Apparatus and methods for forming a lateral wellbore

Abstract

A method and system of forming a lateral wellbore in a time and trip saving manner using a mill/drill to locate and place a casing window. In one aspect of the invention, a lateral wellbore is drilled with liner which is subsequently left in the lateral wellbore to line the sides thereof. In another aspect, the mill/drill is rotated with a rotary steerable system and in another aspect, the mill/drill is rotated with a downhole motor or a drill stem.

1 . A method of using a liner to drill a lateral wellbore of a well, comprising: 
 a) inserting the liner having a mill/drill disposed at one end into a wellbore having a wall therein;    b) directing the mill/drill towards a pre-selected area of the wall;    c) cutting an opening in the wall with the mill/drill;    d) drilling into a formation proximate the opening while advancing the liner to form the lateral wellbore; and    e) leaving at least a portion of the liner in the lateral wellbore.    
     
     
         2 . The method of  claim 1 , wherein the wall is cased with a casing.  
     
     
         3 . The method of  claim 1 , wherein the liner and the mill/drill are rotationally coupled.  
     
     
         4 . The method of  claim 1 , wherein the liner and mill/drill are rotationally independent and rotation of the mill/drill is provided by a downhole motor disposed thereabove.  
     
     
         5 . The method of  claim 1 , wherein the mill/drill comprises an inner portion and an outer portion, the inner portion being selectively removable from the outer portion of the mill/drill.  
     
     
         6 . The method  claim 5 , further comprising: 
 a) removing at least one portion of the mill/drill;    b) replacing the portion of the mill/drill;    c) inserting the replaced portion in the liner; and    d) continuing to advance the liner.    
     
     
         7 . The method of  claim 1 , wherein the rotation of the mill/drill is provided by a rotational force at a surface of the well.  
     
     
         8 . The method of  claim 1 , wherein directing the mill/drill towards the pre-selected area of the wall is performed by a diverter fixed in the wellbore there below.  
     
     
         9 . The method of  claim 8 , wherein directing the mill/drill toward the wall comprises: 
 a) selectively coupling the diverter to the mill/drill;    b) fixing the diverter at a predetermined location in the wellbore;    c) disengaging the coupling between the diverter and the mill/drill;    d) diverting the mill/drill along a slanted surface of the diverter toward the wall to cut the opening.    
     
     
         10 . The method of  claim 1 , further comprising removing at least a portion of the liner extending into the wellbore from the opening.  
     
     
         11 . The method of  claim 1 , further comprising expanding at least a portion of the liner within the lateral wellbore.  
     
     
         12 . The method of  claim 11 , wherein the liner is expanded into a contacting relationship with the opening.  
     
     
         13 . The method of  claim 12 , wherein the liner is expanded into a sealing relationship with the opening.  
     
     
         14 . The method of  claim 1 , further comprising directing the mill/drill by using a bent liner.  
     
     
         15 . A method of drilling a lateral wellbore in a wellbore, comprising: 
 a) inserting a rotary steerable system coupled to a mill/drill into a wellbore having a wall therein;    b) directing the mill/drill towards a pre-selected area of the wall;    c) cutting an opening in the wall with the mill/drill; and    d) drilling into a formation proximate the opening while advancing the rotary steerable system to form the lateral wellbore.    
     
     
         16 . The method of  claim 15 , further comprising coupling the rotary steerable system and mill/drill to a liner and leaving at least a portion of the liner in the lateral wellbore after the lateral wellbore is drilled.  
     
     
         17 . The method of  claim 16 , wherein the liner and the mill/drill are rotationally coupled.  
     
     
         18 . The method of  claim 16 , further comprising removing at least a portion of the liner extending into the wellbore from the opening.  
     
     
         19 . The method of  claim 15 , wherein directing the mill/drill toward the wall comprises using a diverter.  
     
     
         20 . A method of using a liner to drill a lateral wellbore, comprising: 
 a) inserting the liner coupled to a rotary steerable system and a mill/drill into a wellbore having a wall therein;    b) directing the mill/drill towards a pre-selected area of the wall;    c) cutting an opening in the wall with the mill/drill;    d) drilling into a formation proximate the opening while advancing the liner to form the lateral wellbore; and    e) leaving at least a portion of the liner in the lateral wellbore after the lateral wellbore is drilled.