drilling with casing

8/3/2019 Drilling With Casing

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Copyright 2006 by ConocoPhillips Company. All rights

reserved. No part of this publication may be reproduced in any formwithout the express permission of ConocoPhillips Company.

Advanced Drilling: A Technology FocusArea for ConocoPhillips

Michael Wheatall

Drilling Engineering and Operations Manager,

Upstream Technology

ConocoPhillips, Inc.


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Advanced Drilling: COP Focus AreasAdvanced Drilling: COP Focus Areas

Drilling with Casing

Coiled Tubing Drilling Extended Reach/Multi-Lateral/Designer Wells

HPHT Drilling Managed Pressure Drilling

Wellbore Strengthening


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Drilling with CasingDrilling with Casing

Worlds 1st DWC

and Surface BOPfrom floating rig

Conventional time:

91 hrs With CWD and

Surface BOP: 29

hrs


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Types of Casing Drilling

2000+ Casing Sections

Types of Casing Drilling2000+ Casing Sections

51%

31%

18%

Non-RetrievableBHA Liner Drilling

(surface liners andtrouble zones)

Non-Retrievable BHA

Casing Drilling(conductors, vertical wells,and drillable bits)

Retrievable BHACasing Drilling

(directional, multiple bit runs and

formation evaluation)


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Why Drill With Casing?Why Drill With Casing?

CONVENTIONALDRILLING PROCESS

Since 1901

CASING DRILLINGPROCESS

1998 Future

CABLE TOOLPROCESS

1850 1930

Rock Destroying slow FAST FAST

Hole Cleaning slow FAST FAST

Tripping FAST slow FAST


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Stabilizer

Underreamer

Stabilizer

ponycollar

PDC

Bit

External BHA

Crimp-onStabilizer

Crimp-on

Stabilizer

Crimp-onStabilizer

CasingStabilization

Profile

Nipple

Casing

Internal BHA

DLA

Stabilizer

Spacer

Collar

How Do You Drill With Casing?How Do You Drill With Casing?


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Lobo TrendLobo Trend

Casing Drilling began in 2001 to reducetrouble time

120 wells (1.6 million feet of hole) have beendrilled with casing

Lost circulation was almost completely

eliminated Zero stuck pipe incidents

An active drilling program continues where

casing drilling candidates are selected basedon expected problems.

The need to drill directionally is increasing.


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BMT EastBMT East

Spud to Cementing of Intermediate Casing

200 - 300 sack balanced cement plug

7

Csg.

May 2002

10 days

8,103

Casing Drilled

9 5/8

Csg.

4 1/2Csg.

5 1/2

Liner

5,145

7Csg.

9,400

Conv. Offset 2

9 5/8

Csg.

3 1/2Csg.

Sept 2001

19 days

5 1/2

Liner

7

Csg.

6,917

8,162

Conv. Offset 1

9 5/8

Csg.

3 1/2Csg.

7Csg.

7,985

5,272

8,185

Conv. Offset 3

9 5/8

Csg.

4 1/2Csg.


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BMT East C2 WellBMT East C2 Well

7

Csg.

$7,000 Trouble

8,143

Casing Drilled

9 5/8Csg.

4 1/2Csg.

Conventional

9 5/8Csg.

$184,000 Trouble

4,380

Conventional Rig Drilled & set surface csg

Lost circ at 4,380 ft Could not cure lost circ.

Temp. abandoned well

Casing Drilling Rig Moved over well

Drilled out plugs

Cured lost circ. by drilling ahead

Well completed


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Casing Drilling CuttingsCasing Drilling Cuttings


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Smear EffectSmear Effect

Whole Mud Sieve Analysis

0

10

20

30

40

50

8 20 50 100

140

200

>20

0

API Sieve Size

%S

olidsRetained

Casing Drilled

Conventional Drilled

Fine

UltraFine

Co

arse M

edium


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Casing Drilling BenefitsCasing Drilling Benefits

Safer operations well control, pipe handling

Reduced trip time

Reduced open hole trouble time 50% (Lobo)

Reduced drilling time - 15% (Lobo)

Reduced Cost

Uses conventional bits, BHAs and casing

Enhances UB and Managed Pressure Drillingtechniques


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Less Subtle BenefitsLess Subtle Benefits

Dont fight problems, case them off instead

Rig loads smaller Hydraulics needs are less No overpull needed

No setback area

Drill pipe (casing) is always new


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Retrievable Casing DrillingBottom Hole Assembly

7 Casing SectionVertical Wells

DLA(Drill Lock

Assembly)

8 jts7 5/8-in.

casing

7-in.23 lbm

casingto surf

TandemCasing

(internal)Stabilizer

SpacerDrill CollarCasing

shoe

Under reamer(6 1/8 to 8 7/8)

Tandem(external)Stabilizer

6 1/8 PDC bit


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ConocoPhillipsWell 83

Casing Directional DrillingBottom Hole Assembly

with Steerable Motor

Under reamer(6 1/4 to 8 7/8-in.)

Bent Housing Motor4 -in. then 5 -in.(1.5 deg bend)

casingshoe

TandemCasingStabilizer

Drill Lock

Assembly(DLA)

7-in.23 lbmcasingto surf

non-magdrill collar

VibrationsMonitoring

sub

MWD

Float sub

6 -in. PDC bit(3x15 nozzles)

Conoco Phillips


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TandemCasingStabilizer

DLA(Drill LockAssembly)

7 23 lb

Casingto surf

Casingshoe


Drill Collar

Filter sub

4 -in. RotarySteerable System

94 ft

67

5200 lbs

3 IF

Conoco PhillipsWell 89

Casing Directional Drilling

BHA w/ Rotary Steerablefor Verticality

Total Length

Stick-out Length

Hanging weight(in mud)

connections

Spacer

Drill Collar

6 1/8-in. PDC bit(4x10 nozzles)

Well 91: Full Directional Test


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Well 91: Full Directional Test

-1200

-1000

-800

-600

-400

-200

0

200

-600 -400 -200 0 200

Easting (E/-W), ft

N

orthing

(N/-

S),

ft

0

1000

2000

3000

4000

5000

6000

7000

0 1000 2000

Displacement, ft

TVD,

ft

Horizontal PlotVertical Plot

target

Well 91Well 91

Well 79

Well 79

Surf

Loc

SurfLocTD


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Conoco PhillipsWell 91

Casing Directional DrillingBottom Hole Assembly

With Rotary Steerable Syste

Jet Sub

(1x10 nozzle)


6-in. StraightMotor

TandemCasing(internal)Stabilizer

DLA(Drill LockAssembly)

8 jts7 5/8-in.casing

7-in.23 lbmcasingto surf


MWD system

Filter sub

4 RotarySteerable System

6 1/8 PDC bit(4x10 nozzles)

Total LengthStick-out Length

Hanging weight(in mud)

112 ft85

6200 lbm

Casingshoe

RSS Drilling EfficiencyRSS Drilling Efficiency


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RSS Drilling EfficiencyRSS Drilling Efficiency

ROP was within 10% of offset vertical well

Casing drilling benefits captured: No lost circulation events

Minimal reaming time No difficulties in setting casing

OBM not required

Eliminated difficulty of Casing Drilling with steerablemotor No sliding problems

No motor stalling problems

However Vibrations were significant

Multiple RSS washouts


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Key QuestionKey Question

Can the straight hole benefits and initial

directional successes realized in the Lobo Fieldbe transferred to directional casing drilling in ahigher cost offshore environment, such as

Norway?


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2005 Field Test Objectives2005 Field Test Objectives

Directionally drill with larger casing

sizes used at Eldfisk (10-3/4 & 7-5/8) Identify and correct any problems withnew tools

Provide information required to qualifyequipment and tools for use in Norway

Perform directional casing drilling on aconventional rig similar to Norwayplatform rig


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Split Block

Swivel with space forWireline BOP

Top Drive System

Casing Drive System

10 -in. casing


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7 5/8 T t S7 5/8 T t S


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7-5/8 Test Summary7-5/8 Test SummaryDisplacement (ft)

TrueVerticalDepth

(ft)

Previously drilled wellw/10 casing to 3769ft

600ft HZdrill 844 ft

w/7 5/8 csg

TD 4884 ft

DLA/UR set/retrieval tests

planned at 0, 45, and 90 deg

0

500

1000

1500

2000

2500

0 600 1200 1800 2400 3000 3600

10 3/4 T t S10 3/4 T t S


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10-3/4 Test Summary10-3/4 Test Summary

0

500

1000

1500

2000

2500

3000

3500

4000

4500

-500 0 500 1000 1500 2000 2500 3000 3500 4000 4500 5000 5500

Displacement

TrueVertica

lDepth

(ft)

13 3/8 csg @2003ft

KOP: Build to 50 deg testing different rates (planned)

TD 5000ft

Actual Total Depth of the test was 2966 ft, with 15degrees of inclination built.

(planned depth)

ConclusionsConclusions


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Both Directional Casing Drilling tests were a cost

effective dress rehearsal for Eldfisk Norway Directional Casing Drilling technology was

successfully transferred to new casing sizes

Rotary steerable system in the pilot holeprovides effective directional control

Vibrations in the BHA are better understood,their effects have been reduced

O t N !On to Norway!


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On to Norway!On to Norway!

Two Eldfisk wells will be casing drilled in

May 2006

50 degree maximum angle

10-3/4 to 5100 ft (md)

7-5/8 to 10800 ft (md)


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Coiled Tubing Drilling


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Coiled Tubing Drilling

CTD is Drilling with

One Long Joint

Still Need All DrillingEquipment

Shelter

Solids Control

Pumps, Tanks,

Mast... Etc Combined CT/Rig

1st Generation Alaska CTD OperatioWith Drilling Platform

Courtesy ConocoPhillips

2nd Generation CTD in Alaska


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Courtesy BP and ConocoPhillips

Coiled Tubing Drilling UnitCoiled Tubing Drilling Unit

Conventional Drilling packageConventional Drilling package

Arctic Coiled Tubing UnitArctic Coiled Tubing Unit

2nd Generation CTD in Alaska

Work Over UnitWork Over Unit


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3rd Generation CTD Unit: Alaska

Courtesy BP, ConocoPhillips and Schlumberger

Workover Rig in Grey

CTU in Orange

Unitized and Self-Powered

Sister Rig Added toCTD Fleet

CTD: Why all the Interest?


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CTD: Why all the Interest?

0

27.52%

55.04%

82.56%

110.07%

137.59%

165.11%

192.63%

NewWe

ll

NewWe

ll

NewWe

ll

NewWe

ll

NewWe

ll

NewWe

ll

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

Sidetra

ck

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

CTDS

/T

WellCostPe

rcentage

100%

73%

31%

Program Dev. Costs - $/bbl

New Wells - 100% $/BblSidetracks - 113% $/Bbl

CTD S/Ts - 69% $/Bbl

Reserves Development Costs

Greater Kuparuk AreaGreater Kuparuk Area


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Greater Kuparuk Areap

CTD Historical Well Count(includes incomplete wells)

0

5

10

15

20

25

30

1998 1999 2000 2001 2002 2003 2004 2005

# Wells

# Laterals


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High Rate 1D-11High Rate 1D-11

Multi-lat C sand lateral

& maintained motherbore

First Two-window/two-lateral design allowsfuture isolation and re-

entry into each lateral

Longest KRU CTDLateral on record:

Lat 1 : 2,202 / 2,015Lat 2 : 2,812 / 2,584

Initial well tests >5,500 bopd!

2005 CTD Accomplishments at GKA2005 CTD Accomplishments at GKA


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2005 CTD Accomplishments at GKA2005 CTD Accomplishments at GKA

Extended Reach Records for 2 CT (1D-34)

Drilled depth 18350 md (2.2:1)

Lateral length 2630 md

Window milling depth 15721 md OH sidetrack depth 17935 md

Pushing the Envelope: 1Q 04 Quad LateralPushing the Envelope: 1Q-04 Quad Lateral


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Pushing the Envelope: 1Q-04 Quad LateralPushing the Envelope: 1Q-04 Quad Lateral

5224 drilled footage Lower quality A-sand


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Casing Drilling and CTD:

Proven Yet Still Evolving

Technologies

Whats Next?

Casing Drilling and CTD:

Proven Yet Still Evolving

Technologies

Whats Next?

Remote Land Based Exploration WellsRemote Land Based Exploration Wells


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Remote Land-Based Exploration WellsRemote Land-Based Exploration Wells

Challenged Economics for Rotary Drilling:

Market driven drilling cost inflation

Mature basins: smaller structures/reserves Shorter drilling seasons (Canada/Alaska)

Tighter environmental restrictions Difficult logistics is major cost driver

O r ChallengeOur Challenge


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Our ChallengeOur Challenge

Reduce cost of remote land-based exploration drilling by

50% while meeting formationevaluation requirements.

Plan of Attack: Think SmallPlan of Attack: Think Small


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Plan of Attack: Think SmallPlan of Attack: Think Small

Smallest hole sizes possible Reduce materials and logistics cost

Existing technologies and equipment

Leverage ConocoPhillips expertise

Casing drilling Coiled tubing drilling

Requirements 10,000 depth capability Formation evaluation

Rig Options StudiedRig Options Studied


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Rig Options StudiedRig Options Studied

Mining Industry Coring Rigs Depth limitations

Slow drilling in overburden

Major modifications to mud system and well control 1990s Vintage Slim Hole Rigs (4-3/4 min hole size)

Small footprint

Rolligon, truck or heli-transportable

Lengthy move and set-up

Inefficient drilling (lacks automation)

Automated Small Conventional Rig

Swift move and set-up Drill efficiently

Reduced personnel exposure

Large, heavy load while moving

Western Canada Shallow GasWestern Canada Shallow Gas


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Western Canada Shallow Gas

Fit for Purpose Hybrid Coil/Rotary Rig

Hybrid CT/Rotary Drilling UnitsHybrid CT/Rotary Drilling Units


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yb d C ota y g U tsy y g

Wells drilled and cased in about one day

Two wells per day possible

Typical 3000 Well:

7 inch surface casing 8-1/2 hole drilled with 3-1/2 CT or DP

4- inch production casing

6 hole size drilled with 3-1/2 CT

Western CanadaWestern Canada


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Western CanadaWestern Canada

Coil Tubing Drilling Rigs

15 1722 25

36

67

0

20

40

6080

2000 2001 2002 2003 2004 2005Year

Hybrid Rig Count

CanadaCanada


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Wells Drilled by Rig Type

0

5000

10000

15000

20000

25000

2000 2001 2002 2003 2004 2005

Numbe

rofWells

Hybrid Drilled Wells Conventionally Drilled Wells

Small FootprintSmall Footprint


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pp

Drilling with CT - Mast Down DesignDrilling with CT - Mast Down Design


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Automated Pipe Handling SystemAutomated Pipe Handling System


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p g y

Automated Pipe Tub TrailerAutomated Pipe Tub Trailer


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pp

Touch Screen Control PanelTouch Screen Control Panel


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Drilling with CT - Mast Up DesignDrilling with CT - Mast Up Design


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Automated Rig ControlsAutomated Rig Controls


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Automated Pipe Rack with SkateAutomated Pipe Rack with Skate


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Top DriveTop Drive


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Zero Discharge Mud SystemZero Discharge Mud System


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MovingMoving


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MovingMoving


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But Can these Rigs Drill aBut Can these Rigs Drill a


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g

10,000 Exploration Well?10,000 Exploration Well?

4500 maximum depth with 3-1/2 CT

6000 maximum depth with 2-7/8 CT

Low capacity mast (150-200 klb)

Small mud pump (650-850 hp)

Approach: Think Small & Work WellDesign from the Bottom Up

Approach: Think Small & Work WellDesign from the Bottom Up


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Design from the Bottom UpDesign from the Bottom Up

4-1/8 final hole size 3-3/4 bi-center bit (helps with ECD)

Contingency liner option (3-3/16) Extensive experience with this hole size to 18,000 md

Drilling Tools: proven and available

Wireline telemetry Bent housing mud motors

MWD/GR/Resistivity

2-1/4 wireline logging tools Conventional coring equipment

Complete with 2-3/8 or 2-7/8 SL tubing

Slim HoleSlim Hole


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Slim Hole

Design

No Intermediate

Casing4-1/2 x 2-3/8

Final Hole Size:4-1/8

Slim Hole

Design

No IntermediateCasing

4-1/2 x 2-3/8


Slim HoleDesign

Slim HoleDesign


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Design

Intermediate

Casing

7 x 4-1/2 x 2-3/8


Design

Intermediate

Casing

7 x 4-1/2 x 2-3/8


Main Issue: Hybrid Rig LimitationsMain Issue: Hybrid Rig Limitations


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4500 depth limitation based on 3-1/2 CTD to TD

3- CT marginal for 8-1/2 surface hole drilling

10,000 of 3- CT too much for current hybridrigs and difficult to move

Increases final hole size beyond needed 4-1/8

Solution: Casing/Coil HybridSolution: Casing/Coil Hybrid


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Integrate casing drilling technology

Casing drill surface hole and intermediate hole Eliminates need for large diameter CT

Casing drilling plus slim hole design greatly extends

depth range for mast and pumps Retrievable BHA not needed for straight hole sections

2-3/8 coil tubing to drill final 4-1/8 hole Extends rig capacity 10,000 depth

Formation Evaluation OptionsFormation Evaluation Options


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2-1/4 Wireline Logging Tools Array induction

Dual Laterolog

Compensated neutron

Compensated photo-density with PE

Compensated sonic

Standard gamma ray

MFT (pressure tester only) on wireline

High Resolution Micro Imager

Conventional Coring

Well Test through Tubing

Summary: Casing/Coil Hybrid Advantages(over conventional rotary drilling)

Summary: Casing/Coil Hybrid Advantages(over conventional rotary drilling)


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Automated Rig Benefits Reduced personnel exposure

Fast move and rig-up Small location size

Top drive

Slim Hole Well Design Benefits Reduced tangible costs

Reduced mud and cement volumes Reduced cuttings and waste fluid disposal

Reduced hauling

Facilitates zero discharge

Casing/Coil Hybrid AdvantagesCasing/Coil Hybrid Advantages


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Casing Drilling Benefits Smaller rig, less fuel, reduced emissions Reduced trip time

Reduced trouble time (smear effect and notripping)

No drill string reduced hauling

Coiled Tubing Drilling Benefits

Faster drilling (no connections)

Reduced trip time

Managed Pressure Drilling/Underbalanced Drilling

Facilitates use of Oil Based Mud



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Cost reduction goal is achievable

Casing/Coil Hybrid Drilling Concept isfeasible using current technology andavailable equipment

Other Applications Possible


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QUESTIONS?

drilling with casing

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