Drilling with Casing

Reduces Cost and Risk

OVERVIEW
TESCO CASING DRILLING
Asia Pacific Business Unit
DOUG REID
Casing Services Manager
Office: +62 21725 5454
Mobile: +62 811841151
Email: [email protected]

LONNIE WERCHOLUK
Casing Services
Office: +65 6333 7500
Mobile: +60 12 327 9612
Email: [email protected]

ANDREW HARRIS
CASING DRILLING Engineer
Office: +65 6333 7502
Mobile: +65 8138 8710
Email: [email protected]

Outline
Overview of Tesco Corporation

What is and Why drill with Casing

Definition of a good CASING DRILLING Candidate

Available Systems, Commercial Experience

Overview of Casing Drilling Equipment and operations
CASING DRILLING Project planning
Case Histories
Summary / Conclusions

Who Is Tesco?
Tesco Corporation is a global leader in the design, manufacture and service
of technology-based solutions for the upstream energy industry. With a
strong commitment to creating exceptional value, Tesco is able to leverage
in-house research and development to take innovative solutions from
concept to commerciality.

Houston Facility

Calgary Facility

Machining Facility - Calgary

Defining features. . .
Tesco Corporation

A Service Company with global infrastructure

Over 1600 employees, operating in 23 Countries

Pioneer and leader in portable Top Drives, CASING

DRILLING , Casing Running Services

An award winning and strong technology based

organization

Over 100 Patents/ Patents Pending

21 Technical Papers

World Oil 2002 Next Generation Idea Award

Unique combination of services that include the

power train from the Top Drive, to Casing Running to
drilling a well with Casing.

DRILLING WITH CASING - A Definition

A rotary drilling process:

That cases the well as it is drilled
Where the well casing is the drillstring
Where the casing provides hydraulic energy and mechanical
force to the cutting structure

CASING DRILLING
A rotary drilling Process

All BHAs are tripped through

the casing without removing it.

The BHA can be Rot. drilling

assembly, Motor and RSS
directional assembly, etc.
At casing point the BHA is
pulled and the casing
cemented in place.

CASING DRILLING Candidate Selection

The Good Candidate

Wells with Borehole Stability Problems

Wells with significant Lost Circulation

Wells where depleted/ normally pressured zones are encountered

Wells where CASING DRILLING can eliminate a casing string through

slimming down well design

CASING DRILLING eliminates problems related to tripping as BHAs are

trip in/out of the hole inside casing

Utilising a small rig Single mast, small pumps, Limited Horsepower

Available Casing Drilling Systems

Casing String

Non Retrievable Drillable Casing Shoe

+ No rig modification, very easy to implement
+ Can drill out for subsequent casing strings
- Vertical holes only and 1 bit / hole section

Drill Lock
Assembly
Casing Profile
Nipple

Internal
Stabilizers

Directional Retrievable BHAs

Level 3 & 4
+ Allows for multiple bit/bha changes

Casing Shoe

+ Allows directional control, LWD

+ No Rig Modifications Required

Casing String

PD Motor

Under- Reamer

Roller Reamer
Float Collar
MWD / LWD

Tesco XCD diamond enhanced

CASING DRILLING Bit

designed to drill soft to medium-soft

Rotary
Steerable

formations at high rates of penetration

7,500psi UCS
D-exp < 1.0

PDC Pilot Bit

- Requires up-front Eng. / planning.

Levels of CASING DRILLING Systems

CASING DRILLING Experience

3,000,000 plus feet drilled

26
67
7
600
37

332

Casing Drilled with

Rotary Steerable Tools

Directional CASING DRILLING

Drilled while Coring with Casing

Drilled with retrievable assembly

Drilled with drillable shoe. i.e. XCD2, EZ Case

Drilled with disposable bit

Complexity
Updated May 2009

Reaming Tools Level 1

TESCO can provide a selection of
tools best suited to the well bore
conditions to ensure that the
casing string can be run or drilled
to bottom.
Tescos XCD 2
Casing Drill

Tescos Warthog
Casing Reamer

XCD Drillshoe Level 2 Drill-ins

Features of the XCD2
Body made from forged Steel
Spiralled blades to minimise Vibration
Premium PDC cutters lead / gauge of blades
Nose set with TSP diamond cutters
Coated with high density tungsten carbide
Fitted with Nozzles for hydraulic optimisation

Formations of up to 7,500psi UCS

Level 3
CASING DRILLING Retrievable

5 1/2"Casing

Motor Assembly

Drill Lock Assembly

Casing Profile Nipple

l
Top Sub
Quick Release Connect
Bypass Seal Assembly
Axial Lock
Stop Dogs
Torque Anchor

Drill Collar

Jar
Casing Shoe

Stabilizer Sub

MWD

LWD

PD Motor (Bent Housing)

Under-Reamer
PDC Pilot Bit

Setting and retrieving Overview

LEVEL 3 Drillpipe conveyance

PDC Cutter Design

Type 5 Underreamers Design Considerations
Bit Selection & Rock Strength analysis

Match Bit / Underreamer cutter

Include Premium cutters 13mm / 16mm / 19mm

Type 5 19mm Cutter

Type 5 Dual 13mm Cutter

NOTE: Hess Indonesia 17 1/2 Type 5 formations up to 30,000psi

NOTE: Shell Rocky Mtns USA 8 1/2 Type 5 formations up to 20,000psi

Casing Drive System Features & Benefits

DESIGNED FOR CASING DRILLING

Fast rig up and rig down!

Connects directly below the Top Drive

Adapts to All Top Drives rig survey req.

WILL MAKE UP THE CASING No Tongs!

Eliminates conventional casing running equipment:

Allows simultaneous rotation and circulation of casing

CAN REAM & PERFORM WIPERTRIP WITH THE CASING

API 6 5/8 REG RH CONNECTION

HYDRAULIC ACTUATOR

LENGTH 10

Performed 600 jobs in AP 450 with Premium Conn.

TRIP & TORQUE GRAPPLE

North America extended reach liner record

6,790m (md) with a 1,696m(tvd)
PACKER CUP

10 x 9 5/8 L-80 Csg, c/w Hydril 563 connections

Key Success Ability to rotate the csg to reduce
Frictions

STABBING GUIDE

Internal Drive Tool

7 20

Game Changing technology that makes

Operations Safer

Eliminates
Stabber in derrick
Power Tongs
Traveling Rig Elevators
Elevated Work Platforms

Casing Fill-up tools

Rig Floor hands
Circulating head

Reduces
Risk of Stuck Casing
Risk of not getting casing to TD
Well Control Incidents

Fewer Lifts to Rig Floor

- CDS w/ travel frame ready to
lift from the catwalk

- CDS on rotary table for rig up

. Running 9-5/8Vam Top Casing .

1. Pick Up CDS.
2. Make up CDS to top drive.

3. Place joint in V-door with crane.

4. Hoist Joint with CDS.

. Running Casing

5. Tail in joint.

6. Stab joint.
7. Stab CDS.
8. MU & Tq connection.

Uncluttered Floor While Running Casing

Project Selection / Engineering Overview

Project Selection and Planning

Identify fundamental driver
Economics

Review Conventional NPT times vs CASING DRILLING Time /

cost benefits

Technical

Optimize the well plan for CASING DRILLING

Curvature limitations
Torque and drag
Stress Analysis
Hydraulics
Drilling assembly selection

TESCO CASING DRILLING ENGINEERING SOFTWARE

Provide complete Engineering review

of CASING DRILLING well program:
Casing Design
Casing Connections
Bits, Mud, Cementing Programs
Directional Program
Hydraulics Sensitivities ECD/ AV

Well Control
Torque and Drag Analysis
Fatigue
Buckling and Wear

Overview Well Control Level 3

CASING DRILLING Well Control

Five Scenarios in CDWC where potential for a Kick Level 3
Drilling, 0n-bottom BHA locked into casing
Tripping the Dir. BHA on DP False rotary table
Handling the BHA on surface False rotary table
Out of hole with BHA, open ended Casing String
Tripping the BHA, with the Casing Hung in wellhead

Detailed plan with all rig personnel as to the correct monitoring of the well,

Mitigations to prevent an influx and Actions to be taken in case of a

Kick.

CDWC - Scenario 1 Drilling on bottom

An example.
Primary Barrier

Drilling Mud wt.

Secondary Barrier

BOP Casing Rams

Casing Drive System (CDS)
DLA Pack-offs
Float in BHA
Competent Shoe

Action to Take (if a kick occurs)

Risk Mitigation in Place (to prevent a Kick)

Stop pumps (unless on a connection and

the pumps are already stopped) and
space out to ensure that a casing
coupling is not across the rams in the
BOPs.

Drilling with sufficient mud wt to prevent an influx.

Shut in Well with Annular BOP

Obtain SIDPP & SICP
Kill Well with the Drillers Method. Note: Will
have an SCR with the BHA off bottom
and the DLA engaged as flow goes thru
the BHA.

Keep the annulus full, top up on the backside if required

Higher ECD available while CASING DRILLING
Monitor drain back on every connection
Crew to perform Kick Drills

TESCO EXPERIENCE WITH

DIRECTIONAL CASING DRILLING

STEERABLE MOTOR FIELD OBSERVATIONS

(~50+ directional motor sections drilled)

Directional control dependent on casing size.

13-3/8 & 9-5/8 & 7 similar to conventional
Directional control get more difficult with smaller sizes
Wells drilled with inclinations to 90o.

Motor assemblies have a natural build tendency

Motor

MWD NonMag

Dropping angle requires more sliding than building.

Motor selection more critical than for conventional well

Conventional: 12 hole => 9-5/8 or 8 motor

Casing Drilling: 12 hole => 6.75 7 motor.

Orientations are achievable / Sliding may require rocking.

Rotary Steerable CASING DRILLING System

Same surface equipment as conventional
Casing

Same casing accessories.

Motor
Shoe

Rotary steerable tool run in pilot hole

below underreamer.

Underreamer

Mud motor is used to get rpms to bit.

Stabilizers

Eliminates sliding problems, increases

ROP and drills smoother hole.

MWD

RSS
Bit

Casing Drilled 10 , 9 5/8, 7 and 7

CASE HISTORIES

DrillLock
Assy.

Casing
Mud
Motor
Shoe
Underreamer

Case Study Offshore QATAR

TESCOs CASING DRILLINGTM technology, implemented to drill Unstable Shale

formation at high inclination. When Conventionally drilled :
Shale unloads massive amount of cuttings
Significant hole enlargement seen in caliper logs.
Multiple incidents BHAs lost in hole / not get casing to TD
CASING DRILLING
Successfully performed CD operations with no safety incidents or issues
No rig modifications were required

Stabilizers

9-5/8 47 lb/ft L-80 BTC with MLT Rings, casing drilled 2,025 feet

Drilled with 9-5/8 casing from 28 to 75 - degrees inclination while

MWD

making a 26-degree turn utilizing RSS

Eliminated losses and no stuck pipe
Drill Pipe retrieval operation

Drilled a gauged hole with no DHT failure

RSS
Bit

Case Study Offshore Indonesia

CASING DRILLINGTM Campaign (1st Two Wells)

Objective Eliminate a 20 Casing

No incidents or accidents during CD campaign

Drilled 4,206ft with 13 3/8 Casing, losses of 27kbbl/day

No hole problems were encountered T & Ds trended

Directional CD BHA proves ability to steer 13-3/8 Casing

Retrieved BHA on Drillpipe

Cemented Csg, pressure test, FIT for 12 hole section

Next Well to eliminate 20 Casing ($500k/well)

Performance - CASING DRILLING

Saves Well Apache Tx
0

First Conventl Attempt (4/02)

Lost Well at TD ~ 11,500 ft

Measured Depth, ft

2000

4000

Unable to Trip Out for Casing

Cemented Drill Pipe
($ > 1.0 MM) Lost

Lost Circulation
7 Csg Pt
5-1/2 Liner

6000

8000

10000

Second Conventl Attempt

(11/02)

Lost Circ Caused 7.0 Set Early

Required 5-1/2 Liner @ 7.0 CP
Lost Returns at TD ~ 11,600 ft
Stuck Pipe, Well Kicked, Cmt DP
($ > 1.5 MM) Lost

CASING DRILLING

12000
0

10

20

Drilling Days

30

Slight Seepage Losses

Set 7 at 8,085 ft
40
Set 4-1/2 at 11,574 ft
Delivered Productive Well

Summary / Conclusion

CASING DRILLING
Retrievable System ACHIEVEMENTS
Safer operations Well Control , Pipe Handling, etc
Drilled 500+ wells / 800+ intervals (onshore and offshore)
3,000,000+ feet drilled with Casing
Technology applied fit for purpose on conventional rigs

Casing sizes 5 1/2" to 13 3/8"

90 degrees maximum inclination
Less stuck pipe with CASING DRILLING than conventional drlg
Less losses with CASING DRILLING than conventional drlg
Drilled formations from very soft to hard PDC drillable

Casing Drilling Conclusion

Casing Drilling has proven to be feasible.

Reliability and ROP are essential for economic success
Good candidates need a specific problem to be addressed by
casing drilling.
Typical 3 well learning curve to capture learnings & optimise
performance