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Casing While Drilling an Alternative Approach in Drilling Operations for Arabian Formations
By M. M. HOSSAIN and M. M. AMRO*

bstract Casing While Drilling (CWD) has become increasingly attractive as an alternative drilling technology, which provides a means of reducing operational costs substantially as well as avoiding various drilling related problems. The CWD involves drilling and casing a well simultaneously and hence, overall cost of drilling may be reduced significantly by lessening drilling time and various unexpected drilling problems encountered during the conventional drilling process. This technology is readily applicable, specifically in depleted reservoirs as an alternative to under-balanced drilling, which requires special equipment. This article presents the applicability of the concept of CWD in the context of drilling wells in Arabian formation. Complexities associated with drilling these formations, such as unscheduled hole problems, lost circulation, differential sticking and casing jamming due to tight-hole whilst running casing after withdrawal of conventional drill-string etc. are identified. It has been revealed that the CWD technology can be useful to overcome most of these complexities. In order to evaluate the adequate size and capacity of a rig for CWD operation, prediction of torque and drag is vital. Accurate prediction of such torque and drag on drilling deviated wells using CWD techniques is a complex task. In this article, however, a simplified method for predicting torque and drag, especially in drilling deviated wells using a casing string, is proposed. Valuable guidelines are provided based on a field sample case study using the proposed method.

Casing drilling is an alternative option to conventional drilling and will use standard oilfield casing instead of drillstring [4]. Moreover, the CWD approach may be better suited to drill soft formations, which are encountered at the top sections associated with different hole problems. In many fields in Arabian Gulf countries, the surface and intermediate hole sections often caused unexpected problems when drilled conventionally, mainly due to borehole instability and lost circulation. In many situations, wellbore instability necessitated timely back-reaming when tripping out the conventional drillstring and some times the conventional drillstring could not be pulled out and resulted in sidetracking of the well. Applying CWD in such hole sections will replace the conventional drillstring and reduce the operation time spent due to hole problems, and for tripping. At the same time, the casing is run to the bottom. However, prior to using CWD in any particular well, the hole conditions and lithological characteristics of the formations have to be examined in order to evaluate the design criteria of the casing and to improve drilling performance.

One of the main objectives of this paper is to evaluate the potential prospect of the CWD system for improving drilling performance in Arabian formations. For this purpose, different data have been collected and analyzed for different hole sections drilled conventionally. Based on these analyses, the CWD approach has been found as the best alternative to overcome various hole problems. In addition, successful application of the CWD approach requires accurate prediction of different loads, such as torque, drag and fatigue. Prediction of torque and drag in CWD techniques is complex and time consuming, which may not be feasible for industrial routine tasks. In this study, a simplified method has been proposed; and guidelines are provided based on a case study using field representative data. rospect of CWD in Arabian Operation CWD is one of the most promising cost effective technologies of the 21st century. In some drilling operations in the Arabian region, the surface and intermediate sections showed pipe sticking potential, sloughing formations, lost circulation and severe tight-hole conditions. Severe tighthole conditions occurred due to time sensitive marls and shales and are the most consistent contributors to time delays for conventional drilling. Thus, repeated attempts are required to pull out the conventional drillstring due to tight-hole problems and sometimes it is difficult to run the casing through these hole sections resulting in a major time loss. For instance, Figure 1 shows a typical damaged casing, which was pulled out because of sticking due to tight-hole and the casing could not be run into the hole. Timely reaming trips are, however, essential while drilling and prior to running casing to ensure successful operation. Different options were applied to reduce the potential of unscheduled events, such as modification of mud physical properties, making several short trips to overcome open-hole drag forces or running reaming-while-drilling assembly to assure smooth hole condition and to assure running casing to the bottom. Attempts to improve mud physical properties, such as reduction of water loss, seemed

ntroduction CWD has been employed in many countries to improve drilling performance. This technology was applied successfully to drill through depleted reservoirs, overcoming well-bore instability and minimizing mud losses into the depleted zones [1, 2, 3].
* M. M. Hossain, The University of Adelaide, Australia (E-mail: md.hossain@adelaide.edu.au, mofazzalh@yahoo. com), M. M. Amro, King Saud University, Saudi Arabia (E-mail: mamro@ksu.edu.sa). 0179-3187/06/III 2006 URBAN-VERLAG Hamburg/Wien GmbH

Fig. 1

Typical picture of damaged casing obtained from an Oil Company in the Arabian region, which had to be pulled out due to sticking in tight-hole

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to have little effect on face hole section can be tight-hole problems. drilled with a single bit Therefore the running (milled tooth) and the inreaming-while-drilling termediate hole section assembly was applied. can be drilled with an inFigure 2 shows the comsert bit, respectively. ponents of reaming while The data collected were drilling assembly used in divided in three sections some fields to reduce the and can be summarized tight-hole potentials. as follows: However, these options (i) The top section includes would increase the probathe formations Umm Er bility of fishing jobs and Radhuma, Simsima, and would have a negative efMishrif and consists of fect on the drilling perforvery soft limestone and dolomite. It drills very mance and rig time. The fast, with rate of penetrautilization of such an astion of up to 180 ft/h. sembly was necessary alComplete losses generthough it increases the risk of fishing jobs, due to the ally occur at 100 ft of risk of down-hole blade Umm Er Radhuma. High breakage of the three point rate of penetration conreamers [5, 6]. tinues at 120 ft/h for Mishrif formation, which In this article, the CWD consists of limestone. system is proposed, as an (ii) The middle section inalternative to reduce uncludes Ahmadi, Maudscheduled events in these dud, Safaniya, Khafji fields. CWD was successand Shuaiba and confully applied in many sists mainly of shale, countries to eliminate the limestone, chalky limetime and unscheduled stone and sandstone. It events associated with drills at a rate of penetraconventional drilling estion of 150 ft/h. The pecially drillstring trip- Fig. 2 Reaming-while-drilling assembly Shuaiba formation drills ping [7, 8, 9]. at 40 ft/h and tight-hole This article demonstrates was encountered in this section. that CWD technology could be used successfully to drill through formations en- (iii) The lower section includes Kharaib, Lekhwair, Yamama and Sulaiy and concountered at surface and intermediate hole sists of shaly limestone and marly stone. sections in the Arabian Gulf region. The proIt drills at 25 ft/h. Operational probposed CWD features a retrievable positive lems encountered in this section are displacement motor (PDM) associated with mainly tight-hole problems, resulting in the casing. The PDM is a hydraulically frequent pipe sticking. driven downhole motor action based on the Moineau principle. PDM helps to eliminate However, wiper trips with back-reaming the rotation of the casing while drilling; were considered at the bottom of Shuiaba, in therefore, PDM would provide a rotation of the transition-zone between Yamama and the bit, whilst the casing remains in the slid- Sulaiy and additionally in case of occurrence of tight-hole during connection. These ing mode. However, this method requires an exact eval- actions were effective but time consuming. uation of the drilling conditions as well as In these hole sections, time is a very importhe lithology of the formations, in which tant factor for sensitive shale, since the characteristics of this shale change rapidly and CWD will be considered. The following description summarizes the cause unscheduled hole problems, espeoperational conditions when drilled conven- cially by tripping out the drillstring. For intionally and the lithology for the considered stance, Figure 4 shows a typical example of tight-hole problems. Pulling-out resulted in hole sections. a loss of about two days due to back-reaming. Figure 5 shows severe tight-hole conditions, which occurred twice in the same perational Conditions and Lithology Many drilling data and hole conditions, well, in which the conventional drillstring including the lithology of different got stuck and the well was sidetracked refields, were collected with the main objective sulting in a loss of some 22 days. This indito evaluate the potential of CWD technology cates clearly that the time spent handling the in the considered hole sections. The forma- drillstring, caused the sensitive shale to betions in the Arabian Gulf area are approxi- come active, thus leading to tight-hole probmately similar to the formations as shown in lems. This could be prevented if the operaFigure 3. Data collected from different areas tion time required to complete the hole secwere evaluated and it was found that the sur- tion, can be reduced. Thus, in such drilling conditions CWD should be adopted to reduce operation time and costs and it will eliminate conventional drillstring tripping and handling time. Many papers [4, 812] illustrate successful applications of CWD to reduce time and unscheduled events especially in surface hole sections. esign Approach of Casing String Despite tension, collapse and burst pressure, the successful design of the casing running simultaneously while drilling, known as CWD, requires accurate prediction of different effects, primarily torque, drag, and fatigue. The design approaches for casing drilling, however, are somewhat similar to the conventional drilling approach. In conventional drilling engineering techniques, the casing is run after the completion

Fig. 3

Stratigraphic column of the studied area

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Fig. 4

Drilling performance showing tight-hole problems

of drilling a well. The design criteria for casing in such a case are mostly based on maximum load, where emphasis is given primarily to tension, burst and collapse loads. Considerations are also given to account for the consequences of borehole stability, well control, casing setting depths, directional planning, and bit selection. Most of these factors affecting CWD can be predicted with the concept of conventional drilling engineering techniques. The fatigue life and endurance limit evaluation for casing in the case of CWD approach requires special consideration depending on how the operations are performed [8]. The fatigue failures relate mainly to the part of casing which is exposed to an alternate tension and/or compression. This situation can develop in the curved section of the casing string or when the casing is run through the dog leg region by rotation. The installation of non-rotating centralizers and a downhole mud motor can reduce the risk of fatigue failure. In this case a retrievable downhole motor (PDM) provides the option of not having to rotate the casing string while drilling. A retrievable downhole system using a wire-line allows tripping to change the bit or motor without pulling out the casing. However, rotation of the casing may be necessary sometimes to achieve better hole cleaning; therefore, the installation of non-rotating centralizers becomes important. In this design approach a retrievable or drillable bit is recommended. However, in case the bit cannot be retrieved through the casing, it might be left in the hole and the well will be sidetracked. It is also worth mentioning that even if the well is sidetracked, the CWD approach will remain economical. Thus, CWD implementation might not be trouble-free, but will incur less drilling problems than conventional drilling, thus making the CWD approach attractive.

the contact surfaces. Fig. 5 The magnitude of normal contact force can be calculated by [13]. FN = (1)
2

Drilling performance showing severe tight-hole problems, which resulted in pipe jamming and back-plugging
j

(Fa sin ) + (Fa + Wec H sin )

Tj =

k = n 1

(4)

where, Fa is the tensile force contributed from the weight of casing string and can be calculated as [13], Fa = Wec cos (2)

The axial stress due to the weight of the casing requires further modification by adding the incremental tensile force due to drag, which is incurred by rotating or reciprocating the casing. The incremental tension force due to frictional drag during sliding the casing by rotation can be calculated as: Fd = Wec Hcos C f FN (5)

in which H is length of joint segment, which equals the difference from one section to another section or points to be considered as shown in Figure 6, Wec is the effective nominal weight per foot of casing string and equal to Wec = WncBF; is wellbore inclination and is dogleg severity and BF is buoyancy factor. The incremental torsion over a length segment is then calculated as; C f FN D o (3) T = 2 where Cf is the coefficient of friction between the casing string and wellbore surface, and Do is outer diameter of casing string. This coefficient of friction (often called friction factor) depends on several unknown parameters related to well profile, the wellbore wall surface roughness and type of mud. The magnitude of this coefficient, however, is more significantly dependent on the type of mud (oil-based mud or water-based mud) than the material configuration itself [14, 15]. The applicable ranges of friction factors for different types of mud systems vary approximately from 0.25 to 0.35 for a water-based mud, and 0.15 to 0.25 for oil based mud. However, this factor can vary substantially between wells and even in single-hole sections of a given well as a result of wellbore condition and should be derived from field data for each hole section [16, 17]. This value may also vary from region to region and needs adjustment on a history matching basis. The total torque required at the surface can be calculated by summing up all the incremental torques from the point of interest to the surface as:

orque and Drag Prediction The torque developed whilst running the casing is caused mainly by frictional forces between the casing string and the wellbore. The magnitude of such frictional force is the product of normal contact force and the coefficient of friction between

where the plus or minus sign relates to up or down motion of casing. Equations 15 are derived analogously for a conventional drillstring and can be applied to CWD in deviated wells. However, for the casing string, some special considerations are required for further correction of the predicted results obtained using these equations. The magnitude of torque and drag for casing strings are excessive for various reasons, this includes tight-hole conditions, sloughing hole conditions, differential sticking as well as sliding in the wellbore. Inclusion of all these effects makes these equations complex and may need numerical techniques. However, these equations can be used with simple modification based on suggestions made in previous case studies, which includes the application of non-rotating centralizers and/or installation of a down-hole motor. The downhole motor can provide higher speed of the drill-bit than by rotary drilling. Once the casing string enters the build up section, rotation of the casing string with the help of rotary speed may lead to cyclic loads, which in turn cause substantial fatigue damage. The inclusion of a downhole motor can reduce this damage significantly by minimizing the casing string rotation. In this situation, the rotation of the casing string could be reduced significantly by reducing the speed of the rotary table. The inclusion of a downhole motor can supplement the required speed in the drillbit to advance the casing in the wells since the bit rotation is then considered to be the sum of the speed of the downhole motor and the rotational speed
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of the casing. Even if the rotary table is locked, the casing can advance with the combined effect of the downhole motor with the bit and push by WOB. The power consumed at the drill bit in conventional rotary drilling is expressed by [18]; Pr = CTr n r (6) tion the string will be advanced by pushing with the help of the downhole motor attached with bit while the speed of rotary table will be reduced or completely stalled. A non-rotating stabilizer may need to be setup in order to avoid de-tracking of the well. The investigation has been made in this study based on the developed model. A program has been developed for the necessary calculation. The required parameters and calculated torque and drag are presented in the following section. The distribution of resultant torque is presented in Figure 8. The static, upstroke, and down stroke drags are presented in Figure 9. The corresponding well profile is also included in the plot.

and power consumed while drilling with downhole motor is expressed by; Pm = CTmn m (7)

esults and Discussions In this study, the well has been assumed to be drilled to a measured depth of 11,900 ft. The profile is shown in Figure 7. The well has been cased with 9 5/8" of 47 lbf/ft (ppf) casing from the surface to a measured depth of The required torque at the rotary ta12,000 ft. The coefficient of fricble, Tr for a given speed of rotary tation between pipe and inner wall of ble is directly related to surface the 9 5/8" casing is 0.180, and the torque, which can be calculated using Eq. 4. coefficient of friction in the open From Eq. 8, it is clear that the torque hole section is 0.210. Based on this in the bit due to inclusion of information the total torque and downhole motor, Tm, can be redrag for stationary or static, upstroke and down-stroke condiduced by increasing its speed. Also, Fig. 6 Steps for calculating torque and drag in drilling deviated wells tions are calculated using the develthe reduction of rotary speed decreases the torque in the bit. Thus the vided using a heavy drill collar at the end of oped mathematical model. downhole motor can be used as torque re- the drill pipe with bit. The inclusion of a From Figure 8, it can be seen that distribuducer. down-hole motor can supplement the re- tion of torque along the true vertical depth is non-linear in nature. The maximum torque is It is to be noted that Eqs. 15 are used to cal- quired initial bit torque as discussed earlier. culate the contribution of torque and drag for Torque and drag calculations are performed noticed at the surface and it is almost coneach section or segments. The total torque considering the casing string pushes into the stant along the vertical section of the well and drag for the well can be analyzed by add- well by rotational speed from the rotary ta- and independent of the depth of the well. ing each contribution starting from the bot- ble. However, the rotation of the string is not This torque starts decreasing as soon as the tom of the well as shown in Figure 6. The allowed once it starts drilling the build up casing string enters the build up section. The contribution of downhole motor can be ac- section (kick off point) and during building torque at the bottom end of the well or near counted for by normalizing the torque data angle in the deviated section. In this situa- the bit is zero. This is why some mechanism must be setup with the bit in orusing Eq. 8. der to have a starting torque in the bit, while passing the build up section. It is to be noted that ample Case Study torque developed mainly due to A sample case study has the frictional force between the been conducted using casing string and wellbore side the mathematical model as dewalls. However, the reduction of scribed in the previous sectorque distribution relates to the tion. The well profile considside forces, which are created in ered for this case study is the build up section and inclined shown in Figure 7. For simsections due to the tendency of plicity, zero weight on bit the casing string to lie on the (WOB) and initial torque in low side of the wellbore. Morethe bit is assumed. It is to be over the side force is a function noted that sufficient WOB of wellbore inclination to the and initial torque are necesvertical. On the other hand in sary to perform the drilling the vertical section, the side job. The WOB can be pro- Fig. 7 Well profile considered for case study

where, C is a constant, P, T, and n are power, torque, and speed of rotation, respectively. The subscripts m and r are used for downhole motor and rotary table, respectively. If it is assumed that both cases consume the same power, then from Eqs. 6 and 7, the torque in bit due to inclusion of downhole motor can be expressed as: nr (8) Tm = T nm r

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onclusion The drilling conditions and unscheduled events which occurred in some Arabian formations during conventional drilling operations were analyzed. It is evident that the most serious problems especially in intermediate hole sections, occurred due to time sensitive shale. Thus, reducing the total time, in which the zones with time sensitive shale are exposed to the drilling fluid, can solve this problem. This can be achieved using the CWD system. A simplified mathematical model to predict the torque and drag in deviated well drilling using the CWD technique has been proposed and a case study was carried out using this method. Detailed methods of predicting torque and drag calculations showed that the casing would overcome the forces encountered while drilling surface hole with casing; how- Fig. 9 Distribution of different drag forces as a function of true vertical depth (TVD) for extended reach/deviated well ever, two options were suggested to reduce the torque, namely incorporation of positive displace- References [1] Sinor, L. A., et.al.: Rotary Liner Drilling for Dement mud motor and/or installation of pleted Reservoirs, IADC/SPE 39399, IADC/SPE non-rotating centralizers. Drilling Conference, Dallas, Texas, March 36, Based on the case study, it can be inferred 1998. that: [2] Vogt, C., et.al.: Drilling Liner Technology for De The maximum torque develops in the verpleted Reservoir, SPE 36827, SPE European tical section of both deviated and horizonPetroleum Conference, Milan, Italy, October 2224, 1996 tal wells. [3] Alferdo Rios, J., et.al.: Successful Drilling In The developed torque in the vertical secHighly Depleted Formations, SPE paper 74399, tion of a deviated or horizontal well is inSPE International Petroleum Conference and dependent of the TVD of that section. Exhibition, Villahermosa, Mexico, Feb. 1012, The torque distribution starts reducing 2002. when the casing string enters the build up [4] Tessari, R. M., and Madell G.: Casing Drilling A Revolutionary Approach to Reducing Well Costs, section and continues reducing by increasIADC/SPE 52789, IADC/SPE Drilling Confering the TVD for deviated well. ence, Amsterdam, Holland, March 911, 1999. The reduction of torque distribution de[5] Amro, M. M.: Equations predict drill-pipe fatigue pends on the length of the horizontal secin Middle East operations, Gas & Oil Journal, tion. July 10, 2000. The required drag forces for both deviated [6] Shehata, A. and Simpson, M.A.: Utlization of Bi-Center Bit Technology to Solve Undergauge and horizontal wells decreases with TVD.

Fig. 8

Distribution of total torque as a function of true vertical depth (TVD) for extended reach/deviated well

force is constant, yielding constant frictional force between the wellbore wall and casing string. Figure 9, showing the distribution drag forces with true vertical depth (TVD) of the wellbore, indicates that static torque is varying linearly with TVD, whereas there is an increasing tendency of down stroke drag with decreasing depth of the build up section; and there is a decreasing tendency of up stroke drag with decreasing depth of the build up section. It should be noted that there is some point in the build up section after which drag forces are tending to be negative. This point is termed as the free point. Immediately below the free point the drag forces are compressive in nature and above it, the drag forces are tensile in nature. Therefore, if the casing string runs to the wellbore with rotation, it will experience a cyclic load at this point and will undergo fatigue damage. The likelihood of damage increases rapidly with increase of the dog leg severity at the build up section. In order to avoid such damage, it is usually recommended to run the casing string across the deviated section by sliding with the help of a downhole motor rather than rotating the casing string by the rotary table. It is also clear from Figure 9 that the down stroke drag force is less than the static torque as the casing string moves in the direction of gravity and upstroke drag is higher than static drag as the casing string moves against the gravity force. In general, the reduction of torque distribution along the wellbore should be minimized as much as possible to save rig power and to be able to transmit the required torque to the bit. Nowadays there are techniques to reduce the losses of torque especially in drilling horizontal and extended reach wells. These techniques include using special drilling fluids and accessory tools such as adjustable stabilizers and/or non-rotating stabilizers.
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Nomenclature

CWD WOB BF Cf n Do FN Fa Fd H T Wec Wnc

Casing While Drilling Weight on Bit Buoyancy factor Frictional coefficient Rotational speed Outer diameter Normal contact force Axial tensile force Axial drag force Measured depth Torque Eff. nominal weight per unit length of casing Nominal weight per unit length of casing Angle of hole inclination Azimuth of the hole Index of each segment or section of the strings

[7]

[8]

[9]

[10]

i,j,k

Hole Problems in the Dukhan Field, IADC/SPE 39247, IADC/SPE Middle East Drilling Technology Conference, Bahrain, Nov. 2325. 1997. Fontenot, K., Warren, T. W. and Houtchens, B.: Casing Drilling Proves Successful in South Texas, IADC World Drilling 2002, Madrid, Spain, June 56, 2002. Warren, T. M, Angman, P. and Houtchens, B.: Casing Drilling Application Design Considerations, IADC/SPE 59179, IADC/SPE Drilling Conference, New Orleans, Louisiana, 2325 February 2000. Strickler, R., Mushovic, T., Warren, T. and Lesso, B.: Casing Directional Drilling Using a Rotary Steerable System, IADC/SPE 92195, SPE/IADC Drilling Conference, Amsterdam, The Netherlands, March 2325, 2005. Shepard, S. F., Reiley, R. H. and Warren, T. M.: Casing Drilling: An Emerging Technology, SPE 76640, published in SPE Drilling & Completion, March 2002.

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[11] Tarr, B. and Sukup, R.: Casing-while Drilling: The Next Step Change in Well Construction, World Oil, October 1999. [12] Pruner, A.,: Casing Drilling: How the Pieces Fit, World Oil, March 2003. [13] Adam, T. B. Jr., Martin, E. C., Keith K. M. and Young F. S.: Applied Drilling Engineering, SPE Textbook series, Vol. 2, Society of Petroleum Engineering, 1991. [14] Maidla, E. E., Wojtanowicz, A. K.: Field Method of Assessing Borehole Friction for Directional Well th Casing, SPE 15696, 5 SPE Middle East Oil Show, Manama, Bahrain, March, 710, 1987. [15] Maidla, E. E., Wojtanowicz, A. K.: Field Comparison of 2-D and 3-D Methods for the Borehole Friction Evaluation in Directional Wells, SPE nd 16663, 62 Annual Technical SPE Conference and Exhibition, Dallas, Texas, September 2730, 1987. [16] Payne, M. L., Abbassian, F.: Advanced Torque and Drag Considerations in Extended Reach Wells, SPE 35102, published in SPE Drilling & Completion, March 1997. [17] Kinzel, H., Koithan, T.: A New Approach to Calculate the Optimum Placement of Centralizers includes Torque and Drag Predictions, IADC/SPE 36382, IADC/SPE Asia Pacific Technology Conference, Kuala Lumpur, Malysia, Sept., 911, 1998. [18] Hossain, M. M., et al.: Fatigue Life Evaluation: A Key to Avoid Drillpipe Failure Due to Die-marks, SPE/IADC paper 47789, Asia Pacific Drilling Conference, Jakarta, Sept. 79, 1998.

Md Mofazzal Hossain is currently a Lecturer in drilling and completion engineering at the Australian School of Petroleum (ASP) of the University of Adelaide. His research interests include hydraulic fracturing, naturally fractured reservoir modelling, drilling mechanics, sand control and management, wellbore stability, and horizontal and multilateral well technology. Before joining ASP, he was an assistant professor in the petroleum engineering department of King Saud University, Saudi Arabia. He also worked at the University of New South Wales, Australia, and Reservoir Engineering Research Institute, US. Hossain holds BSc and MSc degrees in naval architecture and marine engineering from Bangladesh University of Engineering and Technology and a PhD in petroleum engineering from the University of New South Wales, Australia. He is a member of SPE. Mohammed M. Amro is an associate professor in the petroleum engineering department of King Saud University. Previously, he worked at the German Petroleum Institute in Clausthal, Germany, and for Qatar Drilling Co. in Qatar. Amro holds a BS, an MS and a PhD in petroleum engineering from The Technical University of Clausthal in Germany. He is a member of SPE and DGMK, Germany.

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