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DWC Application Engineering Training Rev.1 PDF
DWC Application Engineering Training Rev.1 PDF
Subject:
Rev No.
Date
Originator
10 Apr 04
Ming Zo Tan
12 Nov 09
Ming Zo Tan
Reviewed By:
PAGE 1 OF 115
LATEST REVISION
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Approved By:
Subject:
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Table of Contents
1. Introduction..........................................................................................................................6
2. Key Drivers for Drilling with Casing .................................................................................7
Reduce Drilling Flat Time .....................................................................................................7
Getting Casing to Bottom ......................................................................................................8
Elimination of Problems Related to Tripping........................................................................8
Drilling Depleted Zone and Overcoming Lost Circulation ...................................................8
Better Borehole Quality .........................................................................................................8
Improve Safety.......................................................................................................................8
Reduce Rental Costs ..............................................................................................................9
Improve Hydraulics ...............................................................................................................9
3. Casing Design Fundamentals............................................................................................10
Casing Strength Properties...................................................................................................11
Yield Strength ..................................................................................................................11
Collapse Strength .............................................................................................................11
Burst Strength ..................................................................................................................11
Loads on Casing...................................................................................................................12
Tensile Force....................................................................................................................12
Collapse pressure .............................................................................................................12
Burst Pressure ..................................................................................................................12
Compression Load ...........................................................................................................13
Other Loadings.................................................................................................................13
Casing Seat Selection...........................................................................................................13
Example of Casing Grade and Weight Selection.................................................................15
4. DwC System........................................................................................................................22
Non-Retrievable (Defyer) System versus Retrievable (Latch) System ...........................22
Casing Drive ........................................................................................................................24
The Defyer .......................................................................................................................27
5. Decision Making Process...................................................................................................32
6. Drillability...........................................................................................................................37
Compressive Strength Analysis ...........................................................................................37
D-Exponent ..........................................................................................................................42
Cone Penetration Test (CPT) ...............................................................................................44
Abrasiveness ........................................................................................................................48
Shale Reactivity (stickiness) ................................................................................................49
Plasticity...............................................................................................................................49
7. Basic Well Log Interpretation ..........................................................................................50
Sonic Log .............................................................................................................................50
Gamma Ray Log ..................................................................................................................50
Neutron Log (Porosity Log).................................................................................................51
Density Log..........................................................................................................................51
Photoelectric Log .................................................................................................................52
8. DwC Hydraulics .................................................................................................................57
Role of Hydraulics ...............................................................................................................57
The Borehole....................................................................................................................57
The Bit (Defyer)...........................................................................................................57
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List of Figures
Figure 1 DwC Total Connection Time Saving ..........................................................................7
Figure 2 DwC vs Conventional Drilling Time Depth Curve.....................................................7
Figure 3 Annular Velocity Comparison.....................................................................................9
Figure 4 Load-Elongation Curve of Casing.............................................................................11
Figure 5 Casing Seat Placement Chart.....................................................................................14
Figure 6 Casing Grade Design Chart ......................................................................................16
Figure 7 Formation Pressure from Next Section TD ...............................................................17
Figure 8 Two Types of DwC Systems.....................................................................................23
Figure 9 Logan Spear...............................................................................................................25
Figure 10 Internal Casing Drive Tool (ICDT).........................................................................25
Figure 11 Modified HE or AZ Spear .......................................................................................25
Figure 12 TorkDrive ............................................................................................................26
Figure 13 Water Bushing .........................................................................................................26
Figure 14 Anatomy of Defyer DT .......................................................................................27
Figure 15 Chip Breaker Holes .................................................................................................28
Figure 16 Largest Defyer DT506 24 x 27 ............................................................................31
Figure 17 Risk Matrix..............................................................................................................33
Figure 18 Candidate Well Selection Flow Chart .....................................................................34
Figure 19 DwC Project Management Flow Chart ...................................................................35
Figure 20 Uniaxial and Triaxial Tests .....................................................................................38
Figure 21 Relationship between compressive strength and porosity.......................................38
Figure 22 Operating Envelop of Defyer DV........................................................................40
Figure 23 Operating Envelop of Defyer DT ........................................................................41
Figure 24 Operating Envelop of Defyer DPC......................................................................41
Figure 23 Sample Chart of D-Exponent ..................................................................................43
Figure 24 CPT Tool .................................................................................................................44
Figure 25 CPT Tool Dimensions .............................................................................................44
Figure 26 Sample CPT Result (Lithology, Density, Undrained Shear Strength) ....................46
Figure 27 Sample CPT Result (Cone Resistance, Sleeve Friction, Pore Pressure) .................47
Figure 28 Abrasiveness by Grain Size and Grain Angularity..................................................48
Figure 29 Bit Balling ...............................................................................................................49
Figure 30 Working Principle of Sonic Tool ............................................................................50
Figure 31 Working Principle of Neutron Logging Tool..........................................................51
Figure 32 Density Tool Gamma Ray Backscattering ..............................................................52
Figure 33 Density and PE Tools Gamma Ray Energy Level Utilisation ................................53
Figure 34 Log Responses in Different Formations..................................................................55
Figure 35 Radioactivity of Common Rock Types ...................................................................56
Figure 36 Hydraulic Data Input Sheet .....................................................................................61
Figure 37 Hydraulics Result Output Sheets Page 1 of 2..........................................................62
Figure 38 Hydraulics Result Output Sheets Page 2 of 2..........................................................63
Figure 39 DwC Economic Analysis Sheet...............................................................................65
Figure 40 Operational Time Comparison Chart ......................................................................67
Figure 41 Time-Depth Curve...................................................................................................67
Figure 42 Float Collar Model 402 ..........................................................................................75
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1. Introduction
Drilling with Casing (DwC) technology utilizes the casing string as a drill string so that casing
is landed on bottom during the drilling process rather than later in a separate installation
process.
In the 1920s casing drilling with retractable bits had been carried out in Poland and France.
From the 1950s onwards, it has been common in some areas of the world to drill-in the
FINAL tubing string, and cement it in place along with the drill bit still attached. Modern
drilling with casing is not limited to only the final string of the well. In fact most modern DwC
jobs involve drilling the surface hole and intermediate hole sections. With the exception of a
few experimental wells, casing has been used to drill specific sections of the wellbore, rather
than the entire hole.
Drilling with Casing can be performed using two kinds of systems. In one system, a down
hole motor, under-reamer and drill bit assembly is latched onto the lowest-most casing joint
by means of a retrievable casing packer tool. As the assembly drills ahead, the casing is
lowered into the hole, either in a sliding or rotating mode. Upon reaching total depth, the
latch-on bottom hole assembly is recovered with a special retrieval tool. A valve system is
then pumped down hole and land in a landing profile before cementing can commence.
Weatherford developed a different system. The assembly comprises of a special drill bit,
called a Defyer, attached to the bottom of the first joint of casing, usually with a float collar
and a joint of casing in between. Drilling torque is transferred from the top drive to the casing
string and Defyer via the casing drive. Casing drive can be a casing drilling spear, Internal
Casing Drive Tool (ICDT), TorkDrive or water bushing.
The unique feature of the Weatherford system is that the Defyer is fully drillable. Once the
targeted depth is reached, there is no drill bit to recover through the casing. Since a float
collar is also run in the casing string, cementing can begin immediately. The next bottomhole-assembly is run and drills-out the shoe track in exactly the same way as conventional
operation. The Weatherford Defyer system is currently applicable in soft to medium
formations, straight hole sections which can be drilled in a single bit run.
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35.0
50.0
30.0
46.0
45.0
31.0
40.0
15.0
10.3
10.0
5.1
21.0
16.8
DwC
12.6
Conv
30.6
30.0
25.0
22.9
20.0
15.3
15.0
8.4
7.6
10.0
33.5
26.8
DwC
20.1
Conv
13.4
6.7
4.2
5.0
0.0
250
Time, Hrs
Time, Hrs
20.6
15.4
40.3
35.0
25.3
20.0
5.0
38.3
25.8
25.0
500
750
Conv
DwC
1000
Depth, MD
1250
1500
0.0
250
500
Conv
DwC
750
1000
Depth, MD
1250
1500
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Improve Safety
Some potentially hazardous operations may be eliminated when drilling with casing. Drilling
surface hole in shallow waters with high currents can require deployment of divers. Divers
are not required when drilling with casing as the string does not have to be POOH.
Hammering operations can be eliminated. Loading and rigging-up pile hammers is often
considered to be one of the most hazardous operations carried out on the rig floor.
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Improve Hydraulics
The annulus area between the BHA/casing OD and borehole ID is reduced in DwC, hence
under same operating conditions DwC deliver higher annular velocity (AV) then conventional
drilling. The improvement ranges from 81% to 134%, averaging 110% (Table 1), therefore a
rule of thumb of DwC annular velocity = 2 x conventional annular velocity can be
established.
OD
DP
5 1/2
OD
Csg
7
Flow
Rate, gpm
500
Vann, ft/min
Conv
DwC
292
527
12 1/4
5 1/2
9 5/8
800
94
45
164
341
2.1 X
17 1/2
5 1/2
13 3/8
1000
217
100
89
192
2.2 X
26
5 1/2
20
1100
507
217
42
98
2.3 X
600
Conv
527
DwC
500
Annulus
Vann, ft/min
400
341
300
DwC Vann
vs Conv
1.8 X
292
192
200
164
98
89
100
42
500
800
1000
9 5/8
13 3/8
1100
20
5 1/2
5 1/2
5 1/2
5 1/2
8 1/2
12 1/4
17 1/2
26
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Load
Fracture Strength
Elongation
Collapse Strength
Collapse strength is defined as the maximum external pressure required to collapse a
specimen of casing. Two types of collapse are observed:
1. Elastic the specimen fails before it deforms
2. Plastic certain deformation takes place prior to failure
Burst Strength
Burst strength (internal yield strength) is defined as the minimum value of internal pressure
required to cause the steel to yield.
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Loads on Casing
A casing is specified by the following parameters:
A casing design exercise involves the determination of factors that influence the failure of
casing and the selection of the most suitable casing grade for a specific operation. The
casing program should also meet the completion and production requirements. A safety
margin is also included in the design to allow for other unknown forces that may be
encountered such as corrosion, wear and thermal effects. The following sections discuss the
criterion for casing design. Only tensile force, collapse pressure, burst pressure and
compression load will be considered in the casing design. Other loadings, with the exception
of (5), cannot be determined by direct application of mathematical equations and will be
accounted for through the use of safety factor.
Tensile Force
Tensile forces originate from casings own weight, bending forces and shock loading. The
uppermost joint of the string is considered the weakest in tension as it has to carry the total
weight of the casing string. A safety factor of 1.6-1.8 is normally applied to the top joint.
Collapse pressure
Collapse pressure originates from the column of mud used to drill the hole. The hydrostatic
pressure is the highest at the bottom of the hole and can be calculated with
P = 0.0519 h
, where
The designer should ensure that the collapse pressure never exceeds the collapse
resistance of the casing at bottom hole temperature. For this purpose the casing collapse
resistance is taken as the load at which the internal diameter of the casing yields. In
designing for collapse, the casing is assumed empty for surface and production casing and
partially empty for intermediate casing.
Burst Pressure
The burst pressure requirement is normally based on two major considerations:
1. the maximum formation pressure envisaged in drilling the next hole section
2. in the event of a kick the entire mud column is displaced by the influx thereby subject
the entire casing to the bursting effect
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At the top of the hole the external pressure due to the hydrostatic head of the mud is zero
and the internal pressure must be supported entirely by the casing body. Therefore, burst
pressure is highest at the top and least at the casing shoe. In production casing the burst
pressure at the shoe can be higher than the burst pressure at the surface in situations when
the production tubing leaks gas to the casing.
Compression Load
A compression load arises in casings that carry inner strings. Production strings do not
develop any compression load since they do not carry inner strings.
Other Loadings
1.
2.
3.
4.
5.
4. From point D move horizontally to the mud gradient line to Point E, where the mud
gradient is 0.57 psi/ft. A vertical line from Point E shows that a hole can be drilled
with a mud gradient of 0.57 psi/ft without fracturing the formation.
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0.40
0.50
0.60
0.70
0.80
0.90
1.00
1.10
1.20
1.30
1000
2000
3000
4000
5000
6000
7000
8000
E
D
8558
9000
10000
11000
B
10320
11000
12000
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TD depth
Casing Size
Mud weight
26
660mm
350ft
107m
20
8.69ppg
1.041kg/l
17-1/2
445mm
6200ft
1890m
13-3/8
8.96ppg
1.073kg/l
12-1/4
311mm
10400ft
3170m
9-5/8
9.76ppg
1.169kg/l
8-1/2
216mm
13900ft
4237m
11.63ppg
1.394kg/l
Safety factors:
Burst
Collapse
Tension
= 1.1
= 0.85
= 1.8
Pf = 0.465 psi/ft
Pf = 0.480 psi/ft
Pf = 0.570 psi/ft
13-3/8 Casing
This string is set at 6200 ft and will be subjected, in the event of a kick, to formation
pressures from the next hole drilled to a TD of 10,400 ft.
Collapse
This pressure acts on the outside of the casing and for the worst possible situation assume
that the casing is 100% evacuated
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Weight
Coupling
SF = 1
K55
54.5
LTC
1130
K55
68.0
BTS
1950
L80
72.0
BTS
2670
SF = 0.85
1130
0.85
1950
0.85
2670
0.85
= 1329
= 2294
= 3141
The collapse resistance values are plotted as vertical lines, as shown in Figure 6.
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Burst
Formation pressure from next TD
= 10400 ft x 0.480 psi/ft
= 4992 psi (344 bar)
(see Figure 7)
Burst at shoe = internal pressure external pressure
Internal pressure
= Pf - (TD CSD) x G
= 4992 (10400 6200) x 0.1
= 4572 psi (315 bar)
(where G = gradient of invading fluid, assumed to be gas having a 0.1 psi/ft gradient)
6200ft
0.1
psi/ft
Fig. 10.13
Pf = 4992psi at 10400ft
External pressure
= CSD x 0.465
Where 0.465 psi/ft is the gradient of mud outside the casing. Therefore,
External pressure
= 6200 x 0.465
= 2883 psi (199 bar)
Burst at shoe
Burst at surface
Thus,
SEC NO.
Subject:
=0
Internal pressure
= Pf (TD) x G
Burst at surface
= Pf (TD) x G
= 4992 10400 x 0.1
= 3952 psi (273 bar)
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Therefore,
The burst line can now be drawn between 1689 psi at the shoe and 3952 psi at the surface;
see Figure 6.
From Table 4, of casing properties, the burst resistances of the available grades are given
below together with adjustment for SF = 1.1.
Table 4 Burst Pressure Including Safety Factor
Burst resistance (psi)
Grade
Weight
Coupling
SF = 1
K55
54.5
LTC
2730
K55
68.0
BTS
3450
L80
72.0
BTS
5380
SF = 1.1
2730
= 2482
1.1
3450
= 3136
1.1
5380
= 4891
1.1
The burst resistance values are drawn as vertical lines, as shown in Figure 6.
Selection Selection should consider the lightest weights first, as these grades are the
cheapest. On the basis of collapse only, Figure 6indicates that the given grades are suitable
for the following depths:
0-3050 ft
3050 4950 ft
4950-6200 ft
K55, 54.5#
K55, 68#
L80, 72#
L80, 72#
K55, 68#
K55, 54.5#
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When selection is based on both collapse and burst, Figure 6 indicates that grade K55,
54.5# does not satisfy the burst requirement from 0 to 4200 ft. Also grade K55, 68# does not
satisfy burst from 0 to 2400 ft. Hence, selection from 0 to 2400 ft is limited to grade L80, 72#.
Below 2400 ft, grade K55, 68# is suitable for collapse from 0 to 4950 ft and for burst from
2400 ft to 4200 ft. Hence, the middle section consists of K55, 68# from 2400 to 4200 ft.
The last section of the hole can only be satisfied by grade L80, 72# in both collapse and
burst; see Figure 6. Hence selection based on collapse and burst is (Table 5 & Table 6):
Table 5 Selected Casing Grade and Weight
Depth
0 - 2400 ft (732 m)
L80, 72#
2400 x 72 = 172.8
K55, 68#
(4200-2400) x 68 = 122.4
L80, 72#
(6200-4200) x 72 = 144.0
= 439.2
Grade and
Weight
144.0 (641)
L80, 72#
144.0 (641)
1650
= 11.5
144
122.4 (544)
K55, 68#
266.4 (1185)
835
= 3.13
266.4
172.8 (769)
L80, 72#
439.2 (1954)
1650
= 3.8
439.2
Cumulative Weight
(x 1000 lb) (kN)
Buoyancy Factor, BF =
BF = 1
67
= 0.863
489.5
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Total tensile force = buoyant weight of casing + tensile force due to pressure testing
(12.437)2 x 2070 ]
= 379,030 + 247,847
= 626,877 lb
SF in tension for top joint
1,661,000
626,877
= 2.65
Biaxial effects Check the weakest grade of selected casing for biaxial effects as follows.
tensile ratio
Weakest grade selected is the K55, 68#, having a body yield strength of 1,069,000 lb and a
coupling strength (LTC) of 835 000 lb. Hence,
tensile ratio
266.4 x 1,000
= 0.319
835,000
For a tensile ratio of 0.319, the collapse resistance of the casing is reduced to approximately
80% of its original (under zero load) value. Hence,
Collapse resistance of K55, 68# = 0.8 x 1950
Under biaxial loading = 1560 psi (108 bars)
Collapse pressure due to mud at 2400 ft (i.e top joint of grade of the K55, 68#)
=
67 x 2400
= 1117 psi (77 bars)
144
Therefore,
SF in collapse for top joint of K55, 68#
=
1560
= 1.40
1117
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Final selection
Table 7 Final Casing Selections
Interval
0-2400 ft (732 m)
2400-4200 ft (1280 m)
4200-6200 ft (1890 m)
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4. DwC System
Non-Retrievable (Defyer) System versus Retrievable (Latch)
System
There are two basic setups used for Drilling with Casing (Figure 8). The first system uses a
bottom hole assembly comprising a positive displacement motor (PDM), drill bit and underreamer. The assembly is latched to the first joint of casing. As the assembly drills ahead, the
casing is lowered into the hole, either in a static or rotated mode. Upon reaching total depth
(TD), the latch-on bottom hole assembly is recovered with a special retrieval tool. A valve
system is run and installed before cementing commences.
The second system (DwC) adopted by Weatherford, utilizes only casing to transmit rotary
torque and weight to the drill bit. No complex bottom hole assembly is required. A drillable
drill bit and valve assembly is made up and run with the first joint of casing. The casing string
is rotated during drilling via casing drive system which conveys torque from the top drive to
the casing. Upon reaching TD, the casing can be cemented immediately. There is no
requirement to trip out any drilling assembly or the bit.
Table 8 lists the major advantages and disadvantages of the Defyer system compared to
the latch system.
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Non-Retrievable System
Casing
Casing
Float
Collar
BHA:
MWD/LwD
Positive
Displacement
Motor
Under Reamer
Bit
DrillShoe
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Non-Retrievable System
Retrievable System
Advantages
Disadvantages
Advantages
Disadvantages
Low cost
High cost
Simple to operate
MwD/LwD capability
No rig modifications
required
Limited DrillShoe
selection
Unable to cement
immediately upon TD
Casing Drive
Three primary types of casing drive tools are currently used :
1. Logan Spear (Figure 9)
2. Weatherford Internal Casing Drive Tool ( Figure 10)
3. Modified HE or AZ spears (Figure 11)
4. TorkDrive (Figure 12)
5. Water bushing (Figure 13)
The slips of the original HE and AZ spear must be modified to left hand release. They are
originally of right hand release. First DwC with TorkDrive Compact has successfully
conducted in July 2008. Current available TorkDrive sizes are TorkDrive 500 tons, TorkDrive
750 tons and TorkDrive Compact 350 tons. The use of water bushing should be avoided if
spear and TorkDrive are available due to the longer time to make or break this tool and risk
of cross threading the thread. Water bushing however can be used as backup tool or serve
as primary drive on large casing sizes not covered by the spear or TorkDrive.
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Spear Mandrel
Spear Pack-off
Stabilizer
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Figure 12 TorkDrive
Figure 13 Water Bushing
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The Defyer
Weatherford have trademarked the Defyer, a Drillable Casing Drill Bit. The Defyer
(Figure 14) is made up to the casing in the same way as a conventional drill bit would be
made up to a drill string. The Defyer has a two-part construction:
1.
A body made from steel, which has the casing connection and a tungsten carbide
gauge section
2.
A nose, which is made from aluminium alloy, upon which is mounted a drillable
cutting structure. Chip-breaker holes (Error! Reference source not found.) in
the tool nose ensure that the aluminium cuttings do not birds-nest the drill bit
with long swarf cuttings as it drills-out through the nose.
The nose and the body are threaded and locked together and the tool is supplied as an
integral unit, as shown. The bit face of the Defyer has nozzles strategically positioned to
clean and cool the cutting structure and flush away the cuttings up the annulus. The
aluminium centre is fully drillable with PDC or roller cone drill bits, or even with another
Defyer.
Aircraft grade
aluminum nose (fully
PDC drillable)
Threaded connection
between the aluminum
nose and steel
body/shoulder
Premium PDC
cutters
PDC drillable
copper nozzles
Gage pad reinforced with
tungsten carbide briquette
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Prototype Defyer
December, 1999
Subject:
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Defyer DV
January, 2000
Defyer DT
May, 2000
Defyer DPC
August, 2003
Subject:
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Defyer DP
February, 2009
Subject:
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Invented in Nov 1999 for drilling in surface casing in the Gulf of Thailand
2.
3.
4.
5.
6.
Subject:
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Risk
Manag
eability
Proba
bility
Cost
Impact
R1
Well Control
R2
Defyer Failure
R3
Shallow Gas
R4
Differential Sticking
R5
Stuck Pipe
R6
Deviation Issue
R7
Cementing Problems
R8
Connection Failure
R9
Lost Circulation
Description
High probabilty due to smaller clearance for expansion of gas from
cuttings. Closing BOP is possible
Contingency plan : Set casing and cment in place. Proceed with
Expandable casing to accommodate the casing point.
The 13-3/8" shoe allows full control of shallow gas kick with BOP
closed.
MW of 9.2 ppg will create an overbalance of max. 350 psi only.
Centralized casing will reduce the risk.
PipeCoal beds may create problem. Limited time exposure with DWC
and less vibration should be able to minimize the problem.
Any minor directional changes can be conducted in the next secton if
required.
Zonal isolation across this surface casing is not critical. To ensure good
isolation around shoe.
For the longer section, drilling must be accomplished with premium
connection.
DWC will create higher ECD in the annulus but within the LOT limit.
Control Flow Rate or ROP.
RISK MATRIX
0
Low
< $150k
2
R9
Probability
3
4
R6
R2
Medium
< $150k-450k
R4
R8
R5
R3
High
> $450k
R7
R1
7
8
9
0
High Risk
4
5
Manageability
Medium Risk
Low Risk
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Candidate
Well
No
vertical ?
require
directional
control ?
Yes
Yes
No
FE, DST,
logging
required ?
Yes
No
No
rig has
topdrive ?
If more
complex op. with kelly
acceptable ?
No
Yes
No
adequate mud
pump Hp ?
Yes
Economic analysis
Drillability analysis
Yes
No
Yes
Commercial proposal
No DwC
SEC NO.
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Contact
client
Client request
for proposal
Give DwC
presentation
Data request to
client
Data valid
/adequate ?
Client
Enquiry
2.
3.
4.
5.
Tool selection (working out which DwC system is best for the
job, do we have the correct tools?)
6.
7.
8.
Review reasons.
revisit proposal or
drop
Confirm
equipment
requirement
Order
equipment
Visit customer to
confirm understanding
of the technical
proposal, confirm price,
deliverability etc
Submit technical
proposal to customer
Client awards
work
Demobilise
and inspect
equipment
for damage
Subject:
SEC NO.
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Subject:
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6. Drillability
Due to limited Defyer design availability as mentioned in Section 4., the first and foremost
task before proposing DwC technology to client is to establish the drillability of the formation
and determined whether a suitable Defyer design is available to take on the expected rock
strengths and drill the targeted distance. Offset data required in a drillability study include:
1. Compressive strength analysis
2. Soil boring and Cone Penetration Test (CPT) result
3. Mud log
4. Bit record
A combination of all the above data in the interpretation produces most the reliable
prediction. One has to be cautious when using bit record alone because it only provides an
overall performance through a section and is difficult to identify individual stringers. If the
record shows that a very light set (4 bladed) 12.25 bit came out in green condition then it is
probably safe to propose a Defyer 2. However if the bit record shows a 6 bladed 13mm
cutter bit coming out with a 1-1 dull grading then it is impossible to determine whether the
dulling effect was accumulated over the entire run length or sustained over a hard and thin
section of the run. This hard and thin section may be sufficiently adequate to terminate a
DwC job prematurely and the consequence will be costly. Well log and rock strength
analysis is a more recent technique for identifying Defyer drillable formations. The well log
data can be used to develop a quantitative estimate of rock hardness.
SEC NO.
Subject:
Shear
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Shear
Subject:
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Since rock samples required for triaxial test are costly to come-by and not readily available,
rock strength analysis using electric log data has been developed and is a relatively new
endeavor to quantify rock hardness. Rock strength analysis tools play an important part in
assisting selection and design of drill bits or rock destruction tools in general. Major drill bit
companies worldwide embarked on developing their respective rock compressive strength
analysis programs back in early 1990s.
Compressional sonic log data has long been used as a general guide or related to rock
hardness. More recently various programs have been developed to characterize rock
strength by using not only compressional sonic log but also shear sonic data, density and
neutron data to compute the unconfined compressive strength. Although this approach is an
improvement over using solely sonic velocities, a calculation of unconfined strength often
understates the actual strength of the formation when the rock is drilled in its pressurized
environment. Therefore some of these programs also include calculation of confining stress
using mud weight and pore pressure to work out the confined compressive strength.
The list below summarizes major rock types in an increasing order of difficulty in drilling.
Typical formations which might be considered suitable for drilling with a Defyer include
types 1 through 7 with softer sandstones (type 8) and some evaporites (types 9 and 10).
Formation types 11 and above are generally not considered Defyer drillable.
1. Clay
2. Mudstone
3. Marl
4. Evaporite
5. Gypsum
6. Shale
7. Siltstone
8. Sandstone
9. Anhydrite
10. Limestone
11. Dolomite
12. Conglomerate
13. Chert
14.Volcanics
SEC NO.
Subject:
Low Strength
4,000-8,000 psi
Medium Strength
8,000-16,000 psi
High Strength
16,000-32,000 psi
Very High
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In addition to general rock types and local names, geologic time is frequently used in
classification of the formation. As a general rule; the older the formation, the harder the rock.
Again exceptions and anomalies exist.
With current Defyer designs, estimated operating envelops for Defyer are displayed in
to Figure 24.
Subject:
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D-Exponent
Most large size top hole sections (13-3/8 and above) are drilled without MWD or logging.
Even if they are logged it will most likely be gamma ray only, which is not adequate for
common rock strength calculation programs. The D-exponent can be calculated and used as
a tool to refer to formation drillability since it only requires drilling parameters as inputs.
The D-Exponent is commonly used to identify abnormally pressured zones in a drilling
sequence. This dimensionless exponent is derived from the energy applied to the drillbit,
namely weight on bit and rotary speed. Sample D-exponent chart is shown in Figure 25
W
ROP KN E
d
where,
ROP = rate of penetration, ft/hr
K = drillability constant
N = rotary speed, RPM
E = rotary speed exponent
W = bit weight, lbs
d = bit diameter, in
D = D-exponent
Rearrange the above equation and assume K=1 and E=1
ROP
)
N
D
W
log( )
d
log(
or modified version,
ROP
)
60 N
D
12W
log( 6 )
10 d
log(
Dc D
10% or 100,000ppm (typical Gulf Coast water) formation water gradient is 0.465 psi/ft or
8.951ppg
(fresh water pressure gradient = 0.433 psi/ft or 8.335ppg)
SEC NO.
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When an over-pressured zone is encountered the ROP will be higher at a similar formation,
WOB and RPM, therefore the D-exponent will decrease. Similarly when drilling softer
formation, the ROP will increase and the calculated D-exponent will decrease. In hard drilling
sections the reverse is true. Caution should be used when comparing D-exponents of
different bit types, especially those of the PDC, roller cone and impregnated bits. These bits
deliver very different cutting actions and thus the D-exponent varies widely when the same
energy levels are applied. For DwC a roller cone D-exponent above 1.0 will potentially
terminate a Defyer runs subject to the thickness of the hard interval.
0
10
0
100
200
300
400
500
600
700
800
SEC NO.
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During the test a cone penetrometer on the end of a series of rods is pushed into the ground
at a constant rate and continuous measurements are made. The cone penetrometer consists
of the cone, friction sleeve, other sensors and measuring systems, and the connections to
the push rods. During the penetration, the forces on the cone and the friction sleeve are
measured. The measurements are carried out using electronic transfer and data logging .
Most commonly measured data suites are the tip resistance-sleeve friction, and tip
resistance + sleeve friction-pore water pressure. The results from a cone penetration test
Subject:
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stratification
soil type
soil density and in situ stress conditions
shear strength parameters
The above evaluations may also be used, directly, for design of piled foundations in sand
and gravel. Indirectly it can be used (shear strength) for piles in clay. For the purpose of rock
/ soil hardness estimation the parameters to look at are undrained shear strength, soil
density and cone resistance.
The preliminary undrained shear strength (Cu) of a clay can be estimated from:
Cu = (qc po) / Nk
where
qc
po
overburden pressure
Nk
According to testing standard ASTM 2166 the undrained shear strength is approximately one
half of unconfined compressive strength.
As at time of writing a definite cone resistance value where Defyer might be damaged is
yet to be established. . There is a classification system for soil hardness from very soft to
very hard but it has to be noted that this classification is very different from that used by bit
companies. 400kPa (58psi) of undrained shear strength, or equivalent 800kPa (116psi) of
formation is considered hard for a clay. This hard formation in CPT classification is not hard
at all in terms of bit application.
Subject:
SEC NO.
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Subject:
SEC NO.
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Figure 29 Sample CPT Result (Cone Resistance, Sleeve Friction, Pore Pressure)
SEC NO.
Subject:
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Abrasiveness
Abrasive formations can wear the bit nose to gage cutting structure very rapidly. Formation
Abrasiveness is governed by the degree of grain size sorting and grain angularity (Figure
30). To drill in abrasive environments, maximum gauge protection must be provided. Also,
due to the frictional heat generated at the cutting edges, bit hydraulics must be optimized to
provide maximum cooling which alleviates graphitization of the PDC or TSP under high
operating temperature.
Figure 30 Abrasiveness by Grain Size and Grain Angularity
High
moderately
well sorted
Abrasivenes
angular
poorly sorted
very well
sorted
sub-angular
sub-rounded
rounded
well rounded
Low
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Plasticity
Drilling a plastic formation can be laborious and slow either with PDC or roller cone bits as
the formation tends to deform instead of fracture or explode. High-pressured shales,
although not always the case, are notorious for creating a plastic drilling environment. In
combating plastic formations, point loading of the cutting structure must be increased. This
can be achieved by using:
Large cutters 19mm or even 25mm
Oval cutters
Triangular cutters (bit companies call Scribe, Arrow etc.)
Sharp TCI on roller cone bits
Subject:
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Sonic Log
The sonic log relies on the propagation of sound waves through the formation (Figure 32).
The waves are generated from a transmitter on the logging tool and an array of receivers,
also located on the tool, monitor the return waves and calculate the time lapse. The shorter
the time interval between sending and receiving the sound wave the denser the formation.
Subject:
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Density Log
Formation density is measured through gamma ray attenuation within the formation. The
sonde contains a radioactive cesium (137Cs) gamma ray source (622 keV) and far and near
gamma ray detectors. Gamma rays emitted by the source experience Compton scattering
(Figure 34), which involves the transfer of energy from gamma rays to electrons in the
Subject:
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formation via elastic collision. The number of scattered gamma rays that reach the detectors
is related to the density of electrons in the formation, which is, in turn, related to bulk
density. Porosity may be derived from this bulk density if the matrix density is known.
Photoelectric Log
The density tool also measures the photoelectric effect factor (PEF) caused by absorption of
low-energy gamma rays. Photoelectric absorption occurs when gamma rays reach energies
of <150 keV after being repeatedly scattered by electrons in the formation (Figure 35).
Because photoelectric absorption depends strongly on the mean atomic number of the
elements in the formation, it varies according to chemical composition and is essentially
independent of porosity. For example, the PEF of pure calcite = 5.08 barn/electron, illite =
3.03 barn/electron, quartz =1.81 barn/electron, and kaolinite = 1.49 barn/electron. PEF
values can therefore give an indication of the chemical composition of the formation and can
be used in combination with natural gamma ray data to identify different clay minerals
Subject:
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Common
Sediment
Pe
CN
Th
b/e
g/cc
c.u.
us/ft
lime
ppm
ppm
Quartz
1.8
2.65
8.0 - 13.0
51.3 - 55.5
-0.04
< 0.15
< 0.4
< 0.2
Calcite
5.1
2.71
8.0 - 10.0
47.6
0.00
< 0.40
1.5 - 15.0
< 2.0
Dolomite
3.1
2.87
8.0 - 12.0
43.5
0.02
0.1 - 0.3
1.5 - 10.0
< 2.0
1.80 - 2.70
25.0 - 45.0
63.0 - 170.0
0.09 - 0.45
2.04
748.0
67.0
-0.02 - 0.03
< 0.3
< 0.2
0.25 - 0.43
< 0.2
Shales
Halite
Common
Evaporites
Coals
Iron
Minerals
Micas
Anhydrite
5.0
2.98
12.3
50.0
0.00
Gypsum
4.0
2.35
18.8
52.5
0.50 - 0.60
Trona
0.7
2.10
18.5
65.0
0.42
Lignite
0.16
1.05
12.8
140.0
0.60
Bituminous
0.17
1.33
16.4
120.0
0.60
10.5
105.0
0.40
Anthracite
0.20
1.57
Limonite
13.0
3.59
57.0
Pyrite
17.0
4.99
90.0
Siderite
14.7
3.94
52.3
Hematite
21.5
5.18
39.0
48.0
44.0
Glauconite
5.5 - 7.1
2.54
23.4
Biotite
6.2 - 6.4
2.99
30.0
51.0
0.06
6.7 - 8.3
< 0.01
2.4
2.82
16.9
49.0
0.13
7.9 - 9.8
< 0.01
2.61
12.8
0.37
0.42
Muscovite
Kaolinite
Clays
4.7
0.19
5.08 - 5.30
1.5 - 3.0
6.0 - 19.0
Chlorite
2.88
25.3
0.32
Illite
2.63
15.5
0.09
4.50
1.0 - 5.0
< 2.0
Smectite
2.02
14.5
0.17
0.16
2.0 - 5.0
6.0 - 19.0
Subject:
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8. DwC Hydraulics
Role of Hydraulics
The purpose of hydraulics in the drilling program can be divided into three main areas: the
borehole, the bit (Defyer) and other drilling equipment.
The Borehole
Drilling mud is pumped down the drillpipe to the bottom of the hole, where it exits the bit and
returns to the surface via the annulus, the region between the outside of the drillstring and
the borehole wall or casing. In doing so it:
1. Transports cuttings from the bottom of the hole to the surface, where they are
removed by a series of meshed shakers and other solids control equipment before
the fluid is re-circulated.
2. Stabilizes the hole well and prevents cave-ins maintaining a pressure on the
formation being drilled.
3. Reduces the risk of formation fluids or gases flowing into the well which, if of
sufficient pressure, can result in dangerous kicks or even blowouts. Mud weight is
usually measured in pounds per gallon (lbs/g) or specific gravity (gm/cc).
The Bit (Defyer)
Drilling mud serves two main purposes with respect to a Defyer .
1. It cleans the cuttings from the bit, preventing bit balling and
2. It cools the cutters by dissipating heat generated at the cutter-rock interface and at
the same time acts as a lubricant to reduce friction and head generation. The cooling
effect is critical in maintaining cutter integrity because excessively high temperatures
can induce graphitization of the TSP in a Defyer and expedite wear rate.
Other Drilling Equipment
Drilling mud supports the operation of other drilling equipment.
1. It drives downhole motors and turbines, utilized especially in directional applications
2. It provides a communications medium for MWD mud pulse telemetry.
Mud Types
Drilling fluid, or mud, is a mixture of liquid, bentonite (a type of clay), weighting material and
various chemicals. Muds are known as water based (WBM) or oil based (OBM) depending
on the liquid used. Modern drill bits, including the Defyer are designed to operate in both
mud systems. The weighting material, often barite, is used to enable the mud to exert
sufficient pressure to contain formation pressures. Clay is added to keep the bit cuttings in
suspension as they move up the hole. The clay also sheaths the wall of the hole, producing
a thin veneer called filter cake, which makes the hole more stable and reduces the risk of
sloughing, where the hole caves in. Numerous chemicals are available to give the mud the
specific properties necessary to drill the hole successfully.
SEC NO.
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Hydraulics Variables
The purpose of a bit hydraulics program is to optimize the mud system, to provide
satisfactory cleaning and cooling at the bit face. The main parameters available to achieve
optimization are flow rate, total flow area of the bit (TFA), mud weight, the plastic viscosity
(PV) and yield point (YP) of the mud. Bit pressure drop, bit hydraulic horsepower and jet
impact force are dependent on some of these parameters. As with many areas of the drilling
operation, choosing values for these parameters is usually a matter of compromise, taking
into account other criteria necessary for successful drilling of the well.
Flow Rate
Maximum flow rate is governed by the power of the pumps. Typical pumps have two
(duplex) or three (triplex) pistons which travel in replaceable liners. For a given liner
diameter, the volume of fluid pumped per actuation is known and thus the flow rate per
minute can be calculated depending on the pump work rate. For any given situation, based
on hole depth, hole diameter, bit type, formation characteristics and mud properties, a
minimum flow rate will exist for successful cleaning and cooling.
Mud Weight
The weight of the mud can be varied during the drilling operation. It is important in controlling
subsurface pressures, to prevent blowouts. Mud weight influences the performance of drill
bits by its effect on bit pressure drop, bit HSI (hydraulic horsepower per square inch across
the bit face) and the chip hold-down effect on cuttings.
Total Flow Area (TFA)
For a PDC bit, the TFA is the sum of the cross sectional areas of the exits of all the nozzles
in the bit. As the diameter of the nozzles utilized in any given bit is increased, so the TFA
increases. For a given flow rate, an increase in TFA will result in lower fluid velocity exiting
the nozzles. The TFA of a Defyer bit can be altered to suit the hydraulic program by
changing the size of the replaceable nozzles. All nozzle exit ports are measured in 32nds of
an inch.
Pressure Drop
The pressure drop across a drill bit is defined as the difference between the pressure of the
mud exiting the nozzles and the pressure of the mud within the drillstring immediately prior to
entering the bit. If the bit pressure drop is extremely high, for a given flow rate and mud
weight, the fluid exiting the nozzles has a correspondingly high velocity. A lower pressure
drop, on the other hand, under the same conditions of flow and mud weight, will result in fluid
exiting the nozzles with lower velocity. Pressure drop is dependent on flowrate, mud weight
and the bit TFA.
Pr essure Drop
Pressure Drop (psi)
Flow Rate (gpm)
Mud Weight (lbs/gal)
TFA (in2)
10,856 is a unit conversion factor.
Subject:
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HSI
Subject:
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Subject:
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Data Input
* INPUT CELL COLOURED
Client
Company
Rig
Well Name
Date
Location
Product
Mud Type
TVD [m]
PV [cp]
YP [lb/100ft]
Casing
Casing
Nozzle
Liner
OD [in]
Nozzle Qty
Size [1/32"]
TFA
0.000
ID [in]
From [mMD]
0.00
To [mMD]
Length [m]
0.00
0.00
100%
O.D. (in)
I.D. (in)
Length (m)
Optional Fixed
Pressure Drop (psi)
0.00
% Cutting in annulus
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
kc
#DIV/0!
SEC NO.
Subject:
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HYDRAULIC CALCULATION
Version 1.0
Company
Rig
Well Name
Date
Location
Product
TVD [m]
Mud Type
100%
PV [cp]
YP [lb/100ft]
Nozzle Qty
TFA
Size [1/32"]
Flow per Nozzle [gpm]
% Flow per Nozzle
Jet Velocity [ft/sec]
RESULTS SUMMARY
BHA Length [m]
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
ECD [ppg]
#DIV/0!
STRING BORE
Component
O.D. [in]
I.D. [in]
Length [m]
Cum. Len
[m]
Pressure
[psi]
% Loss
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
#DIV/0!
SEC NO.
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CASING ANNULAR
Casing ID
[in]
Item
Ann Vel
[ft/min]
Critical V
[ft/min]
Flow Type
Pressure
[psi]
App Visc
[cp]
Slip Velocity
[ft/min]
Pressure
[psi]
App Visc
[cp]
Slip Velocity
[ft/min]
Pressure
[psi]
App Visc
[cp]
Slip Velocity
[ft/min]
LINER ANNULAR
Item
Ann Vel
[ft/min]
Critical V
[ft/min]
Flow Type
Hole Size
[in]
Ann Vel
[ft/min]
Critical V
[ft/min]
Flow Type
#DIV/0!
Subject:
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The following form (Figure 41) can be used to perform a quick and reasonably accurate
economic analysis. The user only needs to supply or amend information in cells with blue
fonts. These include:
1. Header info: country, customer, well name, hole size
2. Detailed operating procedures for both DwC and Conventional for purpose of total
drilling time estimation
3. Rig spread cost per day
4. DwC cost
5. Conventional drilling bit cost (engineer cost if applicable)
For calculating total connection time below inputs are required:
1. Length per stand, usually 40ft (12.19m) for casing and 90ft (27.43m) for drill pipe
triple
2. Time per connection in minutes for casing and drillpipe
3. Miscellaneous time involved in each connection, in minutes, if applicable
4. Section depth-in and depth-out
Also, the costs relating to Defyer , engineer and spear have to be completed in the second
Eng&Spear page (Table 14). The total engineer and spear cost is linked to the main
calculation sheet.
The calculation sheets display below results:
Total hours to drill each section with DwC and conventional drilling
Total costs incurred in both types of drilling
Cost per meter
DwC savings, at a given DwC ROP, compared to conventional drilling. A negative
value mean DwC is more expensive to implement
5. A comparison chart of DwC time versus conventional drilling (Figure 42)
6. Time-Depth curve (Figure 43)
1.
2.
3.
4.
SEC NO.
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PROJECT
CUSTOMER
CASING SIZE
DATE
Version 9.0
Step
Conventional
Hrs
Cum. Day
Deph (m)
1
2
3
4
5
2.00
0.50
3.50
1.00
1.50
0.08
0.10
0.25
0.29
0.35
188.73
188.73
188.73
188.73
188.73
6
7
8
9
10
11
12
13
14
Test LWD and MWD assy. with 3500 LPM and 1800 psi, OK
Continue RIH 26" BHA #2 to 160m, washed down and tag TOC at 168m,
Drilling 26" hole from 188.73 to 527m
Pump Hi-Vis
Flow check
POOH from 527m, sweep hole, download MWD data, L/D BHA
R/U casing equipment
P/U shoe joint, run casing to 424m
P/U and M/U MLS Hanger
0.50
5.00
15.00
2.00
0.50
10.00
0.50
6.00
1.00
0.38
0.58
1.21
1.29
1.31
1.73
1.75
2.00
2.04
188.73
188.73
527.00
527.00
527.00
527.00
527.00
527.00
527.00
15
16
17
18
1.50
1.50
2.50
0.50
2.10
2.17
2.27
2.29
527.00
527.00
527.00
527.00
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
1.50
1.00
2.00
2.50
2.50
2.35
2.40
2.48
2.58
2.69
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
527.00
527.00
527.00
527.00
527.00
Total Distance, m
338.27
338.27
Total Hrs
64.5 hrs
51.8 hrs
2.69 days
2.16 days
Total Days
19.8%
$250,000
$250,000
$10,417
$10,417
n/a
$104,481
$25,000
% Time saving
n/a
$696,875
$643,544
$2,060
$1,902
$53,331
% Cost saving
7.7%
Cost / m
Hrs
Cum. Day
Deph (m)
2.00
0.50
3.50
1.50
0.08
0.10
0.25
0.25
0.31
188.73
188.73
188.73
188.73
188.73
5.00
1.50
1.00
2.50
18.00
2.00
0.50
1.00
1.00
0.52
0.58
0.63
0.73
1.48
1.56
1.58
1.63
1.67
188.73
188.73
188.73
188.73
527.00
527.00
527.00
527.00
527.00
1.50
0.50
0.25
1.50
1.73
1.75
1.76
1.82
527.00
527.00
527.00
527.00
1.00
2.00
2.50
2.50
1.86
1.95
2.05
2.16
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
#N/A
527.00
527.00
527.00
527.00
SEC NO.
Subject:
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12 Nov 2009
Conventional
Length / Std, m
12.2
27.4
10.00
4.00
73
411
527
19
DP Connection Time, hr
0.00
1.27
189
Csg TD, m
527
27
4.50
ON-BOTTOM TIME
DwC
Conventional
26.0
26.0
Depth In, m KB
188.73
188.73
Total Drilled, m
338.27
338.27
Hours On Bottom
13.01
13.01
17.51
14.28
Description
Unit Cost
US$
Total Cost
US$
1.00
$75,000.00
$75,000.00
1.00
$14,481.25
$14,481.25
1.00
$2,500.00
$2,500.00
1.00
$2,500.00
$2,500.00
2.00
$2,000.00
$4,000.00
3.00
$2,000.00
$6,000.00
0.00
$1,750.00
$0.00
$104,481.25
SEC NO.
Subject:
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70
0.5
3.5
60
Test LWD and MWD assy. with 3500 LPM and 1800 psi, OK
1.5
0.5
50
Continue RIH 26" BHA #2 to 160m, washed down and tag TOC at 168m, drilled out
cement, shoe and cleaned out rat hole. Pump sweep & circulate hole clean
POOH
0.5
3.5
0
1.5
0
Pump Hi-Vis
40
HOURS
1.5
0
1
Flow check
2.5
0
2
0.5
0
30
10
18
0.5
20
Wash down fom 519m to 523m (shoe depth) and land the MLS Hanger assy. onto 30"
Landing ring
1
2
0.5
1
0.5
0
1
0
1.5
0
0.3
1.5
10
1.5
1.5
2.5
1.0
1.0
2.0
2.0
2.5
2.5
2.5
2.5
DwC
Conventional
200
Depth, m
300
400
500
600
0.0
0.5
1.0
1.5
2.0
Days
2.5
3.0
Subject:
SEC NO.
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2.
Equipment
1.1.
Defyer 2
1.2.
Float Collar
1.3.
IBOP
1.4.
TIW Valve
1.5.
BOP Stack
1.6.
Casing running equipment - U.C. Slips, Side Door Elevators, Single Joint
Elevators, Tongs, Pairs of equal lengths Slings
1.7.
Casing Drive: Modified DwC Spear or Internal Casing Drive Tool (ICDT)
1.8.
Cement head
1.9.
Cement plugs
Preparation
2.1.
Tally casing. Ensure tally exceeds casing setting depth by at least 10%.
2.2.
2.3.
2.4.
2.5.
2.6.
Check Defyer cutting structure for any damage incurred during transport.
2.7.
Check and record Defyer serial number, tool size and type.
2.8.
2.9.
2.10.
2.11.
Witness the loading of the cement plugs or dart in the cementing head.
2.12.
Calculate maximum allowable pump rate to ensure that ECD pressures do not
exceed formation fracture gradients. Run calculations for drilling fluid and cement
circulation.
2.13.
Calculate the maximum weight on shoe to ensure neutral point is not at surface.
2.14.
Calculate annular volume in barrels per foot for future bottoms up circulating
volumes.
Subject:
3.
SEC NO.
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LATEST REVISION
12 Nov 2009
2.15.
Calculate air weight of total length of casing being run. Ensure lifting equipment
and casing drive ratings are not exceeded.
2.16.
Check burst, collapse, and tensile ratings of casing to ensure they are not
exceeding during drilling and cementing operations.
2.17.
Calculate maximum over pull on casing at setting depth. Maximum over pull may
be limited by casing drive rating or elevator rating.
2.18.
Operations
3.1.
Hold pre-job safety meeting to communicate the Drilling with Casing process.
Ensure everyone is aware of their responsibilities.
3.2.
3.3.
3.4.
3.5.
Make up float collar joint (if float collar isnt included shoe joint)
3.6.
3.7.
Continue running casing to seafloor with side door elevator. Torque connection
as per thread manufacturers specifications.
NOTE: On no account should the Defyer be set on bottom unless full pump rate
and rotation have been achieved.
3.8.
Fill casing every joint. Fill casing to surface every five joints run.
3.9.
Run to last joint before tagging bottom (or seafloor), set casing in slips.
3.10.
3.11.
Make up Spear assembly to TDS. Rig up single joint elevator with appropriate
length
3.12.
Pick up next joint of casing. Stab in and make up to casing in the rotary table.
3.13.
Stab in Spear, turn to the right, pick up spear to engage. Ensure positive
engagement before removing slips.
3.14.
3.15.
3.16.
3.17.
Spud the well (for 13-3/8 casing, start with reduced flow rate of 500gpm to avoid
creating crater at the seafloor).
3.18.
After drilling one joint down, circulate at drilling rate. Monitor system for losses.
The action taken will depend on the severity of the losses. Reducing pump rate
and effectively reducing ECD may stop minor losses.
3.19.
SEC NO.
Subject:
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3.19.2. Zero the weight indicator, record pump pressure and torque
3.19.3. Run down slowly to tag bottom, carefully monitoring WOB, torque and
pressure
3.19.4. It is recommended that the first few meters be drilled down with minimum
weight to be on the Defyer.
3.20.
Drilling Ahead
3.20.1. Always kick in the pumps and rotate before going to bottom
3.20.2. Increase weight gradually to achieve desired ROP
3.20.3. Remember that excessive WOB will reduce tool life
3.20.4. Monitor pump pressure carefully, an increase may indicate bit balling. Pick up
off bottom, rotate at max rpm, and stop and start the pumps several times to
try to wash the Defyer clean of cuttings
3.20.5. Commence drilling of surface hole section.
parameter ranges.
4.
3.21.
3.22.
3.23.
3.24.
Circulate hole clean. Avoid the use of high viscosity sweeps. The annular
velocity is sufficient to clean the hole and the sweep will increase the ECD
pressures, which will increase the possibility of breaking down the formation.
3.25.
3.26.
3.27.
3.28.
3.29.
3.30.
3.31.
3.32.
Check floats to ensure they are holding. Pressure tests may be performed at this
time.
3.33.
3.34.
Contingency
4.1.
Lost Circulation:
4.1.1. While running casing continue to RIH at reduced rate. Fill hole with trip tank
4.1.2. While circulating
Subject:
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4.1.2.1.
4.1.2.2.
4.2.1. Re-pressure plug. Bleed off pressure quickly to close floats (Attempt this no
more than twice!)
4.2.2. Float still not holding: Pressure up to final circulating pressure & WOC
4.2.3. NOTE: Hold pressure for remainder of cement test pump time.
4.3.
Shoe squeeze
Stuck Pipe
Damaged joint
4.5.1. If the joint torques up early or undue wobble is noticed, back out the joint and
check connection. Lay down the joint if necessary and replace with similar
length joint.
4.6.
SEC NO.
Subject:
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Max
Casing
Size
Hole Size
Flow
Annular
Velocity
WOB
RPM
Torque
Flow
Annular
Velocity
WOB
RPM
Torque
in
in
gpm
ft/min
klbs
RPM
kft.lbs
gpm
ft/min
klbs
RPM
kft.lbs
5.000
6.125
65
127
2.0
40
1000
110
215
10.0
120
7.000
8.500
120
127
3.0
40
1000
200
211
13.0
120
7.625
9.875
200
124
3.0
40
1200
350
218
15.0
120
8.625
10.625
200
127
4.0
40
1200
350
223
16.0
120
9.625
12.000
300
143
4.0
40
1500
500
239
18.0
120
13.375
17.000
550
122
6.0
40
2000
1000
223
26.0
120
18.625
21.000
500
130
7.0
40
2500
900
234
32.0
100
20.000
24.000
900
125
8.0
40
3000
1500
209
36.0
100
24.000
28.000
1100
130
11.0
20
3500
1500
177
45.0
80
limited by
connection
Max
Hole Size
Flow
Annular
Velocity
WOB
RPM
Torque
Flow
Annular
Velocity
WOB
RPM
Torque
kft.lbs
in
in
gpm
ft/min
klbs
RPM
kft.lbs
gpm
ft/min
klbs
RPM
7.000
8.500
120
127
1.0
30
1000
310
327
15.0
100
9.625
12.000
300
143
1.0
30
1500
600
286
15.0
150
13.375
17.000
550
122
1.0
30
2000
1100
245
35.0
120
limited by
connection
Subject:
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12. Cementing
There are three basic types of cementing methods that can be performed upon reaching
casing point:
(i)
(ii)
(iii)
Cement head
Inner String
DwC Spear
Cement Head
This is the most common cementing method being used. This method is being used for
cementing smaller diameter casing string such as 13-3/8, 9-5/8 and 7. Below are the
operating procedures for cementing operation that use cementing head.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Upon reaching total depth and land the casing, circulating bottoms up
Rig down DwC spear
Nipple up cementing head and install lines. Hold pre-job safety meeting
Pump spacer (10-15bbl, water or chemical) and pressure test cement lines
Release bottom plug and commence pumping cement
Pump down the calculated amount of cement
Release the top plug
Pump down top plug with displacement fluid (usually water)
Once the bottom plug bumps at the float collar, increase pressure to rupture the
bottom plug disc. Continue pumping and displacing the cement into annulus
After the top plug bumps the bottom plug, check for bump pressure
Pressure test casing as necessary
Release pressure to check if float collar valve holds the pressure and prevent
cement from U-tubing
Rig down cementing head and lines
Upon reaching casing point and landing casing, circulate bottoms up.
Rig down DwC spear.
Pick up first stand of drill pipe and install drill pipe stop collar 3 to 4 feet above
tool joint.
Screw Stab-in stinger to bottom of drill pipe and torque connections.
Place centralizer around stop collar on drill pipe.
Lower drill pipe and centralizer into casing. After centralizer pass top of casing,
place false rotary plate, bowl and slips above casing.
Subject:
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Run drill pipe until the stab-in stinger stinging into the float equipment and set
weight on the receiver.
Make up Top-out connection to the drill pipe landing joint.
Fill volume between casing and drill pipe with mud. Break circulation through drill
pipe.
Rig up cementing line and pump cement.
Displace cement with calculated amount of displacement fluid to remove all
cement from drill pipe.
Check to determine if float equipment is holding by releasing pressure and
observing volume of flow-back.
Pull drill pipe out of hole.
Remove stab-in stinger, centralizer and stop collar from drill pipe.
DwC Spear
This cementing method is normally being utilized for conductor or surface casing section.
Time saving will be the main benefit of this method, while the formation of internal wall
cement sheath is the main disadvantage of this method. Below are the operating procedures
for cementing operation that use DwC spear.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Upon reaching casing point and landing casing, circulate bottoms up.
Break out DwC spear
Rig up pre-made up cementing assembly comprising of drill pipe pup, TIW valve,
side-entry-sub and TIW valve.
Make up DwC spear to the cementing assembly.
Drill down the last casing joint until Texas deck.
Pump sea water or water as the spacer to flush the casing wall of mud before
pumping cement.
Pump down calculated amount of cement.
Pump down viscous fluid as the intermediate fluid.
Pump down required amount of sea water to displace the cement out into the
annulus. Allow 10m of cement above the float collar to avoid having a wet shoe.
Release pressure and check if float holds
Disengage and release the DwC spear.
Rig down the DwC spear and the cementing stand.
Subject:
SEC NO.
PAGE 75 OF 115
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Float Collar
Standard Type 402 Float Collar
Float collars serve several very important roles in the primary cementation phase of the
casing string.
Act as a primary valve to the guide shoe or as a back-up valve to the float shoe.
Provides a landing point for the casing wiper plugs, whose function is to wipe any
mud film from the casing during the cement displacement. It allows this contaminated
cement to be captured in the shoe track instead of being pumped into the annulus.
Pressure holding capability. When a plug bumps against it is referred to as bump
pressure while pressure from annulus on the back side of valve is called back
pressure.
Bumping of the wiper plug confirms to the operator that the displacement is
complete. The valve and cement around it are capable of withstanding long periods
of circulation.
There are few ways on assembling the float collar onto the casing string. Below are the most
common method normally seen:
i.
ii.
iii.
Different float collars will be utilized while drilling with different types of Drill Shoe. Float
collar Model 402 (Figure 1) is normally installed for drilling with Drill ShoeTM 1 and Drill
ShoeTM 2 while Mid-Bore Auto Fill Float Collar, M42A0, and Large Bore Auto-Fill Float
Collar, L42W are the float collars installed while drilling with Drill ShoeTM 3.
Subject:
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Model 402 (Figure 44) is a PDC drillable float collar that being used for drilling together with
DefyerTM 1 and DefyerTM 2. This float collar equips with a single poppet style Sure-Seal 3
valve that able to hold high strength concrete for maximum resistance to circulating erosion,
as well as bump and back pressures.
Figure 45 shows a mid bore auto-fill float collar that contains a surge reducing and debris
tolerant, PDC drillable valve. It is being used for drilling with DefyerTM 3. This float collar is
available in 6-5/8 through 8-5/8 casing sizes. This float collar is designed with two ballactivated check valves. It has optional ball seats available for ball sizes from 1-1/2 to 2-1/8
diameter. Phenolic and zinc alloy balls are the two common types of balls used for this float
collar. The float collar valves have 2-3/8 bores after conversion.
To run in tandem with the 7 Defyer 3 the fiberglass sleeve has to be removed prior to
making up to the casing or DS3 so that the sleeve removal ball need not be dropped and
sleeve will not interfere with the conversion of DS3.
Mid-Bore Auto-Fill Float Collar Model M42A0
Subject:
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Subject:
SEC NO.
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LATEST REVISION
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Subject:
SEC NO.
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LATEST REVISION
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Subject:
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Centralizers
Centralizers utilized for drilling with casing are required to be robust enough to withstand the
casing string rotation and drill the section for extended periods of time. The centralizers have
to be designed with maximum standoff and wear resistance. The centralizers design feature
in mud displacement is another important aspect that helps for superior mud removal during
drilling operation and cementation. Spiralglider HD (Figure 47) and Non-Rotating
Centralizers (Figure 48) are the two types recommended for drilling with casing operation.
Figure 47 SpiraGliderTM HD
Subject:
SEC NO.
PAGE 81 OF 115
LATEST REVISION
12 Nov 2009
Logging Issues
Open hole logging while DwC can be accomplished in a variety of ways that involve LWD
or memory logs (Tesco System). Studies are currently under way for formation evaluation
completed with only cased hole logs.
The technique for running open hole logs can be performed as follows:
Tesco & Baker System - Drill with casing drill to TD with the 4-1/2-in. casing, retrieve drilling
assembly and then ream back to the 7-in. casing shoe. The logs are then run through the 41/2-in. casing just as they would be if the well were drilled conventionally as shown in Fig. 4.
Once logging is completed, the casing is reamed back to bottom and cemented.
Weatherford System - displace collapsible bit to provide access to the logging tool. Follow
same procedures above for logging.
Subject:
SEC NO.
PAGE 82 OF 115
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Cementing Issues
Note that cementing through nozzles of the bit presents an inherent risk of hydrating the
cement slurry potentially causing the cement to flash set. Understanding this is critical to
designing the cementing program and cement slurry to mitigate this risk and ensure a
successful cement operation.
Subject:
SEC NO.
PAGE 83 OF 115
LATEST REVISION
12 Nov 2009
Centralization Issue
In the surface and conductor casing intervals when DwC, the use of centralizers is not
common. Solid centralizers can be added to the casing for directional performance, wear
management, key-seat control, and centralization for cementing. These centralizers have
rigid, hard faced blades and are attached to the casing with a friction fit so that they rotate
with the casing. Non-rotating zinc alloy centralizers have also been used for torque reduction
in directional applications.
Rigid alloy centralizers wear too quickly for most applications and become ineffective or can
be lost in the hole. These tools add cost to the system and in some cases increase the
torque required to turn the casing string.
Skinazi et.al., reported running bow-spring centralizers successfully on a vertical well. This
system used a positive displacement motor to drive the drilling assembly and required
minimum rotation of the casing string.
Subject:
SEC NO.
PAGE 84 OF 115
LATEST REVISION
12 Nov 2009
Equipment
Q. What are the advantages and disadvantages of following DS and FC assembly and which
one is recommended for DwC:
SEC NO.
Subject:
PAGE 85 OF 115
LATEST REVISION
12 Nov 2009
Risk
Q. You have just told us the advantages of DwC in your presentation, but what is the
disadvantage of DwC?
Defyer System
Advantages
Low
Cost
Simple to
operate
No rig modifications
required
Disadvantages
Limited directional control
Limited Defyer
selection
Subject:
SEC NO.
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LATEST REVISION
12 Nov 2009
Q. How to manage and eliminate the risk of shallow gas hazards during drilling with casing?
Higher ECD generated while DwC can help combat shallow gas or dynamically kill the well if gas
influx occurs, as long as this is engineered into the system and everyone directly involved is aware of
their roles and responsibilities.
Operation
Q. How long it takes to rig up equipment?
A. This is dependent on the rig and rig crews familiarity with the system and pre job planning. The
casing drive tool should take no longer than 30 minutes to rig up.
Q. Do you have qualified field engineers available and what is there experience with DwC?
A. Each region has competent and qualified DwC service engineering resources.
Q. how do I drill out the Defyer and how long will it take?
A. There are specific drill out procedures for drilling out cement, float collars and Defyers. Drilling out
the Defyer should take approximately 15 30 minutes if the correct procedure is followed and care
and attention are taken. Bit selection and Defyer size will have an affect on drill out times also.
Q. Can I do this with an RCD installed?
A. If the RCD is capable of sealing on casing then yes is the answer. By employing both MPD and
DwC technologies the job will run just as smoothly.
Q. Are procedures in place if the DS3 blades do not displace?
A. Should the Defyer DPC not displace or there is any doubt that the tool has not functioned then a
junk mill system should be run to remove the blades and PDC cutters from the drill out path.
Use a Junk Mill dressed with crushed carbide and with a Slightly Ground Rough O.D. of 1/8" less than
casing diameter as shown in BHA schematic.
Use at least 10,000lbs. of drill collars and mill with 4 to 10,000lbs. applied, depending upon mill O.D.
Never apply weight first and then start rotating. Never set down on the fish with light weight and spin.
If you wish to stop milling for any reason, always pick up the mill. Spinning in one spot on the fish can
cause the steel to work-harden to such an extent that it will be difficult to restart milling.
A minimum annular velocity of 120 feet per minute should be maintained. If possible a high viscosity
pill should be pumped every hour to 45 minutes of 20 30 barrels while milling and a clean up
sweep pill at the end of milling procedures. Continue milling with the parameters above until Defyer is
drilled out and the ID is clear with no resistance to pass through.
Engineering
Q. Hole cleaning is it better and with the smear effect does this really get better?
Subject:
SEC NO.
PAGE 87 OF 115
LATEST REVISION
12 Nov 2009
A. Hole cleaning is enhanced by annular flow rates. The smear effect does not effect hole cleaning as
only a small portion of the cuttings are left in the hole (less than 20%). These cuttings are ground into
a fine pulp and if not plastered to the wellbore are easily circulated out.
Q. Are there any forces either radial or axial which can have an adverse affect on the casing design?
Q. There are a number of casing drive systems available, each engineered to suit requirements. In
addition each job is evaluated with all parameters and potential permutations taken into account.
Q. Bit longevity; will I get the whole section in one trip? Can you drill my hard limestone, ryholite,
basalt etc?
A. By studying offset well data we can evaluate whether the candidate well is suitable for DwC. An
engineering analysis will be provided once all offset data has been evaluated.
Q. What happens if the Defyer does not reach planned total depth?
A. Drilling with Casing is not the answer for every problem and there are situations where we will
decline jobs. The drillability analysis will determine the likelihood of success and the risk analysis will
be presented to the client.
Q. What type of bit to use and how far can the drillout bit drill after drilling out Defyer?
Drilling out the Defyer does not cause any damage to the bit. The Defyer is completely PDC drillable
and should have no effect on the bit cutting structure or external gauge. How far the bit drills after drill
out will depend on bit selection and formation type. Most commonly used drillout bits are the IADC 11-5 or 1-1-7 type milled tooth bits. If hard formation expected after drillout IADC 4-1-5 type tungsten
carbide insert bit can be used. If PDC is required its recommended to use 5 blades and above and
use less than 200 RPM.
Q. How can the casing connections take the torque or will they fatigue/break?
A. When DwC is deployed in vertical sections with larger casing sizes, fatigue or damage is unlikely
to occur due to low drilling torque and relatively short rotating hours. However in high dogleg, smaller
size casing with long periods of rotation there is a higher potential of casing or connection fatigue.
Different casing connections have different fatigue tolerances and fatigue analysis must be carried out
and provided the casing suppliers.
Q. Which is the maximum inclination angle that can be drilled with DwC?
A. Drilling with Casing does not have the ability to directionally steer although we do have a system to
nudge in soft formations to build angle using a scribe line and gyro survey tools to measure
inclination and azimuth.
Drilling with Casing can be deployed in any hole section although dogleg severity will limit the number
of rotation hours that can be applied to the casing. There are a number of high torque connections
with the ability to withstand bending stresses on the market. Torque and drag studies can be
performed to pinpoint a selection criteria for drilling engineers and casing suppliers.
A number of Drilling with Casing/Liner jobs have been performed in high angle wells with encouraging
results and very little deviation from the original well path.
Q. Do you need a special rig for DwC?
A. To run a Drilling with Casing job no special rig is required. In general terms when Drilling with
Casing is vertical sections with large casing torque is similar to conventional drilling. Pump output
Subject:
SEC NO.
PAGE 88 OF 115
LATEST REVISION
12 Nov 2009
must be sufficient to remove the cuttings and clean the Defyer although Weatherford can set up the
hydraulics to suit the application and equipment.
Q. Why doesnt WFT have a Defyer capable of drilling formations > 20k psi CCS?
A. In order to drill harder formations the diamond content must increase. By making the PDC cutters
larger or by adding more PDC the ability to drill out is reduced.
Q. What are recommended well control procedures in the event of an influx?
A. Standard well control procedures apply. Drilling with Casing or Drilling with liner does not differ
from running standard casing or liners. In the event of an influx the casing drive tool should be
engaged and the flow rate should be increased to increase annular velocity to remove the influx.
SEC NO.
Subject:
PAGE 89 OF 115
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Incident
Where
Apache
China
Carigali
Malaysia
Carigali
Malaysia
Carigali
Malaysia
6
7
No drawings of DS available
10
11
12
13
Brunei Shell
Petroleum
Brunei Shell
Petroleum
Brunei Shell
Petroleum
Brunei Shell
Petroleum
Brunei Shell
Petroleum
Date
Action
Engineering /Manufacturing should address this.
Aug 03
Aug 03
Do not pre make up shoe to float collar joint, make it up on rig floor if
possible. Check float collar condition.
Aug 03
Aug 03
Aug 03
Aug 03
Aug 03
Aug 03
Aug 03
General
Cairn India
May 03
Cairn India
June 03
SEC NO.
Subject:
PAGE 90 OF 115
LATEST REVISION
12 Nov 2009
machined.
Water bushings need to have same inspection inspection procedures
as casing since it will see same forces as the casing it is driving (ie.
MPI, thread inspection and Hydrostatic psi test.)
Nozzle installation documentation must be included with DS paperwork.
This should be verified as soon as received. The specified size + one
size larger and one size smaller nozzles should be shipped loose with
DS.
14
Cairn India
May 03
15
Carigali
Malaysia
Agst 03
16
Chevron
PNG
July 03
17
Indonesia
Agst 03
Cairn India
Agst 03
OSL PNG
Dec 03
OSL PNG
Dec 03
OSL PNG
Feb 04
OSL PNG
Feb 04
OSL PNG
Feb 04
KL
Feb 04
18
19
20
21
22
23
24
25
26
27
28
PTTEP
Thailand
PTTEP
Thailand
April 04
April 04
Shell, Miri
May 04
TorkHead
Murphy
July 04
SEC NO.
Subject:
29
Murphy
Oct 04
30
Murphy
Oct 04
31
CTOC
Sep 04
32
Murphy
Nov 04
33
20 ICDT Stabiliser blades need to be torchcut to pass through the weld butt.
Murphy
Dec 04
PAGE 91 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
34
PAGE 92 OF 115
LATEST REVISION
12 Nov 2009
Murphy
Drag blocks and spring missing from returned package, Murphy broke
down tool as Engineer was sent back to town, back charging for
missing equipment.
35
Murphy
June 05
36
Murphy
Sep 05
Mandrel pin sheared as tool was being made-up on drill floor, tool was
returned to Labuan for repair, 30hrs down time lost due to this incident,
pin was over torqued in Singapore.
36
Murphy
Sep 05
5ft pup joint sheared below the rotary table as 20 spool was being
drilled down to setting depth, recommended that only single joints or
heavy weight drill pipe joints be used to set spools below rotary table.
SEC NO.
Subject:
PAGE 93 OF 115
LATEST REVISION
12 Nov 2009
Subject:
SEC NO.
PAGE 95 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
PAGE 96 OF 115
LATEST REVISION
12 Nov 2009
Shale (1)
Limestone
(fossiliferous)
Shale (2)
Limestone (crystalline)
Sandstone (1)
Mudstone (1)
Sandstone (2)
Mudstone (2)
SEC NO.
Subject:
PAGE 97 OF 115
LATEST REVISION
12 Nov 2009
Bituminous Coal
Chalk
Gypsum
Claystone
Siltstone (1)
Halite
Siltstone (2)
Rock salt
Subject:
SEC NO.
PAGE 98 OF 115
LATEST REVISION
12 Nov 2009
Conglomerate (1)
Obsidian
Conglomerate (2)
Basalt
Quartzite
Granite (1)
Granite (2)
Chert
Subject:
SEC NO.
PAGE 99 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
Subject
Casing Drilling
JSA No
DwC 1
Rev. No.
Revised by
Description: This JSA details generic hazard associated with running of standard oilfield tubulars and tubulars with small external upsets.
Variables include:
Weather conditions.
Size and type of pipe and elevators being used
Peripheral equipment being used
Weatherford Operating/Maintenance instructions pertaining to this task:
TRS/AU/OWI/001 TRS/AU/OWI/011 TRS/AU/OWI/005 TRS/AU/OWI/009A
Accidental Event
Causes
Unrequired equipment left on
rig floor. Poor house keeping
Consequences
Potential injury to
limbs
Potential serious
injury
Potential serious
injury/fatality
from pinch points
or dropped loads
Safe Guards
Prior to rigging up ensure all non essential equipment is
properly stowed away
Ensure all loads are lifted with the correct lifting equipment
and suitable SWL
Tag lines used when moving equipment / heavy loads around
Dogman and deck crews to maintain good communication
when lifting loads to and from the drill floor.
All necessary permits in place
Deck crews to maintain clear communication with crane driver
via radios or hand signal.
Ensure correct slinging of loads
Personnel to avoid working under loads
Beware of pinch points
SEC NO.
Subject:
Accidental Event
Causes
Mechanical failures to lifting
equipment.
Mechanical failures to single
joint elevators. Incorrect
type/size.
Swinging loads
Incorrect use of lift nubbin
Inattentiveness by Floorhands
Poor communication
Consequences
Potential serious
injury / fatality
Potential serious
injury / fatality
Potential serious
injury from
dropped objects
Safe Guards
Ensure correct SWL of lifting equipment.
Pre job checks have ensured that the correct SJE are being
used and that they are in good working order.
Ensure safety pin is inserted prior to hoisting casing into V
Door
Tugger driver to ensure personnel are clear of catwalk prior to
hoisting casing up V Door
Ensure all shackles are moused
If running flush joint pipe ensure that the lift nubbin is correctly
fitted
Floorhands to maintain good communications with driller
Personnel to avoid standing between rotary table and V Door
whilst casing is being hoisted into derrick
Ensure klepo remains on whilst being hoisted up V Door.
Alert driller if klepo falls off.
Ensure tail in rope is of adequate length to tail the casing in
all the way to the rotary table
Driller to maintain good vision of casing coming up V Door
and to pick up weight at a reasonable speed
If running flush joint pipe ensure that the lift nubbin is correctly
fitted
Maintain good communication between Drillfloor and
Pipedeck.
Always use a rope to lower the klepo down the V Door
Alert deck crews when lowering klepo down
SEC NO.
Subject:
Accidental Event
Causes
Injury to hands/fingers
whilst stabbing joint into
stump
Inattentiveness by tong
Injury to floor personnel
operator
being struck by power tong
Inattentiveness by floor hands
whilst guiding tong on and
Poor communication
off the pipe
Surrounding awareness
Consequences
Potential serious
injury to
hands/fingers/fee
t
Potential serious
injury
Safe Guards
Keep feet clear of being directly underneath the joint of casing
Personnel to avoid grabbing hold of the joint of casing by
means of the pin after removing the klepo
Hands to well clear of the pin and collar whilst stabbing the
joint into the stump. Driller to watch this prior to lowering the
joint
The use of a stabbing guide is recommended to aid this
operation
Gloves are recommended for the handling of casing to
prevent serious cuts from sharp threads
Tong operator to ensure Floorhands are ready to assist in
guiding the tong onto the pipe
Tong operator has clearly identified the handles provided on
the power tong to guide the tong on and off the pipe. These
will be identifiable by green paint.
The tong operator will have explained the correct use of the
handles and door latching methods.
Tong operator to adopt a position where he maintains control
of the tong
Tong operator to ensure that the tong is secured out of the
way by the means of a tie back rope after the joint is made
up.
SEC NO.
Subject:
Inattentiveness by tong
operator
Incorrect hand position
Mechanical failure
Surrounding awareness
Potential serious
injury to upper
body.
Serious injury to
hands/fingers
Prior to the job the tong operator will have ensured that all
guards and interlocks are in place and functioning properly
Prior to making up the connection the tong operator will
ensure that the stabber is ready and all personnel are
standing clear of the tong
If a back up tong is being used the tong operator will not
commence rotation of the pipe until the backup tong has a
bite and
Floorhands are standing clear
Ensure back up tong arm is clear of the power tong hydraulics
supply
Periodical checks of the snub line and shackles are essential
throughout the operation.
Potential serious
injury
SEC NO.
Subject:
Subject:
SEC NO.
PAGE 105 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
Issue
Rev
Page
A
6.0
1 of 1
Date
1-Oct-08
Number:
1. CLIENT
Company
Phone No.
Engineer
Batch Drilling
Yes
Block / Permit
Field
No
Spud Date
Well Category
Wellhead Type
Country
Primary Objective
Secondary Objective
Logging/MWD/FEWD ?
Yes
Directional control ?
No
Potential Hazard 1
Yes
No
Potential Hazard 2
3. RIG
Rig Name
RT to SS
Rig Type
Semi-submersible
Water Depth
1109.54
Yes
2894.27
[m]
No
Wt [kg/m]
139.700
25.299
121.082
Csg OD [mm]
Wt [kg/m]
244.475
64.735
218.408
Intermediate
Casing
Csg OD [mm]
Wt [kg/m]
339.725
101.195
311.372
Production
Casing or Liner
Csg OD [mm]
Wt [kg/m]
609.600
281.263
566.738
Conductor
Surface Casing
Min ID [mm]
Grade
Connection
Hole OD [mm]
Incl [deg]
660.4
Min ID [mm]
Grade
Connection
Hole OD [mm]
1599.81
Incl [deg]
444.5
Min ID [mm]
Grade
Connection
Hole OD [mm]
Grade
Connection
Hole OD [mm]
Incl [deg]
Incl [deg]
215.9
Sonic Log
Bit Record
Density Log
Remark
TD [m]
163.07
Mud Log
TD [m]
2338.16
311.15
Min ID [mm]
TD [m]
TD [m]
1805.82
Subject:
SEC NO.
PAGE 107 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
Number:
Issue
Rev
Page
A
6.0
1 of 1
Date
1-Oct-08
Date
WELL INFORMATION
Version 5.0
Operator
Anadarko
Drilling Contractor
Well Name
Merica-1
Rig Name
Ocean Sovereign-169
Job Type
DwC
Rig Type
Jack-up
Hole Size
20
in
0.00
Indonesia
Country
NE Madura III
Field / Block
Water Depth
60.00
RKB - ML
100.58
Formation Name/Age
Pliestocene
Rock Type
Clay
EQUIPMENT
TFA
Drill Shoe Size
24
in
2
Nozzle Qty
14
16
9093063
Casing Category
Production
Casing Size
203
Casing Grade
9 5/8
Spear Size
20
Casing Weight
0.994 in
in
in
36 - 40
ppf
888620
X56
ppf
Casing Connection
E60/MT
Spear Type
Logan
209-725-001
DWC B.H.A.
BACKGROUND READINGS
Pressure [psi]
Torque [ft.lbs]
Finish
Depth [m]
Off Bottom
On Bottom
Flow [gpm]
Off Bottom
On Bottom
1000.00
1000
1000
500
600
650
2000.00
1000
1500
800
700
750
3000.00
1200
1800
1000
900
1000
4000.00
1500
2000
YP
Viscosity
Water Loss
% Solid
H2O / Oil
MUD PROPERTIES
Mud Type
Wt [ppg]
SW
8.60
PV
% Sand
18-Jul-06
8:00 PM
Total Connections
15
Start Drilling
19-Aug-06
12:00 AM
8.0
min
Reach TD
19-Aug-06
6:00 AM
2.00
hr
188
Joints/ Sweep
Sweep @ TD
RUN RESULTS
Total (IADC)
On Bottom
Depth In [mRT]
Drilled [m]
Hours
ROP [m/hr]
Hours
ROP [m/hr]
100.00
183.49
83.49
6.00
13.9
1.09
76.4
WOB [klbs]
Torque [ft.lbs]
RPM
Flow [gpm]
Pressure [psi]
Min
Max
Min
Max
Min
Max
Min
Max
Min
Max
15.0
30.0
60
100
1500
5000
500
600
120
1200
Equipment Damages
QHSE Issue
Remarks
COMPANY REP. :
WEATHERFORD REP. :
SEC NO.
Subject:
Title:
Issue
Rev
6.0
Page
1 of 1
Date
1-Oct-08
Number:
Drilled
Well:
89.0 m
292.0 ft
Hrs OB
1.09
Casing Size:
100
200
300
400
267.3 ft/hr
FLOW , SPP
ROP , RPM
0
20
81.5 m/hr
AV ROP
500
600
70
700
70
200
400
600
800
1000
70
1200
70
Flow, gpm
ROP, m/hr
SPP, psi
RPM
80
80
80
80
TRQ, ft-lbs
WOB, klbs
90
90
90
100
100
100
100
110
110
110
110
120
120
120
120
130
130
130
130
140
140
140
140
150
150
150
150
160
160
160
160
170
170
170
170
180
16.0
180
Depth,m
Depth,m
90
180
0.0
2.0
4.0
6.0
8.0
10.0
WOB, klbs
12.0
14.0
500
1000
1500
2000
TORQUE, lbfts
2500
180
3000
SEC NO.
Subject:
Title:
Number:
Client :
Well No :
ML :
Client Rep :
Rig :
Depth In :
Country :
Loadout Date :
Depth Out :
Field :
Job # :
Mud Type :
Rev
Page
6.0
1 of 1
Date
1-Oct-08
Nozzles /
Port Size
Backup
Y/N?
mRKB
Issue
Torque
(ft.lb)
Description
OD
(in)
ID
(in)
Box
Conn.
Pin
Conn.
Length
(m)
Weight
(ppf)
Serial
No.
D/P Pup
X/O
Spear Mandrel
Slip (Grapple)
Pack-Off
Assembly
Rubber Cup
Bullnose
Casing
Grade:
Float Collar
DrillShoe II
Additional Information :
1- 16"-24" spear 6-5/8" Reg M/U to 43kft-lbs. 9-5/8" - 13-3/8" 4-1/2" IF M/U to 23kft-lbs.
2- 16"-24" spear 7.625-10 Acme M/U to 2.5 kft-lbs, 7.000-4 Acme M/U to 20kft-lbs. 9-5/8" - 13-3/8" 4.500-6 Acme M/U to 10kft-lbs.
LEGEND
Required information
Essential
Prepared By :
Date :
Checked By :
Date :
Subject:
SEC NO.
PAGE 111 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject:
Department:
Fishing Services
9 - 12 Drill Collars
ISSUED BY:
DATE:
REVISION No.:
APPROVED BY:
SIGN/DATE:
PAGE
1 OF 1
SEC NO.
Subject:
Tool Specification
Weatherford
Department:
Fishing Services
Connection
4 1/2" REG
Dressed to
8 1/2" OD
:
:
5 " OD
18" minimum
Body ID
2 1/4" ID
Stabilizer blade OD
8 3/8" OD
Dressed with
Tungsten carbide
Length of tool
36" minimum
ISSUED BY:
DATE:
REVISION No.:
APPROVED BY:
15,000
SIGN/DATE:
PAGE
OF
Subject:
SEC NO.
PAGE 114 OF 115
LATEST REVISION
12 Nov 2009
SEC NO.
Subject: