CD

CASING WHILE
DRILLING

IADC Drilling Manual 12th Edition

IADC Drilling Manual • Copyright © 2015

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 CASING WHILE DRILLING CD–i

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CASING WHILE
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he IADC Drilling Manual is a series of reference guides assembled by volunteer drilling-industry professionals with
T expertise spanning a broad range of topics. These volunteers contributed their time, energy and knowledge in
developing the IADC Drilling Manual, 12th edition, to help facilitate safe and efficient drilling operations, training, and
equipment maintenance and repair.

The contents of this manual should not replace or take precedence over manufacturer, operator or individual drilling
company recommendations, policies or procedures. In jurisdictions where the contents of the IADC Drilling Manual may
conflict with regional, state or national statute or regulation, IADC strongly advises adhering to local rules.

While IADC believes the information presented is accurate as of the date of publication, each reader is responsible
for his own reliance, reasonable or otherwise, on the information presented. Readers should be aware that technology
and practices advance quickly, and the subject matter discussed herein may quickly become surpassed. If professional
engineering expertise is required, the services of a competent individual or firm should be sought. Neither IADC nor the
contributors to this chapter warrant or guarantee that application of any theory, concept, method or action described in
this book will lead to the result desired by the reader.

PRINCIPAL AUTHORS
Moji Karimi, Weatherford International
Eric Moellendick, Schlumberger

REVIEWERS
Kyle Graves, Apache
Don Hannegan, Weatherford International
Calvin Holt, Chevron
Dietmar Neidhardt, Tubefuse Technologies
Bill Rehm, Consultant

IADC Drilling Manual Copyright © 2015

CD–ii CASING WHILE DRILLING

This is a chapter of the IADC Drilling Manual, 12th edition.

Copyright © 2015 International Association of Drilling Contractors (IADC), Houston, Texas.

All rights reserved. No part of this publication may be reproduced or transmitted in any form
without the prior written permission of the publisher.

International Association of Drilling Contractors

10370 Richmond Avenue, Suite 760
Houston, Texas 77042
USA

ISBN: 978-0-9906220-6-2

Printed in the United States of America.

IADC Drilling Manual Copyright © 2015


CHAPTER CD
CASING WHILE DRILLING
Introduction....................................................................CD-1
Non-retrievable casing while drilling........................CD-1
Enhanced rig equipment - surface
drive systems........................................................ CD-4
CwD centralizers.................................................. CD-4
CwD connections, torque rings
and wear bands/sleeves.................................... CD-4
Plastering effect.................................................... CD-5
Operations............................................................. CD-5
Why drill with a non-retrievable
CwD system?........................................................ CD-5
Typical non-retrievable CwD problems......... CD-6
Retrievable casing while drilling.............................. CD-6
Locking assembly................................................. CD-6
Internal duplex stabilizer.................................... CD-6
Underreamer......................................................... CD-7
Operations............................................................. CD-8
IADC Drilling Manual
CASING WHILE DRILLING Contents CD-iii
Contents
Why drill with a retrievable CwD system?... CD-8
Typical retrievable CwD problems.................. CD-8
Liner drilling................................................................... CD-9
Non-retrievable liner drilling............................. CD-9
Non-retrievable liner drilling and setting
sequence................................................................ CD-9
Why drill with a non-retrievable liner drilling
system?................................................................. CD-11
Typical problems with a non-retrievable liner
drilling system..................................................... CD-11
Retrievable liner drilling........................................... CD-11
Why drill with a retrievable liner
drilling system?................................................... CD-12
Typical problems with retrievable liner drilling
systems................................................................. CD-12
Safety and the environment................................... CD-13
Conclusion................................................................... CD-13
Copyright © 2015
 IADC
Safety Toolbox
Essential safety alerts
and other tools for the
crew on the rig floor

IADC SAFETY TOOLBOX

DESIGNED TO SHARPEN SAFET Y SKILL S
Sharpen your safety skills with the new IADC Safety Toolbox. Available at no charge
at www.IADC.org/safety-toolbox, the searchable IADC Safety Toolbox provides easy
access to key IADC safety information, including safety alerts, safety meeting topics,
near miss/hit forms, safety posters and more.

The IADC Safety Toolbox is easy to use. Users can narrow their search by type of
operation (rigging up, lifting, etc), incident classification (LTI, equipment damage,
etc.), body part, location (rig type, etc.), incident type (slip, etc.) and equipment.

The Online Safety Toolbox provides a practical, user-friendly resource that will
seamlessly integrate into daily drilling operations. Contents include:

• 700 IADC Safety Alerts;

• 125 Safety Meeting Topics for JSAs or other meetings;
• Near Miss/Hit Report forms for both drilling and well servicing/workover;
• 60 IADC Safety Posters.

The Online Safety Toolbox puts critical safety related tools and resources directly in
the hands of the rig crew, and is one of several IADC initiatives aimed at enhancing
safety in the industry. Access it today!

www.iadc.org/safety-toolbox
 CASING WHILE DRILLING CD–1

Introduction
Casing while drilling (CwD) technology uses the casing
string as a drillstring so that casing is landed on bottom
during the drilling process, rather than later in a separate
installation process. The technology is typically applied for
purposes of increasing drilling performance, putting trouble
zones behind CwD, and enhancing the integrity/quality of
the wellbore from the resulting plastering effect.

CwD can be performed using two kinds of systems: non-re-

trievable and retrievable. The non-retrievable system’s
assembly comprises a drillable casing bit attached to the
bottom of the first joint of casing. A float collar is usually
run between the first and second joints. Drilling torque is
transferred from the top drive to the casing string and drill
bit via the casing-running tool. The casing-running tool can
be a crossover, a CwD spear or a premium top-drive CwD
system. Once the targeted depth is reached, there is no drill
bit to recover through the casing. Since the float collar is also
run in the casing string, cementing can begin immediate-
ly. After the cement is set, the next bottomhole assembly
(BHA) drills out the shoe track and the casing drill bit.

With the retrievable system, an underreamer and pilot bit

assembly is latched below the casing by means of a retriev-
able locking assembly. As the assembly drills ahead, the
casing is run in the hole, either in a sliding or rotating mode.
Upon reaching TD, the BHA is unlatched and recovered with
a special retrieval tool on drillpipe. Cementing plugs can
then be pumped downhole into a landing profile to complete
the cementing process.
In this chapter, CwD systems are discussed first, and then
liner drilling is covered. The components of non-retrievable
and retrievable systems and their functions are explained in
each section.
Non-retrievable casing while drilling
With non-retrievable CwD, the drillable casing bit is at-
tached to the first joint of casing to eliminate the drillpipe
and hence the need for tripping to recover the bit (see Figure
CD-1). This process also eliminates the need for convention-
al casing running. CwD faced so much resistance initially
since it was thought to create problematic situations such as
stuck pipe and higher equivalent circulating density (ECD)
due to narrow annulus. However, once the technology was
implemented, it was observed that these situations were not
arising. In addition, there were unexpected advantages due
to the special geometry of CwD and the interaction of the
large-diameter pipe with wellbore wall. This interaction is
commonly referred to as the plastering effect.
Figure CD-1: Non-retrievable casing while
drilling. Courtesy Weatherford.
The main component of non-retrievable CwD is the drillable
casing bit. Figure CD-2 shows drillable casing bits.
The installation of a separate float collar in the casing string
allows the cementation operation to begin immediately
once TD has been reached and to be completed as normal.
After waiting on cement, the next drill bit is run and drills
through the shoe track and casing bit before entering new
formation. Alternatively, it may be possible to drill out the
shoe track with another casing bit on the next casing string.
The drillable bit ought to reach the objective depth in one
run; therefore, rock strength and abrasiveness should be
studied before deciding the footage the drillable bit can
drill. Figure CD-3 and Table CD-1 provide some general
guidelines on typical rock types (hardness) drillable with
non-retrievable casing drill bits. For applications outside
the acceptable zone, the required footage to be drilled must
be analyzed further. Of course, for applications with softer
rocks, simpler designs can be used. It is worth mentioning
that in cases where the CwD is the last section of the well
(no drill-out required), conventional bits can be used.

IADC Drilling Manual Copyright © 2015

CD–2 CASING WHILE DRILLING

Figure CD-2: Drillable casing bits. Courtesy

Weatherford & Schlumberger.

IADC Drilling Manual Copyright © 2015

 CASING WHILE DRILLING CD–3

Table CD-1: Lithology and rock strength

for non-retrievable CwD
Very low < 4,000 Gumbo, shales, soft shales, claystones,
strength psi unconsolidated (very soft sands)
chalk, shaley and clayey sandstones,
Low 4,000 -
claystones, shales, (soft) evaporites,
strength 8,000 psi
soft silicones
Conglomerates, sandy and chalky
Medium 8,000 -
limestones, marls, medium-medium
strength 16,000 psi
hard sandstones, hard shales
Hard stringers, hard dolomites,
High 16,000 -
crystalline limestones, brittle (hard)
strength 32,000 psi
shales, hard sandstones
Very fine, tight sandstones, chert,
Very > 32,000
quartzite, igneous and metamorphic
Figure CD-3: Application range for casing drillable bits. high psi
rocks, hard siltstones

Device used
Description Application
for CwD

• Short casing strings (less

than 500 ft);
It is simply a sub with a drillpipe
• Very large casing string, i.e.,
connection (box) up and a casing
Waterbushing 20 in. or larger;
connection (pin) down that is
Crossover • Jobs where reducing flat
positioned between the top drive
time is not the primary
and the casing string.
consideration, e.g., major
hole problems.

The string can be rotated and

CwD spear replaces the
circulated at the same time,
conventional threaded crossover,
making the modified CwD spear
reducing connection time and
an ideal upgrade to the type
ultimately making the worksite
CwD Spear used for running casing. The
safer. The tool is simple to operate
spear can be used to replace
and is field-serviceable.
conventional casing-running
CwD spear is connected directly
tools such as spider-type
to the top drive.
elevators and casing fill-up tool.
ICDT operates in the same way
as the CwD spear. The main ICDT can replace the spider
Internal difference between the tools is elevator and fill-up tool. It
Casing Drive the internal gripping slip area. The also provides a means of
Tool (ICDT) ICDT slips are significantly larger simultaneous circulation,
and have a superior carrying reciprocation and rotation.
capacity.

The automated casing-running

system eliminates the derrick
Internal tools grab the casing man and allows for safe rotation
Top-Drive
from inside and external tools and reciprocation of the casing
CwD System
from outside. string, making drilling with
casing possible with high
efficiency.

Figure CD-4: CwD surface drive system. Courtesy Weatherford.

When drilling with casing, flow rate is considerably less than formations, the bit is jetted for a large total flow area (TFA)
what is used for a conventionally drilled interval of equiva- as the best drilling performance is achieved by maximizing
lent hole size. This is necessary due to the reduced annular flow rate. In more competent formations, the bit is jetted to
clearance and to achieve an optimum ECD. In soft “top-hole” achieve the same hydraulic horsepower or as close as can be

IADC Drilling Manual Copyright © 2015

CD–4 CASING WHILE DRILLING
Figure CD-5: Rotating centralizers for CwD - hardfaced
and non-hardfaced. Courtesy Schlumberger.
obtained to conventional best practice without running jets
smaller than 12/32.
Drilling parameters when drilling with a CwD system are
similar to what are used to drilling a convention interval with
a PDC bit cutting the same size hole (both in terms of WOB
and RPM). The casing string is commonly used to turn the
bit in excess of 100 rpm. In order to achieve rate of penetra-
tion (ROP) that is equivalent to conventional operations, it
is necessary to provide the same amount of energy towards
the destruction of rock both mechanically and hydraulically.
Enhanced rig equipment - surface drive systems
When drilling conventionally, the drillstring is connected to
the top drive by a crossover sub. A crossover from casing to
the top drive is not a standard piece of rig equipment and is
probably not available on the rig unless it has been pre-or-
dered. Applications engineers will ensure that the crossover
is correctly specified to support the string weight, transmit
rotary torque and seal against hydraulic pressure. Non-re-
trievable CwD can be accomplished using several methods
to rotate the casing string (Figure CD-4).
CwD centralizers
In most vertical surface or intermediate CwD applications,
centralization is not a concern. If the CwD or liner drilling
system is deployed in a deviated well, it is critical that the
centralizers installed onto the casing are designed to with-
stand the harsh drilling environment. One strategy that
has been routinely employed is to attach a solid body hy-
dro-formed centralizer to the body of the casing by crimping
it in place. The crimping process ensures the centralizer re-
mains in place both axially and torsionally and also ensures
the contact necessary between the casing and wellbore wall
for the plastering effect to occur.
Another method of centralizing casing is using a non-rotat-
ing centralizer with an internal rubber lining (see Figure CD-
6). The centralizer has a solid body, and the rubber lining
IADC Drilling Manual
Rubber liner with
straight flutes
Venting
holes
Figure CD-6: Non-rotating centralizers for
CwD. Courtesy Weatherford.
acts as a bearing to eliminate casing wear as well as to re-
duce friction and potential damage. This type of centralizer
has been shown to effectively reduce the amount of torque
required when drilling with casing. But because it reduc-
es the mechanical contact with the wellbore wall, it must
be used with caution in wells that depend on the wellbore
strengthening of the plastering effect.
Spray metal technology can also be used to build centraliz-
ers, stabilizers and wear bands directly onto casing for drill-
ing (see Figure CD-7). The resulting blades, ribs and bands
are at least as wear-resistant as steel.
CwD connections, torque rings and wear bands/
sleeves
Casing is designed to be run, not to be drilled with. Hence,
certain modifications might be necessary to allow for drilling
with standard casing. These include:
• Premium CwD connections;
• Torque rings for buttress connections in absence of
special CwD connections to create a positive shouldered
makeup;
• Wear bands/sleeves to protect the casing/couplings
from wear as well as from abrasive environments.
Figure CD-7: Sprayed-on centralizers/stabilizers
for CwD. Courtesy Weatherford.
Copyright © 2015

CwD connections. CwD connections.
Courtesy Tenaris. Courtesy U.S. Steel.
Wear bands/Sleeves. Courtesy TESCO.
Torque rings. Courtesy Premiere.
Figure CD-8: CwD accessories.
Plastering effect
In addition to increasing drilling performance, CwD tech-
nology has also shown strong potential for drilling in weak
sections to mitigate lost circulation and wellbore instability
problems and reduce NPT in drilling operations, specifical-
ly in narrow pore-fracture pressure sedimentary basins and
deep offshore applications. It offers hydraulic improvements
and the ability to plaster cuttings to the wellbore wall, which
may restore the wellbore’s hoop stress by wedging the cre-
ated fractures and/or by increasing the fracture propagation
pressure. Additionally, because of the larger pipe-to-annu-
lus size ratio of CwD compared to conventional drilling, the
casing rotation forms a better mud cake (see Figure CD-9).
Although the increased wellbore containment is explained by
IADC Drilling Manual
CASING WHILE DRILLING CD–5
the plastering of drill cuttings, the true mechanism is not yet
well understood. Pipe size and annular clearance have been
reported as the critical parameters for increasing wellbore
strength. The other factors include the casing’s contact with
the wellbore wall, rotary speed, mud type, time, stress anisot-
ropy, mud hydraulics, thermal effects and penetration rate.
Operations
Non-retrievable CwD systems are made up in the rotary
table in similar fashion to how casing connection and ac-
cessories are installed into a standard shoe track. The main
differences will be in the connection type and the amount of
torque used to make-up all connections in the string (should
be 20% higher than the maximum expected torque required
to drill to TD). This may require power tongs. Floats are in-
stalled in the string that are rated for the expected circu-
lating hours that are required to reach TD and cement the
interval. The placement of the floats is as per the operators
requirements on the amount of shoe track desired. Any
centralization installed on the string is recommended to be
done prior to the arrival of the casing to the rig.
The casing is tripped into the hole using the same methods
as conventional. It is recommended to fill the string at reg-
ular intervals during the trip. After reaching bottom, drilling
can proceed according to the parameters specific to the bit
used and optimized to the specific application. When mak-
ing connections, time in slips should be minimized as much
as possible. If any positive indication of flow is detected, the
well can be controlled using the casing rams sized to the cas-
ing string, in the same way well control is implemented when
running casing. After reaching TD, the well should be circu-
lated till shakers are clean prior to rigging up for cement. Ce-
menting operations are similar to conventional operations.
Why drill with a non-retrievable CwD system?
Advantages include:
• Increased ROP in soft formations (eliminate need for
control drilling due to improved hole cleaning);
• Minimize rig time and floor operations by eliminating
dedicated casing run;
• Utilize the benefits of plastering effect to:
• Reduce or eliminate the risk of lost circulation;
• Reduce differential sticking while drilling depleted
sands;
• Extend casing point to eliminate casing/liner string;
• Reduced overall well costs by reduction of time on well.
One key advantage of CwD with a non-retrievable system
involves the ability to take advantage of the high ROP ex-
perienced while drilling large outer diameter (OD) vertical
top-hole sections. Drilling these top-hole sections has be-
come an increasingly common practice for offshore wells in
multiple locations.
Copyright © 2015
CD–6 CASING WHILE DRILLING
Figure CD-9: A and B describe two plausible mechanisms of plastering effect to increase wellbore integrity. Courtesy Weatherford.
Typical non-retrievable CwD problems
• High torque: Because the casing is larger in diameter and
heavier than drillpipe, the torque required to rotate the
pipe to TD is often much greater;
• Hydraulics: As the casing is larger in diameter than
drillpipe, the annulus between the casing and the drilled
hole is much smaller; therefore, the hydraulics must be
redesigned. Even with optimal mud rheology and
reduced flow, it is very difficult to plan for CwD intervals
deeper than 15,000 ft (5,000 m) due to higher ECDs
that become increasingly hard to manage at greater
depths;
• Tripping casing: The bit must make the minimum casing
depth in a single run to be successful. If the bit is unable
to drill the planned footage to an acceptable casing point,
the only option is to trip the casing to replace the bit.
Retrievable casing while drilling
Retrievable CwD systems provide all the advantages of a
non-retrievable system but add the flexibility to incorporate
directional and measuring/logging while drilling (M/LWD)
tools to both steer and log the well while drilling. Whereas a
non-retrievable system must guarantee that the entire inter-
val be drilled in a single run, retrievable systems allow mul-
tiple trips to replace the drill bit or any other failed logging
or directional component of the BHA. A retrievable system
also assures that the casing can be run to TD, and it captures
many of the savings that have been proven when CwD ver-
tical wells.
The same casing-running systems, centralizers and connec-
tions used with non-retrievable CwD are also used for the
retrievable systems. Retrievable CwD systems use a special
coupling with an internal profile installed above the last joint
in the casing string.
IADC Drilling Manual
The full retrievable CwD will consist of the individual compo-
nents listed below and shown in Figure CD-10. Also required
will be the casing accessories to provide centralization for
cementing and stabilization for drilling.
Locking assembly
The locking assembly must facilitate several requirements
in order for the remainder of the assembly to effectively drill
with casing. The assembly must allow:
• Hydraulic isolation: All drilling fluid pumped from surface
must be directed from the casing into the locking
assembly, into the drillpipe BHA and ultimately through
the bit below;
• Crossover from the casing to drillpipe connection:
Engaging the locking assembly in the profile nipple
provides a downward-facing drillpipe connection used to
connect the drillpipe BHA to the casing used to drive the
string from surface;
• Weight-on-bit transfer: The locking mechanism must
allow weight on bit to be transferred from surface to the
cutting structure;
• Torsional transfer: The locking mechanism must transfer
the torque that allows the drillpipe BHA to rotate at the
same RPM as the string is turning at surface;
• BHA retrieval: The locking assembly must be able to be
used in tandem with drillpipe, wireline or hydraulic
retrieval tools to convey the drillpipe BHA through the
internal diameter (ID) of the casing string on multiple
trips.
Internal duplex stabilizer
The internal duplex stabilizer is used to stabilize the drillpipe
BHA inside the casing shoe joint below the locking assem-
bly. This configuration provides lateral stabilization and en-
sures concentricity of the drillpipe BHA as it exits the casing
shoe joint.
Copyright © 2015

Figure CD-10: CwD BHA with conventional positive displacement motor. Courtesy Schlumberger.
Underreamer
As all components in the drillstring BHA must be smaller
than the drift of the casing to allow conveyance in and out of
the hole, an underreamer must be used to open hole larger
than the casing’s outer diameter. With respect to hydraulics,
it is most common to underream the hole to the same size
that would be used to drill the interval conventionally. For
instance, when drilling an interval with 9 5⁄8-in casing, a 12
¼-in underreamer would be used in tandem with an 8 ½-in
pilot bit.
Successful directional CwD operations require more than
simply having directional tools available that can be run be-
low the casing. BHA response may be quite different when
CwD as compared to drilling with conventional systems.
Extensive pre-project planning must be completed, includ-
ing hydraulics analysis, torque-and-drag modeling, casing
connection analysis and selection, and BHA design. Well-
site implementation and successful execution of operational
procedures at the wellsite are critical to success.
Retrievable CwD BHAs are primarily arranged into three
categories:
• Directional with conventional positive displacement
motor (PDM);
• Directional with rotary steerable systems;
• Short stick-out assemblies (tangents and loss zones).
CwD with a conventional PDM is similar to drilling with a
conventional assembly. The motor orientations are ex-
tremely easy when drilling with the casing because there
is very little twist between the surface and motor. For ex-
ample, Figure CD-11 shows the toolface for about five min-
utes during which time the motor stalled, the drillstring was
picked up and the motor restarted. The tool face changed
less than 10° when the string was picked up and returned to
its original position when drilling resumed.
For larger sizes of casing, no loss of efficiency occurs while
drilling with the steerable tools below the casing, allowing
the operator to take full advantage of the faster tripping and
trouble avoidance benefits provided by CwD. Improved hole
IADC Drilling Manual
CASING WHILE DRILLING CD–7
cleaning while drilling through offshore top-hole intervals
has eliminated the standard practice of control drilling and
allowed wells to be drilled significantly faster with casing
than with conventional drillstrings. Directional drilling with
smaller casing may sacrifice some drilling efficiency due to
the requirement to use smaller motors.
Figure CD-11: Tool face change when CwD
Rotary steerable-based retrievable CwD assemblies, as
shown in Figure CD-12, provide a unique synergy by having
both the drilling hazard mitigation benefits of the plastering
effect and superior hole cleaning by allowing the assembly
to be steered with continuous rotation. CwD assemblies
with conventional PDMs must sacrifice these benefits over
the footage where steering is required.
The drilling hazard mitigation aspects of CwD only occur af-
ter the formation drilled comes into contact with the casing
component of the drillstring. For this reason, it is critical to
manage the length of drillpipe that projects below the cas-
ing shoe or stick-out. In highly unstable formations or where
large amounts of fluids are lost to the formation, it is critical
to begin applying the plastering effect as soon as possible.
In these circumstances, a short stick-out BHA, as shown in
Figure CD-13, is a preferred design hold angle while drilling
through difficult formations. It can also be used while drilling
vertical intervals where more than one bit trip is required to
reach TD.
Copyright © 2015
CD–8 CASING WHILE DRILLING
Figure CD-12: CwD BHA with rotary steerable system. Courtesy Schlumberger.
Figure CD-13: CwD with short stick-out BHA. Courtesy Schlumberger.
Operations
Retrievable casing drilling BHAs are made up in two sections.
First the conventional BHA is picked up and run in hole. Sec-
ondly, the shoe joint is picked up, and the BHA is made up to
the first joint of casing. The casing is then tripped into the hole
using the same methods as conventional. It is recommended
to fill the string at regular intervals during the trip. After reach-
ing bottom, drilling can proceed according to the parameters
specific to the BHA design used and optimized to the specific
application. When making connections, the amount of time
the casing is in slips should be minimized as much as possi-
ble. If any positive indication of flow is detected while drilling,
the well can be controlled using the casing rams sized to the
casing string, in the same way well control is implemented
when running casing. If any positive indication of flow is de-
tected while conducting BHA setting or retrieval operations,
a casing circulating tool is used along with the casing rams to
secure the well. After reaching TD, the well should be circu-
lated until shakers are clean prior to rigging up for cement. As
cementing floats are not present in the string, a cement plug
is pumped into a landing profile to cement the interval.
Why drill with a retrievable CwD system?
Similar to non-retrievable casing drilling systems, advantag-
es include:
• Increased ROP in soft formations (eliminate need for
control drilling due to improved hole cleaning);
• Minimize rig time and floor operations by eliminating
dedicated casing run;
• Utilize the benefits of plastering effect to:
• Reduce or eliminate the risk of lost circulation;
• Reduce differential sticking while drilling depleted
sands;
• Extend casing point to eliminate casing/liner string;
• Reduced overall well costs by reduction of time on well.
IADC Drilling Manual
Additional advantages specific to a
retrievable system include:
• Capability of active directional
control [steerable motor or rotary
steerable system (RSS) in BHA];
• Ability to run logging tools in
BHA;
• Contingency operations to run
subsequent BHAs;
• Eliminate open-hole tripping of
BHA and risks associated with stuck pipe/LIH.
The same advantages can be obtained by the user wheth-
er running a retrievable or non-retrievable casing system,
however, the retrievable CwD system further enables the
capability to run any choice of BHA components (directional
and/or M/LWD).
Typical retrievable CwD problems
• High torque: Because the casing is larger [in terms of
outside diameter (OD)] and heavier than drillpipe, the
torque required to rotate the pipe to TD is often much
greater. This is especially true in directional wells;
• Hydraulics: As the casing is larger (in terms of OD) and
the annulus between the casing and the drilled hole is
much smaller, the hydraulics must be redesigned. Even
with optimum mud rheology and reduced flow, it is very
difficult to plan for CwD intervals deeper than 15,000 ft
(5,000 m) due to higher ECDs that become increasingly
hard to manage at greater depths;
• Stick-out management: The benefits of CwD do not
occur until the casing itself reaches the formations of
concern. For example, if the directional/logging BHA
extends 120 ft past the casing shoe and the ROP is 40 ft/
hr, three hours of drilling are required before any benefit
of plastering effect (reduction in losses, for example)
may be realized;
• Fatigue management: The fatigue performance of the
liner pipe and connections is well understood. The safe
number of total revolutions allowed for any given
application is calculated in pre-job analysis, and total
revolutions are also monitored during job site execution
to ensure the liner can be used to safely drill to TD.
Fatigue management is most critical when high doglegs
are predicted to cause high levels of reversing stresses
on the liner and its connections. The table below shows
Copyright © 2015

the doglegs limits below which the onset of accumulated
fatigue damage to the casing/liner and connections is
not of concern.
Casing Size Dogleg to initiate fatigue
4 ½ in. 8°
7 in. 5°
9 5⁄8 in. 3°
13 3⁄8 in. 1.5°
Wells are commonly drilled with higher doglegs than shown
in the table above; however, advanced fatigue analysis
should be performed to ensure the accumulated fatigue is
within safe limits.
Liner drilling
Numerous operators have utilized the benefits of CwD to
successfully drill through challenging zones, saving both
time and money through increased safety and efficiency, re-
duced NPT and the inherent ability to keep every ft drilled.
Liner drilling, which retains these advantages, must be used
in applications where CwD is not employable because of
hydraulic, torque or well construction limitations. In cases
of drilling the liner through incompetent formations, the
wellbore strengthening provided by rotating the liner casing
against the open hole is anticipated to assist in the reduction
of losses and hole sloughing, the widening of the pore pres-
sure-fracture gradient (PP-FG) windows and the potential
improvement of the section’s formation leak-off test (LOT),
any of which may permit deeper casing points to be realized
as opposed to drilling these sections conventionally.
In some cases of drilling deep wells, where the ability to
deploy CwD is limited by the loading of the casing connec-
tions near the surface, a liner drilling system can be adopted
because drillpipe is situated from the top drive to the liner
top. This allows the transfer of higher surface loads to the
drillstring, as the peak loading is seen on the drillpipe at the
rig floor. The maximum load applied to the liner string is at
the casing connection just below the liner top and is limited
to the torsional and axial loads required to rotate and convey
the liner pipe alone, as all drilling loads are transmitted to
the BHA via an inner string.
When liner drilling operations are applied in reservoir or in-
tervals with hydrocarbon bearing formations, well control is
of paramount importance. When drilling with the liner, drill-
pipe will always be positioned across the BOP and allows
for well control operations using the same procedures and
equipment as a conventional drilling scenario.
Objectives for implementing liner drilling systems depend
IADC Drilling Manual
CASING WHILE DRILLING CD–9
on the benefits necessary to complete the section as quick-
ly, safely and efficiently as possible. On the rig floor, safety
and efficiency of casing running and drilling operations are
improved by the use of the automated casing-running sys-
tem. Below the rotary table, the benefit of always having
the drillstring across open hole, even while tripping BHAs,
can assist in reducing NPT associated with open-hole prob-
lems, such as sloughing, influx, losses, and surge and swab.
In many cases, improved drilling windows help to mitigate
the above issues and potentially allow for casing seats to
be pushed deeper, reducing the number of casing or liner
strings required to reach TD. Due to the fact that during liner
drilling operations are most likely to be applied when drilling
into the reservoir, well control is of paramount importance.
When drilling with the liner, drillpipe is always positioned
across the BOP and in such allows for well control opera-
tions without restrictions. This is a considerable advantage
when compared to normal casing drilling operations, where
the casing is positioned across the BOP and might require
particular BOP configurations.
Non-retrievable liner drilling
Non-retrievable liner drilling technology enables drilling
the liner into the well across depleted or loss zones or un-
stable formations, setting the hanger and packer, and ce-
menting in a single trip. Figure CD-14 shows the non-re-
trievable liner drilling system and the components of the
assembly.
Non-retrievable liner drilling/setting sequence
The installation sequence shows a premium liner drilling
system complete with liner top packer, liner hanger, liner
wiper plug and drill bit (see Figure CD-15). The operation is
set up to activate the system from a single setting ball, ce-
ment the liner, set the packer and retrieve the running tools.
The time and complexity of the setting sequence are consis-
tent with that of a conventional liner system.
A top-drive CwD system is used to trip the liner into the
hole with the drillable casing bit on bottom. The string is
stabilized using casing stabilization capable of surviving the
drilling process. The interval is drilled from surface, much
as in a conventional drilling operation. Attention is paid to
managing the narrow annulus between the liner and parent
casing as well as monitoring torque and vibration of the as-
sembly in open hole. After the target depth of the interval
has been achieved, the liner hanger is set and cementation
begins. The cementation process ends with the packer being
set and the top of cement being reversed off the liner top.
The running tool is then tripped out of hole.
If for any reason the target depth of the interval is not
reached, the liner must be tripped completely out of hole in
order to replace the drillable casing bit. In addition, as no
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CD–10 CASING WHILE DRILLING

Figure CD-14: Non-retrievable liner drilling. Courtesy Weatherford.

Figure CD-15: Non-retrievable liner drilling setting sequence. Courtesy Weatherford.

IADC Drilling Manual Copyright © 2015


Figure CD-16: Retrievable liner drilling. Courtesy Schlumberger.
active directional control is possible, non-retrievable liner
drilling assemblies are typically reserved for vertical appli-
cations or short tangent sections.
Why drill with a non-retrievable liner drilling
system?
Advantages include:
• Increased ROP in soft formations (eliminate need for
control drilling due to improved hole cleaning);
• Minimize rig time and floor operations by eliminating
dedicated casing run;
• Utilize the benefits of plastering effect to:
• Reduce or eliminate the risk of lost circulation;
• Reduce differential sticking while drilling depleted
sands;
• Extend casing point to eliminate casing/liner string;
• Reduced overall well costs by reduction of time on well.
A key advantage of drilling with non-directional liner drill-
ing systems is the mitigation of drilling hazards through the
plastering effect and the subsequent reduction in associated
rig time due to lost circulation and stuck pipe events that
occur when drilling unstable or depleted zones with conven-
tional methods.
Typical problems with a non-retrievable liner
drilling system
• High torque: Though the liner is larger in diameter and
heavier than drillpipe, the torque required to rotate the
pipe to TD is greater, but often not significantly greater
than a conventional BHA. This is of course dependent on
liner length and wellbore geometry, but with liner drilling
systems, torque is far less limiting that in CwD systems,
as the large diameter tubular extends only a fraction of
the distance from TD to surface. As the drilling torque in
most liner drilling systems runs through the liner
connections, the connection must be capable of handling
this safely;
• Hydraulics: The annulus between the liner and the
drilled hole is much smaller, as the liner is much larger in
diameter than drillpipe. This geometrical change
requires careful consideration when planning the drilling
hydraulics. The hydraulics are even different from what
is seen when CwD; because the liner does not extend to
the surface, superior hole cleaning above the liner top
may be difficult to achieve. Careful consideration must
be taken when planning the mud rheology and flow
rates to balance the generation of high ECDs with
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CASING WHILE DRILLING CD–11
sufficient cuttings-carrying capability above the liner.
This is critical to manage and becomes increasingly
more difficult when the liner top is set at higher
inclinations;
• Tripping liner: The bit must make the minimum liner
depth in a single run to be successful. If the bit is unable
to drill the planned footage to reach an acceptable liner
point, the only option is to trip the liner to replace the
bit.
Retrievable liner drilling
Retrievable liner drilling technology enables the liner to be
drilled directionally across depleted or loss zones or unsta-
ble formations while simultaneously logging the well. As the
inner string and BHA are designed to drift through the liner,
the operator has the ability to retrieve the BHA to the sur-
face at will. While replacing the BHA, the liner is temporarily
parked in tension anywhere in the wellbore. Additionally, if
the liner becomes stuck, the BHA can still be pulled safely to
surface, leaving a usable wellbore through which to drill the
next section.
After reaching TD, the liner is permanently hung, and the
drill/logging BHA is retrieved to surface before running the
cementing assembly in hole on a second trip. Figure CD-16
shows the component of the retrievable liner drilling system
assembly.
The drilling assembly is composed of six main components:
• Drilling BHA (below liner shoe);
• Inner string (including BHA below liner shoe);
• Liner string;
• Liner drilling tool;
• Liner top equipment.
The drilling BHA consists of the bit, directional tools, MWD
tools, the underreamer and any other BHA components that
are positioned below the liner shoe. The drilling BHA pro-
vides all functions of steering, measurement and hole en-
largement required to achieve the goals of the planned liner
interval.
The inner string in this application is used to transmit the
torque and weight on bit from the liner-running tool to the
drilling BHA.
The liner string in this application is removed from the
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CD–12 CASING WHILE DRILLING
torque path between the liner drilling tool and the drilling
BHA. The liner string is conveyed from the start of drilling to
the end of the planned interval with minimum torque applied
across its length.
The liner drilling tool is used to cross over from the liner
string to the drillpipe. It transmits torque and WOB from
surface through the liner and to the BHA below. The lin-
er-running tool is also used to convey the liner top packer re-
quired to isolate the drilled interval after drilling is complete.
The liner equipment includes the liner hanger and the pol-
ished bore receptacle (PBR). A liner top packer is introduced
during the cementing run after the retrievable BHA has been
retrieved. The liner top packer isolates the drilled-in liner
from the parent casing string and is activated immediately
following cementing operations.
Why drill with a retrievable liner drilling system?
Similar to non-retrievable liner drilling systems, advantages
include:
• Increased ROP in soft formations (eliminate need for
control drilling due to improved hole cleaning);
• Minimize rig time and floor operations by eliminating
dedicated casing run;
• Utilize the benefits of plastering effect to:
• Reduce or eliminate the risk of lost circulation;
• Reduce differential sticking while drilling depleted
sands;
• Extend casing point to eliminate casing/liner string;
• Reduced overall well costs by reduction of time on well.
Additional advantages specific to a retrievable system in-
clude:
• Capability of active directional control (steerable motor
or RSS in BHA);
• Ability to run logging tools in BHA;
• Contingency operations to run subsequent BHAs;
• Eliminate open-hole tripping of BHA and risks associated
with stuck pipe/LIH.
The same advantages can be obtained by the user wheth-
er running a retrievable or non-retrievable casing system;
however, the retrievable casing while drilling system further
enables the capability to run any choice of BHA components
(directional and/or M/LWD).
Typical problems with retrievable liner drilling
systems
• High torque: Though the liner is larger in diameter and
heavier than drillpipe, the torque required to rotate the
pipe to TD is greater, but often not significantly greater
than a conventional BHA. This is of course dependent on
liner length and wellbore geometry, but with liner while
IADC Drilling Manual
drilling systems, torque is far less limiting that in casing
while drilling systems as the large diameter tubular
extends only a fraction of the distance from TD to
surface. As the drilling torque in most liner drilling
systems runs through the liner connections, the
connection must be capable of handling this safely;
• Hydraulics: The annulus between the liner and the drilled
hole is much smaller, as the liner is much larger in
diameter than drillpipe. This geometrical change requires
careful consideration when planning the drilling
hydraulics. The hydraulics are even different from what is
seen when casing while drilling; because the liner does
not extend to the surface, superior hole cleaning above
the liner top may be difficult to achieve. Careful
consideration must be taken when planning the mud
rheology and flow rates to balance the generation of high
ECDs with sufficient cuttings-carrying capability above
the liner. This is critical to manage and becomes
increasingly more difficult when the liner top is set at
higher inclinations.
• Stick-out management: The benefits of plastering effect
do not occur until the liner shoe reaches the formations
of concern. For example, if the directional/logging BHA
extends 120 ft past the casing shoe and the ROP is 40 ft/
hr, three hours of drilling are required before any benefit
(reduction in losses, for example) may be realized.
• Fatigue management: The fatigue performance of the
liner pipe and connections is well understood. The safe
number of total revolutions allowed for any given
application is calculated in pre-job analysis and total
revolutions are also monitored during jobsite execution
to ensure the liner can be used to safely drill to TD.
Fatigue management is most critical when high doglegs
are predicted to cause high levels of reversing stresses
on the liner and its connections. The table below shows
the doglegs limits below which the onset of accumulated
fatigue damage to the casing/liner and connections is
not of concern.
Wells are commonly drilled with higher doglegs than shown
in the table above; however, advanced fatigue analysis
should be performed to ensure the accumulated fatigue is
within safe limits.
Casing Size Dogleg to initiate fatigue
4 ½ in. 8°
7 in. 5°
9 5⁄8 in. 3°
13 3⁄8 in. 1.5°
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Safety and the environment
The CwD process offers significant improvements related
to safety and the environment relative to conventional cas-
ing-running operations. As for safety, the floor becomes
crowded on many rigs when the conventional casing-run-
ning equipment is rigged up while drillpipe is racked in the
derrick. The casing tongs are often operated from scaffold-
ing set up on the floor as a work platform. A workman is
positioned in the derrick to help align the casing joint in the
elevators. The overall result is an increased potential for
falls from elevated work positions as well as for injuries from
being caught between pieces of equipment as the casing is
picked up, made up and run.
Due to the reduced flow and standpipe pressure require-
ments of the CwD process, the rig is able to use significantly
less fuel during the drilling process. This efficiency gain re-
sults in a net fuel saving that is not only a significant cost
savings, but also an environmental benefit that reduces the
carbon footprint of the drilling process.
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CASING WHILE DRILLING CD–13
Conclusion
The CwD and liner drilling processes are currently being
used by the industry to improve drilling efficiency in some
applications and to provide drilling hazard mitigation in
others. These processes must be implemented with care-
ful attention to ensure that the torque required to reach TD
as well as any fatigue accumulated during drilling does not
affect the ability of the casing to secure the wellbore after
it is cemented in place. Standard practices used with con-
ventional drilling must be reevaluated in the context of the
narrow annulus and adjusted where necessary in order to
optimize drilling performance.
The current toolbox gives the industry the ability to drill near-
ly any interval with either a casing or liner drilling solution.
Because of its increased ROP and superior hole cleaning,
CwD is fast becoming the standard approach to drilling top-
hole intervals, both vertical and directional, as the process
simplifies operations by eliminating the need to run casing
after reaching TD. As more wells are drilled in increasingly
unstable or depleted formations, the technology becomes
more valuable, as it provides economical and technical solu-
tions for achieving drilling objectives. As the understanding
of the mechanism for the plastering effect of CwD becomes
better understood, the shift from anticipating a benefit to
predicting the benefit as part of pre-planning the well will
continue to expand the value of this emerging technology.
Copyright © 2015