reamed hole size and cement
volume calculation.
• Perform a dummy drift run (in conjunction with casing clean-out tools) to
check hole condition (i.e., free of any metal junk in cased hole).
• Spot fresh lubricant mud in open hole prior to running expandable liner.
• Since the expandable liner with inner string has a tendency to get
differentially stuck in the reservoir section, it is very important to run the
expandable liner fast in hole.
• Carefully supervise expandable tubular joint make-up.
• Use freshly made low solid and lubricant mud to fill the expandable liner and
to displace the dart.
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11.0 EXPANDABLE OPEN HOLE LINER
Expandable open hole liners are provided to Saudi Aramco by two companies:
Enventure and Weatherford. Detailed procedure for the Weatherford Metal Skin
open hole liner is provided below as an example. The Enventure expandable
procedure is similar to the Weatherford one.
11.1 Specifications
a) The MetalSkin® Open-Hole Liner will be received on location and will

be unloaded using the specified Weatherford handling procedures to
prevent damage. A Weatherford Field Service Representative or
Technician will supervise the unloading and loading. The MetalSkin®
Open-Hole Liner will be drifted, the threads will be visually inspected,
and the casing will be tallied. All thread cleaning will be performed
safely with no environmental consequence.
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b) The base casing and any other equipment, such as inline centralizers,
landing collars, and the wear bushing, that the cone housing will be
run through or the MetalSkin® Open-Hole Liner expanded through,
must be inspected for adequate clearance. All dimensions must be
verified, and confirmed correct by Weatherford personnel and
Aramco’s well site representative prior to running the MetalSkin®
Open-Hole Liner. Any under-gauge dimensions established must be
opened to the equivalent drift of the base casing prior to running the
MetalSkin® Open-Hole Liner.
c) The drilled hole must be clean and free of obstruction. The base
casing will be cleaned using SPS equipment to remove all junk from
the well.
d) All work string components will be drifted with a minimum 2.0 in. OD
drill pipe drift provided by Aramco.
e) The hole should be well circulated to control losses; and the drilling
mud should be properly conditioned for running the MetalSkin® Open-
Hole Liner. While a certain amount of loss circulation material (LCM)
can be tolerated, LCM concentration should be minimized, and use of
fibrous LCM should be avoided.
f) The base casing and the open hole must be clean, free of obstruction
and drifted to ensure that the launcher is run to total depth. The drift
trip should include two string mills with an OD at least 6.151in. This is
to ensure that the base casing diameter and the hole diameter is large
enough for the MetalSkin® Open-Hole Liner to be run to bottom. A
ring gauge must be used to insure OD is correct prior to RIH.
Notes:
• It is critical that the 7” liner be thoroughly free from any debris or
jagged edges. The final drift run must be run by drifting a BHA as
agreed by Aramco and Weatherford that will insure that the
MetalSkin® Open-Hole Liner is not damaged, or the bend radius is
not exceeded on the connections.
• This drift run must be performed without rotation or pumping to
insure the MetalSkin® Open-Hole Liner is able to reach TD. Any
issues related to this step must be discussed and agreed upon
prior to running the MetalSkin® Open-Hole Liner.
g) The openhole will be under-reamed with a 6⅛” reamer to open the

existing 6⅛” hole to 7” from the 7”casing shoe across the required
setting depth.
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h) RIH with CP Mill and wellbore clean-out assembly (consisting of 7”
junk trapper, 3½” string magnets, 7” scraper, & brush after the bit).
Space out such that when the bit is ±20ft below 5½” MOL proposed
shoe, the junk trapper 29ft above 7” liner shoe.
i) CHC with LVP and weighted HVP while reciprocating to the required
target depth (TD). Circulate at high rate as much as possible and as
per cleanout engineer requirement.
j) Displace well to lubricated solid free selected mud weight. Pull Out Of
Hole (POOH).
k) If hole is clean (no sizeable junk recovered), L/D SPS tools, ready to
run Weatherford MetalSkin® Open-Hole Liner.
l) Aramco rig foreman together with Weatherford representative will

decide whether or not to perform another clean-out run with same
BHA.
Notes:
• A 15° to 30° internal shoulder taper will be maintained on all
MetalSkin® Open-Hole Liner running BHA components. This
includes backup assemblies of all critical components.
• Maximum allowable pressures must be confirmed for standpipe,
mud hose, and top drive before testing lines prior to expansion (if
the expansion through the top drive is planned).
Maximum allowable pressure for the MetalSkin® Open-

Hole Liner is 4,000 psi.
• A separate volume of 100 bbls of the clean mud with the

secondary lubricant (TorqTrim or equivalent mixed with the clean
mud) is required to fill the MetalSkin® Open-Hole Liner while it is
being made up and during expansion. The volume of the
lubricated mud needed to fill the MetalSkin® Open-Hole Liner
along with displacing the dart will be subject to the length of the
application and will be calculated by the SES engineers.
• Wireline unit is to be on standby in case caliper log is to be run.
• If you encounter resistance, (metal junk) work pipe or wash down
w/ max 35,000lb slack-off weights and max 1,500 psi circulating
pressure, if hole is too tight, ream through.
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• Pull back into 7in. casing shoe, carefully observe any drag when
drift BHA re-enters 7in. casing shoe, if any drag or small junk still
in casing or open-hole, continue to pull back until string is free.
Run In Hole (RIH) back to bottom of under-reamed hole. Circulate
bottom up, flow check, pump slug.
• Repeat until no resistance to RIH or POOH with drift assembly.
• Notify the mud logger to set up expansion template for rigs data
acquisition system to monitor hook load, bit depth, and stand pipe
pressure.
11.2 MetalSkin® Open-Hole Liner Installation Procedure
a) The procedure will include the total number of MetalSkin® Open-Hole

Liner will include joints with a pre-expanded length once calculated by
SES Operational Personnel. The Open-Hole Liner may include any of
the following joints:
• 5-1/2 in. MetalSkin® Open-Hole Liner Top Joint; 2 ft Total Length

• 5-1/2 in. MetalSkin® Open-Hole Liner Anchor Joint; 20ft Total
Length (Contains HNBR Elastomers)
• 5-1/2 in. MetalSkin® Open-Hole Liner Joints; 37ft Total Length
• 5-1/2 in. MetalSkin® Open-Hole Liner Pup Joint; 20ft Total Length
b) Conduct safety meeting prior to picking up casing handling

equipment. Confirm responsibilities. Make up the Weatherford
circulating crossover sub with a TIW valve and crossover to drill pipe
connection. Set back, and insure the VM-50 ET-WISE box threads are
not damaged during handling.
c) Rig up 5 ½ in. MetalSkin® Open-Hole Liner casing handling

equipment. Pick up the Cone Housing with MetalSkin® Open-Hole
Liner expansion assembly (pre-assembled at the Weatherford Solid
Expandable workshop) VM-50 ET-WISE Pin Up connected to 1 x 20 ft
pup joint and set carefully in the rotary table. Carefully install safety
clamp, do not over tighten!
d) Pick up 1 Joint of 5 ½ in., 17 lb/ft, VM-50 ET-WISE Pin by Box

MetalSkin® Open-Hole Liner and make up to 20ft pup joint with non
marking wrench supplied by Weatherford. Torque connection to 2,100
ft-lbs optimum torque and confirm gap is correct (All make-up
connections will need to be recorded by the Jam technician and SES
personnel to ensure correct make-up is achieved)
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e) Raise casing to first connection at cone housing. Attach casing tong
and torque to 2,100 ft-lbs optimum torque. Confirm gap with gauge.
Lower casing to rotary table and fill casing with treated mud. Raise
casing to confirm mud is flowing from float shoe.
f) Continue to pick up casing with the crane to the V door and attach to
single joint elevators. Lower in to mouse hole and carefully attach side
door elevators. Lift casing using the supplied VM-50 ET-WISE lift sub
and stab using Weatherford supplied stabbing guide. Start casing with
non-marking wrench. Torque to 2,100 ft-lbs optimum torque. Confirm
torque with gauge. Weatherford to monitor and record all torque turn
and log on torque table sheet.
g) Continue to run the total amount of joints of 5 ½ in., 17 lb/ft, VM-50

ET-WISE Pin by Box MetalSkin® Open-Hole Liner as detailed above.
Note: Casing volumes will be calculated by SES personnel and will be

provided in the running procedures that will identify the interval for
filling the expandable casing and the amount of joints not filled, to
prevent mud overflowing when the inner-string is run.
h) Make up and run 5-½in., 17 lb/ft, VM-50 ET-WISE Pin x Box

Elastomer Joint with 0.130 in HNBR elastomer anchor bands. Take
care not to damage elastomer bands while RIH and setting in slips.
Change out to 3½” elevators. Pick up the “Top Joint” using the box
down STUB ACME lift sub/circulating sub.
i) After making up Top Joint land in rotary as low as possible, carefully

install safety clamp, and cover liner. Rig down casing handling
equipment. Stop for Safety Meeting to discuss running inner-string.
Confirm responsibilities.
j) Install False Rotary Table avoiding any contact with the top of the
MetalSkin® Open-Hole Liner. Rig up to run 3-1/2 in. 13.3# S-135 XT31
drill pipe inner-string.
k) The MetalSkin® Open-Hole Liner will require the following Bottom Hole
Assembly (Please note the specific grading and size of items will differ
as per the application length, size and wellbore trajectory; specific
BHA designs will be supplied by the SES Operational Personnel):
• Weatherford Safety Sub with 3-1/2 XT-31 box connection

• Debris Sub with 3-1/2 XT31 connections
• 3-1/2 in. 34.8# Pony Collar
• Dart Catcher with 3-1/2 XT31 connections
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___________________________________________________________________________________________________________________________
• 3-1/2 in. 13.3# S-135 XT31 drill pipe
• 3-1/2 in. 13.3# S-135 XT31 drill pipe
• 3-1/2 in. 13.3# S-135 XT31 drill pipe
• 3-1/2 in. 13.3# S-135 XT31 drill pipe
l) PU the top Debris Sub with 1 joint 3½ in. 13.3# S-135 XT31 drill pipe
and place in 5½in. MetalSkin® Open-Hole Liner to tag Weatherford
Safety Sub with 10 feet in using top drive. Mark drill pipe where safety
sub is tagged and pick up 3 feet.
m) Observe annulus full. Lower Hydril pressure to ~ 500 psi and close
to prevent MetalSkin® Open-Hole Liner from rotating in rotary table.
Keep rotary table locked and hydraulic valves open while connecting
the safety sub. Check pipe tally. Pick up and rotate the string to
observe and record free rotating torque. Take new PU/SO weights.
Slowly pump to fill MetalSkin® Open-Hole Liner with mud. Stop filling
when mud is returns at surface.
n) Tag Weatherford Safety Sub lightly and make up the inner-string into
the Weatherford Safety Sub with approximately 7 right hand turns,
slacking off weight as needed to facilitate ease of make-up. Actual
torque will be less than or equal to the makeup torque of the VM-50
ET-WISE connection (2,000 ft-lbs). This connection makes up easily
and torque will give the indication that the assembly is fully engaged
into the Weatherford Safety Sub and Bottom Joint. Make sure rotary
table is locked while making up Weatherford Safety Sub. Completely
release torque from inner-string and Open Hydril.
o) Pick up 5-10K lbs over previous string weight slowly to check that
Weatherford Safety Sub is made up. Take new Pick Up /Slack Off
weights. Rig down False Rotary table.
p) While connected to top drive, pump 20 bbls mud with rig pump (200
strokes). Maximum pressure is 1,000 psi. Observe if mud is coming
over top of MetalSkin® Open-Hole Liner, indicating a leak in the
Weatherford Safety Sub. The top of the MetalSkin® Open-Hole Liner
must be visible below the rotary table to confirm a leak at the safety
sub seals.
24 of 28
___________________________________________________________________________________________________________________________
®
q) Rig up to RIH with MetalSkin Open-Hole Liner and continue running
in with the following: (Equipment will be application specific and a list
of required equipment will be provided by a SES personnel).
• 4 in XT-39 (B) x 3-1/2 XT-31 (P) crossover

• 4 in. HWDP, 29.7 lb/ft, G-105, XT-39
• 4¾ in Drill Collar
• 4 in. HWDP, 29.7 lb/ft, G-105, XT-39
• 4 in. drill pipe, 14.0 lb/ft, G-105, XT-39
Note: Install the drill pipe wiper on the first joint of drill pipe.
r) Continue running in the hole with the drill pipe. Fill the string as
calculated by the SES personnel using the fill up hose.
Note: RIH at a controlled rate of ~ 1 stand / 3 minutes. Do not surge

the hole while running the drill pipe to avoid inducing losses. Do not
RIH if you encounter any obstruction. Stop and call Weatherford
Service Engineer to the rig floor after securing the well.
s) Check up and down weights before entering the casing shoe at the
relative setting depth. Fill casing prior to running in open-hole.
Note: Due to chances of becoming stuck, the drill pipe will not be
filled in the open-hole until reaching setting depth.
t) Run in the hole to relative setting depth. Confirm tally. Take up and
down string weights. Position drill pipe for circulating and cementing.
Make up top drive and fill casing. Open top drive connection and drop
setting ball in drill pipe. Reconnect to top drive.
u) Pump the selected amount of mud as pre-determined by the Solid

Expandable representative. Continue pumping slowly until pressure
indication is noted that expansion cone has formed (estimated
pressure is 1,700 psi). Continue to circulate and condition the mud
through the drill pipe screen at 3 to 4 bpm (30 – 40 SPM) until proper
mud properties are achieved. Do not exceed 1,500 psi circulating
pressure.
v) Make up the cementing head assembly with the dart installed in a
suitable pup joint. Rig up to cement while batch mixing cement and
spacer. Pressure test pumps and lines to rig floor to 4,000 psi.
Note: Conduct Toolbox Talk prior to cementing and pressure testing
operations.
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w) Cement as per Aramco/Cementing Co. recommendations. The
cement volume must be accurately calculated to ensure it does not fill
up to the base casing during MetalSkin® Open-Hole Liner expansion.
Cementing calculations will be calculated by SES personnel and
provided as per the application procedures.
x) Release wiper dart on rig floor. Close cement lines to side entry sub
and open lines to pits to wash out pumps and lines. Open valve to the
cementing line and displace the dart at maximum 4 to 5 bpm using the
cementing pump and the cementing lines.
Note: It is not necessary to seat the wiper dart, and it is not necessary
to over displace should the dart not seat at the calculated
displacement.
11.3 Expand MetalSkin® Open-Hole Liner
a) Record the string weight. Pick up 10 tons. Place a vertical reference

mark on tubing and start rotating slowly to the right to release from
shoe. Monitor and record torque. Torque should release after 10
turns. Continue until 12 full turns have been made. It will be necessary
to pick up ~ 1 foot while rotating to maintain minimum compression in
the drill pipe. Make sure cementing unit displacement tanks are full
and barrel counters are zeroed.
b) Pick up drill pipe ~ 3 feet ~ 10Klbs over pull start pumping to initiate
expansion.
Notes:
• The expansion should be initiated at approximately 3,000 psi, and
continue at ~3,000 to 3,200 psi.
• Prior to expanding through hanger joint, stop and break for safety
meeting. The derrick man must come down from the derrick.
c) Resume pumping. The plan is to expand all the 5-½in. MetalSkin®

Open-Hole Liner until cups on expansion assembly is pumped out of
the top joint. When this happens, there will be an immediate drop in
pump pressure. When the pressure decreases after expanding the
last elastomer (6 elastomer bands) reduce pressure not to exceed
2,000 psi. Re-establish the expansion until the top joint has been
expanded and pressure is lost. Pull ~90,000 LBS. over string weight
to complete expansion of the elastomer joint and exit top of
MetalSkin® Open-Hole Liner.
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Note: It is very important that the driller does not stop pulling when
the cone exits to avoid damaging the top of MetalSkin® Open-Hole
Liner when the stretch is relieved from the drill pipe. A minimum of 15
feet should be pulled before the driller stops lifting the drill pipe.
d) If necessary, circulate bottoms up to circulate any excess cement

from the well.
e) Rig down all cementing and surface expansion equipment and pull out
of hole.
11.4 MetalSkin® Open-Hole Liner Float Shoe Milling Procedures
a) Make up the milling BHA as per Aramco specifications. The post-

expanded drift diameter of the MetalSkin® Open-Hole Liner is 5.50 in.
and the nominal ID is 5.575 in.
b) Carefully tag the TOL and record depth.
c) Pressure test the TOL as per Aramco procedures.
Note: Recommended equipment for the MetalSkin® Open-Hole Liner

shoe drill out is a 5.50 in. convex (CP) junk mill, with a 5.50 in. string
mill placed ~6 ft above the mill. Take precaution while the drill out
BHA is RIH to the top of the expanded MetalSkin® Open-Hole Liner. If
the mill takes weight inside the MetalSkin® Open-Hole Liner
(maximum 5,000 to 10,000 lbs), attempt to rotate for maximum 5
minutes. If the mill does not pass after 5 minutes, pull out of hole.
Mill out the MetalSkin® Open-Hole Liner shoe. Milling information will be
provided by SES personnel. Circulate the hole clean to remove the milling
debris from the hole. POOH with the milling tools.
12.0 HOLE PROBLEMS
As re-entry drilling will expose new formations, hole problems may arise. However,
only few new problems could occur compared to drilling new wells. In other words,
the normal hole problems seen in drilling new wells will still exist in re-entries.
(Refer to chapter 2-F)
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12.1 Long Radius Sidetracks
As for the long radius re-entries in which reservoirs containing water and/or
oil are combined, differential sticking issues are valid. This hole problem is
more pronounced specially if the upper exposed reservoirs are much lower in
pressure compared to payzone or the zones below it. Whenever the pipe is in
a slide mode, the formation has the tendency to suck and grab tight the drill
pipe to the wall of the wellbore. The ultimate solution to free the pipe in such
situation is to lower mud weight which could be very tricky and could cause
an unwanted flow.
It is very important to keep in mind that lowering mud weight equivalent to

pore pressure is against Saudi Aramco policy. A minimum overbalance has to
be maintained at all times as shown in the table below (please refer to Well
Control Manual Chapter 4, Section 8.0):
100 psi Overbalance on water reservoirs

200 psi Overbalance on oil wells
300 psi Overbalance on gas wells
Careful planning to avoid differential sticking is essential. Market available

solutions through proper mud additives could mitigate such problems. The
key factor to eliminate differential sticking is to seal the low pressure zone
with a very well constructed filter cake which could act as a barrier to
minimize the suction effect. Systems (such as MaxBridge) that damage
permeability of upper-low pressure reservoir are best to use in such
applications.
12.2 Short Radius Sidetracks
As for the short radius re-entries in which no other reservoir but the payzone
is exposed, parted drill pipes are the biggest problem due to the high bending
stresses applied on the pipe specially during the rotary mode. Since the high
build is already planned, the only way to mitigate such problems is to assure
the quality of the pipe going into the hole.
All drill pipes to be used in curve, horizontal and 1000’ contingency have to
be inspected as per Category-4 DS-1 (TH & Hill Standard Drill Stem-1)
inspection requirements. In addition to the Category-4 DS-1 inspection, a full
UT survey must be applied to the tool joints to 6’ below on both ends. Such
inspection helps removing relatively weaker joints and minimizes the chance
of parting drill pipe while going through high bend section.
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SAUDI ARAMCO WORKOVER MANUAL

Drilling Technical Department September 2013

CHAPTER 8 RE-ENTRY SIDETRACKS

3.0 WELLBORE CLEAN OUT

4.0 CASING EXIT EQUIPMENT & OPERATIONS

4.1 Open Hole Sidetracking

5.0 DESCRIPTION OF DIRECTIONAL DRILLING

5.1 Short Radius Re-Entries

6.0 FEATURES OF A DIRECTIONAL WELL PROFILE

8.0 SHORT RADIUS SIDETRACKS IN GHAWAR FIELD

9.0 ARAB C & D COMBINED SIDETRACK PROCEDURE IN GHAWAR FIELD

10.0 5-1/2” SOLID EXPANDABLE LINER SYSTEM

11.0 EXPANDABLE OPEN HOLE LINER

12.0 HOLE PROBLEMS

CHAPTER 8 RE-ENTRY SIDETRACKS

• Reduces the environmental impact of drilling operations by eliminating

• The geology is known. Log, sample, and production data are

CHAPTER 8 RE-ENTRY SIDETRACKS

• Maintain or extend the operating life of the field.

• Produce reserves that otherwise could not be recovered economically

• Increase production, especially if the well is sidetracked horizontally (2 to 5

• Maximize ultimate recovery, especially if the well is sidetracked horizontally

CHAPTER 8 RE-ENTRY SIDETRACKS

Kickoff Point (KOP)

Buildup Rate (BUR)

End of Buildup (EOB)

CHAPTER 8 RE-ENTRY SIDETRACKS

End of Drop (EOD)

Drop Off Rate (DOR)

True Vertical Depth (TVD)

Measured Depth (MD)

Horizontal Displacement (HD)

Vertical Section (VS)

CHAPTER 8 RE-ENTRY SIDETRACKS

3.0 WELLBORE CLEAN OUT

Casing String Junk String Near bit Bit /

Full Wellbore Clean out BHA

4.0 CASING EXIT EQUIPMENT & OPERATIONS

The second method is applied in casing, which is usually in an existing well.

CHAPTER 8 RE-ENTRY SIDETRACKS

4.1 Openhole Sidetracking

The motor run is designed to build angle at a specific rate. This is

For off-bottom sidetracking, a different method is required. A similar motor

4.2 Cased Hole Sidetracking

4.2.1 Casing Sectioning

The basic procedure is to:

b) Fill the sectioned interval with cement.

c) Drill out to the kick-off depth. Continue drilling as in an openhole

CHAPTER 8 RE-ENTRY SIDETRACKS

4.2.2 Window Milling

Window milling uses a whipstock tool to provide a deflection for the

There are two types of whipstocks. The retrievable-type whipstock is

Weatherford Permanent Whipstock

Weatherford Retrievable Whipstock

CHAPTER 8 RE-ENTRY SIDETRACKS

a) If the Whipstock is a mechanical type, where a solid bed is

c) Tag bed, if a mechanical Whipstock is run; pick to seat same

d) Set the Whipstock by applying weight for the mechanical type or

e) Over pull to shear mills from the whipface.

f) Slide down whipface and start cutting the required window.

CHAPTER 8 RE-ENTRY SIDETRACKS

Basic Procedure of Casing Exit

5.0 DESCRIPTION OF DIRECTIONAL DRILLING