CASING DRILL

Casing Drill Introduction ( 4 pages ) Drill String Stretch ( 2 pages )

Preparation Overview ( 2 pages ) Calculating Applied Weight ( 3 pages )
Rig-Up Overview ( 3 pages ) General Procedures ( 5 pages )
Jetting Overview ( 4 pages ) Surface Formation Support ( 7 pages )
Bit Recommendations ( 5 pages ) Reciprocating the String ( 3 pages )
Bit Pressure Drop Table ( 2 pages ) Turning Drive Pipe ( 2 pages )
Motor Selection ( 3 pages ) Drill Ahead ( yes or no ) ( 1 pages )
Running Tools ( 3 pages ) Drilling Ahead Factors ( 1 pages )
Drive Pipe ( 2 pages ) Starting Drill Ahead ( 2 pages )
Stabilization ( 1 pages ) Erosion of Shoe Formation ( 1 pages )
Bulls-Eye ( 2 pages ) Shallow Water Flows ( 2 pages )
EXIT Divert Excess Volume ( 5 pages )
SPERRY-SUN CASING DRILL PRESENTATION prepared by Don Hodges

SETTING

DRIVE PIPE

OR

STRUCTURAL

CASING

from

FLOATING

RIGS
SPERRY-SUN CASING DRILL: INTRODUCTION ( page 1 of 4 )

RETURNS The Casing-Drill technique is a means of setting Structural Casing or Drive

Pipe from a floating rig. It is primarily used to eliminate the risk of “loosing
the hole” when the drilling assembly is pulled from soft, unconsolidated,
alluvial deposits such as those found in the Gulf of Mexico.

SOFT With the Positive Displacement Motor, operators can simultaneously drill in
UNCONSOLIDATED and set the structural casing with considerable savings in time and money.
SURFACE
FORMATIONS
The use of the hydraulically actuated motor and bit which is slightly under
gage relative to the casing ID helps assure the predetermined casing point
is reached by elimination of internal formation and its associated friction.
DRIVE PIPE The remaining external friction holds the casing in place.
IS FORCED
INTO THE
SOIL BY Subsequent to the casing drill operation, additional time and money can be
ITS OWN
WEIGHT
saved by the Drill-Ahead operation as trip time to pick up the next bottom
AS THE hole assembly is not required.
INTERNAL
FORMATION
AND ITS The Casing-Drill operation was first performed in 1978 and has since been
FRICTION used from the Gulf of Mexico to the South China Seas. It has been utilized
IS DRILLED
OUT AND
in water depths from 200 to the 9,700 feet achieved in 2001. Setting depths
ELIMINATED. have varied from 210 feet to slightly over 400 feet with the most common
being approximately 280 feet.

The Casing-Drill operation has become the standard method used to set
structural casing or drive pipe from a floating rig in areas that have soft
formations. Many customers employ this method, including major operators,
independents, and turnkey operators.
SPERRY-SUN CASING DRILL: INTRODUCTION ( page 2 of 4 )

In the Casing-Drill operation, Drive Pipe is simultaneously jetted in and run

RETURNS
using sea water with returns going to the sea floor. The weight of the casing
and the internal bottom hole assembly is used to force the drive pipe into the
soil forming its own hole as the internal formation is drilled out.
Set drive pipe initially serves as a temporary dam, keeping the upper soft
SOFT formations back while the next section is drilled, again using sea water with
UNCONSOLIDATED
SURFACE
returns to the sea floor.
FORMATIONS
Once the next section is drilled to proper depth, surface casing is run and
cemented into place along with the drive pipe. BOP equipment and riser
are then run with the surface casing providing load support while the
drive pipe lends structural side support.
OVER BURDEN Note. Only external friction between the drive pipe and soil is initially used
PRESSURE
to hold it in place until the next casing string is run and cemented into place.
REMOLDS
SOIL Friction is allowed to increase after setting the pipe by soaking or allowing
AROUND the soil to heal itself around the casing as over-burden pressures squeeze
THE CASING the water from the formation. Some additional vertical or load support may
AS WATER
IS be added by use of a mud mat.
SQUEEZED
OUT It is important that the formation damage be kept to a minimum while drive
pipe is jetted in to maximize the friction of the soil within its holding ability.
Washout of formation areas should be prevented.
Excessive weight placed on set drive pipe should also be avoided until the
surface casing is cemented into place. It must be remembered that only
friction between the soil and the drive pipe holds it in place and that this
may vary with soils having differing frictional factors. It should also be
remembered that the weight of surface casing strings vary and that the
realized weight at landing varies with hole quality.
SPERRY-SUN CASING DRILL: INTRODUCTION ( page 3 of 4 )
KEY TOOLS TO CASING DRILL OPERATION
RUNNING Running Tool: joins the drive pipe and drill string allowing casing to be drilled in and set
TOOL
at one time. Depending on the running tool type, it is then released for either pulling out
of the hole or for drilling ahead.

Bulls-Eye: level indicator mounted to guide base or casing measuring verticality of the
DRILL
COLLARS drive pipe. Typically a 2 or 5 degree model with 2 degrees being preferred.

Drill Collars: 9-1/2” and/or 8” drill collars provide weight.

Other BHA components: Cross-over subs, float subs, pony collars, and other subs are
used as needed. Bit space out dictates selection of individual pieces.

MWD
Stabilizer(s): centralize the string. Optional on casing drill only jobs but needed on drill
ahead jobs in a pendulum assembly.

MWD Tools: are optional. They are normally used on drill ahead jobs for surveys and
STAB
ECD readings.

Positive Displacement Motor: provides rotational torque to the bit as the drilling fluid is
pumped through the motor’s progressive cavities. This allows the cutting of a pilot hole
at the shoe for the casing to then force itself into the formation.
MOTOR

Soft Formation Rock Bit: slightly under-gage bit with respect to the casing ID drills a
pilot hole just prior to the casing shoe and cleans out the internal formation. Rock bits
are recommended as they transmit less torque than other bits might.
BIT
SPERRY-SUN CASING DRILL: INTRODUCTION ( page 4 of 4 )
“ Cookie Cutter “ Effect
The Positive Displacement Motor allows drilling out internal formation within drive pipe, eliminating its associated
friction. Drive pipe uses its own weight along with the weight of the internal bottom hole assembly to force itself
into the formation around the pilot hole cut by the undersized bit. The close fit hole formed allows minimum soak
time for the soil to heal around the casing. Premature build up of external friction during jetting is reduced as
needed by reciprocation of the string, “liquefying” the soil immediately surrounding the casing to allow it to reach
the predetermined depth.

There are multiple, simultaneous events occurring at the bit and drive pipe shoe
during the casing drill operation. These play an especially important role in the start
NO INTERNAL FORMATION OR FRICTION

up at volumes that achieve immediate hole cleaning yet do not broach. These are
separated in illustrations below even though they occur together in unison.

CASING
EXTERNAL FRICTION

FORMS
CONTINOUS
SEAL
WHILE
FORCING
ITSELF
INTO
FORMAION INTERNAL
BIT CUTS FORMATION
PILOT HOLE DRILLED OUT

A Pilot Hole smaller Downward travel of The Drive Pipe Shoe

than the drive pipe Drive Pipe continually wedges sides of pilot hole
is drilled by the bit forms it own seal and into the bit to be drilled up
and motor aiding forms its own closely and discharged up the
penetration into the fitting hole around drive pipe annulus with
FORMATION formation. the drive pipe. other bit cuttings.
SPERRY-SUN CASING DRILL: PREPARATION OVERVIEW ( page 1 of 2 )

5 ADD TO
OVERALL
STRING LENGTH
10

15
ADD TO
20
INTERNAL
BHA
LENGTH
25

30

35
USE RUNNING TOOL
APPLICABLE TO JOB
40

CADA
45
10
Cam Actuated Drill Ahead
CART
Cam Actuated Run.Tool

• Measure Casing. • Measure Drill Collars. • Measure & mark all • Measure Running Tool.
- Assembled length - Measure more than potential BHA - Bottom Effective
determines length needed for bit space components. Length
of internal BHA out options • Assure connection - Top Length above
• Mark for visibility & • Mark each length compatibility. casing
aid in jetting. • Compile list of pieces • Verify tools to be run
• Note: 9-1/2” and 8” • See Wellhead Srv. Rep.
• Determine walls & from other companies For measurements.
weights drill collars common • Compile list of tools
SPERRY-SUN CASING DRILL: PREPARATION OVERVIEW ( page 2 of 2 )
• Hevi-wate is optional with
SOFT FORMATION MWD TOOLS 2 - 10 stands common
ROCK BIT
PUMPS
• Drill Pipe is sized for load
as well as hydraulics
• Volume
BIT • Pressure
LENGTH
• Common Drill Pipe Sizes
5” Drill Pipe
5-1/2” D. P.
6-5/8” D. P.
BIT
STICK
OUT

Drilling Jar not typically

Typical. 6” ±3” run in this section

Measure & record Bit length. Determine pump information. Drill Pipe adequate for volume and
• pump make and type pressure
Determine Bit extension for job. • number of pumps
Drill Pipe adequate for loads plus
Paint Bit white for visibility. • liner sizes of pumps
over-pull required
• output per stroke
Ensure bit nozzles are correctly • maximum strokes allowed Drill Pipe total length sufficient to
sized for planned volume & job. • maximum pump pressure drill at least first section.
• Bit Pressure maximized at the
max volume to be used within Determine that system pressure Drill Pipe stretch calculated based
motor’s operating specs and within operational limits of pumps on depth, weight of drive pipe.
• Requirements of other tools at volume adequate for tools and
Hevi-wate is optional.
such as MWD met. the job.
SPERRY-SUN CASING DRILL: RIG-UP OVERVIEW ( page 1 of 3 )

Bit painted white

for visibility

All tools readied and verified

adequate for the job.
All handling equipment readied
and adequate for job
Minimize time suspended drive
pipe exposed to weather

• Guide Base, etc. rigged up • Shoe Joint painted for 10 feet for • Joints assembled in running order
• BHA stood back visibility under water • Handling ears (if present) removed
• Running tool stood back. • Shoe Joint picked up and hung in • Assembled joint lowered
• Casing handling& make-up rotary. • Sequence repeated through the
tools readied • Next joint picked up and made-up well head joint.
SPERRY-SUN CASING DRILL: RIG-UP OVERVIEW ( page 2 of 3 )

RECORD RECORD
TOTAL TOTAL
WEIGHT OF WEIGHT OF
DRIVE PIPE BHA

NOTE:
CASING
SUSPENDED
IN
ROTARY
ON
SOME
JOBS

• Drive Pipe assembly completed. • Well Head Housing Joint lowered • Bottom Hole Assembly is run in
• Top wellhead housing joint hung with running tool. suspended drive pipe.
in rotary • Suspended in Moon Pool. • Running tool is added as top
• Running tool picked up and • Running tool retracted and stood member of internal BHA.
engaged in housing joint. back to run BHA
SPERRY-SUN CASING DRILL: RIG-UP OVERVIEW ( page 3 of 3 )

CHECKS:
GUIDE BASE
RUNNING TOOL
BULLS EYE
ROTATION

CAUTION
SUDDEN TURN OF STRING
RECORD
COULD AFFECT RUNNING
RECORD WEIGHT
BULLS EYE TOOL. USE CAUTION WHEN
OF TOTAL
READING MAKING UP STANDS
ASSEMBLY

CAUTION
DO NOT MUD MATS, ETC HAVING
LARGE “SAIL AREAS” MAY
DELAY IN
TURBULENT BE CAUSE FOR RESTRICTING
TRIP SPEED SLIGHTLY
SPLASH ZONE

RECOMMEND
OPERATIONS THAT COULD
MOVE RIG OFF LOCATION
DURING SPUD-IN BE
COMPLETED OR
SUSPENDED
CHECK BIT FOR FIRST 150 FEET OF
EXTENSION PENETRATION
ie. BOATS, ETC.
TEST MOTOR

• Running tool engaged into well • Tie-downs released and moon • Trip to mud line
head housing pool support retracted • Fill drill pipe as needed
• ROV verifies bit extension • Record weight of string • Ready pumps, seawater, gel
• Final rigging of guide base, etc • Record bulls eye reading sweeps, etc.
• Bulls-eye set as near zero • Trip in hole - do not delay in • Monitor approach to mud line
as possible. splash zone with ROV
SPERRY-SUN CASING DRILL: JETTING OVERVIEW ( page 1 of 4 )
AVOID BROACHING
START PUMPS AT RATE THAT
NOTE: ASSURES MOTOR START AND
SPUD TO 10 FT: ANNULUS BEING CLEANED
Excessive penetration without AND MAINTAINED AS PATH OF
pumps could cause LEAST RESISTANCE FOR THE
internal pack off resulting in HYDRAULIC FLOW.
2.
broaching
ROV CHECK:
2.and/or
GUIDE BASE ROV CHECK:
running tool release problem AVOID BROACHING
RUNNING TOOL GUIDE BASEor MAINTAIN 5k TO 10k INITIAL
NOTE: RUNNING
BULLS EYE could plugTOOL
bit nozzles APPLIED WEIGHT AND
CALCULATE TRAVEL BULLS EYE
ROTATION OF LAST STAND CONSTANT DOWNWARD
ROTATION TRAVEL OF DRIVE PIPE
TO T.D. ROV MONITORS PENETRATION
ADJUST AND POTENTIAL BROACHING FOR EFFECTIVE SHOE SEAL
IF LESS WHEN PUMPS
1. START
THAN 30 FEET
RECORD MUD
LINE DEPTH
ROV TO WELLHEAD
WITHOUT PUMPS SPUD IN AFTER NO BROACHING
TO 10 FEET OR 10K ASSURED. ( ± 40 FEET )

PICK UP BIT OFF BOTTOM SHUT DOWN IMMEDIATELY IN

1. 3. PRIOR TO STARING MOTOR UPPER SECTION OF HOLE FOR
RECORD WATER ROV REPOSITION ANY PUMP PROBLEMS
DEPTH AT BOTTOM START AT PUMP RATE THAT WILL START PILOT HOLE CUT BY BIT IS
FACTOR IN STRETCH
FOR SPUD IN MOTOR AND CLEAN THE ANNULUS. CONTINUALLY SEALED BY
FOR TRUE DEPTH
Do not create a packed off area which DOWNWARD MOVEMENT
will encourage broaching. Clean hole. SHOE.

• Brush bottom. Record depth • Position ROV at mud line • Start pumps at 75 to 80% of
• Factor in stretch for true depth • Spud to 10 ft without pumps planned volume.
• Record total weight hanging • Pick up bit 1 to 2 feet off bottom • Start penetration upon first
• ROV check guide base, • Assure all valves positioned o.k. significant pressure increase.
bulls eye, running tool • ROV to monitor for broaching on • Maintain ROP with 5k to 10k
• ROV return to bottom start-up. ( usually first 40 feet ) weight applied initially
SPERRY-SUN CASING DRILL: JETTING OVERVIEW ( page 2 of 4 )

DO NOT PLUG OFF RECIPROCATION FREQUENCY

RUNNING TOOL PORTS RETURN TO JETTING
WORKING OF DRIVE PIPE AFTER WORKING
PUMP RATES MUST ALWAYS DEPENDS ON INTERACTION OF
BE AT LEVELS THAT HAS REDUCED
SOIL AND PIPE AND CANNOT FRICTION
CLEAN ANNULUS WHEN BE PRECICTED AS TO EITHER
PENETRATING. TO ACCEPTABLE
ITS FREQUENCY OR TO LEVEL FOR THE
NECESSARY STROKE LENGTH CURRENT DEPTH.
TO REDUCE FRICTION TO
DO NOT WASH OUT • Near zero in upper hole sections
ACCEPTABLE LEVEL.
FOMATION AREAS and before each connection
KEEP DRIVE PIPE MOVING RECIPROCATE DRIVE PIPE • Allow increase near full depth
AVOID PROLONGED WASHING
WORK PIPE ……..
AT ANY DEPTH
• IF ROP SLOWS SIGNIFICANTLY
WITH PROPER WEIGHT APPLIED CONTROL MOTOR DIFFENTIAL
• BEFORE CONNECTIONS MOTOR DIFFERENTIAL REFLECTS
DO NOT STICK
TORQUE THAT COULD BE
THE DRIVE PIPE • DURING DELAYS TRANSMITTED TO RUNNING
KEEP DRIVE PIPE MOVING TOOL. KEEP BELOW 100 PSI.
OR IF PROBLEM - PULL UP RECIPROCATION SPEED: • MOST LIKELY TO OCCUR
TO A SHALLOW DEPTH
• QUICK RATE TO LIQUIFY AFTER WORKING.
FORMATION AROUND CASING • EASE INTO BOTTOM
& REDUCE SKIN FRICTION
• RETURN TO WOB
• Maintain ”5 foot” drill pipe • CONSISTENT RATE FOR SCHEDULE FOR DEPTH
marks at rotary to OVER-PULL & DRAG AS POSSIBLE - LIMITED
drive pipe depth COMPARISON S BY 100 PSI MAXIMUM
AT VARIOUS DEPTHS MOTOR DIFFERENTIAL.
• WITHIN DRILL PIPE
OVERPULL LIMITS

Jet in drive pipe per procedures Work drive pipe only as needed. Return to bottom after working
• Apply weight per WOB rules • Reduce friction to levels • Slow descent nearing bottom
• Pump at rates to clean hole appropriate to current depth • Return to planned WOB for
• Keep drive pipe moving • Work pipe at constant rate current depth as possible
• Pump sweeps as required • Monitor and record over-pull & limiting motor differential
• Work only as needed drag to 100 psi or less
SPERRY-SUN CASING DRILL: JETTING OVERVIEW ( page 3 of 4 )
CALIBRATE DISTANCE
AT CONNECTIONS: PICKUP ABOVE CUTTINGS
NEAR TD:
ROV CHECKS: STOP PUMPS IF NECESSARY
• LET DRAG INCREASE
• BULLS EYE VIEW MUD RING ON CASING
• GUIDE BASE BASED UPON PREVIOUS
• RUNNING TOOL OBSERVATIONS OF SOIL’S RETURN TO JETTING
• ROTATION DRAG, ETC. • LAND WITH SAME WEIGHT
THAT WAS APPLIED BEFORE
PICKUP
Note: Coat hole walls with gel AVAILABLE WEIGHT
sweep if friction excessive and DO NOT EXCEED
cannot be reduced. Do not coat WEIGHT OF CASING ROV
unless formation requires AND BHA
USE 20% SAFETY
FACTOR

MONITOR WEIGHT
INDICATOR CLOSELY

• Reduce over-pull & drag before Minimize soak time needed Calibrate remaining travel when
connections • Allow more friction to remain as nearing drive pipe TD
• Return to bottom before conn. final depth is approached by • Slow or stop pumps while picking
• Perform ROV checks at conn. leaving more drag based upon up above cuttings cloud
• Optional: Pump sweep after observations of previous drag.
• Attempt to use maximum weight • ROV views mud coating around
connection
available to land drive pipe while the drive pipe for remaining travel
Note. Should drag increase to
unacceptable levels above the being cautious of bending pipe • Drill remaining feet stopping at
current stroke area. Set back • Do not make connection in last target depth with same weight
stand and coat hole with gel 30 feet. used just prior to pickup.
SPERRY-SUN CASING DRILL: JETTING OVERVIEW ( page 4 of 4 )

AT DRIVE PIPE SOAK TIME MUD MAT GUIDE LINES

ROV LANDING 2 HOURS IS
used for additional typically used
ROV CHECKS MOST COMMON
• STICKUP
support in waters of
shorter or longer or 2,500 ft or less
• BULLS-EYE
depends on hydrate deflection
jetting observations

CONFIRM STICKUP SOAK TIME LANDING A MUD MAT GUIDE LINES

• Soil may set up and prevent Proper soak time is dependant If a mud mat is used Guide bases and their guide
correction if not done in short on the soil’s friction factor and • Keep drag slightly lower lines should not be turned to
time frame. ability to remold itself around than usual approaching such an extent equipment
• Common to have no visual for the drive pipe as overburden landing to have weight cannot travel down them.
1 hour or more if current is too squeezes water out of this area. available as the mud mat
weak to clear cuttings cloud. lands. Reasons guide bases turn
Alternative: ROV off-bottom • The weight required to reach A rapid 20k to 30k weight • Reactive torque of motor
reading at reference point on full depth and the over-pull, increase is easier to read turning bit to right may
guide base for approximate drag, and speed with which and be certain that the generate turn to left.
immediate stick-up. Also these increased in the above mud mat is completely • Small turns induced during
for checks drilling ahead. sections indicate the soak landed. connections may be worked
time needed. into the string either to the
CHECK BULLS EYE ie. Jetting “too easily” Notes: right or left.
• Bulls Eye change from that requires more soak time. The 20k to 30k weight • Formations can induce a
prior to spud indicates the lessens reacting to string to turn either to the
verticality of the drive pipe. • Drill ahead may require more false readings as mat right or left.
soak time. hits uneven seafloor.
SOAK ON COMPENSATOR A rapid increase lessens Note: turns to 45 degrees are
• String to remain motionless • Tripping out after casing drill the possibility of mat generally acceptable. More
to allow soil to heal around requires minimum soak time “working” its way into severe turns may need to be
around the drive pipe as soil will cure during trip. soft seafloor. corrected.
SPERRY-SUN CASING DRILL: Bit Recommendations ( page 1 of 5 )

SOFT FORMATION RECOMMENDED BIT IS SOFT FORMATION ROCK BIT.

NOTE:
ROCK BIT • Transmits less torque than fixed bladed bits. Readily available.
NOZZLES
TYPICALLY
12” TO 14”
RECOMMENDED BIT SIZE IS 24” OR LARGER
24” OR
LARGER
ABOVE BIT • Typically the size of next hole section is used. See bit exception.
BOTTOM
• Sizes include 24”, 26”, 28”, 30”, 31-1/2”. Limit is ID restriction.
• Note. Large sizes may have 8-5/8 Reg pin. Verify.
NOZZLE RECOMMENDED BIT EXTENSION IS 6” BELOW SHOE. ± 3”
LOCATION
• Bit able to drill hard formations if encountered. Coral, wood, etc.
• Nozzles located inside casing 6” to 8”. Only bit teeth are outside.
BIT
EXTENSION • Hydraulic forces directed to the shoe for effective jetting.
• Recommendation applies to all bits 24” or larger.
RECOMMENDATION: 6” OUTSIDE ± 3” • Recommended range of bit location is 3” to 9” outside. Acceptable
ACCEPTABLE BIT LOCATION RANGE: - 6” to + 9” range is 6” inside to 9” outside. Customer preference.

BIT SIZE EXCEPTION: Bits smaller than 24” OD are not recommended but are used to meet unique customer needs
where casing ID is restricted. 17-1/2” and 20” bits have been run successfully but with some difficulty due to broaching.
These bits tend to be trapped on one side of the casing by the formation with broaching occurring due to the bit hydraulic
forces being concentrated in this small area. We recommend the bit be located 6” to 9” inside the shoe to “cushion” this
effect. The first job done using a 17-1/2” broached with a 6” stick-out and was only completed after repositioning the bit
to 9” inside the shoe. Other jobs have since been completed successfully with bit positioned inside.
BIT TYPE: Soft formation rock bits are recommended as they transmit less torque to the running tool. Two jobs were
done in the past using fixed bladed bits with reactive torque locking up the running tool (Shell/Mars). Two other jobs
have been done using a PDC bit (Unocal). The bit was positioned with the wear area at the shoe and hydraulics were
maximized to ensure most of the cutting action was due to jetting and not by the bit. Reactive torque was kept within
acceptable limits and jobs were completed but is still not recommended for the casing drill portion.
SPERRY-SUN CASING DRILL: Bit Recommendations ( page 2 of 5 )
Why is it recommended that the bit be stuck out below the casing in most cases?
Some customers believe it should stick in. .

Our recommendation that the bit be positioned slightly outside the casing is based on
the possibility of encountering some hard formations or other substance that is not
expected. Casing drill jobs have been done through dead coral reefs, cement that has
8”
6” migrated from another nearby well, and as recently as early 2000 through a wood pile
or submerged forest more than 200 feet thick in 6700 feet of water. It is felt that without
the bit to help in these situations that the targeted depth may not be reached.

It is possible that having the bit stick 6” inside the casing originated with the jetting in
of drive pipe without a motor. It was a practice to saw off a bit and position it where
6” seawater was directed to the shoe bottom. It is also felt by some that this prevents
excess washing around the shoe area. If one looks at both scenarios, one sees that
on the bit where the bit has been positioned outside the casing that the nozzles are
approximately the same distance inside the casing as with sawed off bits .

The final decision as to bit position rests with the customer. Either way can be done
so long as neither are carried to the extremes of the third and fourth illustrations.
22”
On one job a few years ago the bit was positioned inside the casing 22 inches. Our
operator was instructed to not make corrections and to proceed. The targeted depth
was not reached. The string had to be pulled and the bit re-positioned.

On a recent job an untrained directional operator spaced the bit out 36” below the
casing and proceeded with the job. The casing drill job took 8-1/2 hours to reach
depth. The casing fell when drilling ahead. As can be seen in illustration, the bit can
36” extend beyond the casing, cutting an enlarged hole especially given the time to do
so. ( note: not our company, related by customer ).
SPERRY-SUN CASING DRILL: Bit Recommendations ( page 3 of 5 )

36”
Tendency of small diameter bit to broach
A 24” diameter bit is the smallest bit recommended for a casing drill job. All larger bits
24” BIT
are also acceptable so long as they pass through any I.D. restrictions.
452 SQ IN
A large bit distributes the hydraulic forces to all sides of the casing shoe by its size
alone, by its closer size in relation to the casing size, and by its whir or tendency to
move in a circular path inside the casing.

HYDRAULIC FORCE DISTRIBUTED

WITH LARGE BIT & ITS WHIR PATH
A small bit concentrates flow over a smaller area and tends to get trapped by formation
on one side of the casing as it has less mechanical advantage than a larger diameter
bit. All of the hydraulic force of the flow is directed to a small area of the casing causing
that side to broach.

On the first job requiring a 17” bit, it was positioned 6” outside the casing as per our
standard recommendation. Broaching occurred immediately and continued to a depth
of 50 feet. The string was pulled and bit was repositioned to 9” inside the casing shoe
before successfully completing the job.

36” If a small bit must be used, it should be positioned 6” or more inside the casing. The
pumps should be started prior to spud in. The general idea is to clean the formation
908 SQ IN before it can trap the bit to one side.
17”
240 SQ IN At least 3 casing drills have been done using a 17” bit with 36” casing and 2 using a
17” bit with 30” casing. In addition, 2 jobs have been done using a 20” bit with 30”.
Obviously, the closer the bit was in relation to the casing, the easier was the job.

SMALL BIT TRAPPED BY While we have and can do these jobs if required, we cannot recommend them as
FORMATION ON SIDE WITH
HYDRAULICS CONCENTRATED a standard practice.
IN SMALL AREA
SPERRY-SUN CASING DRILL: Bit Recommendations ( page 4 of 5 )
RECOMMENDED NOZZLE SIZES
Proper nozzle selection plays a vital role in a successful casing drill operation
and even more so when drilling ahead. Volumes pumped should be 1000 gpm
or more for adequate annular flow to clean the hole. Some older rigs struggle to
meet this volume and associated system pressures. Newer pumps produce much
higher volumes and pressures. Drilling rates may vary from as low as 50 feet
per hour controlled drilling to more than 500 feet per hour. Water flow hazards
or their potential, create the need to drill part of the hole with seawater, at a
Size nozzle for maximum bit pressure certain flow rate and the other part with mud at a reduced flow rate. Tools may
within limitations of all variables.
have volume or pressure requirements and/or limitations. These variables mean
• Effective drilling
• Expanded drilling range that there is no “one size fits all”. Each job must be looked at individually to
size nozzles for the best possible results.
Generally, nozzles should be sized to produce the highest bit pressure drop possible when pumping the highest planned
volume within the limitations of the drilling tools, rig pumps, and system pressure. It is especially true when aggressive
drilling rates are required for the drill ahead section. Inadequate or weak bit hydraulics can prevent the desired drilling
rate from being achieved or encourage excessive weight application which can cause hole angle problems.
The flow rate range at which effective drilling can continue is expanded downward by maximizing the bit pressure drop.
Planned volume may not be achieved due to a wide variety of reasons ranging from overly optimistic projections to a
variety of rig problems. Flow rates are rarely more than projected but may be less.
An example requiring a maximum range of bit pressure drop occurs when drilling part of a section with seawater and
part with mud to control potential water flow. Desired flow rates may vary from 1700 gpm using seawater to as low as
1000 gpm using mud. Drill rates must be maintained which will assure target depth is reached while using a limited
supply of mud, while the bit hydraulics are at their weakest. Increasing mud flow rate with a corresponding increase in
drilling rate may not be an option as flow rates may be limited by supply of mud. Concentrated mud is frequently cut on
the fly with a vortex mixer, some of which only produce slightly over 1000 gpm. Nozzles must be sized to maximum bit
pressure drop at maximum seawater flow rates in order to have acceptable bit pressure drops with lower mud flow rates.
Adjustments in the planned seawater flow rate may be required.
SPERRY-SUN CASING DRILL: Bit Recommendations ( page 5 of 5 )
RECOMMENDED NOZZLE SIZES ( continued )
The hydraulics of a casing drill job should be considered prior to beginning, even prior to sending tools to the rig. It should
be done by the operating company in their well planning and Sperry-Sun is more than willing to assist. This is an area that
problems frequently occur. Nozzles may not be available to make last minute corrections. Newer rigs tend to not have the
stockpile of nozzles that was common on the older rigs.
It should not be assumed that nozzle sizes are correctly sized. The operating parameters and hydraulics should be verified.
Unrealistic expectations of rig capabilities or emphasis on only one parameter such as annular flow may lead to overly
optimistic flow rate projections. Drilling programs may dictate a certain sized nozzle which may have been “cut & pasted”
from a previous one that was not updated as changes were made. Errors in a “prog” can have an extremely long life.
It is important that the volumes for which the bit nozzles are set up be the volumes achieved. Planned volume may not be
realized due to a variety of reasons which in the past have included:
• Overly optimistic projections. Should get rig’s parameters and commitment to the planned volume rates.
- Rig simply does not have the capacity to produce the flow rate required at the pressures that will be generated.
- Insufficient seawater supply. Sufficient pumps but small charging pumps &/or lines.
- Rig power. Lack of enough power to run pumps as designed. One rig worked on engines every location move.
- Poor pump condition & maintenance on one or all pumps. Small liner sizes. Pop-off valves defective.
• Drill pipe undersized for drilling depth. I.D. dimensions are one of largest factors of total system pressure.
• Under-estimated pressure imposed by of some tools such as MWD. Flow rate restrictions of some tools.
• Flow rate limited during “pump & dump” operations due to slow transfer of mud from supply boat to rig or by
an undersized inline vortex machine which cannot cut or mix the mud at desired rate.
Properly sized nozzles are an important factor in doing a good job for a customer. Because flow rates are rarely more than
planned and are frequently less, it is wise to consider bit hydraulics in a range as opposed to one specific rate. The sizing
of nozzles for maximum bit pressure drop at maximum flow rate allows for the largest effective range.

Formula: Bit Pressure Drop Recommended Minimum Jet velocities of Formula: Bit Jet Velocity
Formula: Bit Pressure Drop Recommended Minimum Jet velocities of Formula: Bit Jet Velocity
250 ft/sec are fairly standard. Less than
Mud Weight (ppg) x GPM 2 2 250 ft/sec are fairly standard. Less than 0.32 x GPM
Mud Weight (ppg) x GPM 200 ft/sec may prevent drilling even in 0.32 x GPM
10858 x TFA2 2 200 ft/sec may prevent drilling even in TFA
10858 x TFA soft surface formations.. TFA
soft surface formations..
SPERRY-SUN CASING DRILL: Bit Pressure Drop Table ( page 1 of 2 )

SEA WATER
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 428.7 222.4 339.7 213.9
3 20 1000 950.0 529.3 247.1 419.4 293.4
1 18 1100 1045.0 640.4 271.8 507.5 390.5
1200 1140.0 762.1 296.5 603.9 507.0
5.0 8.7 3.0 2.0 1300 1235.0 894.4 321.2 708.8 644.6
1400 1330.0 1037.3 345.9 822.0 805.1
Noz TFA 1.169 1500 1425.0 1190.8 370.6 943.6 990.3
Eq FA 1.230 1600 1520.0 1354.9 395.3 1073.7 1201.8
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 388.9 211.8 331.5 194.1
3 20 1000 950.0 480.2 235.3 409.3 266.2
1 20 1100 1045.0 581.0 258.9 495.3 354.3
1200 1140.0 691.4 282.4 589.4 460.0
5.0 8.7 3.0 2.0
1300 1235.0 811.5 305.9 691.7 584.8
1400 1330.0 941.1 329.5 802.3 730.5
Noz TFA 1.227 1500 1425.0 1080.4 353.0 921.0 898.4
Eq FA 1.292 1600 1520.0 1229.2 376.5 1047.9 1090.4
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 290.3 183.0 308.2 144.8
3 22 1000 950.0 358.4 203.3 380.5 198.7
1 20 1100 1045.0 433.6 223.6 460.3 264.5
1200 1140.0 516.1 244.0 547.9 343.3
5.0 8.7 3.0 2.0 1300 1235.0 605.7 264.3 643.0 436.5
1400 1330.0 702.4 284.6 745.7 545.2
Noz TFA 1.420 1500 1425.0 806.4 305.0 856.0 670.6
Eq FA 1.495 1600 1520.0 917.5 325.3 974.0 813.8
SPERRY-SUN CASING DRILL: Bit Pressure Drop Table ( page 2 of 2 )

SEA WATER
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 265.6 175.0 301.4 132.5
3 22 1000 950.0 328.0 194.5 372.1 181.8
1 22 1100 1045.0 396.8 213.9 450.2 242.0
1200 1140.0 472.3 233.4 535.8 314.2
5.0 8.7 3.0 2.0 1300 1235.0 554.3 252.8 628.9 399.5
1400 1330.0 642.8 272.3 729.3 498.9
Noz TFA 1.485 1500 1425.0 737.9 291.7 837.2 613.6
Eq FA 1.563 1600 1520.0 839.6 311.2 952.6 744.7
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 219.9 159.2 287.5 109.7
3 24 1000 950.0 271.5 176.9 354.9 150.5
1 20 1100 1045.0 328.5 194.6 429.5 200.3
1200 1140.0 390.9 212.3 511.1 260.0
5.0 8.7 3.0 2.0 1300 1235.0 458.8 230.0 599.8 330.6
1400 1330.0 532.0 247.7 695.7 412.9
Noz TFA 1.632 1500 1425.0 610.8 265.4 798.6 507.9
Eq FA 1.718 1600 1520.0 694.9 283.1 908.6 616.4
BIT HYDRAULICS BEARING Mud Plastic Yield VOLUME BIT BIT JET IMPACT HYD
NOZZLE CALCULATION ASSY Weight Viscosity Point GPM VOLUME PRESSURE VELOCITY FORCE H.P.
QTY SIZE 900 855.0 187.6 147.1 276.3 93.6
3 24 1000 950.0 231.6 163.4 341.1 128.4
1 24 1100 1045.0 280.2 179.8 412.7 170.9
1200 1140.0 333.5 196.1 491.2 221.8
5.0 8.7 3.0 2.0 1300 1235.0 391.3 212.5 576.5 282.0
1400 1330.0 453.9 228.8 668.6 352.3
Noz TFA 1.767 1500 1425.0 521.0 245.1 767.5 433.3
Eq FA 1.860 1600 1520.0 592.8 261.5 873.2 525.8
SPERRY-SUN Casing Drill: Motor Selection ( page 1 of 3 )

POSITIVE DISPLACEMENT MOTOR (PDM))

DUMP
VALVE Positive Displacement Motors are activated by drilling fluid pumped down the drill
string and into the down hole motor’s progressive cavities. The pressure of fluid
flow through the motor causes the rotor to rotate with the rotational torque being
transmitted to the bit.

POWER
SECTION
ROTOR BASIC COMPONENTS OF FOUR THE MUD MOTOR
STATOR
Dump Valve Sub (optional / frequently omitted)
Avoids wet trips, bypassing or directing fluid though motor automatically. The dump
valve is deactivated when used with a jet sub on casing drill operations.

POWER SECTION ASSEMBLY

Converts hydraulic horsepower to mechanical horsepower providing torque.
COUPLING COUPLING ASSEMBLY
ASSEMBLY
Transmits torque, converting eccentric motion of power section to concentric rotation
of the driveshaft and on to the bit.

BEARING BEARING ASSEMBLY

ASSEMBLY Supports the driveshaft that transmits torque to the bit. In the casing drill operation, it
may also have stabilizer blades which act as centralizers.
ROCK Stabilizer Blades on Bearing Housings ( if used ) are sized to the bit used. Both must
BIT be slightly under gage with respect to the smallest I.D. of the casing.
SPERRY-SUN Casing Drill: Motor Selection ( page 2 of 3 )

Casing Drill History

Historically, the most commonly used motor has been a 9-5/8 High-Speed, Low-Torque
Motor with attached stabilizer blades on the bearing housing of the same O.D. as the bit
being used. A jet sub above the motor diverted that portion of the volume pumped which
exceeded the motor’s capacity of 700 gallons per minute.
The Low-Torque motor was primarily chosen because it stalled easily, limiting potential
reactive torque transmission to the running tool by acting as a ”safety valve “. Excess
torque transmission could cause a running tool to jam as was done on two 1994 jobs of
a batch set when a customer opted to run a spade bit with poor bit hydraulics. Although
a low torque motor was used on this job, the running tools could not be released and
were only removed by rapid, excessive over-pull.
This motor performed well on “casing drill only“ jobs but was limited when drilling ahead.
The motor’s maximum operating parameters of 700 gallons per minute and 375 pounds
per square inch bit pressure drop resulted in minimal bit hydraulics at best. The effective
hydraulics range was narrow with a severe penalty for slowing pumps down.
With increasing rig rates, operational costs, and drilling in deeper waters came an effort to
drill faster and more cost effectively. The number of drill ahead jobs associated with casing
300+ drill no longer was the exception. It became the rule. Along with this change, drilling rates
GPM became more aggressive. The low torque, high speed motor had been acceptable at the
“control drilling” rates but struggled at these faster rates.
7 It was obvious that there were motors better suited to drilling ahead than was the high speed,
0 low torque motor we were using. It was decided to try these motors despite the long held fear
0 of torque transmission to the running tool.
G
P
M
SPERRY-SUN Casing Drill: Motor Selection ( page 3 of 3 )

ROTOR / STATOR Beginning in 1998, we began running medium speed motors on certain drill
ahead jobs where the customers wanted higher volumes and improved bit
hydraulics to drill more aggressively. We experienced no motor generated
1- 2 release problems with running tools of any make and in fact, less problems.
Use of medium speed ( 3-4 ) motors on drill ahead jobs proved successful.
By simply keeping the motor differential pressure below 100 psi, any motor’s
reactive torque is held to an acceptable level. This was easier than expected
due to improved bit hydraulics which increased the jetting factor and lessened
the bit interaction with the soil. Stabilizer blades were moved from the bearing
housing on the motor to the string above in pendulum assembly positions for
emphasis on drilling ahead with no associated problems.
3- 4 It was initially believed that we would continue recommending low torque,
high speed (1/2) motors on casing drill only jobs and medium speed motors
on drill ahead jobs. But that became a mute point with no release problems.
We now consider the 9-5/8 Medium Speed, Medium Torque motor to be the
standard casing drill and drill ahead motor. Its operational parameters allow
1200 gpm and up to 1000 bit pressure drop. We have also ran low speed,
high torque motors and the larger 11-1/4 motors with no release associated
problems.
5- 6 Recommendations for casing drill and drill ahead jobs are now made with an
emphasis on proper setup for the drill ahead portion. Recommendations for
bit nozzle sizes are based upon the customer’s expected flow rate ranges.
Stabilizers are positioned in a pendulum assembly for the drill ahead.

See your Sperry Representative for motor options as well as hydraulic and
bottom hole assembly recommendations.
SPERRY-SUN CASING DRILL: Running Tool - CART ( page 1 of 3 )
CART Space Out Measurements
TOP VIEW EXHAUST PORTS
Cam Actuated Running Tool as tool fits in wellhead housing
ADD TO
OVERALL
STRING LENGTH

There are two types of running tools:

• CART - does not allow drilling ADD TO
INTERNAL
ahead. Shown on this page. BHA
• CADA - does allow drilling ahead. LENGTH
Shown on next page.

Running tools become a part of the bottom hole assembly with the lower section that fits inside the casing being
measured as part of the internal BHA for bit space out purposes. The remaining upper section length is added
to the upper drill string. The running tool seats and locks into the wellhead housing connecting the casing to the
drill string by dogs which extend into profiles inside the wellhead housing. A cam extends the dogs when the
string is turned to the left and allows them to retract when it is repositioned by turning the string to the right.

Running tools resist turning unless its dogs and internal mechanisms are free of downward or upward forces
exerted on them. This is referred to as its neutral point. This point is reached down hole when all of the casing
assembly weight is supported by the soil leaving the rig supporting the drill pipe and BHA. This is the point
that is to be reached to release the tool. It is also the point or weight to avoid for extended periods of time
while jetting. This is true of the CART and the CADA tool shown on next page.

CART running tool connections are 4-1/2 IF pin down and 6-5/8 Reg box up unless special ordered.
CADA running tool connections are 6-5/8 Reg pin down and 6-5/8 Reg box up unless special ordered.
SPERRY-SUN CASING DRILL: Running Tool -CADA ( page 2 of 3 )
TOP
VIEW
Cam Actuated Drill Ahead ( CADA ) Running Tool

The CADA tool allows drilling ahead without a costly trip being
made. The string is first turned to the right to retract the dogs and
free the body. At this point the running tool could be pulled and is
frequently picked up a few inches to show it is free. Additional
actions which vary by the make of the tool are done which free
the stem. Drill ahead then proceeds.
• Running Tool stem is freed after retraction of dogs by shearing
pins or by manipulating a J-slot arrangement. This depends on
running tool make.
• Many CADA tool stems travel approximately 3 inches during
engagement. Adjust BHA space out measurements. See the
wellhead service representative for made up lengths.

• Some CADA tools have safety devices to prevent premature

EXTERIOR VIEW
release when using as a handling tool. These must be removed
Illustration only. For
CUT
more information refer prior to tripping in. Other tools have shear pins and the CART
AWAY
VIEW to wellhead company. tool is used to do most of the handling. Required running tools
are stood back prior to running casing.
CAM EXTENDS OR • Remove Plugs in top of Running Tool prior to running.
RETRACTS DOGS
AS STEM IS TURNED • One wellhead service company occasionally attempts to
restrict the RPM of the string to 50 or less to reduce wear on a
wear bushing inside the tool. Normally this is over-ruled in the
interest of good drilling practices.
SPERRY-SUN CASING DRILL: Avoid Running Tool Release Problems ( page 3 of 3 )

• Control motor differential pressure. Keep differential below 100

psi to keep transmission of reactive torque to the running tool low.
Similar to the illustration on right, there is no difference in reactive
torque between a low torque and high torque motor when neither There is no difference in power of a large
has its bit engaged with the formation. The casing drill operation tractor and a weaker car when their drive
generally has light bit engagement as applied weight is absorbed wheels are not engaged with a surface.
Neither transmit reactive drive torque.
through out the length of the casing.
• Excess differential is most likely to occur on return to bottom after working and abruptly returning to the same
applied weight that was used prior to reciprocation. Return to appropriate weight as differential allows.
• Improved bit hydraulics of the medium speed motors versus high speed motors reduce motor differential
and torque by less bit mechanical engagement with formation as a greater percentage is done by “jetting”.

• Don’t spud too deep without pumps. The resulting pack-off may remain, simply being channeled. This drag
increases running tool release problems. This has often been misidentified as “settlings”.
• Stabilizer blades on bearing housings are a source of drag should any packing occur. Initially eliminated on
drill ahead jobs to create a pendulum assembly. As there were no problems, they are commonly omitted.
• Monitor connection make-up. Potential source of torque transmission to running tool and/or turning string.
• Assure top drive brake is on before starting pumps & motor. Easy to overlook on connection make-up.
• Avoid Applied Weight that places running tool at its neutral point for long periods where it is most subject to
the stem turning. Use either less or more to reduce potential turning of the casing and release problems.
• Assist in determining “neutral point” of running tools. Keep accurate weights on Casing, BHA, & Total String
Weight just prior to spud. Tools are difficult to release at any other weight.
• Recommend that when running tool not be backed up slightly when it is made up. This is done to make it
easier to release but the opposite may occur as momentum can develop ( similar to connection make-up ).
SPERRY-SUN CASING DRILL: Drive Pipe Measurement & Preparation ( page 1 of 2 )

PIN END PIN END

10

BOX END BOX END

15

20 • Drive Pipe is measured to determine the overall assembled

length when it is made-up. Some pin ends differ in the points
25
at which they are properly measured for the correct lengths.
See the connection service representative for these points.
Mark each joint with measurement and total for overall length.
30

• The assembled length of the drive pipe determine the BHA’s

length for the bit to be properly located in relation to the shoe.
52.89
35

• Paint the shoe joint white for first 10 feet for visibility by the
40 ROV at spud in.
5 4 3 2 1
• Paint the wellhead housing joint with 5 foot bands starting
52.93

52.85

52.75
53.32

the top of the housing. Paint 1 foot dashes in between these

10’
bands. Marks will be used to land casing with proper stickup.
36” 36” 36” 36” 36”
1-1/2” 1-1/2” 1” 1” 1” • Determine wall thickness and running order of joints. Mark
this on joints for crane operator.
554# 554# 374# 374# 374#
• Determine total calculated air weight of assembly. Compare
HOUSING MID X-O MID SHOE this to block weight when assembly is picked up.
JOINT JOINT JOINT JOINT JOINT
SPERRY-SUN CASING DRILL: Drive Pipe Measurement & Preparation ( page 2 of 2 )
EXAMPLE OF A DRIVE PIPE JOB
JOINTS DRIVE PIPE SIZE WEIGHTS
SEQUENCE OD SIZE FEET WALL WT / FT AIR BUOYED

Shoe 36.0 38.54 1.000 374 14420 12531

Mid 36.0 39.98 1.000 374 14959 12999
Mid 36.0 39.36 1.000 374 14727 12797
Mid 36.0 39.32 1.000 374 14712 12784
X-O 36.0 40.32 1.000 374 15086 13109
Mid 36.0 39.01 1.500 553 21581 18754
WHH 36.0 42.01 1.500 553 23240 20196

TOTAL LENGTH 278.54 TOTAL WEIGHT 118,723 103,170

EXAMPLE OF COMMON DRIVE PIPE SIZES

VARIOUS DRIVE PIPE SIZE WEIGHTS

JOINTS OD SIZE ID SIZE WALL WT / FT AIR BUOYED

Example 30.0 28.00 1.000 310 310 269

Example 30.0 27.00 1.500 457 457 397
Example 36.0 34.00 1.000 374 374 325
Example 36.0 33.50 1.250 464 464 404
Example 36.0 33.00 1.500 553 553 481
Example 36.0 32.00 2.000 727 727 632
Example 38.0 34.00 2.000 770 770 669
Example 38.0 33.50 2.250 860 860 747
SPERRY-SUN CASING DRILL: Stabilization ( page 1 of 1 )

Another option to be considered is the position of stabilizers. Many casing drill jobs have now
been ran with no stabilizer blades around the Bearing Housing as in the past with no problem.
The bottom hole assembly design and stabilizer positions are recommended to maximize the
drill ahead section.

A. Original configuration for Casing Drill Only. Use for drill

ahead only with ROP restricted and light weight on bit.

B. Acceptable alternative to blades on Bearing Housing. Use

for drill ahead if ROP controlled and light weights used.

C. Slick BHA is acceptable for casing drill only. It is not

recommended for drill ahead.

D. Original drill ahead configuration. Difficult to drop angle

once gained. OK for controlled ROP and light weights.

E. Recommended BHA Pendulum for drill ahead. Use for

soft formation and light weights to be applied.

F. Preferred BHA Pendulum for drill ahead. Use for

medium formation and medium weights to be applied.

G. Preferred BHA Pendulum for drill ahead. Use for

A B C D E F G firmer formation and heavier weights to be applied.

Note. One stabilizer is adequate while two provides more

stiffness and hole wiping.
SPERRY-SUN CASING DRILL: Bulls Eye - Measuring Inclination ( page 1 of 2 )

A bulls eye is the main method used to determine drive pipe

verticality. There are two kinds used. One has 5 lines with
each measuring 1 degree. The other is a 2 degree with each
of its 4 lines being 1/2 degree. The 2 degree bulls eye is the
most sensitive and is therefore recommended.
Bulls eyes may be mounted on guide bases or mud mats,
clasped to the upper part of a running tool, or mounted to
the side of the casing. Casing mounted bulls eyes have the
benefit of being the most rigid as well as being closely tied
to the actual casing itself. These can be more difficult to
view as the ROV may not be able to focus on it from directly
overhead. The other locations may be more susceptible to
error in that they could move independent of the casing.
It is difficult to get the bulls eye mounted exactly as it should
be, in fact it is rare to have the ball at zero when it is time to SHOP PREPARED
spud. Bulls eyes mounted on the casing on a shop prepared MOUNT & BRACKET
surface and mount tend to be “zeroed” out the best.
Care must be taken when viewing the bulls eye as the view
angle can be deceiving. A bulls eye that appears to have a
certain reading from an angle can be totally different when
read from the top.
As it is assumed the heavy casing hangs vertically in the
water, the bulls eye reading while hanging is assumed to
equal zero and for drive pipe to be jetted in vertically, the
reading should not change. Change is what is measured.
SPERRY-SUN CASING DRILL: Bulls Eye - Measuring Inclination ( page 2 of 2 )

There are potential problems with all methods used to determine verticality of drive
pipe. MWD tools cannot be centralized properly, other highly accurate tools must
be “zeroed out” much like the bulls eye on the assumption that the casing hangs
straight, unaffected by ocean currents.

Based upon the assumption that the drive pipe is hanging vertical, the bulls-eye
reading is assumed to be equal to zero. This is normally true and only comes into
doubt when there are fast and deep ocean currents such as the loop currents that
impact jobs in the Gulf of Mexico. Shallow currents have little effect as they act
over a much smaller distance on the much smaller area of drill pipe.

Experience has shown that if the currents are such that they do not hinder ROV
operations, the drive pipe can be assumed to hang vertically and that the bulls
eye reading equates to zero.

Example 1 Example 2 If it is suspected that current has deflected the casing, the string can be slowly
A. 06:00 A. 06:00 rotated while observing the bulls eye. The ball will remain in the same relative
clock position if the casing is vertical and will roll to the opposite clock position
if the reading reflects casing that is deflected by the current.

See examples.
• Example 1 illustrates a ball which stays at 6 o’clock relative to the casing through
180 degrees turn. This is indicative of vertical casing with the one degree reading
being due to mounting.
• Example 2 illustrates a ball which moves from the 6 o’clock position to 12 o’clock.
This indicates the casing is not hanging straight.
B. 06:00 B. 12:00
SPERRY-SUN Casing Drill: Calculating Drill String Stretch ( page 1 of 2 )

The stretch of the string above the running tool should be considered when calculating water depth. This
is often misunderstood on rigs and frequently discounted as being insignificant. This could be a problem.
One customer felt that drive pipe slipped three feet on a job when if had not. Stretch had not been taken
into account originally and cuttings piled around the drive pipe on sea floor covering markings.
Stretch occurs in every drill string from the weight of the string alone. This stretch can be ignored. The
stretch due to the weight of the drive pipe, guide base, and mud mat (if used) is a variable that stretches
the string until it is set and supported by the formation. As the weight is relieved, the stretch contracts,
causing water depth to always be deeper than the drill pipe figures indicate when first spudding in.

Casing Assy Wt in Lbs x Length in Feet

Stretch in feet =
30,000,000 x String Cross Sectional Area

Calculations. October, 2000 example. 335.85 ft 38” & 36” set at 8909 ft having 7.1 ft stretch
Drive Pipe Assembly Wts. Steel ( lbs per gal ) = 65.5 Sea Water (lbs per gal ) = 8.6
OD x Wall Length Wt (lbs)
Buoyancy Factor ( Sea Water ) = ( 65.5 - 8.6 ) / 65.5 = .869
36” x 1.00” 205.65 76988 Buoyed Wt. ( Drive Pipe ) = 197015 x 0.869 = 171,206 lbs.
36” x 1.50” 41.74 23124
6-5/8 Drill Pipe Cross Sectional Area
38” x 2.25” 88.26 75904 = ( 6.6252 - 5.9012 ) x 0.7854 = 7.123 sq. inches
Drive Pipe Weight 176015 Rotary to Mud Line ( Ft ) = 8909
Guide Base Wt 21000 Stretch of 8909 ft of 6-5/8” drill pipe due to 171,206 lbs.
Total Assembly Wt 197015 = ( 8909 x 171206 ) / ( 30,000,000 x 7.123 ) = 7.14 feet

Drill Pipe measurements taken when at neutral weight for release of running tool duplicate these calculations
as the casing assembly weight is no longer supported by the drill string.
SPERRY-SUN Casing Drill: Calculating Drill String Stretch ( page 2 of 2 )
Recommended Stretch Calculations ( prior to job )
Stretch Worksheet Enter Mud Weight 8.60 Buoyancy Factor 0.869
CASING OD DRIVE PIPE SIZE WEIGHTS STRETCH DUE TO WEIGHT OF CASING
JOINTS SIZE FEET WALL WT / FT AIR BUOYED WEIGHT String Tubular Tubular Cross Sec Pounds Stretch
Shoe 36.0 43.00 1.000 374 16088 13976 ONLY Length OD ID Area Per Ft Feet
Mid 36.0 43.00 1.000 374 16088 13976 100,000 917 5.000 3.063 12.27 41.74 0.249
Mid 36.0 43.00 1.000 374 16088 13976 100,000 4,016 5.000 4.276 5.27 17.95 2.538
Mid 36.0 43.00 1.000 374 16088 13976
Mid 36.0 43.00 1.500 553 23788 20665
WHH 36.0 49.00 1.500 553 27107 23548

Total Stretch of suspended weight. 2.787

Total Length 264.00 Total Weight 115,249 100,117 Stretch per 10k weight increments 0.279

Examples of Stretch with various Drill Pipe Sizes

Stretch Worksheet Enter Mud Weight 8.60 Buoyancy Factor 0.869
Drill STRETCH DUE TO WEIGHT OF CASING
String WEIGHT D.String Tubular Tubular Cross Sec Stretch
Tubulars ONLY Length OD ID Area Feet
6-5/8 Hevi-Wate 100,000 1,000 6.625 4.500 18.57 0.180
5-1/2 Hevi-Wate 100,000 1,000 5.500 3.375 14.81 0.225
5" Hevi-Wate 100,000 1,000 5.000 3.000 12.57 0.265
6-5/8 25.20# Drill Pipe 100,000 1,000 6.625 5.965 6.53 0.511
5-1/2 24.70# Drill Pipe 100,000 1,000 5.500 4.670 6.63 0.503
5-1/2 21.90# Drill Pipe 100,000 1,000 5.500 4.778 5.83 0.572
5-1/2 19.20# Drill Pipe 100,000 1,000 5.500 4.892 4.96 0.672
5" 25.60# Drill Pipe 100,000 1,000 5.000 4.000 7.07 0.472
5" 19.50# Drill Pipe 100,000 1,000 5.000 4.276 5.27 0.632
5" 16.25# Drill Pipe 100,000 1,000 5.000 4.408 4.37 0.762
100,000 pounds and 1,000 feet used to facilitate transferring stretch to actual weight and depth.
SPERRY-SUN CASING DRILL: Calculating Applied Weight ( page 1 of 3 )

The casing drill operation utilizes a pendulum effect to jet in drive pipe. Control of applied weight is a major
factor in keeping the casing drill vertical while maintaining an effective rate of penetration. Application of too
much weight at any given depth could lead to angle increase while too little weight could slow penetration,
promoting soil erosion or over working the string.

An initial starting weight of 5,000 to 10,000 pounds is used to keep the shoe forming a moving seal against
the formation as penetration begins. Weight is then gradually increased with depth per guidelines applicable
to the drive pipe assembly being run. See example below.

CHART OF EXAMPLE CASING DRILL STRING.

120 WEIGHT IN 1000 POUNDS
USE EXTREME CAUTION IF USING
110 240 feet of 36” Drive Pipe Assembly
MORE THAN 80% OF WEIGHT
80 % OF AVAILABLE WEIGHT 36.0” x 1.00 wall x 374 ppf x 160 feet
100
SLACKED OFF WEIGHT AT NEUTRAL 36.0” x 1.50 wall x 554 ppf x 80 feet
90
9.50” x 3.00” id x 208 ppf x 120 feet
80
8.00” x 2.81” id x 156 ppf x 120 feet
70
Seawater buoyancy factor = 0.869
60 Minimum weight is equal to buoyed weight of
50 casing only which is below mud line.
The maximum weight is equal to buoyed weight
40 of casing plus bha which is below mud line.
30 RED LINE = CASING & BHA WT
GOLD LINE = CASING ONLY WT 500 pounds per foot is weight of casing assembly
20 BLUE LINE = 500 LBS PER FOOT divided by the length and rounded downward to
a convenient working number. Experience has
10 PENETRATION shown this easy to use with good results.
0
0 20 40 60 80 100 120 140 160 180 200 220 240
SPERRY-SUN CASING DRILL: Calculating Applied Weight ( page 2 of 3 )
WEIGHT CHART CALCULATION FOR CASING DRILL
PENT. CASING CASING AIR WEIGHT BHA BHA AIR WEIGHT WEIGHTS WEIGHTS

DEPTH OD WALL CASING PPF OD ID BHA PPF M IN(K) MAX(K)

0 36.00 1.00 374.2 9.50 3.000 208.5 0.0 0.0

10 36.00 1.00 374.2 9.50 3.000 208.5 3.3 5.1
20 36.00 1.00 374.2 9.50 3.000 208.5 6.5 10.1
30 36.00 1.00 374.2 9.50 3.000 208.5 9.8 15.2
40 36.00 1.00 374.2 9.50 3.000 208.5 13.0 20.3
50 36.00 1.00 374.2 9.50 3.000 208.5 16.3 25.3
60 36.00 1.00 374.2 9.50 3.000 208.5 19.5 30.4
70 36.00 1.00 374.2 9.50 3.000 208.5 22.8 35.4
80 36.00 1.00 374.2 9.50 3.000 208.5 26.0 40.5
90 36.00 1.00 374.2 9.50 3.000 208.5 29.3 45.6
100 36.00 1.00 374.2 8.00 2.813 156.0 32.5 50.2
110 36.00 1.00 374.2 8.00 2.813 156.0 35.8 54.8
120 36.00 1.00 374.2 8.00 2.813 156.0 39.0 59.4
130 36.00 1.00 374.2 8.00 2.813 156.0 42.3 64.0
140 36.00 1.00 374.2 8.00 2.813 156.0 45.5 68.6
150 36.00 1.00 374.2 8.00 2.813 156.0 48.8 73.2
160 36.00 1.00 374.2 8.00 2.813 156.0 52.0 77.8
170 36.00 1.50 553.2 8.00 2.813 156.0 56.8 84.0
180 36.00 1.50 553.2 8.00 2.813 156.0 61.6 90.1
190 36.00 1.50 553.2 8.00 2.813 156.0 66.4 96.3
200 36.00 1.50 553.2 8.00 2.813 156.0 71.3 102.5
210 36.00 1.50 553.2 8.00 2.813 156.0 76.1 108.6
220 36.00 1.50 553.2 8.00 2.813 156.0 80.9 114.8
230 36.00 1.50 553.2 8.00 2.813 156.0 85.7 121.0
240 36.00 1.50 553.2 8.00 2.813 156.0 90.5 127.1
SPERRY-SUN CASING DRILL: Calculating Applied Weight ( page 3 of 3 )

Applied weights commonly used.

30” Casing Drill 400 pounds per foot assuming typical casing string of 1” and 1-1/2” walls.
36” Casing Drill 500 pounds per foot assuming typical casing string of 1” and 1-1/2” walls.
These weights have been used extensively with success. They make it easy for the driller and the casing drill
operator to constantly know the proper weight for the current depth by simply multiplying the penetration depth
times the appropriate weight per foot. Distraction from the job at hand is less than reading a prepared chart.

A method that may be used to establish the maximum weight per foot is simply to divide the weight of the casing
and the internal bha assembly as it is first picked up by the number of feet in the assembly. Round the number
downward to a convenient number that is easily calculated while jetting in. Be sure to include a safety factor near
TD and stay on the light side initially to promote verticality. Use weight of casing only if casing walls are less than
1” thick as they may flex too easily.

The applied weight guidelines limits unsupported bending forces by assuring the majority of compression in the
casing string is below the mud line. It also establishes weights that should be reached before reciprocation is
considered which prevents overworking the soil.

Applied weight must never exceed the total available weight ( casing, bha, & guidebase ) as the string above will
be put into compression and quickly bend. A 20% safety margin should be used under normal conditions.
Caution. When near maximum and ROP suddenly increases with no change in weight, it is likely that the drill pipe
is bowing. Picking up on the string should show an immediate applied weight reduction. If not, it was
bowing. Note also that hevi-wate will bow less than drill pipe without permanently bending.

Another weight to be aware of is the weight which places the neutral weight point at the running tool. This is the
weight setting that will be used to release the running tool. It is also the weight at which any transmitted torque
can impact the running tool. Try to avoid prolonged stays at this weight. The neutral point is easiest found by
subtracting the casing, guide base, and mud mat weight from the total string weight just prior to spud in. The
neutral weight point is that in which the block, drill pipe, and bottom hole assembly is supported with no upward or
downward pressure on the dogs of the running tool.
SPERRY-SUN CASING DRILL: General Procedures ( page 1 of 5 )

PRELIMINARY STEPS
Measure BHA Assure all needed components are available. Measure lengths on all potential BHA
components. Mark lengths on pieces with paint stick. Use list to calculate BHA. Keep list for unexpected
changes. Get detail measurements of final components used to prepare final BHA.
Check Casing Equipment Assure that proper slings and casing handling equipment is available. Verify
casing assembly equipment is on hand and ready.
Measure Casing Obtain an accurate, overall assembled length. Pin protectors may need to be removed to
accomplish this. This will determine the BHA components needed to space out the bit to the required amount.
Paint Casing Paint bottom 10 foot of shoe joint white with a black band at 5 feet to use as visual aid when
tagging mud line. Paint White Bands every 5 feet from top of wellhead housing downward for 40 feet. Paint
narrow stripes at one foot intervals between these bands. These will aid in landing with proper stickup.
Measure Running Tool Lower section which will be effective length inside wellhead housing when made
up is applicable to the BHA length and bit space out.
Pre-stage Guidebase Position and secure applicable guidebase and/or mud mat in moon pool.
Calculate Hydraulics Determine Pump make, type, quantity, liner size, output, and maximum strokes &
pressures allowed. Determine drill pipe size to be used. ( More critical in deeper waters. )
Size Bit Nozzles Size for volumes to be used. Consider rig’s capabilities, overall system pressure, and
the range of the motor and operating parameters as well as that of any MWD tool(s).
Stand Back BHA Reduces time casing hangs in moon pool subject to weather conditions. Often can be
done during rig move or while anchoring.
Stand Back Running Tool Have ready to handle casing when it has been assembled.
Prepare Gel Sweep To use 75 barrels per stand. Lined up as new stand being made up, return
to seawater on fly. Have extra 200 to 300 barrels ready if hole conditions ( excess friction ) require.
Record weights Total weight of BHA. Total Weight of Assembled Casing. Total weight of both
when assembled. Also record Total String Weight just prior to spud.
Calculate Stretch The drill string stretch to be calculated is based upon the drill pipe size and length and
the drive pipe weight as that will be lost once running tool is released. The stretch in deep waters can be
significant, approaching 5 feet.
SPERRY-SUN CASING DRILL: General Procedures ( page 2 of 5 )

Assemble Drive Pipe Casing String.

• Have all handling and assembly tools on rig floor. Verify they are adequate for the job.
• Hold pre-assembly meeting with rig crew. Review assembly plan and method. Discuss safety issues.
• Remove master bushing from rotary and rig up elevators and/or slings for casing.
• Begin by lowering shoe joint through rotary first. Handling ears are torch cut slick to the body. Joint is then
secured at rotary. Next joint is then picked up and made up to the prior joint.
• Sequence is repeated until all joints are run, ending with the Well Head Joint made up and secured in rotary.
• After casing string has been assembled, the running tool stand is picked up and engaged in the wellhead
housing joint by 3 to 5 turns to the left depending on make and model of running tool.
• The casing string is lowered through the rotary and set in the guide base assembly secured in the moon
pool. Record weight of the casing string at this time.
• The running tool is then released by rotating the prescribed turns to the right. It is pulled back through the
rotary and stood back.

Run Internal BHA

• The master bushings are replaced and the internal bottom hole assembly is run through the rotary and into
the suspended casing.
• The running tool stand is then made up to the top member of the BHA and the assembly is lowered to the
wellhead housing joint where it is engaged for the final time. Record weight of BHA at this time.
• The motor is commonly tested at this time while the bit extension is checked by ROV .

Rig and Release GuideBase

• Final adjustments and rig ups are done to the guide base assembly, the bulls eye is leveled, and the running
tool is marked for release purposes. Note bulls eye position at this point, going in water and when hanging.
• After completion of all requirements, the guide base assembly tie downs are released and the complete
assembly is ready for the trip to the bottom. Record weight of complete assembly at this time.
SPERRY-SUN CASING DRILL: General Procedures ( page 3 of 5 )

Tripping in
• During the guide base assembly’s entry into the splash zone, there should be no delays.
• Connections should be made up carefully. A sudden turn in the string could affect the running tool.
• With a large mud mat or guide base trip speed should be controlled to avoid “skating”.
• In deeper waters, it may be necessary to fill drill pipe as required for the size run.

At the mud line.

• Record the water depth using drill pipe figures. Note. Depth will be off by stretch of casing weight.
• Assure footage on last stand to exceed 30 feet. Adjust by picking up or laying down single(s).
• Assure all is ready. Pumps, valves open, seawater and gel sweeps in pits, power assigned, etc.
• Recommend that boats be released prior to start as they may cause excess rig movement.
• ROV to check guide base, bulls eye, rotation, running tool, guidelines, etc.
• ROV to then position itself for spud in and start of jetting to monitor for broaching.

Begin Jetting Drive Pipe

• ROV positioned to monitor spud in and to watch for broaching on start up.
• Spud to approximately 10 foot depth or 10,000 pounds applied weight. Stop at whichever comes first.
• Pick up slightly to get bit off bottom to start motor and do so without excess torque occurring.
• Start pumps slowly until drill pipe is filled. Watch for pressure increase.
• At first sign of pressure slack off slowly while raising the pump rates to approximately 75% of full rate.
• Maintain ROP at such rate as to keep 5,000 to 10,000 lbs applied weight. ROP may reach 300 ft/hr briefly.
( this range will allow motor to operate while keeping the casing sealed at this shallow depth )
• Stop pumps immediately if any problems occur. Solve problems at shallow depths, not near full depth.
• At 30 to 40 feet have ROV return to top, check bulls eye, running tool, and standby to monitor returns.
SPERRY-SUN CASING DRILL: General Procedures ( page 4 of 5 )

Jet in Drive Pipe per procedures.

• After initial start, bring pumps up to full rate, keep constant monitoring of motor differential pressure.
• Increase applied weight with depth per applied weight guidelines for the appropriate depth.
( Weight of drive pipe assembly divided by its length and rounded to convenient number )
• Keep string moving, working as required to maintain an effective ROP.
• Maintain a log of time, depth, applied weight, drag and reciprocation lengths, and other notes.
• Monitor guide base, bulls eye, returns, etc. during jetting and at connections.

Reciprocate String as needed to control friction.

• Frequency of working is not pre-determined but dictated by formation and other conditions.
• Work drive pipe as needed to reduce external friction build-up with the soil to a level which enables the
weight of the casing to force itself into the soil at an effective rate of penetration.
• Work pipe when at maximum weight for depth and rate of penetration slows significantly.
• Work pipe before connections to zero drag as the casing will be stationary.
• Reduce drag to near zero in upper sections of hole. Any drag left never disappears, only accumulates.

Jet to target depth.

• Based upon previous observations, begin leaving some drag as the targeted depth is neared with the
goal of having casing nearly stuck upon reaching TD.
• With 10 to 20 feet to go calibrate footage to get to target depth. “DipStick Method”.
- have applied weight near planned maximum and note exact amount.
- observe exact drill pipe penetration depth per the 5 foot markings on drill pipe.
- have driller pickup up casing string at moderate speed while shutting down pumps.
- have ROV positioned to read paint markings on casing where mud coating ends.
- add the indicated distance to penetration depth at pick up point. Return to bottom.
- jet the required footage while arriving at TD with the same applied weight noted prior to pick up.
SPERRY-SUN CASING DRILL: General Procedures ( page 5 of 5 )

At Target Depth
• Shut down pumps upon reaching TD. Do not pump more than necessary.
• Set compensator on if there is any rig heave. The drive pipe must remain motionless as it soaks.
• Notify ROV and have ROV attempt to determine wellhead housing stickup and final bulls eye reading.
- normal time for visibility to clear is approximately an hour unless current carries cuttings away.
- it will most likely be too late to move casing, once visibility clears enough to verify depth.
- this demonstrates the importance of using the previous “dipstick” method to arrive at correct depth.
- If visibility poor have ROV use its depth meter to approximate stickup by touching on the wellhead.
• Soak per customer directions
- desired soak time varies by customer from 1/2 hour to 4 hours.
- actual decision is best made based upon observations of the jetting job itself.
- if casing drill only, soak time can be shortened as it will soak while tripping.
- if drill ahead, may need longer soak time as there will be no trip time.

At Release of Running Tool

• Assist wellhead service representative as needed.
• Running Tool will be released at or near neutral weight. Total weight of string at mud line prior to
spud less the weight of the drive pipe equals the weight at which there will be no downward or
upward force placed on the dogs of the running tool. This is the weight at which it turns freely.
• If casing drill only, once running tool is free, the string is tripped out of hole.
• If drill ahead, additional actions are made to free stem of running tool, enabling drill ahead.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 1 of 7 )

SOIL FRICTION & DRIVE PIPE

Drive Pipe is held in place by soil friction with its exterior. Little to no support is provided
by the bottom of the casing shoe. Friction holding the casing must be stronger than the
total downward force that will be exerted on it, which includes its own weight and enough
additional weight to latch cementing tools into the wellhead housing joint.
Soils have various friction factors but they all must have a frictional advantage over the
weight of the drive pipe in order to support it. The soil must also have some degree of
mobility which allows this friction to be applied against the casing. Overburden pressures
provide the force to remold the disturbed soil around the casing as water is squeezed out
SIDE FRICTION

and the formation’s grip on the drive pipe is tightened.

The greater the surface area exposed to soil’s friction the greater the total support of the
drive pipe. Soft formations having a low frictional factor require more length to achieve
the total gripping force needed versus those with high friction factors. Larger diameters
can also increase surface area. As an example, the area of 36” x 1” wall casing is 1.44
times greater than 30” x 1” wall with only 1.21 times the weight.
Overburden pressures increase with depth. Pressures, being equal in all directions at any
one depth, exert force horizontally against the casing causing the friction per square inch
to increase with depth. Absent any other variables, the soil’s grip tightens with penetration
from both greater friction and increased surface area.
As Drive Pipe dimensions and lengths must be predetermined, it is advisable to err on
the side of caution in the design of the casing string which will interact with the formation.
The average length used in the Gulf of Mexico is approximately 260 feet with the typical
range being from 205 feet to 400 plus feet.
The designed length of drive pipe should also consideration the formation in which the
LITTLE TO NO
UPWARD shoe will be set. While it provides little direct support to the casing, it does support the
SUPPORT formations above which in turn hold the casing in place.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 2 of 7 )

EXAMPLE: UNDISTURBED SOIL STRENGTH A customer had soil studies done for a South China Seas
25 well batch set done in 1994 producing charts on the
0 ä
ä ä MINATURE VANE formation’s Undisturbed Soil Strength, Ultimate Capacity,
ä ä
9
9 UU Triaxial I and Soak Time.
ä 4 DSS
P 9ä
9
E The Undisturbed Soil Strength Chart demonstrates that
N
40 &=30° rdd=16° N’=q=20 fMAX-0.3KAf, qMAX-20KAf II even in the relatively short distance of a drive pipe job,
E
ä 9
49 ä
III formation characteristics may vary. These variables may
T ä9 have the potential to impact the job.
ä
R ä
A 80
9 IV The chart indicates a hard spot near the surface In this
ä
T ä
+ INTERPRETED SHEAR case and a soft layer of soil just above the target depth.
I ä
9 ä STRENGTH PROFILE The hard area required slightly more aggressive weight
O ä 9
application with little impact. Damage to the deeper soft
ä
N 120
9 area was avoided by making sure there were no delays
ä
ä
ä
V while drilling through it. The planned depth assured that
B +
E the shoe would be in a firm formation providing support
9
L for the formation(s) above.
O
160
VI
ä
&=25° rd
d=20° N’=q=12 fMAX-1.0KAf, qMAX-1.4KAf Just as the formations may vary over the course length
W
9
ä VII of the drive pipe they may vary from one area to another.
ä
S 9 ä Occasional significant formation variables which have
E 200 impacted jobs in the Gulf of Mexico include dead coral
A
reefs, cement migration from a nearby well, sands that
F NOTE: DSS Shear strength baredon:
L Su = ( r / &vc ) x Pc x (OCR) 0.8
react to working with increased rather than decreased
O 240 SOUTH CHINA SEAS friction, and submerged wood debris 300 feet thick. The
O more troublesome formations may be those that are too
R soft. The bottom 150’ of a job in Mississippi Canyon 667
was so unstable that the next section could not be drilled
280
0 0.8 1.6 2.4 3.2 4.0 without the drive pipe being supported by a mud mat.
( KIPS / FT2 )
SPERRY-SUN
EXAMPLE: CASING
ULTIMATE DRILL: Surface Formations & their Support
CAPACITY ( page 3 of 7 )
600
ULTIMATE CAPACITY EXAMPLE: ULTIMATE CAPACITY
The casing drill operation cannot improve the
500
soil’s ability to hold drive pipe. Disturbance of
UPPER
U.E.=.25 x q(ud) ESTIMATE the formation can only be minimized. Casing
400 JETTING drill operations must be done on a individual
L.E.=.40 x q(rem) basis using sound principles and reading the
indicators available.
300
LOWER • WOB within applied weight guidelines
ESTIMATE
JETTING • Pump Rates adequate to clean hole
200 • ROP sufficient to avoid washouts
K • Working String as needed to control friction
100 I • Drag monitored to indicate actions to take.
P • Sweeps as needed to clean hole & coat hole.
PENETRATION S
PENETRATION • Low Motor Differential to restrict torque
0
0 20 40 60 80 100 120 140 160 180 200

450
EXAMPLE: SOAK TIME
400
The study indicates that while soil continues to
350
cure around drive pipe for more than a month a
300 K large percentage is healed in a short period of
SOAK TIME time, with over 50% of the total capacity of the
250 I
SOUTH CHINA SEAS P soil being reached in the first hour. While every
200
S location will differ in the mobility, friction factor,
150 and ultimate capacity of its soil, the time curve is
a fairly accurate description of soak time of the
100
TIME - HOURS casing drill operation. This study also agrees
0 0 5 10 15 20 25 30 35 40 with field observations.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 4 of 7 )
Formation Washout and Friction Loss
Washouts of formation are a potential loss of frictional area(s). In most cases these are a
result of improper casing drill technique and may be indicated by an excessive amount of
time taken to jet in. Reportedly some casing drill jobs have taken 16 to 20 hours.
NO
EXTERNAL The chief cause of a self inflicted washout is an effort to avoid reciprocation with the drive pipe
FRICTION
remaining virtually stationary allowing hydraulic flow to erode the formation. In fact, progress
may only be made due to this erosion. It is preferable to have the disturbed soil kept to a thin
layer surrounding the casing by controlling friction through timely reciprocation. The soil can
more quickly and easily heal as opposed to washed out areas that may never heal and provide
support.
The odd thing about trying to avoid reciprocation is that it may actually increase it as friction
FORMATION
builds more rapidly during slow movements of the casing. Reciprocation may not be reduced
WASHOUT but actually increased with its frequency simply spread out over a larger time frame.

Shoe Erosion and Friction Loss

The maximum holding capacity of the soil can be diminished by shoe erosion and/or formation
sloughing when drilling ahead. The immediate shoe area is not the concern but rather loss of
its support for above formations and their friction. The formations may be weak or erosion may
be encouraged by some drilling practices.
• Do not pump needlessly upon reaching setting depth of casing. It serves no good purpose.
• Expend the least amount of hydraulic energy as possible when starting drill ahead. Start at
a slightly reduced rate but one that will clean hole and bit and allow immediate drilling. This
allows the turbulent bit hydraulics to quickly be replaced by annular flow at the shoe.
• Eroding force of high annular flows can be significant. Restrict volume over that necessary
to maintain required rate of penetration and adequate hole cleaning.
Note: see example of formation problem at shoe on next page. Ref. Mud Mats.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 5 of 7 )
Mud Mats and Support they provide.
Mud Mats are occasionally used for hydrate deflection or to provide support. Some state
that calculations show they cannot support the weight of all drive pipe and surface casing
that could be placed on them. While true, this ignores the support that a mat supplies is in
addition to, not in place of drive pipe friction and that this additional support could prevent
a failure. The amount of load support provided by a mud mat depends on its size and the
firmness of the sea bed. It is typical to see a 20,000 to 30,000 pound increase in slacked
off weight when landing a mud mat. This is not to advocate their use as that is probably a
cost issue. It is simply to define their use as possible support. See example below.

Sloughing-Mud Mat Support: 36” Casing Drill and 24” Drill Ahead Mississippi Canyon 667 March, 2001
36”x336’ drive pipe was jetted from 3020’ to 3343’ The first 140’ was firmer than average requiring working every
10’ beginning at 80’. The formation below 140’ did not require any working. The string was only picked up slightly
to check drag at the connections and near TD. Soak time was extended to 4 hours due the apparent softness of
the soil with a successful 100k over pull test done prior to release. 24” drill ahead then proceeded to 394’ below
the 36” shoe when ECD readings suddenly jumped with the drive pipe suddenly falling 7 feet below the mud line.
The string was retrieved and the drive was jetted in a second time.
The second time a 180k over pull was done with no movement, the drill string was pulled and the motor laid down.
The 24” section was slowly rotary drilled with minimal flow rates. At 182 feet below the shoe, the 36” fell again. The
string was again retrieved. A closer look at well offsets in the area revealed that all of the wells had used mud mats
and all had fell a few feet but were still useable. The string we were attempting to jet in was much heavier with top
joints weighing 860 pounds per foot and we had no mud mat.
The third attempt was done with 393 feet with 2 of the heavier joints replaced with lighter ones. A mud mat was
used and the bottom was cemented before the 24” section was drilled. This was completed with no additional
problems. This is the most obvious case of soft formation falling away from the drive pipe in our records. This was
an “undrillable” formation without a mud mat. Other formations may be slightly firmer but be subject to a similar
problem should erosion at the shoe be excessive.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 6 of 7)

Inadequate Surface Area ( Length ) Green Canyon 854 January, 1999

OVER OVER
BURDEN BURDEN 36” x 180.35’ drive pipe was jetted in from 5467’ to 5640’, soaked 2.5 hours, with the 26” drill
ahead proceeding to 6185’ at which point the drive pipe fell. A second string of 36” x 211.30’
drive pipe was jetted in, soaked, released, motor laid down, 26” section rotary drilled and
completed.
The 36” casing string was shortened to 180 feet from the customers normal 215 feet to reduce
the sting’s weight because he knew the surface formation to be extremely soft. Consideration
was not given to the other factor - reduced frictional area. Pre-job warnings that a longer string
was needed to gain the support needed were ignored until after the failure occurred.
Formations with a small frictional advantage over the weight of the casing need more surface
area ( length in this case ) to attain the total support needed. Note also that soil’s support in a
homogeneous formation becomes greater with depth as the increased overburden pressure
causes a tightening grip against the drive pipe .

Inadequate Surface Area ( Diameter ) South Marsh Island January,1997

30” x 200.21’ drive pipe was jetted in from 515’ to 705’ with 26” drill ahead being completed
to 1540’. The 20” was run and latched into wellhead before the drive pipe fell when an extra
40,000 pounds was set down to try to get a tool to function. The 30” string was pulled and
replaced by a 36” string of similar length which was run successfully.
The engineer stated that the well design prevented the use of a mud mat and that the soil
study indicated that 36” should be run as the formation was slightly too soft to support 30”.
The decision to use 30” was made to save costs.
INADEQUATE
SURFACE If considering 30” casing versus 36” casing, it might be noted that with both having 1 inch
FRICTION walls, the 36” will have 1.44 times the surface area while it will only have 1.21 times the
AREAS
weight.
SPERRY-SUN CASING DRILL: Surface Formations & their Support ( page 7 of 7 )
Drive Pipe and Surface Casing
The drive pipe is temporarily supported by soil friction only. Final support comes when surface
casing is ran and cemented into place along with the drive pipe. Load support is then provided by
the surface casing while the drive pipe provides structural support resisting side flexing.
The surface casing and drive pipe assemblies are joined together prior to and during the cement
operation by a wellhead service company’s rigid lockdown tool(s). Up to 100,000 pounds may be
required to lock the tool(s) into the well head housing. Support from the rig can then be provided
during the cement operation. Once the cement has set sufficiently to assure support, the running
string is released and pulled.
Caution should be used. Application of excessive weight on the drive pipe prior to the setting up of
cement to the degree that it can support the surface casing weight could result in an unnecessary
job failure. The many variables associated with these operations and their impact may not always
be taken into consideration.
Effective weight of surface casing available at wellhead housing of the drive pipe can vary greatly.
This may be due to different grades and weight per foot of the casing or to the total length of the
casing which may vary from 600’ to 3,000’ as well as to the hole itself.
A hole with high drag can absorb much of the casing weight while a hole with little drag may leave
most of the weight available at the drive pipe. Hole sizes for common 20” surface casing may be
either 24” or 26” diameter with the 24” hole typically expected to have more drag. Other factors
such as formation, drilling rates, hole cleaning, and mud weights can impact a hole’s drag and
resulting available weight.
One job having low available weight or high friction of drive pipe may enable early release of the
running string but this does not mean that circumstances of the next job will necessarily enable
early release. Each job may have different “available weight” of surface casing as well as different
ability of drive pipe to support weight.
SPERRY-SUN CASING DRILL: Reciprocating the string ( page 1 of 3 )

The same formation friction which will hold drive pipe in place must be controlled during jetting to
have weight available to enable penetration. Friction increases as the soil continually attempts to
remold itself around the casing, as deeper penetration exposes more surface area of the drive
pipe to the formation.

Friction build-up along drive pipe’s length can absorb the applied weight, preventing it from being
available for an effective rate of penetration. The string must be reciprocated when a significant
significant slowing of penetration with proper weight applied indicates this has happened. Working
breaks friction and liquefies the surrounding soil. The frequency of working the string or the length
of the working stroke cannot be predetermined. Soil characteristics dictate reciprocation and vary
with each well.

Applied weight guidelines with rate of penetration indicate when a string should be worked. Over
pull or drag indicate the working stroke length. Proper use of these indicators prevent over working
or under working the drive pipe.

General Guidelines for Working Drive Pipe

• Work only when ROP slows significantly with proper weight applied relative to current depth.
• Work to zero drag before each connection. Last connection to be more than 30 feet from T.D.
• Monitor initial pickup for excess over-pull. Stay below drill string over-pull limits.
• Work at fast pace ( plus 1 foot per second ) to liquefy soil and reduce friction.
• Work at consistent pace as rate influences weight indicator readings.
• Work at established pace to enable comparisons to be made at differing depths.
• Work until over pull has been reduced to acceptable levels relative to hole depth.
- Drag in upper sections reduced to less than 10,000 lbs. Remaining drag never disappears.
- Drag is allowed to remain in lower sections as conditions warrant. Allow drag increase near T.D.
• Return to bottom, gradually returning to appropriate weight as motor differential allows. A sudden
increase in applied weight could generate excess motor differential and transmit torque.
• Work string slowly during any delays. A motionless string at depth could result in stuck pipe.
SPERRY-SUN CASING DRILL: Reciprocating the string ( page 2 of 3 )

One advantage of the casing drill operation is its speed. However, the primary goal in
setting drive pipe should be to set it in a timely manner, consistent with good practices
that cause minimal soil damage. This allows the soil to achieve the maximum holding
capacity which its frictional and mobility characteristics allow.

Failure to work the string in an effective, timely manner may be one of the chief causes
of improperly set drive pipe. Excess weight application can cause the casing to deviate
from vertical. Jetting at one depth for long periods or jetting too slowly may encourage
soil erosion or washed out areas that do not properly heal as the over-burden pressures
attempt to squeeze the water from the disturbed soil in the process of remolding itself
around the casing. This results in less frictional area to support the casing.
NO
EXTERNAL
FRICTION
Drive pipe must be kept moving. It should be worked when, and only when, soil friction
build-up along the pipe has slowed the rate of penetration to an unacceptable level while
having the proper weight applied for the present depth.Goals of working should be:
• Prevent expenditure of too much hydraulic energy at any one depth causing washout(s)
which may not heal with the total surface friction area being reduced.
.
• Keep disturbed soil to a thin layer immediately surrounding the drive pipe to minimize
the soak time required for the soil to heal around the casing.
• Speed ROP by reducing friction, allowing completion in a timely manner.
• Note. Near setting depth allow friction build up. Don’t break drag down completely.

Soil healing is better facilitated by the thin layers of disturbed soil from penetration and
AVOID LOSS OF working the casing string as opposed to voids where excess washing occurred. Working
FRICTION
AREAS depends on the soil. Its frequency has varied from zero to 50 or more times. A string
FROM
WASHOUTS which does not require working or jets in too easily may indicate that the soil will not hold
KEEP STRING the casing in place. One that is properly done but still requires multiple working with high
MOVING drag usually indicates that it will hold the casing in place.
SPERRY-SUN CASING DRILL: Reciprocating the string ( page 3 of 3 )
FORMATION INFLUENCES
Formations differ, having various frictional and mobility factors. Soil conditions influence
penetration rates, weight applied, and working frequency. Soft soils that require little to no
EXCESS
working may be cause for concern that there is not enough friction to support the drive pipe.
FRICTION Hard formations such as sands, coral reefs, and migrated cement from a nearby well may
AREA dictate exceeding weight application guidelines and frequent working.
ABOVE
WORKING
AREA Occasionally a formation is penetrated easily only to later build up excessive drag. This may be
above the reach of the current stand being jetted as indicated by over pull remaining with the
string worked at its highest stroke. If repeated attempts fail to break this drag, it is best to
pull and set back the stand(s) until the problem area can be worked and to then coat the hole
with a gel sweep. Then replace stand(s) and resume normal jetting. Experience has shown
that this is much more effective as opposed to fighting to make hole and risking over worked
or washed out areas. Note. Gel sweeps should only be used to clean the hole unless a
friction problem is known to exist as friction is desired once drive pipe is in place.

One job in 6700 feet of water had wood beginning at 40 feet and continuing past the drive pipe
landing depth. This required application of 50,000 pounds over the appropriate weight with only
3 to 4 feet of penetration being made before reciprocation was required. Over pull
would break down immediately with a 5 foot stroke. Bit torque could not be controlled as it
broke through the wood. This was so severe that the drill ahead tool had to be pulled and
replaced by a regular running tool. Job was eventually completed successfully.

One job had cement in the soil which had migrated from a nearby well. This required 80,000
excess application of weight at 5 foot depth to make penetration. The alternative was to not
make hole and to broach. Excess weight was required to a depth of 75 feet before conditions
returned to near normal. This job was similar to others such as jetting through dead coral reefs.
SPERRY-SUN CASING DRILL: Reciprocating the string ( page 3 of 3 )
RIG INFLUENCES
Frequency of reciprocation is also influenced by the rig and its equipment. Delays or periods
of non-movement promote increased friction as the soil continually attempts to remold itself
around the drive pipe. During any equipment problems, the string should be kept moving. If
delay is expected to be of a long duration, pull stands and wait at a shallow depth that cannot
stick the pipe prematurely. Greater movement of drive pipe equates to less friction build up
and less working.
Connection make-up time greatly influences reciprocation frequency. A slow connection not
only looses time directly but also looses the additional time spent working the drill string to
break the higher than necessary built up friction. A phenomenon associated with the makeup
of all connections is that the built up drag tends to slightly higher that the depth at which
the connection was made. Rigs with a high working stroke enable this area to be reached,
making it easier to break this friction. Note. This should only be done when it is certain that
drag is at a level that will permit returning to the normal working area.

VERTICAL EFFECT OF WORKING

Reciprocation of the drill string has a correcting effect on the verticality of drive pipe if the rig
is directly above the well as it should be. Drive pipe pulled directly upward tends to straighten
any deviation from vertical that may have been induced by application of excessive weight.
The shoe then tends to trim any formation that is off-center as it returns to bottom with light
weight applied. This is the reason that hard formations where excess weights were applied
can be set near vertical. These formations not only required extra weight but also extra
reciprocation. One condition to always avoid is to penetrate long distances with excessive
weight.
Note: the location of the rig should be as near over the well as is possible to promote drive
pipe verticality. Boats should not be tied up during the early stages of a casing drill job as
they may pull the rig off location.
SPERRY-SUN CASING DRILL: Turning the Drive Pipe Assembly ( page 1 of 2 )

Many wellhead systems use a guidebase with guidelines. The guidebase must not rotate to the point that
proper installation of subsea equipment is prevented. It is difficult to know if this occurs without a ROV.
The ROV uses its heading when sighting across two posts to determine rotation. Guidelines can be eyed
for straightness in the moon pool but this is only partially effective and only at shallow water depths.

Mud motors may impart reactive torque to the left as the bit turns to the right. Keeping motor differential
pressure to a minimum reduces this tendency. Although many casing strings may turn slightly to the left,
a substantial number also turn to the right which cannot be due to the motor. Other causes of rotation
include the formations and torque which is trapped in the string during connection makeup and which is
then worked into the string. Typically the rotation is not to the degree that it needs correcting. One well
head service company uses a swiveling guidebase assembly which also does not need correcting.

If necessary the guidebase rotation can be corrected. This was done on a 25 well batch set in the South
China Seas which had a unique need for the wellheads to be oriented to a 306.8º heading ( ± 2º ). This
was done successfully with few problems and very little lost time. A gyro was mounted on the guidebase
which provided constant updates with no delays. The corrections were done at 190’ to 200’ depth.

Turning the drive pipe works due to two factors. First, the running tool is difficult to turn when it is not at
neutral weight. Second, friction has a limited amount of force with which to hold the casing. When the
string is moved vertically the friction attempts to hold the casing ( tensional force ) in place, leaving little
if any to counteract the torque force. Torque virtually disappears when string is move vertically. For this
reason the string can be turned at or near full depth.

The above statement does not advocate turning the casing string. It only is an attempt to make clear that
it can be done. The turning of the drive pipe must be done cautiously in small increments with close
monitoring or it should not be done at all.
SPERRY-SUN CASING DRILL: Turning the Drive Pipe Assembly ( page 2 of 2 )

METHOD TO TURN CASING STRING IF ABSOLUTELY REQUIRED.

• Have ROV monitor each step closely. The ROV takes heading readings to determine orientation.
• Should a correction be required in the orientation of the drive pipe string, it is easiest to do it as high
as possible where frictional forces are less but can be done at deeper depths.
• Assure each step will be done with caution and closely monitored or don’t do it.
• Make sure running tool is not at, nor will it get to neutral weight during adjustment.
• Pre-load 2000 to 5000 pounds of torque in the top drive keeping below torque levels that would affect
the running tool or drill string connections.
• Have driller turn string in small increments of 45 degrees or less. Check that this has not rotated stem
of running tool both before and after working string.
• Work pipe upwards, allowing toque to work into casing string, turning the string. May require several
trips to obtain turn desired. Tendency is to over correct.
• If turn is achieved, release top drive brake to eliminate any trapped torque.
• Return to bottom, check turn achieved. May loose some of the turn on return.
• Repeat procedure until desired effects achieved. Monitor during entire operation.

The above is not a recommendation that the procedure be done. Only statement that it can be done.
There are two obstacles to doing this procedure. First is the natural opposition by many of the well
head service company personnel. Second is the fact that it seems to attract a committee of well
intended help but one which hinders getting it done. A certain degree of trial and error is involved
and the operation must be done with patience.
SPERRY-SUN CASING DRILL: Why Drill Ahead or Not Drill Ahead ( page 1 of 1 )

The decision to drill ahead or to trip out,and change the bottom hole assembly before drilling
the next section is influenced by several factors. They include economic reasons, hole or
angle concerns, operational problems or a combination of these.

Economically, the Drill-Ahead operation is most justified when:

• Rig Rates are high magnifying value of trip time savings.
• Water depth is great, increasing trip time and associated costs.
• Rig is slow on trip or change over time, increasing costs.
• Next hole section is short maximizing cost savings of drill ahead.

Other reasons the Drill-Ahead method has been employed:

• Hole is to be control drilled and angle is important concern.
• Rotary revolutions must be lessened or controlled for guidelines, wellhead housing
wear, etc.

Reasons that Drill Ahead operation has not been employed.

• “Pump & Dump” operation where a mud is to be used to control a water flow and the
possibility of gumbo is high. The running tool with its relatively small ports runs a
substantial risk of packing off should gumbo be severe which can lead to the drive
pipe falling.
• Utilization of extra soak time required for soft formations or other hole problems.
• Future equipment or supplies to not be immediately available making time savings
irrelevant.
• Failure to release running tool for drilling ahead.
• Pump rates to be beyond a mud motor’s capabilities.
SPERRY-SUN CASING DRILL: Drilling Ahead Factors ( page 1 of 1)

Drilling-Ahead

Factors monitored while drilling ahead:

Rate of Penetration
Weight on Bit
Total System Pressure
Motor Differential Pressure
Rotary Speed and Torque
Inclination
E.C.D. Readings
Returns at well head housing
Flow checks at connections

Important factors:
Planned pump rates are achieved pump rates.
Both Annular and Bit Hydraulics considered.
SPERRY-SUN CASING DRILL: Start Drill Ahead ( page 1 of 2 )

The CADA running tool is released by rotating the drill string prescribed number of turns to
the right which retracts dogs that have locked the body of the tool into the wellhead housing.
The CADA tool is free at this point to be pulled out of the hole. When drilling ahead and
depending on tool design, shear pins are either sheared by additional torque or the tool is
picked up slightly and turned slightly to right to align a J-slot. These additional actions
release the stem along with the rest of the drill string to pass through the tool body to allow
drilling ahead.

Start Drill Ahead…………...

• Pickup bit off bottom. Lift string as high as possible leaving running tool seated in wellhead.
• Lock top drive brake. There is to be no string rotation until stem clears body ( 3 to 5 ft ).
• Pump at slightly reduced rate. Must be adequate to start motor and clean bit as less will not
allow drilling ahead and could lead to shoe formation erosion by extended stay(s) at shoe.
• Immediately start to drill, quickly changing the bit hydraulic turbulence to annular flow at shoe.
• Weight is monitored closely, any substantial increase indicates that stem is not free. Excess
weight cannot be used to force drilling as this will lead to bent pipe.
• Once stem has cleared body start string rotation at moderate RPM until stabilizers clear shoe.
• Keep initial applied weights relatively light to encourage verticality. A straight start allows a
higher average ROP to be achieved versus being forced to later drop angle.
• Increase pump rates as flow around shoe changes from bit turbulence to annular flow.
• Speed string rotation to desired rate when stabilizers clear casing. Begin normal drilling.
Note: faster revolutions ( near 100 ) usually promote a straighter, vertical hole.
SPERRY-SUN CASING DRILL: Start Drill Ahead ( page 2 of 2 )

FAILURE TO DRILL AHEAD

One of three reasons may make the start of drilling ahead difficult or in some rare cases
cause it to fail altogether:
• The CADA tool may not have released internally due to mechanical malfunction or sand
getting in the mechanisms.
• The bit may be packed off and balled up. There must be sufficient hydraulic power and jet
velocity to adequately clean the bit.
RELEASE
• The mud motor may have stalled either because it got packed off in the release process
FAILURE
and/or the pumped volume is too low to start the motor.

The bit is often packed off and balled up by the drop of the stem as it is released from the
running tool. This makes the motor more difficult to start and requires the bit be cleaned.
Raising the string slightly and increasing volume usually solves these conditions.
BALLED BIT
Pumping too slowly can prevent drilling ahead. Multiple attempts and extended stays at the
shoe not only loose time but can also lead to the shoe erosion that low volumes are intended
to prevent.

Recommend adequate volume and immediate drilling away from shoe to expend the least
amount of turbulent hydraulic energy possible in this area. Bit turbulence is replaced by
annular flow with a few feet of penetration.

It is important to immediately recognize failure to drill ahead. There should be little weight
required to proceed. If any significant weight is taken - stop immediately.

See this and other concerns on next page

STALLED
MOTOR
SPERRY-SUN CASING DRILL: Erosion of Shoe Formation ( page 1 of 1 )

The maximum holding capacity of the soil and drive pipe can be reduced in the shoe
area. The reduction is not directly from loss of the bottom as the shoe itself provides
little support but in loss of side frictional surface area should sloughing occur. This
could be the result of the formation being weak and/or it could be encouraged by

NO FRICTION
FRICTION FRICTION
SURFACE SURFACE some drilling practices.

There are four drilling practices to consider to minimize this potential problem.
• Excess pumping on reaching drive pipe depth. Stop pumps quickly. Pumps can
always be started again if needed during release of running tool.
• Expend the least amount of turbulent bit hydraulic energy at the shoe as is possible
when starting drill ahead operation. Pump rates may be reduced slightly but not less
than required to start the motor and/or clean the bit. Either a stalled motor or a balled
up bit could cause erosion by increased time spent in shoe area. It is better to start
WEAK
pumps at a rate that assures drilling can proceed, quickly moving away from this
FORMATION area so that bit hydraulic turbulence in this area is quickly replaced by annular flow.
• Jet sub washout as it passes shoe. Reduce this concern by avoiding delays in this
area with pumps at full rate. Drill past quickly. The use of a medium speed motor
will eliminate need for a jet sub unless very high volumes required.
• Eroding force of high annular flow rates can be significant in soft formations. This
could include the shoe area where the flow exits the smaller open hole as it enters
the drive pipe annulus. The shoe area is exposed to the annular flow for the entire
time of the drill ahead section. While high flow rates assist in drilling and cleaning
Balled Up Bit prevents
drill ahead. Must have the hole, volume simply for the sake of volume alone, could be harmful to weak
adequate jet velocity to formations in the shoe area. A volume compromise may be considered in known
clean the bit. weak areas.
SPERRY-SUN CASING DRILL: Shallow Water Flow Zones ( page 1 of 2 )

Some areas in the Gulf of Mexico have shallow water flow zones. There are various methods
employed in drilling through these zones. They include:

Slow, controlled drilling rate in an attempt to not fracture a weak zone and avoid the flow.
This had limited success and is costly in drilling time.

Simply drill through the zone and allowing it to flow while drilling continues.
This can result in huge areas being washed out with accompanied cement problems.

Drill at very fast rate where the cuttings act as a weighted mud thereby holding the flow back.
This has proven successful when it has been completely thought through and committed to.
The one overriding principal is to load the hole to a certain and consistent point meeting an
pre-established ECD reading that equates to a particular mud weight. All other parameters
and drilling practices take a backseat to meeting this one goal. ie, back reaming, pauses in
drilling with pumps on, surveys, hole inclination, gel sweeps, etc. There must be penetration
occurring any time pumps are on.

“Pump & Dump”. Drill with weighted mud to hold flow back with returns back to the sea.
Drilling through actual or suspected shallow water flow zones with weighted mud with returns
to the sea floor is currently the predominant method used. There are two styles employed:
• Drill with seawater until a flow in encountered and then switch to a weighted mud. This is to
done quickly to avoid large washed out areas in the hole. One advantage of this is that it
identifies whether or not there is a flow for future use.
• Switch to the weighted mud at a predetermined depth above the suspected or known water
flow zone. The advantage of this style is there is no formation damage. The disadvantage
is that mud may have been used that was not required as there was no actual flow. This
not only applies to the current well but to future wells as well.
SPERRY-SUN CASING DRILL: Shallow Water Flow & Pump & Dump” ( page 2 of 2 )
“Pump & Dump”. (continued)
The “Pump & Dump” operation is usually drilled at a fast rate. There is a need to make the most
hole while using the least amount of mud due to the expense of the mud and logistics. The mud
is usually brought out in a concentrated form and cut back on the rig.
There are three concerns that should be considered when going to a pump & dump operation.
• Total available mud. The total mud required is often under estimated. Recommend checking
how much mud it will take pumping and drilling at the operator’s stated rates and comparing
this to the total available.
• It will be difficult to get surveys from an MWD tool due to the “U-tube effect” of the heavier
mud falling through the drill string. It is not held back by the lighter seawater.
• Gumbo has a high possibility of occurring using mud, especially fresh water gel mud which
is very reactive with gumbo formations. Hi-salt muds tend to be less of a problem.
Gumbo problems may be so severe that a drill ahead operation may not be feasible as the
restricted openings in the running tool are subject to completely packing off, creating the
equivalent of a giant hydraulic cylinder. The bond between the drive pipe and soil can be
weakened with the casing subsequently falling. One cannot count on the gumbo to push the
running tool up. Although this has occurred, there have also been instances where a “free” tool
has taken 300,000 pounds of over-pull to pull out of the wellhead housing.
If a gumbo attack is probable, it may be wiser to pull running tool before drilling ahead. If it is
just possible or if it is not known whether mud will be used, everyone that can contribute to
recognizing this problem when and if it occurs should be placed on a high alert status. This
includes drillers, ROV personnel, and MWD staff should PWD readings be available.

Wells in their early stages have been lost to gumbo. Drive pipe has fallen due to gumbo. Gumbo
has covered well head housings with 10 feet of stickup to the point that they were unusable.
SPERRY-SUN Hydraulics: Diverting Flow and Calculations ( page 1 of 5 )

A. Flow In DIVERTING EXCESS FLOW

Motor’s may be equipped with either a by-pass rotor or a jet sub to divert that portion of flow which
would exceed normal capacity of the rotor/stator. Flow will initially route itself through the diverting
path until the pressure of the flow through the nozzle(s) reaches the point needed to overcome the
frictional resistance of the motor to turn. Volume will then route itself between the rotor/stator and
the diverting path in the ratios needed to maintain a pressure equilibrium under varying flow rates
and motor resistance levels. Pressure equalizes within a conduit.
MOTOR FLOW WITH BY-PASS ROTOR
A motor with a by-pass rotor which diverts excess flow from the rotor/stator has the advantage
BY PASS ROTOR

of the flow reuniting before exiting from the bit. This makes bit hydraulic changes less severe
than the changes that occur when a jet sub is used. Uniform motor resistance pressure results
in a constant by-pass volume with increases in volume going through the stator. Flow through
the stator and by-pass vary as bit engagement with soil changes the motor differential pressure.
Higher differential pressures create greater resistance to the motor turning which generates
more by-pass and less stator volume to keep pressures equalized. Flow is greatest through the
rotor/stator when off-bottom and flow through the by-pass must only equalize with the motor
operational pressure.
MOTOR FLOW WITH JET SUB
A jet sub diverts a portion of flow prior to entry into the motor which does not exit through the bit
as it does with by-pass rotor. Flow volumes through the jet sub and the rotor/stator fluctuate from
both differential changes and volume changes with a much greater impact on the bit hydraulics.
Changes in nozzle sizes on both the jet sub and the bit have a greater impact on bit hydraulics
as well as the flow ratios through the rotor/stator and jet sub. As with the by-pass rotor, motor
operational pressure and differential pressure impact fluid flow ratios. Unlike the by-pass rotor,
bit pressure drop directly affects fluid diversion ratios.
B. Flow Out
SPERRY-SUN Hydraulics: Diverting Flow and Calculations ( page 2 of 5 )
Example: Hydraulic Worksheet for motor with By-Pass Rotor.
CASING DRILL HYDRAULIC WORKSHEET 01/01/2002 Bit Nozzles By-Pass Nz
Customer Info QTY SIZE QTY SIZE
Location and Lease Info input nozzle sizes on right 1 22 1 28
input motor data in highlighted fields 1 22
input mud properties. 1 22
input volume to be calculated. 1 22
TFA 1.485 TFA 0.601
Equivalent Bit TFA 1.563
9-5/8 SperryDrill R3/4 Slick Straight Motor with By-Pass Rotor Mud properties Motor Total
Motor Maximums Off-Btm Ave. Max Motor B.Assy Mud Plastic Yield By-Pass Drillng
Volume Bit Operate Mtr Diff Mtr Diff Max Loss Weight Viscosity Point Nozzle Volume
GPM Pressure psi psi psi RPM % ppg pv yp tfa gpm
1200 750 100 200 400 375 5 8.6 3 2 0.601 1400
Mud Mtr Hydraulics Stator ByPass Motor Motor System & Total BIT HYDRAULICS
(rotor) (rotor) Op. Differential ByPass Volume B.Assy Bit Bit Jet.Vel. Impact Hyd. Motor
gpm gpm psi psi Press gpm gpm gpm Press. (ft/sec) Force H.P. RPM
StartGPM-OffBottom 0.0 213.7 100 0 114.8 213.7 10.7 203.0 14.8 43.7 39.6 1.8 0
MaxGPM@OffBtmMtrPsi 1200.0 213.7 100 0 747.9 1413.7 70.7 1343.0 647.9 289.4 1734.3 507.8 375
MaxGPM@AveMtrDiff 1200.0 370.1 100 200 1099.2 1570.1 78.5 1491.6 799.2 321.4 2139.3 695.6 375
MaxGPM@MaxMtrDiff. 1200.0 477.8 100 400 1412.6 1677.8 83.9 1593.9 912.6 343.5 2442.8 848.8 375
GpmOffBtm&MaxBitPsi 1307.3 213.7 100 0 850.0 1521.0 76.0 1444.9 750.0 311.4 2007.6 632.4 409
Hyd's Off-Bottom Calc 1029.9 370.1 100 0 935.4 1400.0 70.0 1330.0 635.4 286.6 1700.9 493.2 322

The example hydraulic worksheet above demonstrates the various paths and pressures of flow when using a by-pass rotor.
Nozzles sizes and volumes can be adjusted to achieve the best overall hydraulics for drilling.
Recommended calculations are threefold. At a certain volume, calculate flow ratios:
• Off-bottom. Highest flow through rotor/stator section. Check against motor maximum flow.
• Maximum motor differential. Use to assure minimum rotor/stator volume met. Do not use to calculate maximum motor volume.
• Drilling motor differential.Volume motor is most exposed to. Best to establish working range - not one volume.
Note: use of maximum differential to calculate the maximum allowable volume results in over-pumping motor should the
differential not be achieved and maintained. The more conservative method would be to use off-bottom motor pressure.
SPERRY-SUN Hydraulics: Diverting Flow and Calculations ( page 3 of 5 )
Example: Hydraulic Worksheet for motor with Jet Sub
CASING DRILL HYDRAULICs with Jet Sub 12/02/98 Bit Nozzles Other Nozzles
customer information This sheet is set up to calculate hydraulics: QTY SIZE QTY SIZE
Step1. Input Nozzle qty and sizes motor and bit hydraulics with jet sub above. 1 18 3 16
Step 2. Input Motor Operational Parameters. 1 18
Step 3. Input Mud Properties. Note: Set MWD length & ID to zero if there is none or if 1 18
Step 4. Input MWD length & ID. MWD is above jet sub. Only input data if MWD is between 1 16
Step 5. Set Volume to zero to reset interation fields. jet sub and motor. TFA 0.942 TFA 0.589
Step 6. Set Volume to desired calculation amount. Equivalent Bit TFA 0.991
9-5/8 SperryDrill R3/4 Slick Straight Motor with Jet Sub Mud properties below jet sub Total
Motor Operational Max.s Off-Btm Ave. Max Motor B.Assy Mud Plastic Yield MWD MWD Drillng
Volume Bit Operate Mtr Diff Mtr Diff Max Loss Weight Viscosity Point Length Eq.ID Volume
GPM Pressure psi psi psi RPM % ppg pv yp ft sq in gpm
1200 750 100 200 400 375 5 8.6 3 2 43.00 2.25 1400.0
Mud Mtr Hydraulics Motor MWD Total Jet Sub Total BIT HYDRAULICS
Section or Other Motor Pressure Volume Volume B.Assy Bit Bit Jet.Vel. Impact Hyd. Motor
gpm psi psi psi gpm gpm gpm gpm Press. (ft/sec) Force H.P. RPM
StartGPM-OffBottom 0.0 0.0 100.0 100.0 209.3 209.3 0.0 0.0 0.0 0.0 0.0 0.0 0
MaxGPM@OffBtmOpPress 1200.0 188.8 100.0 1449.1 796.8 1996.8 60.0 1140.0 1160.3 387.3 1970.1 771.9 375
MaxGPM@AveDrillDiff 1200.0 188.8 200.0 1549.1 823.8 2023.8 60.0 1140.0 1160.3 387.3 1970.1 771.9 375
MaxGPM@MaxDrillDiff. 1200.0 188.8 400.0 1749.1 875.4 2075.4 60.0 1140.0 1160.3 387.3 1970.1 771.9 375
Off Btm Hyd's at Selected Rate 827.7 96.0 100.0 748.0 572.5 1400.0 41.4 786.3 552.0 267.1 937.3 253.3 259

The example hydraulic worksheet above demonstrates the various paths and pressures of flow when using a jet sub to divert
excess flow. Nozzles sizes and volumes can be adjusted to achieve the best overall hydraulics for drilling.
The calculation of hydraulic flow is much more complicated than when using a by-pass rotor. The flow diverted through the jet
sub is such that the pressure of this flow equals the bit pressure, the motor operational pressure, and the motor differential
pressure. The solution to the flow paths and pressures are more easily solved by iterations. First, bit pressure at a certain
volume is calculated and added to the motor pressure. Then the volume discharged through the jet sub which would equal
the summed pressures is calculated. The cycle is repeated with the bit volume being increased incrementally until the bit
volume and sub volume equal the amount required.
The above example is from an excel spreadsheet having the bottom line set up for circular references and iterations with the
result of these iterations being 827.7 gpm through the motor plus 572.5 gpm diverted through the sub totaling the 1400 gpm
desired. Note that an MWD was included below the jet sub which also influenced the net ratio.
SPERRY-SUN Hydraulics: Diverting Flow and Calculations ( page 4 of 5 )
A. Flow In FORMULAS FOR MOTORS WITH BY-PASS ROTOR
• Nozzle flow & pressure relationship gpm2 x mw = 10858 x DPTFA x tfa2
• Nozzle Flow Area ( NFA ) ( SqIn ) NFANZ = ( Nz size / 32 ) 2 x .7854
• Bit Total Flow Area ( TFA ) ( SqIn ) TFA BIT = nfa 1 + nfa 2 + nfa 3 + nfa 4 . . .
• Bit Equivalent Flow Area ( EFA ) EFA BIT = tfa BIT x ( 1-( BrgLoss% / 100 ))
• Bit Pressure Drop ( PSI ) DP BIT = ( mw x gpm2 ) / ( 10858 x efa BIT2 )
• Nozzle Pressure Drop ( PSI ) DP NZ = ( mw x gpm2 ) / ( 10858 x nfa NZ2 )
• Nozzle Volume ( GPM ) GPM = ( ( 10858 x DP NZ x tfa NZ2 ) / mw ) 0.5
• Nozzle TFA ( SqIn ) TFA = ( ( mw x gpm2 ) / ( 10858 x DP NZ ) ) 0.5
• Bit Jet Velocity ( Ft / Sec ) JVBIT = ( 0.32 x Bit GPM ) / TFA BIT
BY PASS ROTOR

Example. Given: 24” hole Drill Ahead at 1400 gpm using seawater at 8.6 ppg.
• Motor: Operation Pressure = 100 psi, Max Differential = 400 psi Max Bit Pressure = 750 psi
Max Volume = 1200 gpm, Bearing Assembly with 5% fluid loss.
• Motor having a 28 nozzle in by-pass rotor. Then Nz TFA = (28/32)2 x .7854 = 0.601 sq in
• Bit nozzles = 4 x 22. Then TFABIT = ( ( 22/32 ) 2 x .7854 ) x 4 = 1.485 sq in
• Equivalent Flow Area w/ 5% Brng Loss. Then EFABIT = 1.485 x ( 1 - ( 5/100)) = 1.563 sq in
• By-Pass flow off-bottom GPM = (( 10858 x 100 x 0.6012 ) / 8.6 )0.5 = 213.6 gpm
• Flow through rotor stator section = 1400 gpm - 213.6 gpm by-pass = 1186.4 gpm
• Bit Pressure Drop at rejoined gpm = ( 1400 2 x 8.6 ) / ( 10858 x 1.563 2 ) = 635 psi
• Bit jet velocity ( check to be over 200 ft/sec). JV BIT = ( 0.32 x 1400 ) / 1.563 = 248 fps

• this exercise demonstrates that volume through rotor/stator is near maximum. Bit pressure drop is near maximum.
Set-up is near optimum for motor hydraulics at the calculated volume. Nozzles are properly sized under conditions
as stated but should be adjusted should volume change due to other conditions. It is recommended that hydraulics
be viewed within a operating range as opposed to one specific volume. Bit hydraulics should be set near maximum
at the maximum anticipated volume as conditions are rarely better than expected but can be less than expected.
B. Flow Out
SPERRY-SUN Hydraulics: Diverting Flow and Calculations ( page 5 of 5 )
FORMULAS FOR MOTORS WITH JET SUB
• Nozzle flow & pressure relationship gpm2 x mw = 10858 x DPTFA x tfa2
• Nozzle Flow Area ( NFA ) ( SqIn ) NFANZ = ( Nz size / 32 ) 2 x .7854
• Bit Total Flow Area ( TFA ) ( SqIn ) TFA BIT = nfa 1 + nfa 2 + nfa 3 + nfa 4 . . .
• Bit Equivalent Flow Area ( EFA ) EFA BIT = tfa BIT x ( 1-( BrgLoss% / 100 ))
• Bit Pressure Drop ( PSI ) DP BIT = ( mw x gpm2 ) / ( 10858 x efa BIT2 )
• Nozzle Pressure Drop ( PSI ) DP NZ = ( mw x gpm2 ) / ( 10858 x nfa NZ2 )
• Nozzle Volume ( GPM ) GPM = ( ( 10858 x DP NZ x tfa NZ2 ) / mw ) 0.5
• Nozzle TFA ( SqIn ) TFA = ( ( mw x gpm2 ) / ( 10858 x DP NZ ) ) 0.5
• Bit Jet Velocity ( Ft / Sec ) JVBIT = ( 0.32 x Bit GPM ) / TFA BIT

Example. Given: 24” hole Drill Ahead at 1100 gpm using seawater at 8.6 ppg.
• Motor: Operation Pressure = 100 psi, Max Differential = 300 psi Max Bit Pressure = 375 psi
Max Volume = 1000 gpm, Bearing Assembly with 5% fluid loss.
• Jet Sub with 3 x 16 nozzles. Then Nz TFA = (16/32)2 x .7854 x 3 = 0.589 sq in
• Bit nozzles = 4 x 18. Then TFABIT = ( ( 18/32 ) 2 x .7854 ) x 4 = 0.994 sq in
• Equivalent Flow Area w/ 5% Brng Loss. Then EFABIT = 0.994 x ( 1 - ( 5/100)) = 1.046 sq in
• Bit Pressure Drop at iterated ( 669.1 gpm ) = ( 669.1 2 x 8.6 ) / ( 10858 x 1.046 2 ) = 323.9 psi
• Total Off-bottom pressure = 323.9 bit pressure + 100 motor pressure = 423.9 psi
• Total jet sub volume = (( 10858 x 423.9 x 0.589 2 ) / 8.6 ) 0.5 = 430.9 gpm
• Total volume = 669.1 gpm through motor & bit + 430.9 gpm through jet sub = 1100 gpm
• Bit jet velocity ( check to be over 200 ft/sec). JV BIT = ( 0.32 x 669.1 ) / 1.046 = 204.6 fps
• Note: iterations were necessary to arrive at the 669.1 gpm.

• This exercise demonstrates low bit hydraulics. These were typical with the older low-torque, hi-speed motors that
were predominantly used prior to 1998. These motors were adequate for casing drill jobs but the poor volume and
bit hydraulics were inadequate for aggressive drilling ahead. It was very important to properly set up these jobs as
there was little room for error having a small effective range in which to operate.