Drilling apparatus and methods for reducing circulation loss

A liner running/setting tool for setting a drilling liner relative to a casing adjacent a severe loss zone of a well comprising:

• a collet retainer nut circumscribing a drill string in the well and moveable between a first position and a second position axially relative to the drill string;
• a collet having an end coupled with the dual wall drill string, and a distal end engaged with the drilling liner when the collet retainer is in the first position, and selectively disengaged from the drilling liner when the collet retainer nut is in the second position;
• a collet retainer nut activation mechanism controllable by an operator to move the collet retainer nut between the first position and the second position;
• a packer element circumscribing the drilling liner and in mechanical communication with the collet retainer nut, the packer element in an unenergized state when the collet retainer nut is in the first position, and in an energized state when the collet retainer put is in the second position, so that when the collet retainer nut activation mechanism moves the collet retainer nut from the first position to the second position, the packer element is energized and seals the space between the drilling liner and the casing;
• and
• a toothed liner hanger slip circumscribing the drilling liner and in mechanical communication with the packer element, the toothed liner hanger slip disengaged from the casing when the packer element is not energized, and lockingly engaged with the casing when the packer element is energized, the toothed liner hanger slip preventing relative movement between the drilling liner, and the casing when lockingly engaged with casing.

A loss mitigation bottom hole assembly for use in a wellbore in a severe loss zone of a formation, comprising:

• a drill bit for drilling the wellbore;
• a dual wall drill string connecting the drill bit to a fluid source, and having a first fluid passage for delivering fluid to a drill bit, and a separate second fluid passage for returning the fluid away from the drill bit;
• a drilling liner circumscribing and attached to a portion of the dual wall drill string, and surrounding the drill bit while drilling, the drilling liner having an end adjacent the drill bit to contain the fluid exiting the drill bit and prevent the fluid from entering the severe loss zone of the formation;
• a fluid return area adjacent the drill bit between the dual wall drill string and the drilling liner, the fluid return area receiving fluid exiting from the drill bit;
• and
• a cross-over port assembly providing fluid communication between the fluid return area and the second fluid passage, the cross-over port assembly comprising:
• a valve having a first end and a second end, and movable between an open position and a closed position;
• and
• a passage between the fluid return area and the second fluid passage bisected by the valve;
• the first end of the valve in pressure communication with the first fluid passage and the second end of the valve in pressure communication with the fluid return area, so that when pressure in the first fluid passage exceeds pressure in the fluid return area, the valve moves toward the open position.

A method to control lost circulation in a severe loss zone in a subsurface formation the method comprising;

• (a) drilling a wellbore in the subsurface formation using a first bottom hole assembly until the wellbore reaches the severe loss zone in the formation;
• (b) removing the first bottom hole assembly from the wellbore;
• (c) running a second bottom hole assembly into the wellbore, the second bottom hole assembly including a dual wall drill string, a drill bit, and a drilling liner extending to an end of the drill bit distal from the dual wall drill string;
• (d) drilling through the severe loss zone using the second bottom hole assembly and positioning the drilling liner to extend to the end of the drill bit distal from the dual wall drill string, so that while drilling the drilling liner progresses through the severe loss zone along with the drill bit and prevents drilling fluid from entering the formation in the severe loss zone;
• (e) removing the second bottom hole assembly from the wellbore.

A method to control lost circulation in a severe loss zone in a subsurface formation the method comprising;

• (a) drilling a wellbore in the subsurface formation using a first bottom hole assembly until the wellbore reaches the severe loss zone in the formation;
• (b) removing the first bottom hole assembly from the wellbore;
• (c) running a second bottom hole assembly into the wellbore, the second bottom hole assembly including a dual wall drill string, a drill bit, and a drilling liner extending to an end of the drill bit distal from the dual wall drill string;
• (d) drilling through the severe loss zone using the second bottom hole assembly and positioning the drilling liner to extend to the end of the drill bit distal from the dual wall drill string, so that while drilling the drilling liner progresses through the severe loss zone along with the drill bit and prevents drilling fluid from entering the formation in the severe loss zone;
• (e) removing the second bottom hole assembly from the wellbore;
• (f) setting the drilling liner relative to a casing in the wellbore above the severe loss zone prior to step (e);
• and
• (g) initiating step (f) by introducing a radio frequency identification (RFID) tag into the well to communicate with an RFID detector in the second bottom hole assembly.