SPE 139020

Casing-Drilling Application in the Depleted La Cira Infantas Mature Field,

Colombia
E.A. López and P. Antonio Bonilla, Occidental de Colombia

Copyright 2010, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Latin American & Caribbean Petroleum Engineering Conference held in Lima, Peru, 1–3 December 2010.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or
members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is
restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Field redevelopment reflects the unique foci of the integrated project team built between Ecopetrol and Oxy to redevelop the LCI
oilfield. La Cira Infantas (LCI) is the oldest Colombian field, production started almost at the beginning of the twentieth century
and since late 2005 is under a redevelopment phase, increasing production by more than 5 times in less than 5 years.
Redevelopment involves over 1500 wells being drilled or worked over in order to increase recovery factor by about 8% from the C
sands. Hundreds of wells are scattered throughout this brownfield which is divided in two principal areas, Cira and Infantas. This
field is crossed by faults characterized by depleted and shallow gas bearing formations, challenging drilling with loss of circulation
and well control issues, somehow unpredicted given the faulty nature of the area and the impact on the producing sands of
previous EOR and drilling campaigns (early to mid twentieth century) (Fig. 1).

This paper will describe the benefits of using the casing while drilling technology to drill wells where loss of circulation is
anticipated, successfully eliminating flat times that otherwise would be used to cure losses when drilling conventionally due to the
smearing effect which is enhanced by the addition of bridging agents and loss circulation material; and setting casing at the
planned TD.

Drilling with casing has shown that 10% cost reduction and 30% time savings were achieved against conventional drilling,
with additional potential to reduce costs and time by improving the operational times employed for drill-out, BHA recovery, and
cementing operations.

Project Development
Redevelopment in LCI has greatly leaned on drilling; there is much more drilling activity than workovers as a result of the success
of the drilling campaign. Successful drilling stands on the following aspects of managing a drilling program: offset data analysis,
application of drilling practices, deployment of technology, and cost control. Focusing on offset data analysis is the key for
developing a successful drilling program since this is the only information available about the actual behavior of the formations to
be drilled. Focusing on drilling practices enhances the chances of success. Deployment of technology allows to obtain step changes
needed to boost drilling performance, and efficiently managing drilling costs makes the continuity of the project attractive to the
Operator.

A variety of practices and technologies are being implemented to achieve significant improvements in drilling wells: drilling
mud formulation, state-of-the-art drilling rigs, drilling bits and BHA design, engineered drilling practices, and contractors
management to name a few.
2 SPE 139020

LA CIRA AREA

INFANTAS AREA

MAIN MUD
LOSSES AREA

Fig. 1– La Cira-Infantas Location. Middle Magdalena Valley.

A 5-well project performed with casing while drilling was designed and executed in order to address issues such as borehole
stability, lost circulation, fluids control and the need to get past troublesome formations, ultimately leading to evaluate the casing
while drilling technology and its application in LCI, the pilot project consisted of various wells to provide a consistent learning
curve and implementation of learning and practices. All the wells reached the geological targets and the production casing was set
at the required depths, in addition real-time formation evaluation data was acquired.

The pilot project provided the grounds to solving design and operating problems and starts an optimization process to make the
project attractive. Careful planning detail and collection and implementation of learning was essential to the success of the project
given the fact that a large percent of the deficiencies in the execution process are due to the lack of project definition and planning
rather than poor operations. The execution of the drilling programs required significant planning sessions and daily post appraisal
meetings at the rig site and contact with the office upon completion of each well step, developing a very strong and consistent
learning curve thus when losses were experienced the methodology to drill with casing was already in place. (Fig. 2).

12

11

10

8 AVG: 5.1 Days AVG: 6.4 Days

6
11.21

5
8.98
8.44 8.22
4 8.02
7.56 7.56
7.13
6.54
3 5.71 5.85 5.58
5.15 5.08 5.27 5.15
4.27 4.29 4.58 4.52
2 3.69 3.60 3.54

Cw D 1 Cw D 2 Cw D 3 Cw D 4 Cw D 5 Well 1 Well 2 Well 3 Well 4 Well 5 Well 6 Well 7 Well 8 Well 9 Well Well Well Well Well Well Well Well Well
10 11 12 13 14 15 16 17 18

Fig. 2-Drilling Days CwD vs. Loss Circulation Wells.

SPE 139020 3

Well Engineering
Essential to the application of technology is proper engineering and risk analysis. Drilling with casing demands the same basic
engineering required to drill any well, however was necessary for this project to pay close attention to the next challenging
process:

Casing Design. The casing is the same used to case any well in the LCI field, but to be able to withstand the extra stresses due
to the high RPM’s, rig capacity needs to be checked and drilling torque simulations for different situations must be performed, the
main answer form this is the use of torque rings wich provide metal-to-metal contact in the buttress connection increasing the
torque limit at the connection. Also, cold welded stabilizers/centralizers are placed along the BHA to improve standoff for
cementing.

Well Control. The well control barriers were identified for all circumstances, including the case when the BHA is being
retrieved (Thread Casing Drive function).

BHA retrieval method and procedures. Defined hanging procedure for the casing prior to retrieve the BHA. In the pilot project
the drill pipe method to retrieve the BHA instead of the wire line method was elected due to availability and positive feedback
from other Oxy Business Units across the world.

Cementing. Set a double check valve cement retainer to act as float equipment with wireline prior to the cementing job.

Optimization of the directional profile, which results in a more efficient operation and also meets the geological objectives of
the well.

Drilling fluid and solids control, selecteing not only the most compatible drilling fluid to insure good hole cleaning and
chemically stabilizing the hole but also the right rheological properties to insure a successful execution of the well program.

Logistics. Insured the materials and equipment were ordered on a timely basis, selecting vendors and service companies who
have the ability to supply goods and services promptly.

Issues
Lost circulation is the loss of whole mud from the annulus into a formation. The losses in Infantas field can occur into formation
voids (vugs to caverns), into fractures (either natural or created), or into gravel beds. Losses into natural or created fractures are
initially relatively slow but increase in severity with time.

Losses occur mainly when drilling through depleted sands or in the vicinity of faults. Lost circulation problems related to
drilling through depleted sands are compounded by the low fracture gradient in the sands and the high mud weight required to
minimize compressive failure in adjacent shales. Losses can also be natural -almost impossible to prevent -,and induced.

For depleted sands, the best way to manage lost circulation is to prevent, rather than cure, the problem.

Preventing induced losses means preventing the accumulation of wellbore pressures from exceeding the fracture strength of the
exposed formation. The accumulation of wellbore pressures results from a combination of hydrostatic pressures including:
• cuttings loading in the annulus
• friction pressures while circulating
• plugging the annulus with mud rings in high fluid-loss zones or large “chunks” of shale that have heaved into the
borehole as a result of formation sensitivity to the drilling fluid
• surge or swab pressures while moving the drillpipe

In hydraulic fracturing, as in lost circulation in natural or created fractures, there are four factors that contribute to fracture
width: volume, viscosity, and velocity of the fracturing fluid plus the differential pressure across the fracture face. To permit
closure of the fracture, any of these factors must be decreased. Because the volume or viscosity of the fluid that has passed through
the fracture can’t be changed, the only alternative is to attempt to change the velocity of the fluid and/or the differential pressure
across the fracture face to alter the lost-circulation problem. When fractures are opened during drilling, either natural or induced,
the rate of lost circulation increases dramatically with time due to the volume of mud lost into the fracture. For this reason, the
sooner a lost-circulation problem in fractures can be stopped, the easier it will be to stop the problem.
4 SPE 139020

Risks associated with loss circulation are managed by preparing a detailed drilling procedure consisting of matched drilling
parameters per formation and strict adherence to the mud program since it differs from the one used in wells drilled with
conventional technology; the main changes are related with the mud weight window and tight ECD control due to the major
pressures losses in the annulus rather than inside the BHA.

The "smear effect" is a phenomenon seen in casing drilling, usually in sand-shale sequences. Cuttings generated with CWD are
unusually small, while those returned to surface with conventional drilling are much larger. Because of the CWD side-load forces,
the cuttings are pulverized in the narrow annulus and as they travel toward surface the particles apparently become embedded in
the wellbore wall and help form a natural seal that is much more impermeable than a wall cake produced by mud additives alone.
The interesting feature is that of achieving significantly reduced losses despite running higher than normal ECDs. (Fig. 3)

Fig. 3–Cuttings size CwD.

Case History
Mud losses were experienced in the fourth well of the CwD campaign; for this well the surface hole was cased with a 9-5/8”, 36
Lbs/feet casing to 336 feet. Then production hole started with a conventional directional assembly with a 9-7/8” bi-center bit from
336 feet to 1,119 feet, reaching an inclination of 17.4°. After pulled the conventional assembly, the production hole was continued
drilling with the CwD assembly composed of a 6” PDC bit, 4-3/4” rotary steerable system, MWD-LWD operated with
electromagnetic telemetry. This assembly was hanged at the bottom of a 7”, 26 Lbs/feet production casing to 3,548 feet (TD). (Fig.
4)

Locking M echanism – BHA part BHA (~140 ft long)

Drill Lock
Pony DC M onel UR M WD/L WD RSS
Assem bly (DLA)

Internal
Stabilizers

Locking M echanism – Casing part

Pup Joint Casing Profile CSG Shoe Joint Directional

Nipple (CPN) Guide Shoe

Fig. 4–Casing While Drilling BHA with RSS + MWD/LWD BHA.

The 6” bit was fitted with interchangeable nozzles, being the TFA equal to 0,407 in2. The average ROP with this bit was 78,5
ft/hr. In this well the drilling operation was interrupted due to partial mud losses and complications due to a piece of rag being
stuck in the float valve.

In the first three wells of the CwD campaign the cement retainer was set using the pipe tally to correlate the CCL log in depth;
for this particular well a 11 ft pup joint was included in the casing string to correlate the depth, which proved to be an easier and
faster way to set the cement retainer.
SPE 139020 5

Mud Losses
While drilling at 1,743 feet mud losses in the order of 200 bbl/hr were observed, drilling was stopped and 40 bls of LCM pill were
pumped. Then, was continued drilling to 1,756 feet where the cumulate of losses was 200 bbl. Moreover, was drilled to 1,831 feet
losing 75 bbl/hr where another LCM pill was pumped on the fly; after that continued drilling with partial losses of 52 bbl/hr to
1,981 feet where another LCM pill was pumped on the fly reducing the mud losses to a rate of 28 bbl/hr while continued drilling to
2,095 feet, finishing with a rate of losses of 10 bbl/hr when reached 2,545. In this well the directional BHA length was 138 feet
thus once the well was drilled to 1,881 feet the casing was reaching the top of the thief zone and curing through the smearing effect
started. Was noticed that once the casing past 1,981 feet, was no necessary to add more LCM pills to the system.

Total losses were in the order of 570 bbl whereas the average losses in both fields is in the order of 1,480 bbl per well. The
following features in regards to the smearing effect were identified:
• Losses are reduced even with higher ECD’s (12 to 13 ppg instead of 9.5 to 10.0 ppg).
• Filter Cake is smeared into the wall and is not scraped off by bit passage or tool joint impacts.
• Cuttings are grounded up finer and less cuttings volume returns to surface, they have nowhere to go but into the borehole
wall.

The losses lasted as long as the directional BHA passed by the thief zone, diminishing the losses due to the effect of the LCM pill.
However, once the casing passed by the thief zone, losses had halted, thus eliminating the need of pump additional LCM pills,
drilling stops to spot and cure losses before continue drilling and perceived formation damage. NPT caused by losses can reach up
to 50% of the duration of the well, and since there are shallow gas bearing formations, well control is certainly a risk always
present. In this case losses were cured quickly and there was no need to perform any well control operation because the mud
column was always constant. (Fig. 5)

500

450

400

350

300
AVG: 229.5 US/ft AVG:261.9 US/ft
250

413
200 397
376
338
150 307
273 262
256 256
243 236 233
223 217 222 215
208 211 207 207
100 180
198
182

50

Cw D 1 Cw D 2 Cw D 3 Cw D 4 Cw D 5 Well 1 Well 2 Well 3 Well 4 Well 5 Well 6 Well 7 Well 8 Well 9 Well Well Well Well Well Well Well Well Well
10 11 12 13 14 15 16 17 18

Fig. 5–Cost/ft CwD vs. Loss Circulation Wells.

Challenges
When drilling into the thief formations where losses are experienced there is also loss of hydrostatic pressure; the gas from the
shallow gas bearing formations, below the surface casing shoe, start to flow at low pressure. Thus, drilling is affected
simultaneously by influxes and mud losses, which requires additional time and resources to control. Some times the BHA’s have
experienced attempts to become differentially stuck while performing well control because the rig is equipped with a conventional
BOP stack where the string must be static to prevent damage to the pipe rams or the annular preventer. As the Casing While
Drilling technology has been identified as a potential alternative to drill the wells in areas where mud losses are anticipated, a
rotating BOP must be installed on top of the annular preventer in order to close an rotate the casing at all times while circulating to
control the well, thus, eliminating the risk to get stuck with an expensive assembly.
6 SPE 139020

Conclusions
Casing drilling can be applied in any drilling project, anywhere in the world, allowing the re-development of a depleted mature
field with wells in which mud losses are anticipated, employing less time and reduced cost than conventional drilling, making the
redevelopment of this type of fields attractive to operators whose campaigns would be compromised by the costs associated to
mud losses.

Drilling with casing has showed that a 10% cost reduction and a 30% time savings were achieved against conventional drilling,
with additional potential to reduce costs and time by improving the operational times employed for drilling-out, BHA recovering,
and cementing operations.

This technology can be applied in all vertical or deviated wells where mud losses are anticipated. The success of the
application is owed to the fact that drilling does not stop, and the tools in the drill-string as well as the resources available allow to
continue drilling while curing, in parallel, the mud losses. These factors made this application competitive against conventional
drilling, and allowed to drill safely through troublesome formations, ultimately leading to make the redevelopment project in this
field attractive for the Operator.

Acknowledgements
The authors would like to thank Ecopetrol and Occidental management including the service companies who committed to the
project and the contributions made by their representatives and all our colleagues at every level in the project.

References
1. Tessari. R. M., Madell, Garret, Warren, Tommy, “Drilling with Casing Promises Major Benefits”, Oil and Gas Journal, Vol.
97 No. 20, May 17, 1999, pp 58-62.
2. Laurent, M, Angman, P, and Oveson, D., “Hydraulic Rig Supports Casing Drilling”, World Oil, Sept. 1999, pp 61- 66.
3. Warren, Tommy M., Angman, Per, and Houtchens, Bruce. 2000. Casing Drilling Application Design Considerations. Paper
IADC/SPE 59179 presented at the IADC/SPE Drilling Conference and Exhibition, New Orleans, Louisiana, USA, 23-25
February.
4. Robert Strickler, Todd Mushovic, Tommy Warren, and Bill Lesso. 2005. Casing Directional Drilling Using a Rotary Steerable
System. Paper SPE/IADC 92195 presented at the SPE/IADC Drilling Conference and Exhibition, Amsterdam, The
Netherlands, 23-25 February.
5. López E., Bonilla P., Castilla A., Rincón J., 2010 “Casing Drilling Application with Rotary Steerable and Triple Combo in
New Deviated Wells in Cira Infantas Field” Paper SPE 134586 presented at the SPE Annual Technical Conference and
Exhibition held in Florence, Italy, 19-22 September 2010.