DWC Application Engineering Training Rev.1 PDF

Subject: SEC NO.
DRILLING WITH CASING PAGE 1 OF 115

APPLICATION ENGINEER LATEST REVISION –
TRAINING MANUAL 12 Nov 2009
Rev No. Date Originator Reviewed By: Approved By:

0 10 Apr 04 Ming Zo Tan
1 12 Nov 09 Ming Zo Tan

Subject: SEC NO.
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
Subject: SEC NO.
Other Drilling Equipment ................................................................................................57

Mud Types ...........................................................................................................................57
Hydraulics Variables............................................................................................................58
Flow Rate .........................................................................................................................58
Mud Weight .....................................................................................................................58
Total Flow Area (TFA)....................................................................................................58
Pressure Drop...................................................................................................................58
Hydraulic Horsepower/Square Inch (HSI).......................................................................59
Jet Impact Force (JIF) ......................................................................................................59
Cooling versus Cleaning ......................................................................................................59
Weatherford DwC™ Hydraulics Calculation Sheet ............................................................60
9. DwC Economic Analysis....................................................................................................64
10. Generic DwC Procedure..................................................................................................68
11. Recommended Operating Parameters...........................................................................72
12. Cementing.........................................................................................................................73
Cement Head........................................................................................................................73
Inner String Stab-in..............................................................................................................73
DwC Spear ...........................................................................................................................74
Float Collar ..........................................................................................................................75
Standard Type 402 Float Collar.......................................................................................75
Mid Bore Float Collar Model M42A0 .............................................................................76
Large Bore Float Collar Model L42A .............................................................................78
Centralizers ..........................................................................................................................80
13. DwC Related Issues..........................................................................................................81
Well control Issues...............................................................................................................81
Stuck Pipe Issues..................................................................................................................81
Fishing through Casing ........................................................................................................81
Logging Issues .....................................................................................................................81
Directional Drilling Issues ...................................................................................................82
Cementing Issues .................................................................................................................82
Tubulars and Connections Issues.........................................................................................82
Casing Wear Issue................................................................................................................83
Centralization Issue..............................................................................................................83
14. DwC Frequently Asked Questions .................................................................................84
Capability.............................................................................................................................84
Equipment ............................................................................................................................84
Risk ......................................................................................................................................85
Operation..............................................................................................................................86
Engineering ..........................................................................................................................86
13. Lessons Learned...............................................................................................................89
APPENDIX 1. Photos of Rock ..............................................................................................95
APPENDIX 2. DwC Job Safety Analysis.............................................................................99
APPENDIX 3. DwC Data Request Form...........................................................................105
APPENDIX 4. DwC Job Report Form ..............................................................................107
APPENDIX 5. Defyer™ 3 Milling Assembly ....................................................................111
APPENDIX 6. Roller Cone Bit IADC Chart.....................................................................114
Subject: SEC NO.
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
Subject: SEC NO.
Figure 43 Model M42A0 Mid Bore Auto-Fill Float Collar.....................................................76

Figure 44 Model L42A Large Bore Auto-Fill Float Collar .....................................................78
Figure 45 SpiraGliderTM HD ...................................................................................................80
Figure 46 Non-Rotating Centralizer ........................................................................................80
List of Tables
Table 1 DwC AV vs Conventional AV .....................................................................................9
Table 2 Sample Casing and Mud Programs.............................................................................15
Table 3 Collapse Resistance Including Safety Factor..............................................................16
Table 4 Burst Pressure Including Safety Factor ......................................................................18
Table 5 Selected Casing Grade and Weight ............................................................................19
Table 6 Selected Casing and Calculated Safety Factor ...........................................................19
Table 7 Final Casing Selections...............................................................................................21
Table 8 Advantages and Disadvantages of Non-Retrievable (Defyer™) System over
Retrievable (Latch) System..............................................................................................24
Table 9 Evolutions of Defyer™...............................................................................................28
Table 10 Restriction to DwC Application ...............................................................................32
Table 11 Risk Definitions ........................................................................................................33
Table 12 Common Electric Log Responses.............................................................................54
Table 13 Connection Time and On Bottom Drilling Hour Calculation...................................66
Table 14 Engineer and Spear Costs Estimation Sheet .............................................................66
Table 15 Mid Bore Float Collar Specifications .......................................................................77
Table 16 Model L42A Large Bore Float Collar Specifications...............................................79
Subject: SEC NO.
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 1950’s 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 bottom-
hole-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.
Subject: SEC NO.
2. Key Drivers for Drilling with Casing
Reduce Drilling Flat Time

A key benefit of DWC is time reduction. The time associated with tripping pipe and running
casing, including much of the circulation time involved, is removed. Connection time savings,
assuming 3.5 minutes for 90ft drill pipe and 5 mins for 40ft casing, at an on-bottom ROP of
50m/hr is 12%. At 100m/hr ROP the saving increases to 18% (Figure 1)
DwC vs Conventional Drilling Time DwC vs Conventional Drilling Time

at 100m/hr at 50m/hr
35.0 50.0
45.0 46.0
30.0
31.0
40.0
25.8 38.3 40.3
25.0 35.0
25.3
30.6 33.5
20.6 30.0
Time, Hrs
Time, Hrs
20.0 21.0
25.0 22.9 26.8
15.4 16.8
15.0 DwC DwC
20.0 20.1
10.3 12.6 Conv 15.3 Conv
10.0 15.0
13.4
5.1 8.4 7.6
10.0
5.0 4.2 6.7
5.0
0.0 Conv 0.0 Conv

250 500 DwC 250 500 DwC
750 1000 750 1000
1250 1500 1250 1500
Depth, MD Depth, MD
Figure 1 DwC Total Connection Time Saving
These are purely connection time savings.

DwC™ also eliminates other non-
productive time (NPT) involved in
operations such as reaming, circulating hi-
vis pills, conductor clean out runs etc.
There are other potential savings from
unscheduled events, for instance, hole
collapse. Typical total time savings from
DwC are in the range of 30% to 50% of
the time from section spud to leak off test.
Example of flat time reduction is shown in
Figure 2.
Figure 2 DwC vs Conventional Drilling

Time Depth Curve
Subject: SEC NO.
Getting Casing to Bottom

DwC does away with drill pipe tripping and casing running and indirectly eliminates time
dependent wellbore deteriorations which frequently prevent casing from reaching bottom.
The fact that the casing is always on bottom ensures that where the Defyer™ drills to is
where it can be cased. There is literally no concern over casing not reaching bottom with
DwC.
Elimination of Problems Related to Tripping

Tripping of the drillstring may result in many other problems such as surge and swab effect,
lost circulation, key-seating, borehole stability problems and well control incidents.
Elimination of pipe tripping prevents the occurrence of these problems.
Drilling Depleted Zone and Overcoming Lost Circulation

Lost circulation is the most severe problem that occurs in matured field and weak formations.
It is a contributing factor to the next most serious problem - stuck pipe.
On the surface it might seem that DWC would not be a good option because the casing
could get stuck before reaching casing point. One would also expect lost circulation to be a
potential problem with DWC because the smaller annular clearance between the casing and
borehole wall increases the frictional pressure losses, thus increasing the ECD. In fact, what
has been found is that DWC significantly reduces lost circulation. The exact mechanism that
provides this benefit is not proven yet, but it is believed to be the result of mechanically
working drilled solids into the face of the borehole, smearing drilled cuttings and mud solids
into the borehole wall. This plastering effect mechanically builds an impermeable filter cake.
The proven experience of reducing lost circulation and stuck pipe coupled with the fact that
well control is much safer when the well can be circulated with pipe on bottom makes a
compelling argument that DWC should be the first choice for drilling these difficult zones.
Better Borehole Quality

The inherent stiffness of the casing string in the wellbore produces a less tortuous hole,
providing a smoother wellbore and reducing the risk of key-seating and mechanical sticking.
The stiff assembly also is less prone to vibrations, reducing the mechanical impact damage
on the borehole wall. Drillstring vibrations have been attributed to borehole stability problems
and oval shape holes.
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.
Subject: SEC NO.
Reduce Rental Costs

Drilling with Casing eliminates the need for conventional bottom hole assembly (BHA)
components, and can eliminate the need for one or more strings of drill-pipe.
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.
Table 1 DwC AV vs Conventional AV
Hole OD OD Flow Annulus Area, in^2 Vann, ft/min DwC Vann

Size DP Csg Rate, gpm Conv DwC Conv DwC vs Conv
8 1/2 5 1/2 7 500 33 18 292 527 1.8 X
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
400
341
Vann, ft/min
292
300
192
200 164
89 98
100
42
-
500 800 1000 1100
7 9 5/8 13 3/8 20
5 1/2 5 1/2 5 1/2 5 1/2
8 1/2 12 1/4 17 1/2 26
Flow, Csg , DP , Hole
Figure 3 Annular Velocity Comparison

Subject: SEC NO.
3. Casing Design Fundamentals

Conventionally drilling a hole to a gas or oil reservoir requires two operations. One is to drill
the hole, and the second is to periodically line the hole with steel pipe, or casing. Once
installed, this casing is cemented in place to provide additional support and a pressure-tight
seal.
Casing in a well serves several important functions:

 Prevents caving of the hole
 Provides a means of containing formation pressure by preventing fracturing of upper,
weaker zones
 Provides a means for attaching surface equipment (blowout preventer and production
tree)
 Confines production to the wellbore
 Allows segregation of formations behind the pipe and thereby prevents inter-
formation flow, and permits production from a specific zone
 Permits installation of artificial life equipment for producing the well
 Provides a borehole of known diameter for further operations
One or more of the following strings of casing are required in every well:
 Conductor pipe
 Surface casing
 Intermediate casing
 Liner string
 Production casing (oil string)
In casing design one needs to fully understand the following three important strengths of
casing.
 Yield Strength
 Collapse Strength
 Burst Strength
Subject: SEC NO.
Casing Strength Properties
Yield Strength
Yield strength is the maximum load point on the Load-Elongation curve (Figure 4) where
Hooke’s Law is no longer applicable. The ratio between stress and strain along the portion
OA defines Young’s modulus, E. Before the yield point (eg. Point A) the casing elongation is
elastic meaning the casing will return to its original dimensions when the load is removed.
Beyond the yield point the casing yield becomes plastic, resulting in permanent deformation
even when the load is removed. Loading beyond the yield point results in a change in
internal structure of the material and in a loss of strength.
Ultimate Tensile Strength

Yield Strength
Load
Fracture Strength
O Elongation
Figure 4 Load-Elongation Curve of Casing
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.
Subject: SEC NO.
Loads on Casing
A casing is specified by the following parameters:
 Outside diameter and wall thickness

 Weight per unit length, normally weight per foot or meter
 Type of coupling
 Length of joint
 Grade of steel
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 casing’s 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  = mud weight, ppg

h = depth, ft
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
Subject: SEC NO.
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. bending with tongs during make-up

2. pull-out of the joint and slip crushing
3. corrosion and fatigue failure
4. pipe wear from running wireline tools and drill string
5. additional loadings from treatment operations such as squeeze cementing, acidising
and hydraulic fracturing
Casing Seat Selection
1. Plot the pore pressure gradient; the mud pressure gradient and the fracture gradient
against depth as shown in Figure 5.
2. Starting at hole TD (11,000ft), draw a vertical line through the mud gradient until it
intersects the fracture gradient line. In our example the mud gradient at TD is
0.94psi/ft and a vertical line through it (A-B) intersects the fracture gradient line at
Point B, 10,320ft. Above 10,320ft the mud gradient of 0.94 psi/ft will exceed the
fracture gradient. Thus formations above 10,320ft have to be protected and cased off
with casing.
3. Above 10,320ft the hole must be drilled with a mud weight less than 0.94 psi/ft. The
new mud gradient is obtained by drawing a horizontal line (B-C) from Point B to the
mud gradient line. Point C shows the new mud gradient of 0.85 psi/ft. Draw vertically
from Point C until the fracture gradient line is intersected at Point D, at 8558ft. Point
D establishes the maximum depth that can be drilled before changing to the new
mud gradient of 0.85 psi/ft. Hence a intermediate casing has to be set at 8558ft.
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.
Subject: SEC NO.
Pressure Gradient (psi/ft)

0.30 0.40 0.50 0.60 0.70 0.80 0.90 1.00 1.10 1.20 1.30
0
1000
2000
3000
4000
5000
Depth (ft SS)
6000
7000
8000
E
8558
D
9000
10000 C B
10320
11000 11000
A
12000
Pore Pressure Gradient, psi/ft Mud Pressure Gradient, psi/ft
Fracture Gradient, psi/ft Surface casing
Intermediate casing Intermediate casing or protection line
Protection casing or liner
Figure 5 Casing Seat Placement Chart

Subject: SEC NO.
Example of Casing Grade and Weight Selection
An exploration well to be drilled to a total depth of 13,900ft (4327m). Casing and mud
programs are as in Table 2:
Table 2 Sample Casing and Mud Programs
Hole Size 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 7” 11.63ppg 1.394kg/l
Safety factors:
Burst = 1.1
Collapse = 0.85
Tension = 1.8
Formation fluid gradient:
0-6200 ft Pf = 0.465 psi/ft

6200-10400 ft Pf = 0.480 psi/ft
10400-13900 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
Collapse Pr essure  0.0519  mud weight ( ppg )  depth ( ft )
Collapse pressure at surface = 0
Collapse pressure at TD = 0.0519 x 8.96 x 6200 = 2886 psi (199 bar)
The collapse line is drawn between 0 at the surface and 2886 psi at 6200 ft, as shown in
Figure 6
From Table 3 the collapse resistances of the available grades as adjusted for a safety factor
of 0.85 are as follows:
Subject: SEC NO.
Table 3 Collapse Resistance Including Safety Factor
Collapse resistance (psi)

Grade Weight Coupling
SF = 1 SF = 0.85
1130
K55 54.5 LTC 1130 = 1329
0.85
1950
K55 68.0 BTS 1950 = 2294
0.85
2670
L80 72.0 BTS 2670 = 3141
0.85
Figure 6 Casing Grade Design Chart
The collapse resistance values are plotted as vertical lines, as shown in Figure 6.
Subject: SEC NO.
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
Figure 7 Formation Pressure from Next Section TD
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)
Thus,
Burst at shoe = 4572 – 2883 = 1689 psi (116 bar)
Burst at surface = internal pressure – external pressure

Subject: SEC NO.
External pressure =0
Internal pressure = Pf – (TD) x G
Therefore,
Burst at surface = Pf – (TD) x G

= 4992 – 10400 x 0.1
= 3952 psi (273 bar)
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 SF = 1.1
2730
K55 54.5 LTC 2730 = 2482
1.1
3450
K55 68.0 BTS 3450 = 3136
1.1
5380
L80 72.0 BTS 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 K55, 54.5#

3050 – 4950 ft K55, 68#
4950-6200 ft L80, 72#
On the basis of burst only, Figure 6gives the following selection:
0-2400 ft L80, 72#

2400-4200 ft K55, 68#
4200-6200 ft K55, 54.5#
Subject: SEC NO.
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 Grade and Weight Weight in Air (lb)

0 - 2400 ft (732 m) L80, 72# 2400 x 72 = 172.8
2400 - 4200ft (1280 m) K55, 68# (4200-2400) x 68 = 122.4
4200 - 6200 ft (1890 m) L80, 72# (6200-4200) x 72 = 144.0
Total weight in air = 439.2
Table 6 Selected Casing and Calculated Safety Factor
Weight of Safety factor = yield

Grade and Cumulative Weight
Section (x 1000 strength ÷cumulative
Weight (x 1000 lb) (kN)
lb) (kN) weight
1650
144.0 (641) L80, 72# 144.0 (641) = 11.5
144
835
122.4 (544) K55, 68# 266.4 (1185) = 3.13
266.4
1650
172.8 (769) L80, 72# 439.2 (1954) = 3.8
439.2
 m 
Buoyancy Factor, BF =  

 s 
 67 
BF = 1   = 0.863
 489.5 
The inside diameter of L80, 72# is 12.347 in (313.6 mm). Therefore

Subject: SEC NO.
Total tensile force = buoyant weight of casing + tensile force due to pressure testing
 
= Weight in air  BF  +  ID   testing pressure
2
4 

= [ (439.2 x 0.863) x 1000 ] + [ (12.437)2 x 2070 ]
4
= 379,030 + 247,847
= 626,877 lb
1,661,000
SF in tension for top joint =
626,877
= 2.65
Biaxial effects Check the weakest grade of selected casing for biaxial effects as follows.
weight carried by weakest jo int

tensile ratio 
yield strength of body (or coupling )
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,
266.4 x 1,000
tensile ratio = = 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#
collapse resis tan ce

=
collapse pressure
1560
= = 1.40
1117
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Final selection
Table 7 Final Casing Selections
Interval Grade and Weight
0-2400 ft (732 m) L80, 72# (107 kg/m)
2400-4200 ft (1280 m) K55, 68# (101 kg/m)
4200-6200 ft (1890 m) L80, 72# (107 kg/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 under-
reamer. 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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Retrievable System Non-Retrievable System
Casing
Casing
Float
Collar
BHA:
MWD/LwD
Positive
Displacement
Motor
Under Reamer
Bit
DrillShoe
Figure 8 Two Types of DwC Systems

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Table 8 Advantages and Disadvantages of Non-Retrievable (Defyer™) System over

Retrievable (Latch) System
Non-Retrievable System Retrievable System

Advantages Disadvantages Advantages Disadvantages
Low cost Limited directional control Ability to steer with PDM High cost
More complicated to set up

Simple to operate Cased hole logs only MwD/LwD capability
and operate
Wide range of bit

No rig modifications Limited DrillShoe™
selections to suite Rig modification required
required selection
formation and distance
Landing in sub-sea well

Zero risk of irretrievable Risk of irretrievable tool in
head could be an issue
tools in the hole the hole
(upcoming solution 2010)
Cementing can commence Unable to cement

immediately upon TD 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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Figure 9 Logan Spear
Slip with Stop Ring
Spear Mandrel
Spear Pack-off
Stabilizer
Figure 10 Internal Casing Drive Tool (ICDT)

Figure 11 Modified HE or AZ Spear
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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.
Figure 14 Anatomy of Defyer™ DT
Aircraft grade
6mm round TSP pressed aluminum nose (fully
into the aluminum PDC drillable)
High Velocity Oxy Fuel

(HVOF) hardfacing on AISI 4145 or ST52
aluminum surface grade steel
Threaded connection
between the aluminum
PDC drillable
nose and steel
copper nozzles
body/shoulder
Gage pad reinforced with

Premium PDC tungsten carbide briquette
cutters
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Figure 15 Chip Breaker Holes
To date, three cutting structure options are available; dense Tungsten Carbide, Thermally
Stable Diamond (TSP) and Polycrystalline Diamond Compact (PDC). When the casing is
rotated, the cutting structure cuts the rock with a shearing action, in the same way as PDC
cutters on a conventional PDC drill bit.
The installation of a separate float collar in the casing string allows the cementing operation
to begin immediately upon reaching terminal depth. After ‘waiting-on-cement’ the next drill bit
is run and drills through the shoe track and Defyer™ before entering new formation.
Alternatively, it may also be possible to ‘drill-out’ the shoe track with another Defyer on the
next casing string. Drill-out can take between 10 minutes and 60 minutes, depending on size
and style of the bit used.
There are 4 main families of Defyer™ since the inception of the prototype in 1999, namely
Defyer™ DV, Defyer™ DT and Defyer™ DPC and Defyer™ DP (Table 9).
Table 9 Evolutions of Defyer™
Prototype Defyer™
December, 1999
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Defyer™ DV
January, 2000
Defyer™ DT
May, 2000
Defyer™ DPC
August, 2003
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Defyer™ DP
February, 2009
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Fast facts about the Defyer™ :
1. Invented in Nov 1999 for drilling in surface casing in the Gulf of Thailand
2. First tool run in January 2000
3. Became a standard technique in the Gulf of Thailand by April 2000
4. Patents applied for in 1998/1999/2000
5. Smallest Tool (as of end 2008) 4-1/2” x 6-1/8”
6. Largest Tool (as of end 2008) 24” x 27”
Figure 16 Largest Defyer DT506 24” x 27”

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5. Decision Making Process

When considering whether to apply DWC, the decision-making process for operators often
involves two stages. The first stage is a fundamental decision whereby the overall risks-
versus-benefits are evaluated. Refer to Table 11 and Figure 17 for the risk analysis
examples.
Essentially, the operator asks whether sufficient drivers exist to make this fundamental
change in the way the company constructs its wells. Once these hurdles are overcome, the
second stage begins. This stage requires more detailed evaluation, because each step of
the process has to be planned to determine whether any overriding problems exist.
In general, the benefits of DwC™ include the ability to reduce drilling “flat” time, overcoming
hole related problems, and simplifying the entire drilling process.
The key to evaluating any potential application of DwC™ technology is having sufficient
information available to make a decision.
Important considerations include:

1. Selection skills and DwC™ experience: The DwC™ string must make it to the
required total depth without needing to be pulled, so detailed knowledge of drilling
conditions must be part of any evaluation.
2. An estimate of the potential flat time savings versus the potential risks involved.
3. Tubular strength considerations require knowledge of casing thread strength.
4. Since annular velocities in DwC™ are higher (because of the reduced annular
space), hole erosion can be a problem. The combination of the fluid velocity needed
to lift cuttings, the fluid volume that must be pumped to clean the bit, and erosion
possibilities may preclude DwC™ in certain cases
5. Restrictions to DwC (Table 10)
6. Risks associated with DwC (Table 11 and Figure 17 Risk Figure 17) should be
considered when proposing the DwC™ system.
Table 10 Restriction to DwC Application
1 Required full coring operations to take samples.

2 Required open-hole logging.
3 Required Drill Stem Test.
4 Average ROP less than 50 ft/hr (med. Hard formation)
5 Require directional control eg. build-up section.
6 Excessive differential-P >1500 psi(WBM).
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Table 11 Risk Definitions

RISK DEFINITION
Ref Manag Proba Cost

Risk Description
No. eability bility Impact
High probabilty due to smaller clearance for expansion of gas from

R1 Well Control 8 7 H
cuttings. Closing BOP is possible
Contingency plan : Set casing and cment in place. Proceed with
R2 Defyer Failure 6 5 H
Expandable casing to accommodate the casing point.
The 13-3/8" shoe allows full control of shallow gas kick with BOP
R3 Shallow Gas 8 5 H
closed.
MW of 9.2 ppg will create an overbalance of max. 350 psi only.
R4 Differential Sticking 8 4 M
Centralized casing will reduce the risk.
PipeCoal beds may create problem. Limited time exposure with DWC
R5 Stuck Pipe 8 5 M
and less vibration should be able to minimize the problem.
Any minor directional changes can be conducted in the next secton if
R6 Deviation Issue 6 4 M
required.
Zonal isolation across this surface casing is not critical. To ensure good
R7 Cementing Problems 7 6 M
isolation around shoe.
For the longer section, drilling must be accomplished with premium
R8 Connection Failure 7 5 M
connection.
DWC will create higher ECD in the annulus but within the LOT limit.
R9 Lost Circulation 8 3 L
Control Flow Rate or ROP.
RISK MATRIX
0 Cost Impact Legend
1
Low
< $150k
2
3 R9
Medium
< $150k-450k
R4
Probability
4 R6
R8 R5 R3
5 R2
High
6 R7 > $450k
R1
7
0 1 2 3 4 5 6 7 8 9
Manageability
High Risk Medium Risk Low Risk
Figure 17 Risk Matrix

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Figure 18 Candidate Well Selection Flow Chart
Candidate
Well
No
vertical ?
require Yes
directional
Yes control ?
No
FE, DST,
Yes
logging
required ?
No
rig has No
topdrive ?
If more
No
complex op. with kelly
acceptable ?
Yes
adequate mud No
pump Hp ?
Yes
Economic analysis Drillability analysis
Yes
tech. & econ No

Justifiable ?
Yes
Commercial proposal No DwC

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Figure 19 DwC Project Management Flow Chart
Identify client and Contact Give DwC Client request Data request to Data valid Data analysis and
application client presentation for proposal client /adequate ? feasibility
Client
Enquiry
DwC proposal is written and requires the following work:

1. Review well profile to determine if DwC is applicable
2. Formation Studies (review of offset drilling and wireline data.
Calculate rock strength and drillability)
3. Review drilling rig specifications/capabilities (is the rig
capable of operating a DwC system?)
Visit customer to
4. Review casing program (is the casing proposed suitable for confirm understanding
Submit technical
DwC?) of the technical
proposal to customer
proposal, confirm price,
5. Tool selection (working out which DwC system is best for the
deliverability etc
job, do we have the correct tools?)
6. Confirm that all tools are available and can be delivered on
time, redesign tools if necessary.
Review reasons. Client awards
7. Price out the system revisit proposal or work
8. Write a customised drilling program/running procedure (all drop
DwC jobs are unique)
Confirm Internal DwC report generated and

equipment entered into database and feedback to
requirement Global DwC
Run DwC job. Demobilise Consolidate field reports, write formal

Order Mobilise equipment and Field personnel and inspect report and submit to customer
equipment personnel to location generate job equipment
report for damage
Give information to accounts for
invoicing
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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.
Compressive Strength Analysis

The most accurate compressive strengths of a rock can be obtained by performing two types
of destructive tests. In a Uniaxial test (Figure 20) the sample is placed in the cell and a load
is applied in a vertical direction until the rock fails. Rock strength can then be calculated from
the force applied and the dimensions of the sample. The derived rock strength through this
test is the Unconfined Compressive Strength (UCS).
In a Triaxial test a confining stress (3) is applied to the rock sample in the cell at the same
time as a vertical load is being applied until the rock fails. This method is called The
Confined Compressive Strength (CCS) and is the more accurate reading of the two tests
and is closer to the actual in-situ rock compressive strength.
Rock samples normally fail in a sheared manner. The angle of shear is the angle between
the plane of shear (fracture) and the horizontal plan. The larger the shear angle, the softer
the rock is.
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Shear Shear
Figure 20 Uniaxial and Triaxial Tests
Figure 21 Relationship between compressive strength and porosity

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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 1990’s.
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 6. Shale 11. Dolomite

2. Mudstone 7. Siltstone 12. Conglomerate
3. Marl 8. Sandstone 13. Chert
4. Evaporite 9. Anhydrite 14.Volcanics
5. Gypsum 10. Limestone
Photos of some common rocks encountered during drilling is shown in Appendix 1.
It must be noted that within each of the formation groups many sub-groups exist. Some of
these sub-groups are not Defyer™ drillable. One has to be cautious about equating the
formation name to rock type, especially shales. For example the Laffan Shale in Dubai and
Wolfcamp Shale in Texas, both are carbonate rocks. The Gearle Siltstone formation in part
of North West Australia is actually shale formation. Similar anomalies exist for formations
called "sandstone."
The tectonic effects of migration, burial and subsequent uplift should also be taken into
account. As an example, the North Sea is a highly complicated geologic basin in which early
formations have undergone significant uplifting. Formations which were deposited at great
depths only to be further buried before being uplifted are much firmer than similar rock types
that have not undergone such migration and diagenisis.
Rock strength or hardness can also be classified into the following categories in relation to
unconfined compressive strength:
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gumbo, shales, soft shales, claystones, unconsolidated

Very Low Strength < 4,000 psi (very soft) sands
chalk, shaley & clayey sandstones, claystones, shales,
Low Strength 4,000-8,000 psi (soft) evaporites, soft siltstones
conglomerates, sandy & chalky limestones, marls,
Medium Strength 8,000-16,000 psi medium-medium hard sandstones, hard shales
hard stringers, hard dolomites, crystalline limestones,
High Strength 16,000-32,000 psi brittle (hard) shales, hard sandstones
very fine, tight sandstones, chert, quartzite, igneous and
Very High > 32,000 psi metamorphic rocks, hard siltstones
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.
Figure 22 Operating Envelop of Defyer™ DV

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Figure 23 Operating Envelop of Defyer™ DT
Figure 24 Operating Envelop of Defyer™ DPC

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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
D
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
log( )
D N
W
log( )
d
or modified version,
ROP
log( )
D 60 N
12W
log( 6 )
10 d
D can be corrected for mud density as follow,
mud weight for normal gradient

Dc  D 
actual mud weight in use
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)

Subject: SEC NO.
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 1 10
0
100
200
300
400
500
600
700
800
Figure 25 Sample Chart of D-Exponent

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Cone Penetration Test (CPT)
Cone Penetration Test data can be useful in estimating formation hardness when other
drilling and log information is not available. CPT provides information about soil type and
geotechnical parameters such as shear strength, density, elastic modulus, rates of
consolidation etc. Other probes can also be incorporated in the CPT tool (Figure 26) such as
a seismic cone, resistivity probe, soil sampler, hydrocarbon probe and even video probe to
acquire additional information.
Figure 26 CPT Tool
Figure 27 CPT Tool Dimensions
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: SEC NO.
can, in principle, be used to evaluate:
 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 = measured cone resistance
po = overburden pressure
Nk = 17-18 for normally consolidated (NC) clays
= 20 for overconsolidated (OC) clays, like London Clay
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.
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Figure 28 Sample CPT Result (Lithology, Density, Undrained Shear Strength)

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Figure 29 Sample CPT Result (Cone Resistance, Sleeve Friction, Pore Pressure)
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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
Degree of Grain Size Sorting Degree of Grain Angularity
very angular
very poorly sorted High
angular
poorly sorted
Abrasivenes
sub-angular
moderately
sub-rounded
well sorted
rounded
very well
well rounded
sorted
Low
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Shale Reactivity (stickiness)

Reactive clay and shale can adversely affect the performance of the Defyer™ especially in a
water-based drilling environment. These clays and shales become hydrated after chemically
reacting water molecules from the drilling fluid. A formation becomes sticky if it satisfies
below conditions:
 The volume of shale (shaleyness) exceeds 40%
 Smectites and Montmorillonites constitutes more than 40% of the clay minerals
 The clay bound water is 10 - 20% of total porosity
Sticky clays are difficult to clean and tend to plug op the face volume or the junk slot area,
referred to as bit balling (Figure 31). To avoid bit balling hydraulics of the Defyer™ must be
optimized to provide maximum cleaning in reactive formations. Nozzle placement is also
crucial during the design phase of Defyer™ to enhance cleaning of the cutting structures.
Figure 31 Bit Balling
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
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7. Basic Well Log Interpretation

Wireline and mud logs provide invaluable information about the formation characteristics of a
well bore. Several types of logging tools exist, each capable of measuring different
properties through various techniques. Logging service companies provide the tools and
personnel who operate the equipment and analyze the results. Three of the most useful
logs, for bit selection and analysis of bit performance, are the sonic, the gamma ray, the
density and the neutron logs. By combining the results obtained from each of these logs, it is
possible to determine much about the formation. However, taken in isolation logs can give
misleading impressions.
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.
Figure 32 Working Principle of Sonic Tool
Gamma Ray Log

By detecting the degree of naturally occurring gamma radiation in the formation, the gamma
ray log can identify shale zones, which emit higher levels of radiation. The log differentiates
between shale and non-shale and is sufficiently accurate to detect thin beds of shale and
clays. Clean sedimentary formations usually have a very low level of radioactivity. The
gamma ray log is one of the few that provides useful data in cased wells. It is therefore used
as a correlation curve for depth matching between individual logging runs, with lithologic
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markers or the seafloor acting as reference points.
Spectral Gamma ray determine amount of potassium, uranium and thorium, and may be
used for clay typing, mineralogy, and ash-layer detection. Potassium and thorium tend to
concentrate in clays and shales. An increase of potassium in carbonates can be related to
either the presence of algal material or glauconite, whereas the presence of uranium is often
more closely associated with organic matter. Thorium is commonly found in ash layers.
Neutron Log (Porosity Log)

Formation porosity was determined using the accelerator porosity sonde. The sonde
incorporates a neutron generator which produces high energy (14.4 MeV) neutrons (Figure
33). Neutron detectors (epithermal and thermal) then measure the number and arrival times
of neutrons at different distances from the source. Neutrons emitted from the source are
slowed by collisions with nuclei in the formation, experiencing an energy loss that depends
on the relative mass of the nuclei with which the neutrons collide. Maximum energy loss
occurs when a neutron strikes a hydrogen nucleus because it has the same mass as a
neutron. As hydrogen is mainly present in pore water, the neutron log essentially measures
porosity, assuming pore-fluid saturation. However, as clays and hydrocarbons also contain
hydrogen, the log often overestimates raw porosity and the results should be treated with
caution.
Figure 33 Working Principle of Neutron Logging Tool
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: SEC NO.
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.
Figure 34 Density Tool Gamma Ray Backscattering
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: SEC NO.
Figure 35 Density and PE Tools Gamma Ray Energy Level Utilisation

Subject: SEC NO.
Table 12 Common Electric Log Responses
Pe ρb Σ ∆t ΦCN K U 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
Common Calcite 5.1 2.71 8.0 - 10.0 47.6 0.00 < 0.40 1.5 - 15.0 < 2.0
Sediment Dolomite 3.1 2.87 8.0 - 12.0 43.5 0.02 0.1 - 0.3 1.5 - 10.0 < 2.0
Shales 1.80 - 2.70 25.0 - 45.0 63.0 - 170.0 0.09 - 0.45
Halite 4.7 2.04 748.0 67.0 -0.02 - 0.03 < 0.3 < 0.2
Common Anhydrite 5.0 2.98 12.3 50.0 0.00 0.25 - 0.43 < 0.2
Evaporites 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
Coals Bituminous 0.17 1.33 16.4 120.0 0.60
Anthracite 0.20 1.57 10.5 105.0 0.40
Limonite 13.0 3.59 57.0
Iron Pyrite 17.0 4.99 90.0 39.0
Minerals Siderite 14.7 3.94 52.3 48.0
Hematite 21.5 5.18 44.0
Glauconite 5.5 - 7.1 2.54 23.4 0.19 5.08 - 5.30
Micas Biotite 6.2 - 6.4 2.99 30.0 51.0 0.06 6.7 - 8.3 < 0.01
Muscovite 2.4 2.82 16.9 49.0 0.13 7.9 - 9.8 < 0.01
Kaolinite 2.61 12.8 0.37 0.42 1.5 - 3.0 6.0 - 19.0
Chlorite 2.88 25.3 0.32
Clays
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: SEC NO.
Figure 36 Log Responses in Different Formations

Subject: SEC NO.
Figure 37 Radioactivity of Common Rock Types

Subject: SEC NO.
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.
Subject: SEC NO.
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.
Flow Rate 2  Mud Weight

Pr essure Drop 
10856  TFA 2
Pressure Drop (psi)

Flow Rate (gpm)
Mud Weight (lbs/gal)
TFA (in2)
10,856 is a unit conversion factor.
Subject: SEC NO.
Hydraulic Horsepower/Square Inch (HSI)

HSI provides a measure of the hydraulic power consumed at the bit and is a function of flow
rate and bit pressure drop, as well as hole diameter, and will, therefore, increase as the flow
rate is increased. However, as flow rate becomes higher, the TFA will eventually need to be
increased to maintain a suitable pressure drop, in which case the HSI will once again fall.
Flow Rate  Bit Pr essure Drop

HSI 
1714  Hole Area
Flow Rate (gpm)

Bit Pressure Drop (psi)
Hole Area (in2) = /4 x (hole diameter)2
1,714 is a unit conversion factor.
Jet Impact Force (JIF)

The jet impact force is the force which is exerted on the bottom of the hole by the fluid exiting
the nozzles when the bit is on bottom. It is a function of jet velocity, mud weight and flow
rate.
Flow Rate (gpm)
Mud Weight (lbs/gal)
TFA (in2)
1,932 and 0.32086 are unit conversion factors.
Cooling versus Cleaning

In soft formations, where penetration rates are high and a large volume of cuttings is
produced, failure to clean the bit will result in bit balling. This is the case especially in water
reactive shales when a water based mud is being used. In harder formations, cleaning the
bit becomes secondary to cooling the cutters. If the cutters overheat, the diamond layer will
degrade and rapid cutter wear will follow. Therefore, it is apparent that bits for different
formations require different hydraulics. These requirements must be balanced in the bit
design and the hydraulics program calculated to suit the formation being drilled.
Subject: SEC NO.
Weatherford DwC™ Hydraulics Calculation Sheet

This spreadsheet was written to assist in the hydraulic analysis of the Weatherford Defyer™
casing drilling system (Figure 40). It is designed to estimate down hole conditions and allow
the user to determine the depth and pressure to which the tool can be run given certain
drilling parameters. The pressure drop calculated in the bore and annulus are based upon
the Power Law flow model which is an empirical flow model valid for drilling muds.
The hydraulic program can be used for DwC as well as conventional drilling. The first sheet
of the hydraulic calculation sheet requires the data to be completed in the cells shaded
yellow. Information required include well designs, mud properties, BHA configurations and
dimensions and nozzles installed in the Defyer / Bit.
The results can then be viewed on the Output sheets. This sheet will be printed in two A4
size pages. No data should be entered or formula modified in the Output sheet. The
worksheet will indicate slip velocity within different section of the well. If the annular velocity
is lower then slip velocity a message will be prompted to alert the user.
Subject: SEC NO.
Data Input
* INPUT CELL COLOURED
Client
Company Rig
Well Name Date
Location Product
Hole and Rheology

Hole Size [in] Mud Type
Measured Depth [m] Mud Wt. [ppg]
TVD [m] PV [cp]
Flow Rate [gpm] YP [lb/100ft²]
Casing Casing Liner Nozzle

OD [in] Nozzle Qty Size [1/32"]
ID [in]
From [mMD] 0.00
To [mMD]
Length [m] 0.00 0.00 TFA 0.000
PDM Flow Bypass
% Flow Through Bit 100%
Maximum Allowable SPP [psi]
Bottom Hole Assembly Fixed pressure drop

Item O.D. (in) I.D. (in) Length (m) overrules pressure drop
Optional Fixed
Pressure Drop (psi) calculated from bore ID
0.00
Bit / DrillShoe body
Annulus Loading Parameters

ROP [m/hr]
Cuttings density [g/cc]
Cuttings Size [in]
Cutting Rate Rate, in³/min 0
% Cutting in annulus #DIV/0!
Effective Static Annular Mud Weight [ppg] #DIV/0!
Power Law index n #DIV/0!

K #DIV/0!
Consistancy index kc #DIV/0!
Figure 38 Hydraulic Data Input Sheet

Subject: SEC NO.
HYDRAULIC CALCULATION
Version 1.0
Company Rig
Well Name Date
Location Product
Hole Size [in] Flow Rate [gpm]

Measured Depth [m] PDM Flow Bypass
TVD [m] Flow Through Bit [gpm]
Mud Type % Flow Through Bit 100%
Mud Wt. [ppg] Maximum Allowable SPP [psi]
PV [cp]
YP [lb/100ft²]
Nozzle Qty TFA

Size [1/32"]
Flow per Nozzle [gpm]
% Flow per Nozzle
Jet Velocity [ft/sec]
RESULTS SUMMARY
BHA Length [m] Bit Pressure Loss [psi] #DIV/0!
String Bore Pressure Loss [psi] % Bit Pressure Loss [psi] #DIV/0!
Annular Pressure Loss [psi] Jet Velocity, [ft/sec] #DIV/0!
Stand Pipe Pressure Loss [psi] #DIV/0! Bit HHSI [hp/in²] #DIV/0!
ECD [ppg] #DIV/0!
STRING BORE
Cum. Len Pressure
Component O.D. [in] I.D. [in] Length [m] % Loss
[m] [psi]
#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!
Bit / DrillShoe body #DIV/0!
Total String Bore Pressure Loss (psi) #DIV/0!
Figure 39 Hydraulics Result Output Sheets Page 1 of 2

Subject: SEC NO.
CASING ANNULAR
Casing ID Ann Vel Critical V Pressure App Visc Slip Velocity
Item Pipe OD [in] Length [m] Flow Type
[in] [ft/min] [ft/min] [psi] [cp] [ft/min]
Length pressure loss, psi
LINER ANNULAR
Ann Vel Critical V Pressure App Visc Slip Velocity
Item Liner ID [in] Pipe OD [in] Length [m] Flow Type
[ft/min] [ft/min] [psi] [cp] [ft/min]
OPEN HOLE ANNULAR

Hole Size Ann Vel Critical V Pressure App Visc Slip Velocity
Item Pipe OD [in] Length [m] Flow Type
[in] [ft/min] [ft/min] [psi] [cp] [ft/min]
Total Annular Pressure Loss [psi] #DIV/0!
Figure 40 Hydraulics Result Output Sheets Page 2 of 2

Subject: SEC NO.
9. DwC Economic Analysis

Cost saving is one of the primary drivers for adopting Drilling with Casing. As such a detailed
economic analysis is imperative in order to justify implementation of the technology. Crucial
information required for the economic analysis includes:
 Drilling rig spread cost

 Benchmark conventional drilling performance
 Historical non-productive time
 PDC or roller cone bit cost in conventional drilling
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:
1. Total hours to drill each section with DwC™ and conventional drilling
2. Total costs incurred in both types of drilling
3. Cost per meter
4. 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)
Subject: SEC NO.
DRILLING WITH CASING ECONOMIC ANALYSIS

COUNTRY PROJECT
CUSTOMER CASING SIZE
DATE Version 9.0
Step Conventional Hrs Cum. Day Deph (m) Drilling with Casing Hrs Cum. Day Deph (m)
R/U Casing equipment, M/U MLS hanger w/ landing
1 R/U Casing equipment, M/U MLS hanger w/ landing assembly 2.00 0.08 188.73 assembly 2.00 0.08 188.73
2 R/D casing equipment 0.50 0.10 188.73 R/D casing equipment 0.50 0.10 188.73
3 M/U 26" BHA, RIH same to 48m 3.50 0.25 188.73 M/U 26" BHA, RIH same to 48m 3.50 0.25 188.73
4 Verification & Down load data MWD assy. 1.00 0.29 188.73 Verification & Down load data MWD assy. - 0.25 188.73
5 Continue M/U 26" BHA #2 and RIH same to 155m 1.50 0.35 188.73 Continue M/U 26" BHA #2 and RIH same to 155m 1.50 0.31 188.73
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
6 Test LWD and MWD assy. with 3500 LPM and 1800 psi, OK 0.50 0.38 188.73 clean 5.00 0.52 188.73
7 Continue RIH 26" BHA #2 to 160m, washed down and tag TOC at 168m, 5.00 0.58 188.73 POOH 1.50 0.58 188.73
8 Drilling 26" hole from 188.73 to 527m 15.00 1.21 527.00 R/U casing equipment and DwC Spear 1.00 0.63 188.73
9 Pump Hi-Vis 2.00 1.29 527.00 P/U shoe joint and RIH to 188.73m 2.50 0.73 188.73
10 Flow check 0.50 1.31 527.00 Casing drilling 26" hole from 188.73 to 527m 18.00 1.48 527.00
11 POOH from 527m, sweep hole, download MWD data, L/D BHA 10.00 1.73 527.00 Pump Hi-Vis 2.00 1.56 527.00
12 R/U casing equipment 0.50 1.75 527.00 Flow check 0.50 1.58 527.00
13 P/U shoe joint, run casing to 424m 6.00 2.00 527.00 L/D excess casings, space out 1.00 1.63 527.00
14 P/U and M/U MLS Hanger 1.00 2.04 527.00 P/U and M/U MLS Hanger 1.00 1.67 527.00
Wash down fom 519m to 523m (shoe depth) and
15 Cont. running casing to 519m 1.50 2.10 527.00 land the MLS Hanger assy. onto 30" Landing ring 1.50 1.73 527.00
16 Wash down fom 519m to 523m (shoe depth) and land the MLS Hanger 1.50 2.17 527.00 L/D DwC Spear 0.50 1.75 527.00
17 Circulate hole clean 2.50 2.27 527.00 Change long bails to drilling bails 0.25 1.76 527.00
18 L/D circulating head, change long bails to drilling bails 0.50 2.29 527.00 RIH stinger with 17 std 1 single 5" DP to 505.61m 1.50 1.82 527.00
M/U cement head, surface line and change to long
19 RIH stinger with 17 std 1 single 5" DP to 505.61m 1.50 2.35 527.00 bails 1.00 1.86 527.00
20 M/U cement head, surface line and change to long bails 1.00 2.40 527.00 Circulate hole clean with 150% volume 2.00 1.95 527.00
21 Circulate hole clean with 150% volume 2.00 2.48 527.00 Pump cement 2.50 2.05 527.00
22 Pump cement 2.50 2.58 527.00 Rig down cement head, POOH 5" DP 2.50 2.16 527.00
23 Rig down cement head, POOH 5" DP 2.50 2.69 527.00 #N/A
24 #N/A #N/A
25 #N/A #N/A
26 #N/A #N/A
27 #N/A #N/A
28 #N/A #N/A
29 #N/A #N/A
30 #N/A #N/A
31 #N/A #N/A
32 #N/A #N/A
33 #N/A #N/A
34 #N/A #N/A
35 #N/A #N/A
36 #N/A #N/A
37 #N/A #N/A
38 #N/A #N/A
39 #N/A #N/A
40 #N/A #N/A
Total Distance, m 338.27 338.27
Total Hrs 64.5 hrs 51.8 hrs
Total Days 2.69 days 2.16 days
% Time saving - 19.8%
Rig Rate, USD/day $250,000 $250,000
Rig Rate, USD/hr $10,417 $10,417
DwC Cost, USD n/a $104,481
Bit Cost, USD $25,000 -
Extra Savings, USD n/a
Total Drlg Cost, USD $696,875 $643,544
Cost / m $2,060 $1,902
Cost saving, USD - $53,331
% Cost saving - 7.7%
Figure 41 DwC Economic Analysis Sheet

Subject: SEC NO.
IADC DRILLING TIME ESTIMATION
CONNECTION TIME
DwC Conventional
Length / Std, m 12.2 27.4
Conn. Time / Std, min 10.00 4.00
Tripping Rate, m/hr 73 411
DP Out/TD, m - 527
Single Trip DP Connections 0 19
DP Connection Time, hr 0.00 1.27
Top Csg Depth, m 189
Csg TD, m 527
No.of Csg Connections 27
Csg Connection Time, hr 4.50
ON-BOTTOM TIME
DwC Conventional
On Bottom ROP, m/hr 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
Predicted IADC Drilling Hours 17.51 14.28
Table 13 Connection Time and On Bottom Drilling Hour Calculation
DwC ENGINEER AND SPEAR COST ESTIMATION
Qty per well Unit Cost Total Cost

Item Description
(estimated) US$ US$
1 20" x 24" DS2 1.00 $75,000.00 $75,000.00
2 Spear 7-day Lump Sum Rental 1.00 $14,481.25 $14,481.25
3 Spear Mob / Demob 1.00 $2,500.00 $2,500.00
4 Spear Redress Charge 1.00 $2,500.00 $2,500.00
5 DwC Supervisors mob. / demob. 2.00 $2,000.00 $4,000.00
6 DwC Supervisor service charge 3.00 $2,000.00 $6,000.00
7 2nd DwC Supervisor service charge 0.00 $1,750.00 $0.00
Total estimated DwC cost $104,481.25
Table 14 Engineer and Spear Costs Estimation Sheet

Subject: SEC NO.
DwC vs Conventional Operations Comparison

70 R/U Casing equipment, M/U MLS hanger w/ landing assembly
R/D casing equipment
M/U 26" BHA, RIH same to 48m
2
Verification & Down load data MWD assy.
0.5
60 3.5 Continue M/U 26" BHA #2 and RIH same to 155m
1 Test LWD and MWD assy. with 3500 LPM and 1800 psi, OK
1.5
0.5
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
5 POOH
2 0
50 Drilling 26" hole from 188.73 to 527m
0.5
3.5 R/U casing equipment and DwC Spear
0 P/U shoe joint and RIH to 188.73m

1.5
0
15 Casing drilling 26" hole from 188.73 to 527m
5
40 Pump Hi-Vis
1.5
0 Flow check
1
HOURS
2.5 0 L/D excess casings, space out

2
0.5
0 L/D DwC Spear
30 POOH from 527m, sweep hole, download MWD data, L/D BHA
10 R/U casing equipment
18 P/U shoe joint, run casing to 424m
0.5 P/U and M/U MLS Hanger
Cont. running casing to 519m

20
6
Wash down fom 519m to 523m (shoe depth) and land the MLS Hanger assy. onto 30"
Landing ring
1
2 Circulate hole clean
1.5
0.5
1 1.5 Change long bails to drilling bails
0.5
0
1
0 2.5
1.5 RIH stinger with 17 std 1 single 5" DP to 505.61m
10 0 0.5
0.3
1.5 1.5
M/U cement head, surface line and change to long bails
1.0 1.0
2.0 2.0
Circulate hole clean with 150% volume
2.5 2.5
Pump cement
2.5 2.5
Rig down cement head, POOH 5" DP
0
DwC Conventional
Figure 42 Operational Time Comparison Chart
Sisi-Nubi DwC vs Conventional Time Depth Curve

100
Conventional
Drilling with Casing
200
300
Depth, m
400
500
600
0.0 0.5 1.0 1.5 2.0 2.5 3.0
Days
Figure 43 Time-Depth Curve

Subject: SEC NO.
10. Generic DwC Procedure

13-3/8” and 9-5/8” Drilling with Casing Operating Procedures
Note: DwC for 13-3/8” and 9-5/8” are similar except operating parameters, sizes of casing
handling and DwC equipments.
1. 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
2. Preparation
2.1. Tally casing. Ensure tally exceeds casing setting depth by at least 10%.
2.2. Visually inspect casing.
2.3. Drift casing on pipe rack and in V-door.
2.4. Clean threads and apply API casing thread lubricant.
2.5. Ensure shoe joint has the Defyer™ made up to it.
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. Check that all Defyer™ ports/nozzles are clear.
2.9. Confirm that there is no debris in the Defyer™.
2.10. Ensure all of the above equipment is on location.
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: SEC NO.
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. Hold pre-job safety meeting to review well control procedures.
3. Operations
3.1. Hold pre-job safety meeting to communicate the Drilling with Casing process.
Ensure everyone is aware of their responsibilities.
3.2. Make up Spear Assembly c/w 10’ DP pup joint. Rack back.
3.3. Rig up casing handling equipment: slips, side door elevator, tongs
3.4. Pick up shoe joint with Defyer™ attached.
3.5. Make up float collar joint (if float collar isn’t included shoe joint)
3.6. Thread lock bottom joints.
3.7. Continue running casing to seafloor with side door elevator. Torque connection
as per thread manufacturer’s 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. Rig down side door elevator.
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, ½ turn to the right, pick up spear to engage. Ensure positive
engagement before removing slips.
3.14. Break circulation on the up stroke to reduce initial circulating ECDs.
3.15. Slowly bring pumps up to calculated drilling circulating rate.
3.16. Record pick-up and slack off weights.
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. Initiating the Drilling Process in Open Hole
3.19.1. Pump at high flow rate, rotate at about 40 rpm
Subject: SEC NO.
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. Utilise recommended drilling
parameter ranges.
3.21. Record pick-up and slack-off weights at each connection. Monitor for any
abnormal trends.
3.22. Check the connection between Spear mandrel and pack-off assembly
periodically, tighten up if necessary.
3.23. Drill to plan TD.
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. Stop pumps and check well for flow.
3.26. Work the casing to ensure it is free.
3.27. Rig down the casing drive.
3.28. Rig up the cementing head.
3.29. Establish circulation on the up stroke.
3.30. Perform cement job per cement program.
3.31. Bump plug with pressure specified by company representative.
3.32. Check floats to ensure they are holding. Pressure tests may be performed at this
time.
3.33. Rig down cementing head and casing running equipment.
3.34. Nipple up wellhead and BOPs.
4. 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: SEC NO.
4.1.2.1. While drilling – reduce circulating rate, pump LCM as required.

4.1.2.2. Casing landed - Begin cementing immediately
4.1.3. While cementing - Land Hanger or position casing at setting depth
4.1.3.1.1. Continue cementing minimum acceptable rate
4.1.3.1.2. Partial returns: Monitor % returns with trip tank
4.1.3.1.3. Total lost returns: Fill hole w/ trip tank
4.2. Float fails to hold
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
4.3.1. Bradenhead squeeze from surface
4.4. Stuck Pipe
4.4.1. Refer to Operator’s procedures.
4.5. 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. Well Flow - Casing in stack
4.6.1. Refer to Operator’s procedures
Subject: SEC NO.
11. Recommended Operating Parameters
Recommended Operating Parameters for DrillShoe 2
Min Max
Casing Annular Annular
Hole Size Flow WOB RPM Torque Flow WOB RPM Torque
Size Velocity Velocity
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
limited by
9.625 12.000 300 143 4.0 40 1500 500 239 18.0 120
connection
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
Recommended Operating Parameters for DrillShoe 3
Min Max
Casing Annular Annular
Hole Size Flow WOB RPM Torque Flow WOB RPM Torque
Size Velocity Velocity
in in gpm ft/min klbs RPM kft.lbs gpm ft/min klbs RPM kft.lbs
7.000 8.500 120 127 1.0 30 1000 310 327 15.0 100
limited by
9.625 12.000 300 143 1.0 30 1500 600 286 15.0 150
connection
13.375 17.000 550 122 1.0 30 2000 1100 245 35.0 120
Subject: SEC NO.
12. Cementing
There are three basic types of cementing methods that can be performed upon reaching
casing point:
(i) Cement head

(ii) Inner String
(iii) 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. Upon reaching total depth and land the casing, circulating bottoms up
2. Rig down DwC spear
3. Nipple up cementing head and install lines. Hold pre-job safety meeting
4. Pump spacer (10-15bbl, water or chemical) and pressure test cement lines
5. Release bottom plug and commence pumping cement
6. Pump down the calculated amount of cement
7. Release the top plug
8. Pump down top plug with displacement fluid (usually water)
9. 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
10. After the top plug bumps the bottom plug, check for bump pressure
11. Pressure test casing as necessary
12. Release pressure to check if float collar valve holds the pressure and prevent
cement from U-tubing
13. Rig down cementing head and lines
Inner String Stab-in
This cementing method is normally utilized for the large diameter casing string such as 20”
and 18-5/8”. Below are the operating procedures for cementing operation that use inner
string.
1. Upon reaching casing point and landing casing, circulate bottoms up.
2. Rig down DwC spear.
3. Pick up first stand of drill pipe and install drill pipe stop collar 3 to 4 feet above
tool joint.
4. Screw Stab-in stinger to bottom of drill pipe and torque connections.
5. Place centralizer around stop collar on drill pipe.
6. Lower drill pipe and centralizer into casing. After centralizer pass top of casing,
place false rotary plate, bowl and slips above casing.
Subject: SEC NO.
7. Run drill pipe until the stab-in stinger stinging into the float equipment and set
weight on the receiver.
8. Make up Top-out connection to the drill pipe landing joint.
9. Fill volume between casing and drill pipe with mud. Break circulation through drill
pipe.
10. Rig up cementing line and pump cement.
11. Displace cement with calculated amount of displacement fluid to remove all
cement from drill pipe.
12. Check to determine if float equipment is holding by releasing pressure and
observing volume of flow-back.
13. Pull drill pipe out of hole.
14. 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. Upon reaching casing point and landing casing, circulate bottoms up.
2. Break out DwC spear
3. Rig up pre-made up cementing assembly comprising of drill pipe pup, TIW valve,
side-entry-sub and TIW valve.
4. Make up DwC spear to the cementing assembly.
5. Drill down the last casing joint until Texas deck.
6. Pump sea water or water as the spacer to flush the casing wall of mud before
pumping cement.
7. Pump down calculated amount of cement.
8. Pump down viscous fluid as the intermediate fluid.
9. 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.
10. Release pressure and check if float holds
11. Disengage and release the DwC spear.
12. Rig down the DwC spear and the cementing stand.
Subject: SEC NO.
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. 1ea of float collar installed above the drill shoe

ii. 1ea of float collar installed one joint above the drill shoe
iii. 1ea of float collar installed above the drill shoe and 1ea of float collar installed one
joint above the drill shoe.
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.
Figure 44 Float Collar Model 402

Subject: SEC NO.
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.
Mid Bore Float Collar Model M42A0
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 ball-
activated 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
Figure 45 Model M42A0 Mid Bore Auto-Fill Float Collar

Subject: SEC NO.
Table 15 Mid Bore Float Collar Specifications

Subject: SEC NO.
Large Bore Float Collar Model L42A
Model L42A (Figure 46) is a large 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. For
security purpose, this float collar is designed with two ball-activated check valves. It has
optional ball seats available for ball sizes from 1-1/2” to 3-1/2” diameter. Phenolic and zinc
alloy balls are the two common type of balls used for this float collar. The float collar valves
have 4” bores after conversion.
To run in tandem with the 9-5/8” 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.
Figure 46 Model L42A Large Bore Auto-Fill Float Collar

Subject: SEC NO.
Table 16 Model L42A Large Bore Float Collar Specifications

Subject: SEC NO.
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 centralizer’s 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
Figure 48 Non-Rotating Centralizer

Subject: SEC NO.
13. DwC Related Issues
Well control Issues

Many well control incidents occur while tripping pipe. These well control incidents are
avoided with the DwC™ process because pipe tripping is eliminated. In the event of a kick
while DwC™ a normal kick control mechanism will apply with a simpler pressure loss
calculation and more stable bottom-hole variation during gas circulation.
BOP Rams for casing mean less time closing the annulus, in the event of a kick.
Stuck Pipe Issues

Stuck pipe normally occurs during a kick situation or when returns are lost close to casing
point.
The need to preserve the BOP seal while circulating out the kick means the pipe must
remain static for the time required to control the well. With DwC™ the well can still be saved
as there is no need to attempt a trip-out once the well has been controlled. Drilling can
resume after the cementing job with no time lost due to stuck pipe. This would not be
possible with conventional drilling technology.
Fishing through Casing

It is possible to conduct conventional fishing operations to recover junk from the hole while
DwC™.
A fishing operation can be conducted using conventional tools (mills, junk baskets, magnets,
etc). The only difference is that these tools are run in and out of the hole with the wireline,
thus making the process faster than having to trip the drill string each time a fishing run is
made. The casing may actually be used similar to washover pipe to assist in the fishing
operation.
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 4-
1/2-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.
Directional Drilling Issues

Tesco System: the directional BHAs could be run and retrieved with the wireline without any
difficulty. The directional drilling performance needs to consider the rigidity of casing i.e.
preferable the vertical, slight build/ drop or holding sections only.
Directional response has been observed to be consistent, but with a slightly lower build rate
than expected from similar directional tools run conventionally.
Steering with the casing was easy because little twist was observed between the bottom
hole and surface when the motor was oriented.
For an aggresive build-up directional profile (above 4 deg/100ft), drilling could be initiated
with the conventional Directional BHA , pull out and continue with DwC™ to section TD in the
holding section.
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.
Tubulars and Connections Issues

When designing the casing string for a DWC application, the additional stresses applied to
the casing during the drilling operation must be considered.
Warren et.al. described the mechanics of buckling and fatigue in a DWC operation.
The effect of buckling, wear and fatigue must be addressed to ensure that the integrity of the
casing string is not compromised either while drilling or for the expected life of the well. A
casing failure during the drilling operation would be disastrous; however, limiting the life of
the well due to wear or fatigue on the casing string while drilling would be equally
catastrophic even though not immediately apparent. Calculations show, as expected,
buckling loads are much higher with large diameter casings.
To date most work done with this system has been at shallow depths where casing size is
generally larger.
To date the majority of shallow casing strings have used standard buttress connections
without incident. Some API standard casing threads have been tested to destruction,
showing these connections would withstand three times normal make-up torque prior to
being damaged. For longer casing strings, high torque connections are required. Part of the
engineering process prior to DWC requires a careful analysis of the torque requirements.
Based on the results of the torque analysis, an appropriate connection should be selected. A
number of proprietary connections available "off-the-shelf" that are suitable for most
applications with higher torque requirements.
Subject: SEC NO.
Casing Wear Issue

DwC™ using the casing rotation method could develop a serious casing wear problem while
drilling to the next casing point. The rotating casing will rotate with a rubbing action of casing
couplings against the cemented casing ID when pipe protection is not in placed.
Casing wear is kept to a minimum when DwC™ with Downhole latching assembly whilst the
sassing slides through the cemented casing ID.
The development of reliable casing protectors is required. In most cases they are required
when casing rotation is employed especially for longer drilling period. For a shorter drilling
period, an acceptable casing wear will allow casing rotation with minimum or nor protection.
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.
14. DwC Frequently Asked Questions
Capability
Q. Can you Drill in 30” conductor?
A. Weatherford has designed a 30” x 34” Defyer DT and a Water Bushing drive system to
transmit rotation to the casing however we have not manufactured these products as of May
2008.
Q. Can you directionally drill with casing?
A. The cement in place cannot be drilled directionally in the true sense of the word however
with the Defyer ‘Nudge’ system we can build angle in soft formations by jetting a pocket.
Q. During nudging DwC™ drilling, how to measure and control the azimuth and inclination?
A. There are a couple of ways of achieving this.
The first is to use a simple scribe line from Defyer to surface and drill to TD while managing
the nudge and drilling process. Once the casing has been cemented in place a gyro survey
will display the results.
The second system is more accurate but requires additional set up. A specially modified float
shoe is deployed in the string with a mule shoe landing sub for the gyro tool. Survey can be
run by either running down the casing after the casing drive tool is released or by rigging up
permanently through the top drive and running through the casing drive tool. Both systems
work perfectly well however the latter does require additional hardware.
Q. Can DwC™ be performed from a floating vessel?
A. DwC™ can be performed from a floating vessel if deployed on a liner hanger system or if
the rig is equipped with a surface BOP system. Conventional drilling on a subsea template
requires reaching TD as the wellhead or casing hanger are being landed which is not an
ideal situation.
Q. Why we are not recommending using Kelly rig whereas basically DwC™ can be done on
Kelly Rig with more complex operation will be involved?
A. Although slightly more complex and time consuming DwC™ can be performed on a
Kelley rig. As with all DwC™ operations, sufficient planning, following procedures and the
instructions of the service engineer will ensure success.
Equipment
Q. What are the advantages and disadvantages of following DS and FC assembly and which
one is recommended for DwC™:
Subject: SEC NO.
Q. DS + FC + 1 ea joint 13 3/8” Casing
A. The only advantage of using option (a) is the shoetrack length is very short and therefore
will take much less time to drill out. There is no room for error when displacing cement which
may result in a wet shoe and a poor cement bond around the casing shoe.
Q. DS + 1 ea joint 13 3/8” Casing + FC + 1 ea joint 13 3/8” Casing
A. Option TWO is the preferred method as it allows for slight over displacement. The
equipment used to run a DwC™ job does not differ from a standard casing string and as a
result normal cementing practices should be followed.
Risk
Q. You have just told us the advantages of DwC™ in your presentation, but what is the
disadvantage of DwC™?
Defyer™ System
Advantages Disadvantages
Low Limited directional control

Cost
Simple to Cased hole logs only

operate
No rig modifications Limited Defyer™

required selection
No risk of leaving tools

in the well
Cementing can commence

immediately upon reaching
TD
Q. Is casing easier to differentially stick?
A. Differential sticking should not be a problem as the casing is continually rotated with optimized flow
rates and hydraulics to suit the application. Mud weights can be lowered or managed pressure drilling
(MPD) techniques can be employed to reduce the overbalance.
Subject: SEC NO.
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 ½ 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.
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 1-
1-5 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 it’s 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.
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 doesn’t 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.
Subject: SEC NO.
PRODUCT CHAMPION TRAINING MANUAL LATEST REVISION –
12 Nov 2009
13. Lessons Learned

Ca Incident Where Date Action
se
1 Broken lugs on DS Nozzle wrench Apache Engineering /Manufacturing should address this.
China
2 Broken lugs on DS Nozzle wrench Carigali Aug 03 Engineering /Manufacturing should address this.
Malaysia
3 Cement debris blocks DS nozzles lost 3.5 hrs Carigali Aug 03 Do not pre make up shoe to float collar joint, make it up on rig floor if
Malaysia possible. Check float collar condition.
Carigali
4 O ring leaking on spear Aug 03 Pressure test spear assembly prior to shipment to rig.
Malaysia
Packer cup held pressure and did not bleed
off when debris blocked nozzles. When Build precautionary note into the procedures ‘ ensure pressure is bled
5 Aug 03
picking up out of casing water sprayed rig off prior to documenting the spear’
floor.
Poor rig alignment 6 hours lost time. Bent Brunei Shell Emphasize importance of proper rig alignment at project prespud
6 Aug 03
torque tube Petroleum meeting with rig contractor in attendance.
Only one spare pack off rubber sent for DS3 Brunei Shell Ship at least 3 spare packoff rubbers per spear.
7 Aug 03
test run Petroleum These are cheap compared to potential rig time loss.
Brunei Shell DS drawings should be included in the shipping crate with DS.
8 No drawings of DS available Aug 03
Petroleum Manufacturing should be responsible for this.
Brunei Shell
9 Ball seating Issue with DS3. Aug 03 What is status? Is engineering working on this?
Petroleum
Brunei Shell
10 DS3 Blade displacement Aug 03 What is status? Is engineering working on this?
Petroleum
Grapples and packer cups for specific casing These items need to have full traceablility. Manufacturer’s drawings
wt. On a number of occasions the wrong and packing slips must be verified at shipping dock and receiving dock.
11 General
grapples and packer cups have just about WFT agents need to be trained to ensure correct equipment is
been mobilised. transported.
Poor rig alignment causes difficulties with Refer to Case 6. This issue needs to be communicated in the planning
12 Cairn India May 03
connections phase.
20” Grapples could not pass into the casing.
13 Cairn India June 03 Manufacturing needs to be consulted on this for recommendations.
Segments were found to be incorrectly
Subject: SEC NO.
12 Nov 2009
machined.
Water bushings need to have same inspection inspection procedures
14 Water Bushing leaking Cairn India May 03 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.
Carigali This should be verified as soon as received. The specified size + one
15 Wrong nozzles installed Agst 03
Malaysia size larger and one size smaller nozzles should be shipped loose with
DS.
Chevron
16 Spear Damage lug broke off July 03 Investigations being undertaken
PNG
What is extent of damage and operating parameters under which spear
17 Spear Damage unspecified Indonesia Agst 03
was run?
New 20” Slip segments unable to pass Have Dril-Quip provide dimensional specs. for H-60 connector and
18 Cairn India Agst 03
through H-60 connector verify compatibility with 20” slip segments.
AZ Grapple wickers sitting in threads.
Connectons need to be addressed in planning stage to spear can be
19 Distance from stop plate to top of wickers to OSL PNG Dec 03
properly sized for slip engagement.
short for K Fox connection
Rotating, Pick Up and Slack off weights not
20 OSL PNG Dec 03 Build into Procedures
recorded
DrillShoes shipped without specifying See Case 14. Engineer needs to communicate nozzle design prior to
21 OSL PNG Feb 04
installed nozzles. shipment.
Manufacturing to send DS’s without thread locking nozzles allowing for
22 Nozzles thread locked into DrillShoe OSL PNG Feb 04
change if required.
No torque guide lines given in DwC When DwC Procedures are made up ensure that the torque limitations
23 OSL PNG Feb 04
Procedure. of the Casing are Highlighted
No last casing size on DwC Field Report
24 KL Feb 04 Change the Template and distribute
Sheet
25 PTTEP
Failure of packer cup rubber April 04
Thailand
26 PTTEP
Spear grapple drops out April 04
Thailand
27
Bull Plug ID found to be 1” restricting flow Shell, Miri May 04
28 TorkHead Murphy July 04 Swivel failed. A report completed by Andreas Carlsson. Swive can’t
Subject: SEC NO.
12 Nov 2009
rotate freely even after being dismantled and lubricated. Attributed to

mechanical failure.
No poundage stamped on the grapple, only found serial number and
Wrong wt grapple supplied made up to the
29 Murphy Oct 04 later the poundage after disassembling the grapple on the rig. Installed
spear
backup grapple onto the tool.
Initially suspected the tong marks on the slope of mandrel prevented
the grapple from expanding smoothly. But after grinding away the
Grapple had to be hit down with hammer
30 Murphy Oct 04 marks the problem still exist. Suspected the grapple was pinched
before biting.
somewhat resulting in higher forces needed to make it expand and
engage.
ICDT was ‘sticky’, when attempting to turn left to release the grapple the
casing turned as well. At times casing tong was used to prevent casing
from turning. Slack off the weight quicker seemed to help loosen the
grapples and fix the problem.
Grapple difficult to release. New Weatherford
31 CTOC Sep 04 When attempting to release the spear at the Texas deck after TD, the
ICDT
grapple jammed while it started to come out of the collar, probably due
to the deck not being level. Re-levelled the deck again. Slacked off
weight and tried turning left with high torque (casing pup started backing
off). Pick up with high over-pull and grapple started to come out of the
casing.
6-5/8” box x 4” pin XO was sent instead of requested 6-5/8” box x 4-1/2”
32 Wrong XO was sent to the rig Murphy Nov 04
pin
The E60/MT connector was welded on the ID also, which was not
expected. According to the engineering drawing the weld prep and
20” ICDT Stabiliser blades need to be torch- welding were on the OD only. The internal upset created by the butt
33 Murphy Dec 04
cut to pass through the weld butt. prevented the pack-off stabiliser blades from passing through. The
ICDT was laid down and blades were torch-cut by some 1/8” to solve
the problem.
Subject: SEC NO.
12 Nov 2009
34 20” ICDT not serviced on return from job Murphy
Drag blocks and spring missing from returned package, Murphy broke
down tool as Engineer was sent back to town, back charging for
35 Drag blocks and springs missing from ICDT Murphy June 05
missing equipment.
Mandrel pin sheared as tool was being made-up on drill floor, tool was
20” ICDT, Pin on mandrel sheared as tool
36 Murphy Sep 05 returned to Labuan for repair, 30hrs down time lost due to this incident,
was being made-up.
pin was over torqued in Singapore.
5ft pup joint sheared below the rotary table as 20” spool was being
36 5ft Pup joints Murphy Sep 05 drilled down to setting depth, recommended that only single joints or
heavy weight drill pipe joints be used to set spools below rotary table.
Subject: SEC NO.
12 Nov 2009
Bright Ideas
1 Bit Breaker for Defyer casing bit
2 Tool Box
3 Basket for spear
4 Cheap disposable cover/protectors for cutting structure on DS2
Subject: SEC NO.
APPENDIX 1. Photos of Rock

Subject: SEC NO.
Limestone
Shale (1)
(fossiliferous)
Shale (2) Limestone (crystalline)
Sandstone (1) Mudstone (1)
Sandstone (2) Mudstone (2)

Subject: SEC NO.
Bituminous Coal
Chalk
Gypsum Claystone
Siltstone (1) Halite
Siltstone (2) Rock salt

Subject: SEC NO.
Conglomerate (1) Obsidian
Conglomerate (2) Basalt
Quartzite Granite (1)
Granite (2)
Chert
Subject: SEC NO.
APPENDIX 2. DwC Job Safety Analysis

Subject: SEC NO.
APPLICATION ENGINEER TRAINING MANUAL LATEST REVISION –
12 Nov 2009
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 Consequences Safe Guards

Unrequired equipment left on Potential injury to Prior to rigging up ensure all non essential equipment is
Potential trip hazards
rig floor. Poor house keeping limbs properly stowed away
Ensure all loads are lifted with the correct lifting equipment
Poor handling techniques and suitable SWL
Personnel being struck by Potential serious
Poor communication and Tag lines used when moving equipment / heavy loads around
heavy loads. injury
surrounding awareness Dogman and deck crews to maintain good communication
when lifting loads to and from the drill floor.
All necessary permits in place
Poor communication and
Deck crews to maintain clear communication with crane driver
surrounding awareness Potential serious
via radios or hand signal.
Injury to deck personnel Failure to lifting equipment injury/fatality
Ensure correct slinging of loads
whilst handling tubulars Incorrect or poorly understood from pinch points
Personnel to avoid working under loads
procedures or dropped loads
Beware of pinch points
Mechanical failure
Subject: SEC NO.
12 Nov 2009

Ensure correct SWL of lifting equipment.
Mechanical failures to lifting Pre job checks have ensured that the correct SJE are being
equipment. used and that they are in good working order.
Mechanical failures to single Ensure safety pin is inserted prior to hoisting casing into V
Injury to deck personnel
joint elevators. Incorrect Potential serious Door
while hoisting tubulars to
type/size. injury / fatality Tugger driver to ensure personnel are clear of catwalk prior to
rig floor.
Swinging loads hoisting casing up V Door
Incorrect use of lift nubbin 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
Poor communication and
Ensure klepo remains on whilst being hoisted up V Door.
surrounding awareness
Injury to floor personnel Alert driller if klepo falls off.
Incorrect fitting of Klepo Potential serious
whilst hoisting tubulars into Ensure tail in rope is of adequate length to tail the casing in
Inadequate length of tail in injury / fatality
the derrick all the way to the rotary table
rope
Driller to maintain good vision of casing coming up V Door
Inattentiveness by Driller
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
Injury to personnel whilst Potential serious
Inattentiveness by Floorhands Pipedeck.
Lowering klepo down V injury from
Poor communication Always use a rope to lower the klepo down the V Door
door dropped objects
Alert deck crews when lowering klepo down
Subject: SEC NO.
12 Nov 2009

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
Incorrect hand position
Potential serious Hands to well clear of the pin and collar whilst stabbing the
Injury to hands/fingers Inattentiveness by driller
injury to joint into the stump. Driller to watch this prior to lowering the
whilst stabbing joint into Inattentiveness by Floorhands
hands/fingers/fee joint
stump Incorrect PPE
t 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
Inattentiveness by tong
Injury to floor personnel will be identifiable by green paint.
operator
being struck by power tong Potential serious The tong operator will have explained the correct use of the
Inattentiveness by floor hands
whilst guiding tong on and injury handles and door latching methods.
Poor communication
off the pipe Tong operator to adopt a position where he maintains control
Surrounding awareness
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.
Subject: SEC NO.
12 Nov 2009
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
Inattentiveness by tong Potential serious
Injury to floor personnel standing clear of the tong
operator injury to upper
during make up of If a back up tong is being used the tong operator will not
Incorrect hand position body.
connection with power commence rotation of the pipe until the backup tong has a
Mechanical failure Serious injury to
tong bite and Floorhands are standing clear
Surrounding awareness hands/fingers
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.
Incorrect or poorly understood
procedures Correct PPE and lifting techniques to be used.
Poor line of Pipe not to be moved while installing centralisers
Injury to personnel from Potential serious
sight/communication Sufficient personnel for the job
centralisers injury
Inattentiveness by rig crew or Hole cover over rotary table to prevent dropping nails or
driller hammer into well.
Incorrect hand positing
Subject: SEC NO.
12 Nov 2009
Casing stabber and driller to maintain good communication.

Refer to stabbing JSA
Driller to ensure that he has taken the weight prior to
releasing the slips. Floorhands to maintain good
communications with driller during this operation.
Personnel to stand clear of rotary table whilst casing string is
being lowered into the hole.
Inattentiveness by Stabber When setting down the weight in the slips Floorhands to
Potential serious
Inattentiveness by Driller ensure that their hands are in the correct position on the slip
injury/fatality
Dropped casing string Inattentiveness by Floorhands handles to set the slips.
Operational
Poor communication If using Power Slips / Manual Slips floormen to observe slips
delays
Potential mechanical failure set correctly and alert Driller if problem arises
Driller to ensure that when running flush joint pipe adequate
clearance is maintained between the safety clamp and the
slip body prior to setting down weight and releasing the
elevators.
A good practice is to place the safety clamp after the weight is
set down and prior to the elevators being released.
Ensure lift nubbin is removed prior to picking up the next joint
IF A CASING STABBER IS REQUIRED, PRIOR TO THE RUNNING OF ANY PIPE THE CASING STABBING JSA WILL BE COVERED
Subject: SEC NO.
APPENDIX 3. DwC Data Request Form

Subject: SEC NO.
Issue A
Title: Drilling with Casing Data Request Form Rev 6.0
Page 1 of 1
Number: Date 1-Oct-08
1. CLIENT
Company Phone No.

Engineer Email
2. WELL AND LOCATION
Number of Wells 1 Block / Permit

Batch Drilling Yes No Field
Well / Project Name Spud Date
Well Category Wellhead Type
Country
Primary Objective
Secondary Objective
Logging/MWD/FEWD ? Yes No Directional control ? Yes No
Potential Hazard 1 Potential Hazard 2
3. RIG
Rig Name RT to SS 2894.27 [m]

Rig Type Semi-submersible Spread Cost, USD
Water Depth 1109.54 [m] Top Drive connection
Equipped with Top Drive Yes No Tubular Running Com.
4. TARGET CASING & LINER
Csg OD [mm] Wt [kg/m] API Drift [mm] Min ID [mm] Grade Connection Hole OD [mm] Incl [deg] TD [m]
Conductor
139.700 25.299 121.082 660.4 1599.81
Csg OD [mm] Wt [kg/m] API Drift [mm] Min ID [mm] Grade Connection Hole OD [mm] Incl [deg] TD [m]
Surface Casing
244.475 64.735 218.408 444.5 2338.16
Intermediate Csg OD [mm] Wt [kg/m] API Drift [mm] Min ID [mm] Grade Connection Hole OD [mm] Incl [deg] TD [m]
Casing 339.725 101.195 311.372 311.15 163.07
Production Csg OD [mm] Wt [kg/m] API Drift [mm] Min ID [mm] Grade Connection Hole OD [mm] Incl [deg] TD [m]
Casing or Liner 609.600 281.263 566.738 215.9 1805.82
5. OFFSET INFORMATION FOR FEASIBILITY AND DRILLABILITY STUDY
Rock Strength Analysis Digital Drilling Data Daily Drilling Report

Sonic Log Bit Record Density Log
Mud Log
Remark
Subject: SEC NO.
APPENDIX 4. DwC Job Report Form

Subject: SEC NO.
Issue A
Title: Drilling with Casing Log Rev 6.0
Page 1 of 1
Date Version 5.0
WELL INFORMATION
Operator Anadarko Drilling Contractor

Well Name Merica-1 Rig Name Ocean Sovereign-169
Job Type DwC Rig Type Jack-up
Hole Size 20 in Water Depth 60.00 m
Max Hole Angle 0.00 ° RKB - ML 100.58 m
Country Indonesia Formation Name/Age Pliestocene
Field / Block NE Madura III Rock Type Clay
EQUIPMENT
TFA
Drill Shoe Size 24 in Nozzle Qty 4 2
0.994 in²
Drill Shoe Type 2 Nozzle Size, 1/32" 14 16
Drill Shoe S/N 9093063 3
Casing Category Production Spear Size 9 5/8 in
Casing Size 20 in Slip Catch Range 36 - 40 ppf
Casing Weight 203 ppf Slip Part No. 888620
Casing Grade X56 Slip Serial No.
Casing Connection E60/MT Spear Part No. 209-725-001
Spear Type Logan Spear Serial No.
DWC B.H.A.
BACKGROUND READINGS
String Weight [klbs] Torque [ft.lbs] Pressure [psi]

Start 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
MUD PROPERTIES
Mud Type Wt [ppg] PV YP Viscosity Water Loss % Sand % Solid H2O / Oil
SW 8.60
TIMINGS & SWEEP
Run Date & Time

Run-In-Hole 18-Jul-06 8:00 PM Total Connections 15 Volume / Sweep [bbl] 188
Start Drilling 19-Aug-06 12:00 AM Estimated Time / Connection 8.0 min Joints/ Sweep
Reach TD 19-Aug-06 6:00 AM Total Connection Time 2.00 hr Sweep @ TD
RUN RESULTS
Total (IADC) On Bottom

Depth In [mRT] Depth Out [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] RPM Torque [ft.lbs] 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. :

Subject: SEC NO.
Issue A
Title: DRILLING w CASING LOG Rev 6.0
Page 1 of 1
DRILLING w CASING LOG

Company: - Well: - Casing Size: 20
Drilled 89.0 m 292.0 ft Hrs OB 1.09 AV ROP 81.5 m/hr 267.3 ft/hr
ROP , RPM FLOW , SPP

0 100 200 300 400 500 600 700 0 200 400 600 800 1000 1200
70 70 70 70
ROP, m/hr Flow, gpm
RPM SPP, psi

80 80 80 80
WOB, klbs TRQ, ft-lbs
90 90 90 90
100 100 100 100
110 110 110 110
120 120 120 120

Depth,m
Depth,m
130 130 130 130
140 140 140 140
150 150 150 150
160 160 160 160
170 170 170 170
180 180 180 180

0.0 2.0 4.0 6.0 8.0 10.0 12.0 14.0 16.0 0 500 1000 1500 2000 2500 3000
WOB, klbs TORQUE, lbfts
Subject: SEC NO.
DwC Assembly Schematic Issue A

Title: Modified DwC Spear Rev 6.0
Page 1 of 1
Client : Well No : ML : mRKB

Client Rep : Rig : Depth In : m
Country : Loadout Date : Depth Out : m
Field : Job # : Mud Type :
Note: Complete coloured cells Casing Drilling String Configuration

Torque OD ID Box Pin Length Weight Serial Nozzles / Backup
String Component Description
(ft.lb) (in) (in) Conn. Conn. (m) (ppf) No. Port Size Y/N?
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. LEGEND
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. Required information
Essential
Prepared By : Date : Checked By : Date :

Subject: SEC NO.
APPENDIX 5. Defyer™ DPC Milling Assembly

Subject: SEC NO.
Milling BHA For Defyer DPC
Weatherford Department: Fishing Services
9 - 12 Drill Collars
(“Casing Drift OD”) String

Stabilizer 4 ½" Reg. Box X
Pin Connection
Crossover Bitsub 4 ½"

Reg. Box X Drill Collar
Connection Box
Boot Basket Approx. 6 5/8”

OD 4 ½" Reg. Box X Pin
Connection
(“Casing Drift OD”)

Flat Bottom Semi-Conebuster Bladed Rough
OD Ground Half Smooth
4 ½" Reg. Pin Connections
ISSUED BY: DATE: REVISION No.: APPROVED BY: SIGN/DATE:

PAGE 1 OF 1
Subject: SEC NO.
Tool Specification
Weatherford Department: Fishing Services
8 1/2" OD Flat Bottom Semi-Cone Buster Bladed Junk Mill

Rough OD Slightly Ground
Specifications
Connection : 4 1/2" REG
Dressed to : 8 1/2" OD
Body OD (fishing neck) : 5 ½" OD

Length of fishing neck : 18" minimum
Body ID : 2 1/4" ID
Stabilizer blade OD : 8 3/8" OD
Dressed with : Tungsten carbide
Length of tool : 36" minimum
Make-up torque (FT/LBS)

Top connection (rotary conn.) : 15,000
(4 1/2" REG)
ISSUED BY: DATE: REVISION No.: APPROVED BY: SIGN/DATE:

PAGE 1 OF 1
Subject: SEC NO.
APPENDIX 6. Roller Cone Bit IADC Chart

Subject: SEC NO.
12 Nov 2009

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Subject: SEC NO.

DRILLING WITH CASING PAGE 1 OF 115

Rev No. Date Originator Reviewed By: Approved By:

1 12 Nov 09 Ming Zo Tan

Other Drilling Equipment ................................................................................................57

Figure 43 Model M42A0 Mid Bore Auto-Fill Float Collar.....................................................76

2. Key Drivers for Drilling with Casing

Reduce Drilling Flat Time

DwC vs Conventional Drilling Time DwC vs Conventional Drilling Time

0.0 Conv 0.0 Conv

Figure 1 DwC Total Connection Time Saving

These are purely connection time savings.

Figure 2 DwC vs Conventional Drilling

Getting Casing to Bottom

Elimination of Problems Related to Tripping

Drilling Depleted Zone and Overcoming Lost Circulation

Better Borehole Quality

Reduce Rental Costs

Table 1 DwC AV vs Conventional AV

Hole OD OD Flow Annulus Area, in^2 Vann, ft/min DwC Vann

Figure 3 Annular Velocity Comparison

3. Casing Design Fundamentals

Casing in a well serves several important functions:

Casing Strength Properties

Ultimate Tensile Strength

Figure 4 Load-Elongation Curve of Casing

A casing is specified by the following parameters:

 Outside diameter and wall thickness

P = 0.0519  h , where  = mud weight, ppg

The burst pressure requirement is normally based on two major considerations:

1. bending with tongs during make-up

Casing Seat Selection

Pressure Gradient (psi/ft)

Figure 5 Casing Seat Placement Chart

Example of Casing Grade and Weight Selection

Table 2 Sample Casing and Mud Programs

Hole Size TD depth Casing Size Mud weight

Formation fluid gradient:

0-6200 ft Pf = 0.465 psi/ft

Collapse Pr essure  0.0519  mud weight ( ppg )  depth ( ft )

Collapse pressure at surface = 0

Collapse pressure at TD = 0.0519 x 8.96 x 6200 = 2886 psi (199 bar)

Table 3 Collapse Resistance Including Safety Factor

Collapse resistance (psi)

Figure 6 Casing Grade Design Chart

Formation pressure from next TD

= 10400 ft x 0.480 psi/ft

Burst at shoe = internal pressure – external pressure

Figure 7 Formation Pressure from Next Section TD

External pressure = CSD x 0.465

External pressure = 6200 x 0.465

Burst at surface = internal pressure – external pressure

Internal pressure = Pf – (TD) x G

Burst at surface = Pf – (TD) x G

Table 4 Burst Pressure Including Safety Factor

Burst resistance (psi)

0-3050 ft K55, 54.5#

On the basis of burst only, Figure 6gives the following selection:

0-2400 ft L80, 72#

Table 5 Selected Casing Grade and Weight

Depth Grade and Weight Weight in Air (lb)

Table 6 Selected Casing and Calculated Safety Factor

Weight of Safety factor = yield