Drilling and Production Operations Ref: INDEX SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 INDEX Page 1 of 1 Introduction HPHT 01 HPHT Drilling Techniques and General Procedures HPHT 02 HPHT Well Control Procedures HPHT 03 HPHT Equipment, Design and Materials HPHT 04 Drilling Engineering Considerations HPHT 05 Management and Control HPHT 06 References and Further Reading HPHT 07 SECTION 1 Drilling and Production Operations Ref: HPHT 01 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 INTRODUCTION Page 1 of 5 TABLE OF CONTENTS 1. INTRODUCTION.................................................................................................... 2 1.1 DEFINITION OF HPHT .................................................................................... 2 1.2 OBJECTIVE ..................................................................................................... 2 1.3 CODES AND STANDARDS ............................................................................. 3 1.4 HPHT FIELDS AND AREAS ............................................................................ 3 1.5 DIFFICULTIES ASSOCIATED WITH HPHT DRILLING................................... 3 1.6 APPLICATION OF HPHT PROCEDURES....................................................... 4 INTRODUCTION 1. Page 2 of 5 INTRODUCTION The planning of high pressure, high temperature (HPHT) wells should be carried out by very experienced Engineers who have a broad well engineering background. This document is aimed at these Engineers and therefore, many general well engineering concepts will not be discussed. Only specific HPHT issues will be described in detail. It also highlights generic industry practices for consideration and, as a result, many of the issues are written with a strong emphasis on terms such as ‘will, should and shall’. 1.1 DEFINITION OF HPHT An HPHT well is both high pressure (pressure control equipment rated in excess of 10,000psi is required) and high temperature (the undisturbed formation temperature at total depth is greater than 300F). The main driver is the pressure criterion but temperature effects are significant too. If only one of these conditions is present, then this document may still apply in many areas. HPHT wells require a higher degree of engineering effort and preplanning for well design, due to the tighter margins between the pore and fracture gradients and the thermal loads arising from higher temperatures. The project engineering time required for an HPHT well design may be significantly more than for a standard well. As a result, it is normal practice to identify and put in place, a specific multidiscipline project team; well in advance of the anticipated spud date for such wells. 1.2 OBJECTIVE The objective of this document is to provide Drilling Engineers with a broad outline of issues associated with the planning and operational execution for an HPHT well. They should use this document as guidance, in order they know where to obtain the specialist type of information for an HPHT well and understand the key issues. The Institute of Petroleum (IP) Model Code of Safe Practice Part 17: Well Control During the Drilling and Testing of High Pressure Offshore Wells, May 1992, will form the primary link for this manual, in terms of HPHT well practices and planning. Projects should therefore be planned on the basis that they satisfy the requirements of IP 17, and deviations from the document should be explained and justified. INTRODUCTION 1.3 Page 3 of 5 CODES AND STANDARDS Codes, Standards and Guidance applicable to HPHT wells are still based on the traditional range of documents within the oil industry, such as API. However, there are a number of specific documents that should be used for HPHT wells. These include, but are not limited to: Institute of Petroleum (IP) Model Code of Safe Practice Part 17: Well Control during the Drilling and Testing of High Pressure Offshore Wells, May 1992 National Association of Corrosion Engineers (NACE) MR0175-99: (Assessment of H2S and CO2) Institute of Petroleum (IP) Guidelines for ‘Routine’ and ‘Non-routine’ Subsea Operations from Floating Vessels (Riser analysis, structural strength, integrity of subsea systems), August 1995 1.4 HPHT FIELDS AND AREAS HPHT reservoirs have been developed since the early 1970s. Regionally they exist in the North Sea, North America and mainland Europe but are not yet extensive. There are HPHT fields in production, or under development offshore UK, offshore Norway, onshore USA, offshore in Mobile Bay USA, onshore Italy and onshore Austria. In addition to the HPHT nature, these fields are characterised by: Great depths High H2S/CO2 and possibly Mercury levels High levels of dissolved salts High drilling and equipment costs The US fields are predominantly gas, while the North Sea and Italian fields contain high levels of condensate, or are volatile oils. In the North Sea, most are in the Central Graben area. 1.5 DIFFICULTIES ASSOCIATED WITH HPHT DRILLING The main issue of HPHT wells centres around the cost. The combination of depth and the higher pressures and temperatures will require drilling rigs with a high specification. Drilling becomes exponentially slower with depth and additional casing strings are required compared to conventional wells. INTRODUCTION Page 4 of 5 Additionally, longer multidiscipline team planning schedules and high-specification equipment lead-times for equipment such as Non API casing strings, wellheads/xmas trees and duplex flowlines, all have an impact on the project cost. The risk of an incident such as a well influx also requires additional emphasis on preplanning, training and operational drilling practices. As a general guide, HPHT wells experience approximately a two-fold increase in well control incidents, over and above a conventional well. This has an impact on cost and safety procedures. 1.6 APPLICATION OF HPHT PROCEDURES The method that should be adopted for HPHT projects requires a multidiscipline approach for all of the planning and operations. It is unrealistic and inefficient for disciplines to work in isolation for such projects. It is normal practice that a team will be identified and formed at the conceptual stage in order to plan, identify areas of concern and optimise the well design with all of the personnel and companies associated with the project, prior to commencement of operations. In particular, the drilling contractor and the main service providers, will become part of the core team at a very early stage, for risk assessment and contingency planning. The team would look at life of well/field issues at the start of the project and would consist of drilling, production, reservoir, petroleum, facilities and completion engineers, together with geological, geophysical and petrophysics explorationists. Examples of the application of HPHT procedures are: Defining a clear envelope for the well design for worst case scenarios eg the assumption that H2S is present, unless conclusively proven that it is not. All tubulars potentially exposed to reservoir fluids should be NACE H2S sour service resistant, to reduce the risk of sulphide stress corrosion cracking. The objective is to identify the impact of corrosive toxic gases and, where possible, design the problems out of the system, prior to commencement of operations Identifying the limitations of the well design to all parties in order that operational procedures are realistic. For example, highlighting exploration drill stem testing (DST) thermal limitations, as opposed to long-term thermal production loads (Exploration v Development) Utilising teamwork from a variety of disciplines, for critical operations such as long heavy casing strings. Performing a casing design structural VME (von Mises Equivalent) Triaxial analysis at the design stage. Focusing on material selection, premium connector qualification testing, manufacturing and inspection criteria, the drilling fluid system, casing running procedures and equipment, casing cement slurry design, capability of the drilling rig derrick system, contingencies etc Integrating engineering and operations personnel as one team, by defining the well objectives clearly and recognising the knowledge and skills set of all the key personnel. This is to ensure there are no gaps in the well engineering processes for the project for all phases. An example is the inclusion of the drilling contractor for the development of the project well control procedures and optimisation of drilling assemblies for the hole sections, to maximise hydraulics and hole cleaning INTRODUCTION Page 5 of 5 Focusing on training and human factors for contingencies and emergency response exercises at an early stage, prior to commencing the drilling of the HPHT transition zone Defining interfaces and roles/responsibilities for the operator and drilling contractor The key message is: ‘The application of HPHT procedures and systems requires the involvement of all personnel at all levels for planning, operations, contingencies, risk assessments and emergency response’ SECTION 2 Drilling and Production Operations Ref: HPHT 02 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 1 of 12 TABLE OF CONTENTS 2. HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES...................... 2 2.1 PREPARATION ............................................................................................... 2 2.1.1 Rig Floor Equipment ................................................................................... 2 2.1.2 Well Control Equipment.............................................................................. 3 2.1.3 Downhole Equipment.................................................................................. 4 2.2 DRILLING OPERATIONS ................................................................................ 4 2.2.1 Equipment .................................................................................................. 4 2.2.2 Drilling Practices......................................................................................... 4 2.2.3 Circulating System...................................................................................... 6 2.3 TRIPPING OPERATIONS ................................................................................ 6 2.3.1 Operations Prior to Tripping........................................................................ 6 2.3.2 Operations Whilst Tripping ......................................................................... 6 2.3.3 Operations After Tripping............................................................................ 8 2.4 CORING........................................................................................................... 8 2.4.1 Coring Equipment ....................................................................................... 8 2.4.2 Coring Procedures...................................................................................... 8 2.5 CASING WEAR.............................................................................................. 10 2.6 BOP TESTING ............................................................................................... 11 HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES 2. Page 2 of 12 HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES This section discusses the typical preparation and procedures that would be required for a high pressure, high temperature (HPHT) well. It assumes the worst case, an offshore well with a semi-submersible rig. It should be noted that the issues highlighted as techniques and procedures have a strong link to IP 17 and generic industry practices. Depending on the rig type and drilling contractor, many of the areas discussed below would generally be developed by the operator and drilling contractor. It would be normal practice subject to legislation and regulations in use around the world, to identify which well control procedures would act as the base document, for review and assessment for the HPHT project. Some drilling contractors may have specific HPHT Drilling Operations and Well Control Manuals for a specific rig. The operator would normally then include additional issues specific to their requirements, as addenda to each respective manual, with the consent of the drilling contractor. This would typically require an HPHT Bridging Document. 2.1 PREPARATION 2.1.1 Rig Floor Equipment The specific instructions summarised below are a guide to identifying instructions for drilling equipment: All pressure gauges used in the drilling and well control circulating system will be calibrated to ensure they are accurate and consistent A float valve will not be run in any bottom hole assembly (BHA) after the intermediate casing is set (typically the 13-3/8in) A Gray Type non-return valve (NRV) will not be kept on the drill floor but will be available for use on the rig A Hydril dart sub will be included in every BHA. The dedicated drop-in dart will be kept fully serviced in the drillers dog house. The Driller will ensure that, on each trip out of the hole, the dart sub is checked for damage and erosion. The dart will be checked that it will pass through every component in the drillstring above the dart sub, including the stab in valves kept on the drill floor. The dart must be rated for the temperature and pressures that could be encountered in the well. Note: During weekly testing of surface equipment, the dart will be installed in the dart sub and pressure tested as stated within the drilling programme. Two 15,000psi, full-opening safety valves will be kept on the drill floor with crossovers, for each type of connection in the drillstring HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES 2.1.2 Page 3 of 12 Well Control Equipment The choke manifold and blowout preventer (BOP) will be lined up in the following manner and checked at the start of each shift by the driller: All failsafe valves closed Valves lined up to allow flow from the choke line through the autochoke, to the poor boy degasser, to the liquid seal and on to the header box. Valves must be lined up for a ‘fast shut-in’. The glycol injection pump will be permanently rigged up to allow immediate use The driller will function test the remote actuated valves to the mud gas separator (MGS) and the MGS bypass line at the start of each shift, and ensure that the port/starboard directional valves are lined up for the prevailing wind direction The maximum allowable annular surface pressure (MAASP) control is to be disconnected at the remote choke control console. Note: If the MAASP control is activated on the maximum setting, this would open the choke and allow a continued influx into the well. This can make the well control situation worse, as this would result in the gas venting off, which in turn would introduce new influxes into the wellbore ie work on the basis that fracture at the shoe is preferable. The slow circulating rate (SCR) pressures are to be taken with the mud pumps and the kill pump. The kill pump SCR pressures are to be taken with 1/2bbl/min as the lowest circulating rate using the drill floor remote operating controls. Kick sheets will be updated after taking the SCR pressures. SCR pressures will be taken at the remote choke control panel: At the start of each shift After changes to the mud weight/properties After changes to the BHA Note: The taking of SCRs at the beginning of each shift needs to coincide with the flushing of choke and kill lines and trip tank, if mud is stored in these components. The barytes bulk lines will be purged at the start of each shift. Ensure that the surge tanks are full at the start of each shift. Bulk storage tanks will be fluffed up once a day Both the poor boy and vacuum degassers are to be operated at least once during each shift. If instrumentation is installed on the dip tube, it is to be checked against the mud weight on a daily basis A 15,000psi kill sub complete with spacer sub and chicksan swivel, will be made up, pressure tested and available on the rig floor at all times HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 4 of 12 The choke manifold and the MGS temperature and pressure data monitoring equipment are to be function tested every week. This is to be performed in place if possible 2.1.3 Downhole Equipment Non-magnetic drill collars are required in the BHA if survey tools are required, for directional surveying purposes The bit nozzle selection will take into consideration the potential for pumping of lost circulation material (LCM), barytes and cement plugs for control of lost circulation. The bit nozzle selection will be planned such that the issues of hydraulics and LCM are considered together. The minimum nozzle size will be 1/2in 2.2 DRILLING OPERATIONS 2.2.1 Equipment For Kelly Drilling, a safety valve will be used below the kelly so that the kelly can be safely disconnected, during HPHT well control operations For Top Drive Drilling, the well will be drilled in singles, using a ‘drilling kelly’ comprising two pup joints with saver subs above and below, separated by a number of full-opening drillpipe safety valves (at least two). This arrangement will ensure that the top drive can always be safely disconnected during high pressure well control operations. (This arrangement would be used at some point prior to the HPHT transition zone) 2.2.2 Drilling Practices On any indication of flow, the well will be shut in according to the ‘fast shut-in’ technique. The Driller will be responsible for shutting in the well and will not require confirmation from the Toolpusher or Operator Drilling Supervisor Once optimised, drilling parameters will be kept constant to allow rapid identification of drilling breaks. The Driller will not allow the bit to ‘drill off’ and the compensator will be kept in mid stroke When drilling into, or while in an over-pressured formation, drilling parameters will be controlled, so that not more than one connection gas influx is present in the hole at any one time HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 5 of 12 When oil based mud (OBM) is used, drilling breaks of 5ft will be flow checked for a minimum of 15 minutes. If the flow check indicates no flow, drill an additional 5ft and if the drilling break continues, circulate bottoms up before drilling ahead. Circulate bottoms up, shutting in the well as bottoms up is c. 1,500ft below the BOPs. When water based mud (WBM) is in use, flow checks will be for a minimum of 5 minutes, or until it is established that the well is not flowing Drilling parameters will be continuously monitored by both the mud logging and rig sensor packages. Any discrepancies between the two systems will be investigated and rectified. Any deviation between physically observed parameters and monitored parameters will also be investigated The temperature of the mud returns will be monitored at the header box at all times. Any changes to the temperature trend will be fully investigated. The implication of the changes on the maximum continuous working temperature rating of the elastomer goods will be discussed and corrective action taken as necessary. Drilling operations will be suspended if the temperature of mud returns at surface exceeds an agreed maximum or if the temperature measurement system fails Note: *The limits will be set down by the drilling contractors operations manual and agreed with the operator as part of the HPHT bridging document. When operations dictate that a sample requires to be circulated to surface for investigation, the following will be used as a precautionary measure to prevent sudden release of gas at surface. The well will be shut in on the upper annular when the sample is c.1,500ft below the BOPs and directed through the choke line and over a full-open choke. Circulation will continue until the sample is out of the well and gas levels return to a normal level, or shut-in procedures have to be initiated If drilled, connection or trip gas levels in the mud increase significantly, then the well should be shut in on the upper annular and circulation continued through an open choke to the poor boy degasser (taking into account choke line losses). The well will be circulated in this manner until the gas levels have normalised. If gas levels do not return to normal levels, further action may be required and discussed with onshore operational personnel (Drilling Superintendent) Whilst drilling into, or in a overpressured transition zone, the mud weight will be increased in accordance with the indications of overpressure. If the pressure transition zone occurs in a low permeability limestone formation, the most reliable method of detecting overpressure is increasing gas levels. The background gas level will be normalised by the Mud Logger for penetration rate and circulation rate, so that a reliable trend can be followed. Drilling will stop and mud weight increased if the continuous normalised background gas levels increase above 5%. Drilling will not continue until the background gas level has been reduced to the previous level HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES 2.2.3 Page 6 of 12 Circulating System Mud weights in and out and pit levels are to be monitored and recorded every 15 minutes. When recording the mud weight, the temperature at which the mud has been weighed must be stated and corrected to a specific reference temperature. A graph should be constructed identifying the change in ‘mud density variation with temperature’ at surface to highlight the reduction in mud weight as the temperature increases Additions to the active system will only be made by the Mud Engineer. All additions will be discussed with the Drilling Supervisor, Toolpusher, Driller and Mud Logger prior to implementation. Mud transfer operations will not be conducted on the active system while drilling into, or in overpressured formations. If a mud transfer is necessary, drilling operations will be suspended until the operation has been completed and the pit levels have been established 2.3 TRIPPING OPERATIONS 2.3.1 Operations Prior to Tripping Determine the maximum pipe speed, taking into account swab/surge pressures. These figures will be given to the Driller prior to tripping operations The Driller should line up the trip tank and fill in a trip sheet. A trip sheet from the previous trip out of the hole should be available The Toolpusher will provide the Driller with written instructions containing the necessary information about the trip, ie reason for trip, prevailing pore pressure regime and tripping overbalance, and ensure that the Driller and crew are fully aware of the correct well control procedures while tripping The Driller is to ensure that the rig floor is fully prepared to shut in the well, a drillpipe safety valve is nearby and fitted with the correct crossover and the drop-in dart is ready for use. Ensure that the dart passes through the safety valve All efforts will be made to cure any static losses to the well, prior to tripping out of the hole 2.3.2 Operations Whilst Tripping A wiper trip back to the last casing shoe should be performed to confirm that pipe can be pulled out of hole (POOH) safely and to confirm by circulating bottoms up after wiper trip that there is sufficient trip margin (assessed by monitoring the bottoms up gas levels). More detailed instructions for the wiper trip are as follows: Prior to tripping whilst using OBM systems, perform a 15 minute flow check across the trip tank to ensure that the well is stable. In WBM systems, flow check for a minimum of 5 minutes and until the well can be confirmed to be static HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 7 of 12 Pump a heavy slug to avoid a wet trip and resultant uncertainty concerning fluid flow volumes. Calculate the slug size and return volume to give c.200ft of dry pipe. Allow slug to stabilise, with the top drive/kelly disconnected and ensure that the correct volume of fluid returns as the slug equalises. Note: The rule-of-thumb for a non-tapered drillpipe string on return mud volume due to pumping a slug is: Slug Volume (bbl) x (Slug Weight (ppg)/Mud Weight (ppg) – 1) = Extra Mud Volume at Surface (bbls) Start pulling out of hole to the shoe, monitoring the drop in fluid level. Do not fit a pipe wiper until the hole fill has been confirmed If the hole is not taking the correct volume of fluid, carry out the following: Stop tripping Install a full opening safety valve Flow check the well in OBM systems for a minimum of 15 minutes across the trip tank. In WBM systems, flow check for a minimum of 5 minutes and until the well condition (static, or flowing) is established If static: Run in hole (RIH) to bottom, monitoring hole volumes with the trip tank. While circulating bottoms up, shut in the well as bottoms up is c. 1,500ft below the BOP. If flowing: Initiate shut-in procedures. Refer to the Well Kill Decision Tree. Assuming the flow check is confirmed acceptable, continue tripping out of hole to the casing shoe and perform a minimum of a 15 minute flow check in OBM systems across the trip tank. In WBM systems, perform a minimum of a 5 minute flow check, or until the well kill can be established as being static Then run back to bottom, monitoring hole volumes and taking into account surge pressures. Circulate the hole ensuring the first slug is circulated out. Close in the well when bottoms up is c. 1,500ft below the BOP. Watch out for a pit gain as any gas comes out of solution. If necessary, increase the trip margin and perform further check trip. In some circumstances, it may be required to pump out of the hole Once a trip margin has been established, drop survey barrel if applicable. Start the trip out of hole and perform periodic 15 minute flow checks at casing shoe and prior to pulling BHA through BOP HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 8 of 12 If the trip is interrupted for any reason, install the drillpipe safety valve. If the hole fill pump fails during the trip, do not fill the hole through the drillpipe Whilst the drillstring is out of the hole, the blind/shear rams will normally remain open. The well will be monitored by circulating across the hole with the trip tank. If the blind/shear rams are closed, the well will be monitored by circulating across the BOP by pumping down the kill line and up the choke line with returns to, and suction from, the trip tank if possible (subject to the BOP configuration) If a 7in liner has been run, the following additional procedure will be performed. The reduced clearance between the drillstring and the 7in liner will increase the likelihood of swabbing whilst tripping. For this reason, the check trip performed as part of a trip out of hole should be extended past the shoe to the top of the liner. When pulling out of a hole with a tapered 3-1/2in to 5in drillstring, additional flow check procedures for the OBM, or WBM systems will be performed: When the bit is at the liner overlap Prior to the 3-1/2in drillpipe entering the BOP 2.3.3 Operations After Tripping When back on bottom, prior to further drilling or coring, circulate bottoms up to check for gas. Circulate the hole until bottoms up are c.1,500ft from the BOP. Shut in and circulate out through a fully opened choke 2.4 CORING 2.4.1 Coring Equipment A circulating sub will be run above and as close to the core barrel as possible Ensure both the core barrel and circulating sub ball will pass through all restrictions in the drillstring The inner core barrel is to be perforated, or have a pressure-relieving device installed to avoid pressure being trapped in the barrel 2.4.2 Coring Procedures For exploration drilling, the length of the core barrel to be run in a new reservoir section will be a maximum length of 90ft for the core barrel. Subject to the operational trip out of the hole having no problems, the length may be increased based on a local risk assessment and approval from the Drilling Superintendent and drilling contractor. If the well is appraisal, or development with good offset data, these criteria may be modified, subject to the well design and operational conditions HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 9 of 12 Note: Coring operations will not be performed if there is a high probability of encountering an overpressured transition zone. The hole will be circulated and the mud conditioned, prior to the core ball being dropped Attention will be given to the calculation of swab pressures and critical tripping speeds, prior to pulling out of the hole with the core barrel Coring operations will only be undertaken when there is confirmation that the objective sand has been penetrated After penetrating the objective sand, coring operations will only be undertaken if a 10 stand check trip confirms there is sufficient overbalance, prior to tripping out of the hole After cutting the first core, tripping procedures will be used as discussed in Section 2.3 When recovering the core barrel, the following tripping procedure will be used: POOH to c.1,500ft below the BOPs RIH to c.3,000ft below the BOPs. Shut in the well as a precautionary measure to prevent sudden release of gas at surface. The well will be shut in on the upper annular and directed through the choke line and over a full open choke. Circulation will continue until the sample is out of the well and gas levels return to a normal level, or shut in procedures have to be initiated POOH to c.1,000ft below the BOPs RIH to c.3,000ft below the BOPs. Shut in the well and repeat the exercise of circulating out any potential gas through the choke manifold If hole stable and gas levels normal, POOH to surface Monitor drill floor and surrounding area with H2S monitors Prior to recovering the core to surface, clear the drill floor of non-essential personnel and ensure all personnel ‘mask up’ with breathing apparatus (BA) sets on the assumption that H2S is present in the core. The BA sets will not be removed, unless there is clear evidence that H2S is not present. The same procedures will apply to the handling of repeat formation test (RFT) samples and side-wall cores. HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES 2.5 Page 10 of 12 CASING WEAR Casing wear from drillpipe rotating can cause a significant impact on the strength of the casing, which may lead to weakening, down-rating and ultimately rupture, during pressure testing. This can lead to delays in the project and require the installation of a contingency tieback. Casing wear is also discussed within Section 3 of the Casing Design Manual. The locations most susceptible to wear are doglegs in the upper part of the hole, where high tension loads in the drillstring hold the rotating tool joints against the casing. As the tool joints gall and grind their way into the casing wall, a crescent shaped groove is produced, deepening as drilling progresses. For HPHT wells this has an impact primarily on the intermediate and the production casings, as they will experience the most rotating revolutions during the drilling of the well (deeper drilling becoming exponentially slower). In terms of risk to the well, casing wear needs to be addressed on two fronts, design and operational monitoring. The risks can be minimised at the design stage by consideration of the following: Establish strict dogleg severity limits, especially near the wellhead Run heavier wall casing directly at the sections that casing wear is anticipated to be highest, eg below the wellhead connection, for an evaluated length Ensure the pre-tender rig audit identifies the type of hardbanding in use for the drillpipe tool joints Identify the ‘wear factors’ that may occur from the mud type in use (oil based or water based) Estimate the planned total rotating hours and speed anticipated inside the casing, for all operations Include a casing wear safety factor as part of the casing design Utilise a proprietary casing wear software planning programme, prior to the start of the project Design and agree drilling practices with the drilling contractor as part of the well programme The risks can be minimised at the operational stage, by consideration of the following procedures: Ensure the correct hardbanding on the tool joints of the drillstring is utilised across the areas of anticipated wear Ensure the inclination of the BOP system/wellhead is limited to a maximum of 1 degree HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES Page 11 of 12 Consider the use of a baseline multi-fingered caliper log or equivalent, in combination with a cased hole North Seeking Gyro, in the last casing above the reservoir Spend time to minimise ‘localised doglegs’ at or near surface. In particular, at the wellhead area. This should be linked to the survey programme frequency, as it is becoming more common to utilise measurement while drilling (MWD) systems even for certain types of vertical exploration wells Consider the use and optimum placing of drillpipe protectors in the region where high wear is expected Install two high grade ditch magnets in the return stream header box. Collect and measure the steel samples to establish a trend analysis, in order to identify if there is a wear problem The amount of wear on the wellhead and flex joint wear bushings will be measured and recorded each time the BOPs are pressure tested If significant wear is suspected in the last casing string prior to entering the overpressured transition zone, consider the running of a multi-fingered caliper log, followed by a pressure test of the casing Feed back the casing wear monitoring results into the well design, to check if the actual results has an impact on the design factors 2.6 BOP TESTING The requirements for BOP testing will need to be agreed and finalised by the operator and the drilling contractor, as part of the well programme. The frequency of BOP tests will also depend very much on the specific policies of the drilling contractor’s operations manual and the operator’s internal policies. For an HPHT well it is probable that the main BOP system will be rated to 15,000psi. For a semi-submersible this may be a single 18-3/4in system, whereas a jack-up may be a two-stack system, comprising a 21-1/4in x 5,000psi BOP and 13-5/8in x 15,000psi BOP. The IP 17 document discusses the issues associated with Testing and Inspection of Pressure Control Equipment under Section 4.11 and should be referred to as a datum. There will be specific milestones where the BOP system and glycol injection line will be pressure tested. These may typically include the following: On the pressure test stump to the full rated working pressure for all components, prior to first nipple up At intervals not exceeding an agreed timeframe with the drilling contractor, typically 14 days Prior to drilling out of the casing shoe HPHT DRILLING TECHNIQUES AND GENERAL PROCEDURES After installation of wellhead seal assemblies After completion of repair work on the system Page 12 of 12 Note: Annulars will generally be tested to c.70% of their rated working pressure once installed. The rams will generally be tested to a value, greater than the maximum anticipated shut-in wellhead pressure. If an annular has been used during a stripping operation, then it will be re-tested on completion of the well control operation. If it is not possible to obtain a satisfactory pressure test, then the lower marine riser package (LMRP) will be retrieved and the annular inspected/repaired assuming the rig is a semi. This will require a temporary well suspension. This will typically consist of the following: A cement plug tagged and pressure tested to a value greater than the leak off test (LOT) across the deepest casing shoe, plus A kill weight mud, plus A retrievable packer fitted with a storm valve and adequate length of drillpipe, set directly beneath the wellhead If flexible lines are used as high pressure choke and kill lines, the IP 17 document Section 5 should always be used to check that issues such as storage, handling, transportation, inspection, annual survey, pressure testing and repair are taken into consideration. The capability and integrity of the hoses will be part of the drilling contractor’s rolling maintenance and survey programmes based on annual and major surveys at five-yearly intervals. They will form part of the rig pre-tender audit checklist, prior to the start of the project. In particular, it is important to obtain evidence of the working history of the flexible lines, eg well control incidents, maximum pressure experienced and type of fluids used SECTION 3 Drilling and Production Operations Ref: HPHT 03 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 HPHT WELL CONTROL PROCEDURES Page 1 of 11 TABLE OF CONTENTS 3. HPHT WELL CONTROL PROCEDURES .............................................................. 2 3.1 HPHT WELL CONTROL PHILOSOPHY.......................................................... 2 3.2 HPHT SHUT-IN PROCEDURES ...................................................................... 3 3.2.1 Influx Whilst Drilling. ................................................................................... 3 3.2.2 Influx Whilst Tripping .................................................................................. 3 3.2.3 Influx While Out of Hole.............................................................................. 4 3.3 CONFIRMATION OF INFLUX .......................................................................... 4 3.3.1 Drilling Operations ...................................................................................... 4 3.3.2 Tripping Operations .................................................................................... 5 3.3.3 Determining Size of Influx........................................................................... 5 3.4 PRE-KILL MEETING........................................................................................ 6 3.5 HPHT WELL KILL PROCEDURES.................................................................. 7 3.5.1 Bullheading................................................................................................. 7 3.5.1.1 Preparation ................................................................................................ 7 3.5.1.2 Procedures ................................................................................................ 8 3.5.2 Bit on Bottom.............................................................................................. 9 3.5.2.1 Preparation .............................................................................................. 10 3.5.2.2 Procedures .............................................................................................. 10 3.5.3 Tapered Drillstring .................................................................................... 11 HPHT WELL CONTROL PROCEDURES 3. Page 2 of 11 HPHT WELL CONTROL PROCEDURES It should be noted that the issues highlighted here as procedures have a strong link to IP 17 and generic industry practices. 3.1 HPHT WELL CONTROL PHILOSOPHY It would be normal practice for the operator and drilling contractor to jointly develop a ‘HPHT Well Control Bridging Document’ for a high pressure, high temperature (HPHT) well based on satisfying the generic requirements of IP 17 (Section 2.4 and 2.5 for shut-in and well kill procedures). During the development of the bridging document, well control simulation studies would be carried out for the well design, based on various influx scenarios for the proposed mud system. It is important to note the different behaviour characteristics of oil based mud (OBM) as opposed to water based mud (WBM). The purpose of the simulations would be to confirm the capabilities of the rig surface equipment to safely handle a well control incident and confirm if hydrates could occur at the blowout preventer (BOP) well control system. The outputs of the studies would normally be included as an appendix and used in estimating glycol injection volume requirements. It is also important to understand that the key philosophy for HPHT wells is to minimise the influx volume early, as the expansion at surface caused by a kick from an HPHT well can be very large compared to the same influx volume for a standard well. Therefore, the following issues should be considered based on links to IP 17 Section 2.5 and generic industry practices: The well will be shut in on any sign of flow, using the ‘fast shut-in’ method to minimise the influx volume. The valve immediately upstream of each choke shall be kept closed After shutting in the well, the choice of well control technique used to kill the well will depend upon the manner in which the kick was taken and the decision tree developed by the operator and drilling contractor (Based on IP 17, Driller’s Method, Wait and Weight Method, Bullheading and Volumetric Method) The bullheading technique has proved successful in dealing with discrete kicks, such as those swabbed in while tripping. Kicks taken while drilling may prove difficult to bullhead, as the influx will be mixed with the drilling fluid. The degree of dispersion into the mud is related to the time that the well is allowed to flow, before the pumps are shut down and the rate at which the influx enters the well (ie the well productivity). Additionally, if high H2S levels are a possibility, bullheading may prove a more desirable option than bringing the fluids to surface Attempt to minimise the volume of hydrocarbons reaching surface To limit surface pressures, temperatures and gas volumes to within the safe handling capacities of all the individual components of the BOP system HPHT WELL CONTROL PROCEDURES Page 3 of 11 To vent or flare gas at surface, in a controlled and safe manner Do not assume that there will be sufficient warning, such as background gas, while drilling through the transition zone When background gas reaches an arbitrary level (agreed with drilling contractor in the bridging document), all work permits will be withdrawn and the standby boat notified accordingly 3.2 HPHT SHUT-IN PROCEDURES The following points summarise the key issues to consider for shut-in procedures, assuming a semi-submersible with a top drive system. 3.2.1 Influx Whilst Drilling Stop drilling Pick up off bottom and switch off pumps Open the failsafe valves in the upper chokeline and close the upper annular Check well is shut in Record initial closed in drillpipe and annulus pressures. (Assistant Driller assembles crew at rig floor) Notify the Toolpusher and Operator Drilling Supervisor Check string space out Close upper pipe rams Adjust annular closing pressure Land drillstring and hang off on upper pipe rams Close ram locks Determine influx volume and prepare to kill well 3.2.2 Influx Whilst Tripping Set pipe in slips with tool joint at rotary table, checking no tool joint across pipe rams Install the full opening, drillpipe safety valve Close safety valve Open the failsafe valves in the upper choke line and close the upper annular HPHT WELL CONTROL PROCEDURES Page 4 of 11 Check well is shut in Record initial closed in annulus pressure. (Assistant Driller assembles crew at rig floor) Notify the Toolpusher and Operator Drilling Supervisor Make up and install the well kill circulating assembly Check space out Close upper pipe rams Adjust annular closing pressure Land drillstring and hang off on upper pipe rams Close ram locks Open drillpipe safety valve and record pressures Prepare for well kill and to strip in. (The pump down dart may need to be pumped down to achieve this) 3.2.3 Influx While Out of Hole Open the failsafe valves in the upper chokeline and close the upper annular Close shear rams Close shear ram locks Record initial closed in pressure. (Assistant Driller assembles crew at rig floor) Notify the Toolpusher and Operator Drilling Supervisor Assess well kill options: Stripping in, Volumetric method, Bullhead 3.3 CONFIRMATION OF INFLUX If doubt exists as to whether or not an influx has occurred, the following key issues should be considered 3.3.1 Drilling Operations In some circumstances it is possible that pressure, in excess of that caused by the kick zone, can be trapped in the well. This can be caused by: Pumps left running after well shut-in Influx is migrating up the hole HPHT WELL CONTROL PROCEDURES Page 5 of 11 Pipe has been stripped into well, without bleeding correct volume of mud If trapped pressure is suspected carry out the following: Ensure accurate pressure gauges are fitted to the drillpipe and annulus, carefully monitor drillpipe and casing pressure Using a manual choke, bleed a small volume of mud from the annulus to a suitable measuring tank If both drillpipe pressure and casing pressure have decreased, continue to bleed mud from well in increments When the drillpipe pressure no longer decreases as mud is bled from the well, record the drillpipe pressure as the shut-in drillpipe pressure (SIDPP). Stop bleeding mud from the well If SIDPP or/and shut-in casing pressure (SICP) are present, circulate out the potential influx maintaining a constant bottom hole pressure If there are no shut-in pressures, circulate until the potential influx is c.1,500ft below the BOP. Close the BOP and continue circulating through an open choke 3.3.2 Tripping Operations If there are no shut-in pressures, open up the well and flow check for 15 minutes. If no flow exists, run in hole (RIH) to bottom and circulate the hole until the potential influx is c.1,500ft below the BOP. Close the BOP and continue circulating through an open choke If either SICP or SIDPP is detected, then the drillstring will have to be stripped back to bottom and the influx circulated out of the well, maintaining a constant bottom hole pressure 3.3.3 Determining Size of Influx The kick size will be determined from the pit gain at surface, checked and confirmed with the Mud Loggers. The classification of the kick will be made by analysis of the shut-in casing and drillpipe pressure profiles over time and the pit gain The pit gain at surface provides a guide to the volume of the kick. With this information, together with the annular geometry and surface pressures, it is possible to estimate the influx density. The following is a guide: Gas: 0.05 to 0.2psi/ft Oil: 0.3 to 0.4psi/ft Water: > 0.4psi/ft HPHT WELL CONTROL PROCEDURES Page 6 of 11 It is recommended all kicks are assumed to contain a certain proportion of gas. Bottom hole pressure estimates may also be improved by taking into account corrections to the mud density, for compressibility and thermal expansion. 3.4 PRE-KILL MEETING Prior to conducting well kill operations it is normal practice to hold a pre-kill safety meeting before commencing with the well kill. After the well is shut in, secured and pressures monitored, a pre-kill safety meeting will be held with the following personnel: Drilling rig Offshore Installation Manager (OIM) Drilling contractor Toolpusher Operator Drilling Supervisor Operator Drilling Engineer Mud Engineer Cementing Engineer Mud Logging Engineer At the safety meeting, clear lines of responsibility and communication will be discussed and confirmed, relative to the well control bridging document The following critical parameters need to be considered prior to making the final well kill decision: Clear understanding by all parties of the maximum anticipated surface volumes and surface pressures that will occur during the well kill operation The anticipated likelihood of hydrate formation under the anticipated surface and wellhead conditions. The hydrate formation curve that was prepared as part of the well control pre-planning simulations can be used as a guide for the conditions under which hydrates will form The critical slow circulating rate (SCR) for the poor boy degasser pressure can be estimated for varying slow circulating rates to ensure that the operating pressure is not exceeded and the liquid seal is not broken. (The poor boy degasser performance curve, will form part of the well control bridging document.) An optimum circulating rate can then be selected which will minimise surface pressures and pipe erosion and will not reduce the integrity of the mud gas separating equipment Temperature drops across the adjustable choke (where preparations may have to be made to heat the choke manifold). The predicted temperature drop across the adjustable choke will form part of the agreed well control, bridging document HPHT WELL CONTROL PROCEDURES Page 7 of 11 The likely effect of the chosen SCR on the surface pressures and the volume of free gas at surface When all information has been collated, the well kill plan will be agreed and communicated to all personnel onshore and offshore; to ensure all key issues are identified and understood 3.5 HPHT WELL KILL PROCEDURES The operator and drilling contractor will jointly develop the various types of well kill procedures and decision trees at an early stage, as part of the HPHT bridging document. 3.5.1 Bullheading Bullheading may be the preferred option for one or more of the following reasons: When a very large influx has been taken, especially where there are doubts regarding the volumes in the annulus When a kick has been taken off bottom and it may not be possible to strip in all the way to bottom When displacement of the influx by conventional methods may cause excessive pressures, or volumes of gas at surface If the influx contains unacceptably high H2S levels that could create additional hazards at surface, to personnel and equipment If rapid pressure increases require prompt action If the open hole section is short. This depends upon the characteristics of the open hole section, to ensure fluid is not being bullheaded higher up in the hole, above the point of the initial well influx 3.5.1.1 Preparation The following information should be recorded and available, prior to drilling into the high pressure transition zone: Limiting pressures for bullheading that may affect the integrity of the wellbore pressure vessel, including: The last leak off test (LOT) data, the working casing burst pressure (excluding allowances for casing wear and temperature etc) and the pressure operating envelope of all surface equipment HPHT WELL CONTROL PROCEDURES Page 8 of 11 Once it has been established that an influx has entered the wellbore and a decision has been made to bullhead, the following information should be known, prior to commencement of operations: The size of the influx and its location in the wellbore The location of the weak zones in the open hole section and the consequence of fracturing the formation(s) The estimated fracture pressure of the reservoir. This should be used with the current mud hydrostatic pressure to determine the surface fracture pressure The type of influx and the estimated relative permeability of the formation The quality of the filter cake at the permeable formation The stabilised drillpipe and annulus pressures, to establish actual formation pressure With the information available, annulus pressure profiles should be calculated at points of interest, for various bullhead pressures at surface. From this, a maximum injection pressure should be established. The volume to be bullheaded will depend on both the volume of the influx and the way in which the influx was taken. An influx taken while drilling may be strung out in the drilling fluid (subject to mud type, OBM or WBM) and so may require a bullhead volume greater than the influx volume. This can be calculated using the circulating rates at the time of the influx, together with the rate at which the influx was taken and the time taken to shut in the well. An influx that is swabbed in while tripping can be sized and the bullhead volume should equal the influx volume. It is important to note that the above issues and information can and should be worked as well planning scenarios, during the well design and programme development. This would be performed utilising commercially available computer well control simulators and software. 3.5.1.2 Procedures Ensure sufficient mud of the current weight is available for the operation and that the line to the kill pump suction is clear Line up the BOP and choke manifold to pump with the kill pump down the kill line, through the lower kill failsafe valves. Ensure surface equipment is pressure tested to above the maximum injection pressure Start the bullhead operation at a slow rate such that the volume versus pumping rate can be monitored. Attempt to keep the rate constant during the operation and plot the volume versus pumping rate in a similar way, as the leak off graph. Allow for compressibility of the mud as the pressure is brought up to the injection pressure HPHT WELL CONTROL PROCEDURES Page 9 of 11 As bullheading continues, surface pressure should decrease as the mud displaces the influx. Surface pressures should be monitored and plotted at regular intervals to check that the influx is being bullheaded away. If the injection pressure does not fall, it may be as a result of mud being injected into a formation above the influx The injection pressure may increase during the operation as the permeability of the reservoir is damaged. If the injection pressure approaches the maximum allowable surface pressure, stop the pumps and allow pressure to stabilise. Recommence at a slower rate, keeping within the maximum pressure limits. If it becomes impossible to bullhead without exceeding maximum pressure limits ie fracture pressure, the decision to continue bullheading in excess of this pressure will depend upon the volume of the remaining influx and the position of the bit in the hole. Once the calculated volume of influx has been bullheaded back to the formation, bleed off any trapped pressure and shut in the well to monitor drillpipe and casing pressures If the shut-in pressures have fallen, it may be reasonable to assume that the operation has been successful. It should be remembered that if the kick was taken while drilling, it is unlikely the drillpipe and casing pressures will be the same due to the dissemination of the influx in the mud (subject to mud type, OBM or WBM). If the bullheading was seen to be successful, then it should be continued until the drillpipe and casing pressures are similar. The subsequent well kill operation will depend on how the kick was taken and will be influenced by the following: If the influx was taken while drilling, then the well can be killed utilising the original shut-in pressure information If the bit is off bottom, then it will be necessary to strip back to bottom using standard stripping procedures. A circulation should then be performed maintaining a constant bottom hole pressure, to clear the wellbore of disseminated gas If the bullhead procedure is not seen to be successful, then consideration will have to be given to: Stripping back to bottom and circulating out the influx at a rate dependent on its size and limitations of the surface equipment Initiating operations for the suspension of the well 3.5.2 Bit On Bottom The well kill process and decision tree will have been prepared as part of the well programme with all relevant parties. In particular, for well suspension and evacuation: Suspension of the well kill operation, if the temperature measured upstream of the choke manifold exceeds a pre-determined maximum, or if the temperature monitoring system fails HPHT WELL CONTROL PROCEDURES Page 10 of 11 Note: *This figure value will depend on the type of rig, specific policies in use by the drilling contractor. A different drilling contractor may specify a lower limit. This would be identified as part of the rig audit prior to acceptance, as it may require a rig upgrade with possible costs. Evacuation procedures are to be in place and initiated as part of the contingency plan, if choke pressures rise unexpectedly when circulating out a kick. (Surface pressure profiles during well control are to be calculated in advance) 3.5.2.1 Circulating out an influx through the rig surface pressure equipment, is a standard well control procedure. In dealing with high pressure gas condensate influxes, consideration must be given to the large volumes of gas liberated at surface and the stresses this imposes on the surface equipment. As highlighted in the previous section, the bullheading technique can be used to reduce the influx volume whenever possible 3.5.2.2 Preparation Procedures The initial stages of the well kill circulation will be as a standard well kill method. At all times during the circulation, monitor the choke manifold and, if available, the BOP temperature. If at any time the temperature approaches the defined limit by the drilling contractor (eg 220F at the choke manifold, or 250F at the BOP), the pumps should be stopped and a slower SCR selected Note: Use should be made of temperature charts based on the maximum anticipated temperatures in the choke line, for the various hole sizes. These would normally be prepared as part of the well thermal simulations for the well design and well control bridging document. Special precautions and procedures are required once the top of the influx is c.1,500ft from the BOP: Reduce the SCR to the critical predetermined value Commence injection of glycol at the BOP choke manifold. (The rate of injection will have been calculated previously as part of the well planning) As the gas reaches the choke, monitor the differential pressure between the mud gas separator (MGS) and the liquid seal The reading on the liquid seal hydrostatic pressure gauge indicates the maximum operating pressure of the MGS. In the event of failure of this sensor, or if it proves to be unreliable, the maximum operating pressure of the poor boy degasser will be equivalent to the liquid seal being filled with a gas cut condensate, having a 0.3psi/ft gradient. (It cannot be assumed that the liquid gradient in the dip tube is mud. At best, the mud gradient is likely to be heavily gas cut. At worst, it is likely to be a gas cut condensate, with a gradient of 0.3psi/ft) HPHT WELL CONTROL PROCEDURES Page 11 of 11 Note: The limitations and efficiency of the poor boy degasser will be determined between the drilling contractor and operator at the well planning stage, based on the separation capacity of the MGS and the blowdown capacity. (The blowdown capacity of a MGS is that flowrate which is sufficient to cause enough pressure to blow out the liquid seal at the base of the MGS). If either the buffer tank or MGS approach their maximum agreed operating pressure, then: Close the choke Shutdown the pumps Allow pressure to dissipate in the MGS Restart circulation at a lower SCR 3.5.3 Tapered Drillstring If a drilling liner was installed to allow the well to progress, such as 7in, a tapered drillstring will be required. A well kill with a tapered string is different from a conventional single string. The drillpipe pressure does not decrease linearly with the pump strokes because of the different capacities of the two drillpipe sizes SECTION 4 Drilling and Production Operations Ref: HPHT 4 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 HPHT EQUIPMENT, DESIGN AND MATERIALS Page 1 of 16 TABLE OF CONTENTS 4. HPHT EQUIPMENT, DESIGN AND MATERIALS.................................................. 2 4.1 BOP EQUIPMENT ........................................................................................... 2 4.1.1 BOP Equipment.......................................................................................... 2 4.1.2 Choke and Kill Lines ................................................................................... 2 4.1.3 Choke Manifold........................................................................................... 3 4.1.4 Hydrate Suppressant Injection Facilities ..................................................... 3 4.2 SURFACE GAS HANDLING FACILITIES........................................................ 4 4.2.1 Mud Gas Separator .................................................................................... 4 4.2.2 Blowdown Line ........................................................................................... 5 4.3 HIGH PRESSURE KILL FACILITIES............................................................... 5 4.3.1 Kill Pump .................................................................................................... 5 4.3.2 Cement Unit ............................................................................................... 5 4.3.3 Kill Lines ..................................................................................................... 6 4.3.4 Bulk Transfer and Mixing System ............................................................... 6 4.3.5 Emergency Power ...................................................................................... 6 4.4 ADDITIONAL RIG INSTRUMENTATION......................................................... 7 4.4.1 Temperature Sensors ................................................................................. 7 4.4.2 Pressure Sensors ....................................................................................... 7 4.4.3 Pit Level Monitoring .................................................................................... 7 4.4.4 Remote Monitoring Facility ......................................................................... 8 4.5 4.5.1 CASING DESIGN............................................................................................. 8 Casing Setting Depth.................................................................................. 9 4.6 WELLHEADS AND XMAS TREES ................................................................ 10 4.7 WELL TESTING/COMPLETION DESIGN AND EQUIPMENT ....................... 12 4.7.1 Well Testing ............................................................................................. 14 4.7.2 Well Test Packer Fluid ............................................................................. 14 4.8 EQUIPMENT SELECTION/AVAILABILITY.................................................... 16 HPHT EQUIPMENT, DESIGN AND MATERIALS 4. Page 2 of 16 HPHT EQUIPMENT, DESIGN AND MATERIALS It should be noted that issues highlighted for equipment, design and materials have a strong link to IP 17 and generic industry practices. 4.1 BOP EQUIPMENT It is of the utmost importance that the correct equipment is identified and selected when drilling a high pressure, high temperature (HPHT) well. IP 17 highlights this under Section 4 of the document and discusses specific requirements relating to Equipment Standards, Inspection and Testing. This also links to the API Recommended Practices 53 and 16E. In particular, this should link firmly to the audit of the rig, to assess the technical capability for an HPHT well. To summarise, the complete blowout preventer (BOP) system is regarded as a safety critical piece of equipment, so the operator should be able to identify and obtain good evidence of the maintenance and working history of the equipment from the drilling contractor. This is part of the rig class certification requirements and may also be covered by local legislation in various areas around the world (eg verification requirements in UKCS). 4.1.1 BOP Equipment BOP rams will be fitted with high temperature elastomers, having a continuous working temperature rating of 250F and a peak working rating of 350F for one hour peak service All BOP components should be rated for H2S sour gas service, in accordance with NACE MR0175-99. Shear ram blades must be of high strength, high hardness alloy steel which is not necessarily limited to Rockwell Rc22. These alloys should be certified for H2S service If using variable bore rams (VBRs) within the BOP system, the temperature limits for continuous and peak working should be assessed to ensure they are consistent with the rest of the BOP system 4.1.2 Choke and Kill Lines Choke and kill lines and their elastomers will be rated to the same pressure, temperature and H2S sour service as the BOP rams Flexible hose used in choke and kill lines, will be to the same pressure, temperature and H2S service as the choke and kill lines. They should have a continuous working temperature of 250F and a peak working rating of 350F for one hour peak service HPHT EQUIPMENT, DESIGN AND MATERIALS 4.1.3 Page 3 of 16 Choke Manifold The choke manifold shall be fitted with a data monitoring system, which remotely measures temperature and pressure downstream of the chokes. This information should be available remotely at the Drillers’s console. Data from these instruments should be used during well kill operations to ensure that the equipment is used within its operating design limits. (Refer to IP 17 Section 4.2 Choke and Kill Manifold) Accurately calibrated digital pressure gauges should be installed on the standpipe and choke manifold. These gauges should be used for well control operations The following choke manifold valves should be remotely operated: A valve upstream of each choke Valve downstream of choke, which isolates the mud gas separator (MGS) Overboard line valve The choke manifold shall have the same pressure, temperature and H2S rating as the BOP rams Note: In the case of gas at surface, the Joule Thomson cooling effects (adiabatic expansion) can reduce the temperature up and downstream of the choke considerably. This not only affects the metallurgical properties of the equipment but also creates problems due to hydrate formation. Temperatures downstream of the choke can go as low as c. -100F due to the expansion of pure methane, when controlling a gas kick from a high pressure well. Therefore, equipment should be designed to cope with extreme low temperatures as well as high pressures. 4.1.4 Hydrate Suppressant Injection Facilities A hydrate suppressant injection system (glycol injection system) will be fitted upstream of the choke (before gas is returned) to prevent hydrate formation. The suppressant system shall have a minimum pressure rating equal to the BOP rams. The hydrant suppressant system should be hooked up, tested and ready for immediate service. Glycol can also be injected at the BOPs by pumping down the kill line, with either the cement pump or dedicated kill pump. Adequate volumes of glycol should be calculated to store on the drilling rig, injecting with the cement unit, or dedicated kill pump to handle a major gas kick (this will be estimated and logged as part of the well control bridging document). The hydrant suppressant injection facilities would normally consist of two air driven Haskell pumps, in parallel with stainless steel piping to the injection points, upstream of the choke. Note: Glycol is generally useful for controlling hydrates at temperatures above c. -50F. HPHT EQUIPMENT, DESIGN AND MATERIALS 4.2 Page 4 of 16 SURFACE GAS HANDLING FACILITIES The design and capability of the MGS will influence gas handling of a well control influx at surface for a given gas handling capacity. IP 17 Section 4.3 highlights the main issues and includes the handling capacity, instrumentation, hydrostatic mud seal and bypass overboard lines. However, the main issues for consideration are summarised below. 4.2.1 Mud Gas Separator The drilling rig will be fitted with an MGS capable of handling large volumes of free gas, which could be present when brought to surface in a well control incident. The MGS needs to be sized to safely handle the maximum anticipated flowrate during well kill operations The liquid seal downstream of the MGS should be capable of typically maintaining a positive seal of c.5.0psi against the MGS, while a fluid of 0.3psi/ft gradient is being circulated through the system The function of the MGS is to remove slugs of gas from the mud return line and direct them through the derrick vent line. It is not designed to remove all of the gas from the mud. This function is performed by the mud room vacuum degasser The maximum gas handling capacity of the MGS will determine the maximum allowable kill rate and requires assessment. This requires simulation to identify the capacity to separate and vent the gas through the MGS during a well kill, without blowing out the liquid seal for various pumping rates. If the maximum handling gas capacity is reached during well control, the pump rate should be slowed down to prevent blowing the liquid seal The liquid seal will be dependent on the maximum operating pressure of the MGS. The maximum operating pressure is dictated by the hydrostatic pressure of the fluid in the liquid seal, via a dip tube. The density of the fluid in the liquid seal could vary during a well control incident, due to the entrainment of gas, condensate, or oil in the mud To determine the maximum allowable operating pressure of the MGS, a pressure sensor is installed at the base of the liquid seal. This pressure is displayed on the drill floor near the remote choke control panel. Generally, the pressure in the MGS should not exceed 80% of the liquid seal pressure. This value then acts as a datum for calculating the maximum gas flowrate that can be safely handled from the MGS performance graph After determining the maximum allowable gas flowrate, the maximum circulating rate that can be used for a given choke pressure can be read in from the graph, showing values of gas production at various slow circulating rates (SCRs) HPHT EQUIPMENT, DESIGN AND MATERIALS 4.2.2 Page 5 of 16 Blowdown Line There will be a blowdown line fitted downstream of the choke and prior to the MGS. This is generally rated to 5,000psi and capable of a high gas flowrate, in the order of c.50mmscf/day The blowdown line will be used for the following circumstances: If the pressure in the MGS cannot be maintained below the maximum allowable If the line from the choke manifold to the MGS fails, or becomes blocked with hydrates 4.3 HIGH PRESSURE KILL FACILITIES 4.3.1 Kill Pump A high pressure, low volume kill pump (usually cement unit) rated to 15,000psi working pressure will be fitted and incorporate 15,000psi fluid ends. At least one fluid end shall be fitted with liners and pistons rated to 15,000psi, with additional sets as backup The kill pump should be capable of SCRs in the order of +/-0.5bbl/min It should be independently driven and not rely on power from the installation It may prove necessary to curtail operations if the kill pump is not operational during the HPHT section of the well The pump will be capable of being run at the unit, and remotely from the drill floor. It will allow the well to be circulated, should rig power be lost The accuracy of all pressure monitoring equipment for checking wellhead pressures and pump pressures must be regularly checked and calibrated Good communication links will be provided between the pump room and drill floor 4.3.2 Cement Unit The cement unit will be rated to 15,000psi. Because of the low volume rates required when cementing in the HPHT section, it may be necessary to dress both fluid ends with 15,000psi liners and pistons The unit will also incorporate low range pressure gauges for leak off tests (LOTs) and an accurate pressure and pump volume recorder. Direct mud feed from the active pit is required, to ensure accurate measurement of pit volumes during well kill operations The cement unit will normally be used to perform BOP pressure tests HPHT EQUIPMENT, DESIGN AND MATERIALS Page 6 of 16 The high pressure lines from the cement unit to the rig floor must be pressure tested to 15,000psi, prior to entering the HPHT section of the well 4.3.3 Kill Lines A certified high pressure line from the kill pump to the rig floor with a circulating head and flexible line, ready for quick make-up, should be available High pressure kicks will utilise a 15,000psi kill assembly which incorporates a drillpipe pup joint, full opening safety valve and side entry kill sub fitted with an HP low torque hammer connection, to the high pressure kill line. The assembly should be pressure tested, prior to entering the HPHT section of the well 4.3.4 Bulk Transfer and Mixing System The bulk transfer and mixing system will be designed such that it can mix and deliver the required kill mud at high speed, in order to perform the well kill Bulk transfers of pre-mixed heavy mud should consider the maximum weight that can be safely stored and transferred, taking into account the capabilities of all pumps and hydrostatic pressures of the system The weighting up rate, ie psi/ft per bbls/hr will be established, relative to the capabilities of the bulk transfer and mud mix system (high rate barytes mixers) 4.3.5 Emergency Power If the installation loses power during a well kill, the emergency generator will be capable of supplying sufficient power to run the: Main air compressor Mud mix pump Agitator Fuel oil transfer pump HPHT EQUIPMENT, DESIGN AND MATERIALS 4.4 Page 7 of 16 ADDITIONAL RIG INSTRUMENTATION Additional rig instrumentation should be made available on the rig to monitor critical well parameters. This data will be displayed where it is visible from the remote choke operating console. 4.4.1 Temperature sensors shall be placed at the following locations: At the BOP and upstream of any coflexip hose Upstream of the choke on both choke and kill lines Buffer tank Downstream of the choke Mud in and out Well test flowline upstream of all chokes 4.4.2 Temperature Sensors Pressure Sensors Pressure sensors shall be placed at the following locations: Mud gas separator Liquid seal hydrostatic head Buffer tank Upstream of the choke Kill pump and mud pump 4.4.3 Pit Level Monitoring The installation will have an accurate pit level monitoring system. For floating operations, there will be a minimum of two pit sensors placed in all active pits. Where a mud logging unit supplements the installation instrumentation, a systematic cross check will be performed for both systems, in order that discrepancies and datum calibrations can be established All tanks including the settling pits should be monitored and will include a pit volume totaliser The trip tank will be monitored with an accurate volume sensor and will include an additional independent means of measurement HPHT EQUIPMENT, DESIGN AND MATERIALS 4.4.4 Page 8 of 16 Remote Monitoring Facility The kill pump (cement unit) will have a remote control facility at the drill floor (this will enhance communications during the well control operations). 4.5 CASING DESIGN A specific manual on casing design is available which discusses the principles of well design and aspects associated with HPHT wells, under Section 9 of the manual. However, it is worth highlighting key issues, which can affect the well planning process. Due to the special requirements associated with HPHT wells, a full Triaxial VME (von Mises Equivalent) analysis should always be performed as part of the well design. This is important due to the large temperature effects on axial load profiles and combined burst and compression loading. As a result of this approach, the design will be performed by computer software and uniaxial hand calculations, to confirm the general computer outputs of the software. It is likely that a Senior Drilling Engineer, in conjunction with an independent internal review and third party assessment, will design wells of this nature. The main areas that require consideration are: A full VME analysis for the well design, including all anticipated drilling, testing/production loads Well test philosophy utilising a kill weight, or underbalanced packer fluid (should there be a need for a tie back) Thermal effects and modelling for drilling and production loads, highlighting limits of design (hottest from long-term production and coldest from scale squeezing) Annular fluid expansion (AFE) effects and modelling, arising from closed annuli (buckling and wellhead loading) H2S and CO2 considerations, using the NACE document Accurate assessment of pore and fracture gradient curves, including error bars and probabilities of accuracy, for risk assessment Accurate estimation of maximum pore pressure and reservoir composition at well depth Modelling of kick tolerances with mud systems (gas solubility in oil base fluids) for estimation of maximum wellbore loads, due to the narrow margins, between pore and fracture pressures Reductions of tubular material yield strength, at high temperatures Casing wear causing reduced mechanical strength of tubulars (see Section 2.5) Tighter functional specification and inspection criteria, for tubulars and connectors HPHT EQUIPMENT, DESIGN AND MATERIALS Page 9 of 16 Qualification testing of premium tubular connectors, to confirm axial and compression capabilities Assessment and analysis of the wellhead connector and riser system (semi-submersible, IP Guidelines) as part of the well design pressure vessel Assessment and analysis of wellhead system and conductor, as part of well design pressure and thermal loads Assessment and modelling of intermediate casing shoe depth and anticipated LOT prior to drilling into the high pressure zone, as part of well design casing seat selection Note: Changing just one aspect of an HPHT well design, or load condition, can create a significant overall change, due to the interaction of pressure and temperature. Therefore, focusing on a tight specification and inspection criteria for the tubulars and connectors, can reduce and minimise risk of failure during the operational phase of the project. ie attempt to remove risk at the design phase. 4.5.1 Casing Setting Depth For HPHT wells, casing seat selection is critical. A common design would be a 5 string design, based on drilling 8-1/2 (8-3/8)in through the reservoir section, with the contingency to drill 6 (5-7/8)in hole in the event of well problems, or increased overbalance in the reservoir. By way of example, we will consider the North Sea Central Graben Basin for a well design. The casing seat selection for HPHT wells is focused toward the intermediate string (generally 13-3/8in) and the production string (generally 10-3/4in/9-7/8in) and should be selected by consideration of the following issues: The casing should be set at a minimum depth to ensure sufficient fracture gradient (LOT) to provide adequate kick tolerance for drilling the reservoir Maximum depth of Top Jurassic should be known, in order to determine the minimum and maximum length for the high pressure transition zone, for selecting the production casing shoe depth The depth where the kick tolerance while drilling (hunting) for the production casing, reduces to a predetermined unacceptable limit, should be known and not exceeded In practice, the setting depth of the production casing depends on the pressure transition zone at the base of the Cretaceous, which depends on the effectiveness of the reservoir seal. The pressure transition can either occur rapidly, over a short interval (c.100ft) or gradually, over a longer interval c.1,000 to 1,500ft. HPHT EQUIPMENT, DESIGN AND MATERIALS Page 10 of 16 The intermediate casing (13-3/8in) must be set sufficiently deep to ensure that a high mud weight can be used to allow the production casing to be set deep into the transition zone. In practice, this means casing off the Paleocene sands and drilling through the ‘dirty’ Ekofisk Chalk Formation until the clean Limestone of the Tor Formation is penetrated for a certain distance, to obtain the required LOT. It is important to design the well with this criteria, as the LOT at the 13-3/8in shoe drives the well design and the number of casing strings required from this point. The kick tolerance criteria for the intermediate string will probably require a ‘limited kick’ design approach, (see Section 5 of the Casing Design Manual) as it may not be able to satisfy the 100bbl gas kick criteria. This requires an iterative well design assessment based on LOT sensitivities, as a function of the 12-1/4in hole depth. This will normally be discussed and agreed as part of the well control ‘bridging document’. Ideally, the production casing should be set as deep as possible into the base Cretaceous, to obtain a higher LOT. This is due to the increasing pore pressure and to case off potential sands/fractured zones. Where the pressure transition occurs over a short interval, it may be possible to set the production casing deep (subject to the LOT at the intermediate casing and the 12-1/4in hole condition). However, the production casing may have to be committed high if permeable formations are penetrated below the transition. This leaves a long 8-1/2/(8-3/8)in hole and increases the risk of penetrating weak formations not capable of supporting the mud weight, required to drill the reservoir. This may then require the 7in liner to be set early, as a drilling liner, followed by the drilling of 6/(5-7/8)in hole through the reservoir to well depth. 4.6 WELLHEADS AND XMAS TREES The design and assessment of wellheads and xmas trees demands the same depth of rigorous review and specification, to satisfy the maximum anticipated loads and operating envelope for all conditions during drilling, production and service. Subassembly components of wellhead and tree systems that are most affected by HPHT conditions are the non-metallic elements used for casing annulus, tubing hanger and tree valve seals. Extreme temperatures subject almost all non-metals to premature ageing and high pressures can lead to failure of these components by deterioration, extrusion and explosive decompression. Wellhead and tree systems comprise many components that require sealing interfaces between them. The sealing interfaces often have non-metallic primary, or secondary components unsuitable for long term HPHT production applications. All metal sealing systems eliminate the problems associated with system degradation caused by deterioration of non-metal parts. The key issues to consider for wellheads and xmas trees are: Elastomers: High temperatures and pressures leading to premature ageing and seal extrusion. API qualification tests have demonstrated that elastomer use is limited to temperatures up to c.300F. If these are used on HPHT wells, evidence of the capability for short and long-term use for safety critical components is required HPHT EQUIPMENT, DESIGN AND MATERIALS Page 11 of 16 Metal-to-Metal Seals: Preferred sealing method for HPHT wells for all pipework, tubulars, valves and safety critical systems. They may incorporate a combination of resilient elastomers as backup to the primary metal sealing system Performance Testing: API has established minimum requirements for performance testing of wellheads and production xmas trees. API Specification 6A Wellhead and Xmas Tree Equipment defines the pressure, temperature and fluid compatibility classes for wellhead equipment. Pressure classes range from 2,000 to 15,000psi, temperature classes range from 75 to 350F and fluid compatibility classes range from sweet to sour service. HPHT operational temperatures of 400 F exceed the 6A specification temperature classification and require additional procedures to qualify equipment for HPHT service Xmas tree valves are fire tested as specified in API Specification 6FA, Fire Test for Valves. Tree valves are pressurised to 75% of design pressure and subjected to o 2,000 F for 30 minutes to simulate a platform fire. The valves are expected to contain their pressurised internal fluid, without significant leakage during and after the fire and operate without leaking after the fire is extinguished. Wellhead and xmas tree connections are qualified to the requirements of API Specification 6FB, Fire Test for End Connections Laboratory Test Results: This provides the opportunity to verify the API specifications through qualification testing based on specific temperature and pressure limits For example, this requires performance testing key components within the wellhead and xmas tree systems for HPHT service, as specified by API Specification 6A. This may require a range to 400F to simulate anticipated production temperatures, in conjunction with fire resistance testing. Typically, this requires performing the tests at the anticipated extreme range of temperatures and pressures. Other issues to consider for the functional specification and qualification testing may be: The required Product Specification Level (PSL) specification, eg build to PSL 3 but with PSL 4 gas testing (API Spec 6A) Sand Trim requirements (API Spec 14D) Well life cycle issues such as trapped fluid pressures on initiation of production, or if the system was on fire Wire cutting capability of valves Cumulative stress cycles, leading to cyclic fatigue (as part of Finite Element Analysis, FEA) Compatibility with well fluids (hydrocarbons, CO2 and H2S) Lock down design for wellhead housings and hangers HPHT EQUIPMENT, DESIGN AND MATERIALS Minimum number of wellhead penetrations Uniform stress distribution for critical components 4.7 Page 12 of 16 WELL TESTING/COMPLETION DESIGN AND EQUIPMENT Well testing and completion design should be treated as part of the HPHT project in the same way as casing design. Due to the special requirements associated with HPHT wells, a full Triaxial (von Mises Equivalent) analysis should always be performed as part of the design process. This is required due to the various effects of the combined loads and high pressures and temperatures. As a result, designs will be performed by computer software and uniaxial hand calculations, to confirm the computer outputs. It is likely that a Senior Petroleum Well Test and Completion Engineer, in conjunction with equipment vendors and an independent third party, will design the drill stem testing (DST)/completion. One of the key issues to note is the well test/completion design and assessment of equipment must not be performed in isolation. It is important that the issues of concern are discussed and planned at an early stage, as part of the well design process. Often on standard wells the decision to perform a well test (and planning) is left until near the end of the drilling of the well. HPHT projects do not allow this type of approach to be used. The main areas that require consideration are: A full VME analysis for the well design, including all anticipated, testing/production loads based on worst case scenarios Well test philosophy utilising a kill weight, or underbalanced packer fluid (should there be a need for a tieback) Pressure test programme for the wellbore, prior to displacing to an underbalanced packer fluid Performing a risk analysis and hazard identification for all operations, associated with the DST/completion Use of a completion type design as a DST string Redundancy and contingencies for equipment (eg multiple data acquisition gauge carrier systems) Optimising minimum production casing/liner size for productivity, well test and completion objectives. (Maximum size of: perforating guns, subsurface safety valves and packers) Chemical composition of completion fluids relative to formation pressure and degradation of seals and tubulars HPHT EQUIPMENT, DESIGN AND MATERIALS Page 13 of 16 Assessment and use of control line fluids for DST/completion surface controlled subsurface safety valves (SCSSSVs) for HPHT conditions Thermal effects and modelling for all testing and production loads, highlighting limits of design (hottest from long-term production and coldest from scale squeezing) Annular Fluid Expansion effects and modelling, arising from closed annuli (buckling and wellhead loading) H2S and CO2 considerations, highlighting limitations on various tubulars, using the NACE document Assessment of sand production (erosion), water production (corrosion, CO2) Assessment of perforation techniques and explosives as a function of exposure time and downhole temperature Accurate assessment of bottom hole pressure, including error bars and accuracy, for risk assessment Linking well test objectives to the data obtained during drilling, by formation evaluation techniques (MWD, LWD, coring, wireline logs, RFT, MDT etc) Accurate estimation of maximum pore pressure, temperature and reservoir composition at reservoir well depth Modelling of production flowrates relative to pressure and temperature, for estimation of maximum wellbore loads and formation of hydrates Assessment and use of DST/completion packers. Capability of fixed versus retrievable packers Reductions of tubular material yield strength, at high temperatures, including corrosion resistant alloys Tighter functional specification and inspection criteria, for tubulars, connectors, surface DST packages and all downhole equipment Qualification testing of premium tubular connectors, to confirm axial and compression capabilities Simplifying use and choice of seals for DST/completion design, to maximise use of metal seal technology and high temperature elastomeric seals. (Linking seal requirements for downhole and surface equipment by use of proven technology and evidence of qualification testing) Assessment and analysis of the wellhead connector and riser system, (semi-submersible IP Guidelines) as part of well design operating envelope, for shut down of testing and emergency disconnect HPHT EQUIPMENT, DESIGN AND MATERIALS Page 14 of 16 Assessment and analysis of wellhead system and xmas tree, as part of well design pressure and thermal loads Design, layout and hazard assessment of DST surface equipment including emergency shutdown (ESD) systems, with the drilling contractor at an early stage (link to initial rig audit at pre-tender stage, to identify capabilities of rig) Design DST and completion operations to minimise wireline operations and downhole accessories (wellbore safety and reliability) Requirement and assessment of cement evaluation tools for well integrity and perforating of reservoir (CBL/VDL/USIT/CET type tools) 4.7.1 Well Testing Well test and completion design will typically include the following load cases and tubing stress calculations, taking into account maximum and minimum temperatures/pressures: Tubing pressure test Maximum well flow Surface shut-in Downhole shut-in Tubing leak Bullhead for well kill Pressure test below packer 4.7.2 Well Test Packer Fluid Probably the single biggest issue for HPHT DST and completion design is the choice for using, either a weighted, or underbalanced packer fluid. Using a DST as a design basis, the choice of packer fluid has a significant impact on the well test programme, equipment, operations and capability of the casing design. For example, if an overbalanced mud is used as the DST packer fluid, the production casing design (10-3/4 x 9-7/8in) will not be able to withstand the most dominant load; that of a tubing leak at surface, on top of the packer fluid. The differential burst (external – internal pressures), at the base of the production casing, would not be capable of coping with this specific load case. This can be overcome by installing a tieback string which protects the production casing but also introduces new complexities, such as trapped annular expansion forces, minimum clearance diameters for the test string and additional time/cost to the project. HPHT EQUIPMENT, DESIGN AND MATERIALS Page 15 of 16 The decision of an overbalanced kill fluid versus an underbalanced fluid requires detailed assessment and risk analysis for both methods; highlighting the positive and negative aspects of each system. However, there is now much more widespread use of water as a packer fluid and industry has built up a detailed database of its use, including benefits, problems and incidents. The choice of the fluid has a direct impact on the perforation method, test string design, testing procedures, well kill and safety of personnel and drilling rig. The following lists summarise some of the advantages and disadvantages for each system: Kill Weight Fluid Advantages: Safety: hydrostatic kill fluid Reduced differential pressure across the packer element and seal assembly Reduced differential pressure for DST tools Disadvantages: Poor reliability of DST tools (pressure transmission, plugging of pressure ports) Rheology of mud (gels, barytes settling) Minimal clearances/high surge pressures whilst running plugs, packers Difficulties for setting TCP firing head pressure shear values Difficulties in performing wireline operations Casing design complexities. Tubing leak at surface requiring a tie-back, trapped annular fluid pressures Underbalanced Fluid Advantages: Casing design. Can remove the requirement for a tieback, reduces differential burst pressures for production casing, and provides greater annular clearance for test string design Provides solids free and clean downhole environment for equipment Improved reliability and functioning of downhole test tools Ease of circulation and reduced frictional pressures for test string Quality pressure tests of downhole equipment and wellbore HPHT EQUIPMENT, DESIGN AND MATERIALS Page 16 of 16 Wireline operation capability improvements Reduced surface temperatures while flowing due to higher conductivity of water over mud Disadvantages: Safety: Not a well kill fluid Consequence of high pressure at wellhead, from leak at packer Higher differential pressure across packer element and seal assembly Higher differential pressure for DST tools Adequate barriers in place for emergency disconnect (no kill fluid in annulus) Casing Design: Requirement to thoroughly inflow test wellbore and liner lap, prior to finally pulling out of hole Well kill: longer and possibly more complex Gas migration can take place in the annulus at a much higher rate Drilling rig BOP system and equipment must be able to achieve a full recovery of well, with the drillstring out of the hole, if wellbore integrity fails (ie leak at liner lap requiring a full strip-in to the bottom of the wellbore to perform a well kill) It would be normal practice to assess all of the above issues as part of a detailed hazard and operability study (HAZOP). However, the impact of the DST/completion design on the overall well design, requires early assessment. 4.8 EQUIPMENT SELECTION/AVAILABILITY Selection and timely availability of equipment are key factors in the success of HPHT wells. In planning HPHT wells, the long lead times and stringent QA requirements for critical equipment such as casing, tubing, wellheads and completion equipment need to be taken into account. Failure to do so can result in well delays, design compromises and significant additional costs. Procurement strategies for equipment need to be formulated well in advance. In some cases, equipment rental may be advantageous. Equipment backup and the availability of contingency stocks (eg casing for a relief well) also need to be considered in the design, assessment and planning phase. Standardisation and equipment sharing between Assets should be encouraged. The longest lead items are generally for casing and tubing, wellhead, xmas trees and completion equipment These items are also the most critical in terms of performance and cost and require detailed early planning. Finally, requests for additions and tests to the functional specification, such as qualification testing, will add time and cost. SECTION 5 Drilling and Production Operations Ref: HPHT 05 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 DRILLING ENGINEERING CONSIDERATIONS Page 1 of 28 TABLE OF CONTENTS 5. DRILLING ENGINEERING CONSIDERATIONS.................................................... 3 5.1 ESTIMATION OF PORE PRESSURE AND FRACTURE PRESSURE............. 3 5.1.1 Pore Pressure Prediction............................................................................ 3 5.1.1.1 Empirical Methods of Prediction................................................................. 4 5.1.1.2 Modelling Tools.......................................................................................... 5 5.1.2 5.2 Fracture Pressure Prediction and LOT Data............................................... 6 DRILLING FLUIDS........................................................................................... 7 5.2.1 Types of Systems ....................................................................................... 7 5.2.1.1 5.2.1.2 5.2.2 Oil Based Muds ......................................................................................... 7 Water Based Muds .................................................................................... 8 Drilling Fluid Planning and Operations ........................................................ 9 5.2.2.1 Planning..................................................................................................... 9 5.2.2.2 Operations ............................................................................................... 10 5.2.2.3 Drilling Fluids: Well Control...................................................................... 11 5.3 CASING RUNNING OPERATIONS................................................................ 11 5.3.1 5.4 Equipment Selection................................................................................. 12 CEMENTING OPERATIONS ......................................................................... 13 5.4.1 Equipment ................................................................................................ 13 5.4.2 Slurry Designs .......................................................................................... 14 5.4.2.1 Slurry Testing........................................................................................... 14 5.4.3 Spacers .................................................................................................... 17 5.4.4 Simulations............................................................................................... 17 5.4.5 Temperature Estimation ........................................................................... 18 5.4.6 Contingency Planning............................................................................... 18 5.5 TEMPERATURE PROFILES.......................................................................... 19 5.5.1 Temperature Hazards............................................................................... 19 5.5.2 Temperature Sources ............................................................................... 20 5.5.3 Modelling Temperature Profiles ................................................................ 20 DRILLING ENGINEERING CONSIDERATIONS 5.6 Page 2 of 28 WELLBORE EVALUATION ........................................................................... 21 5.6.1 Formation Evaluation................................................................................ 21 5.6.2 Casing/Cement Integrity Monitoring.......................................................... 24 5.7 IDENTIFICATION OF TRANSITION ZONE ................................................... 24 5.8 SLIMHOLE DRILLING ................................................................................... 25 5.9 WELL MANAGEMENT .................................................................................. 26 5.10 EMERGING TECHNOLOGY.......................................................................... 27 5.10.1 Expandable Solid Tubular Technology ................................................... 27 5.10.2 Mud Pulse Telemetry ............................................................................. 28 5.10.3 Coil Tubing Perforating .......................................................................... 28 DRILLING ENGINEERING CONSIDERATIONS 5. Page 3 of 28 DRILLING ENGINEERING CONSIDERATIONS This section emphasises the importance of carrying out detailed pre-planning to minimise the uncertainties, reduce risk, ensure safety and remove potential problems at the design stage, with a dedicated multi-discipline team. Spending time to define the well objectives and well type will benefit the project during the operational phase. For example, if the high pressure, high temperature (HPHT) well is a vertical exploration with a short-term well test, then the design and thermal modelling will not be as complex, compared to a well that experiences long-term production loads. 5.1 ESTIMATION OF PORE PRESSURE AND FRACTURE PRESSURE One of the key areas of HPHT well planning is a detailed analysis and use of the subsurface geological uncertainties and drilling data, in order to generate realistic pore and fracture pressures for the well. There are various methods and techniques for estimating the pore and fracture data. Additionally, offset data and regional basin studies, should form part of the initial preparation for a HPHT project. Once these have been assessed and used to obtain a profile, statistical techniques and confidence levels may also be employed to perhaps define a minimum and maximum range. However, once all of the data has been assessed, it is recommended that a realistic pore and fracture gradient plot be constructed, in order that all team members are planning the well with the same information. It is important to recognise that the pore pressure is the result of a number of different methods and the main pore pressure/fracture pressure prediction process may change with depth. 5.1.1 Pore Pressure Prediction The burial history of a sedimentary column with a given composition and heterogeneity will determine its framework strength and the pressure and temperature of the fluids in the pore space at any depth. Both the burial history and the composition of the sedimentary column are subject to uncertainty. Indirect data may be used to constrain these uncertainties and define most likely values for a given depth, including minimum and maximum values. The reliable estimate of a permeable formation pore pressure is provided by a repeat formation test (RFT) type test/measured data. Similarly, formation strength can only be accurately estimated from an extended microfrac test. Any other indirect assessment of pressure, or strength is subject to uncertainty until calibrated. These uncertainties will vary with methods, or data used and need to be carefully evaluated. Page 4 of 28 DRILLING ENGINEERING CONSIDERATIONS In the prognosis of pressures it is essential to carry out a proper analysis, paying attention to interdependencies of the various parameters. For instance, compounding of worst case scenarios (eg shallow reservoir, highest possible overpressure and longest possible hydrocarbon column) will result in either an undrillable well, or in a very dangerous situation due to a severe overbalance. A multi-disciplinary teamwork approach between the geoscientists, petroleum/reservoir and the drilling engineer, should promote risk management, minimise risk and result in a realistic pressure profile. There are no hard and fast rules for the prediction of rock strength, fluid pressure or temperature. All techniques rely to a large extent on empirical relationships, or require assumptions of rock property parameters that are not routinely available by direct measurement. A detailed analysis of the data is, therefore, important. 5.1.1.1 Empirical Methods of Prediction This is by far the most common practice to date. It essentially means careful analysis of all pressure and strength data in an area, in order to deduce predictive relationships of pore pressure and formation strength with depth. The following issues should be considered: Basin fill history (tectonic setting, sedimentation rates, vertical/lateral permeability contrasts) Temperature history (heat flow, maturation) Hydrocarbon habitat (generation, expulsion, migration) Regional temperature/depth relation (drill stem test (DST), corrected RFT, corrected bottom hole temperature (BHT)) Regional rock strength/depth relation (leak off test (LOT) data, minifrac data, mudlog records, regional stress field) Indirect pore pressure estimates: trip connection gas, wellbore instability such as cavings Regional pressure/depth relation (mud weights, RFT, DST, gains/losses) Depth of onset of overpressures (shallowest possible from seismic) Thickness of transition zone (likelihood of stacked pressure cells) Hydrocarbon effects column lengths) A real distribution of overpressures (pressure cells, sealing faults) Borehole breakout direction for regional fault studies and wireline logs from wells (composition, pressure gradients, and maximum They highlight the importance of maintaining a quality database, for all indicators of pore pressure and formation strength. DRILLING ENGINEERING CONSIDERATIONS 5.1.1.2 Page 5 of 28 Modelling Tools All of the following methods should be used with respect by researching the data from a wide variety of sources. These are essentially based on calibrated, semi-empirical functions. Examples are the d-exponent data from offset wells, Eaton's method, Eaton Modified, Hottman and Johnson’s method, etc. All these algorithms attempt to predict pressure and strength via effective stress porosity relations from sonic and resistivity logs; careful calibration with RFT and minifrac data is, however, necessary. These methods are essentially hindsight methods. Application of MWD/FEWD and real-time processing techniques are also available, which can help modify the pressure prediction whilst drilling. The following are examples taken from an extensive body of literature, on the subject of pore and fracture pressure modelling: Another method discussed by Bowers, GL: Pore Pressure Estimation from Velocity Data: Accounting for Overpressure Mechanisms Besides Undercompaction (SPE 27488) discusses a new method, that utilises virgin and unloading curve relations, to account for both undercompaction and fluid expansion overpressure. A Central North Sea example is included and compares the estimated pressures with mud weights used during drilling and RFT data. It can be seen that outside the chalk, the pore pressure estimates are in good agreement with the measured values. However, within the chalk, as was discussed within the paper, the predictions are essentially a guess. Some of the conclusions within the paper are Failure to account for the absence or presence of fluid expansion overpressure can lead to large errors in the estimated pore pressure. Therefore, it is important to have a systematic approach for estimating pore pressure due to both undercompaction and fluid expansion. Such an approach has been presented. It consists of two key elements: 1) a pair of velocity versus effective-stress relations that account for overpressure mechanisms besides undercompaction, and 2) a procedure for determining when each relation should be used. Both elements are equally important. Another SPE Paper 28297 (Ward CD, Coghill K, Broussard, MD) The Application of Petrophysical Data to Improve Pore and Fracture Pressure Determination in North Sea Central Graben HPHT Wells, discusses pore pressure estimation methods, based on a shale disequilibrium compaction model and proposes that excellent results can be obtained by deriving porosity from density, or deep resistivity data. This porosity, together with a lithology estimation from the gamma ray, are input into an effective stress loading limb (ESL) model that calculates pore and fracture pressures through all major lithologies. Basin modelling tools can also be used to predict (largely qualitative) pressures. The advantage is if a source rock is identified which is currently generating gas; it can be inferred that this interval has a potential for overpressure, generated by fluid expansion. In individual regional areas there may be a dominant and preferred pore pressure and fracture pressure evaluation technique. The reader is advised to deploy this if there is a local reason for so doing. DRILLING ENGINEERING CONSIDERATIONS 5.1.2 Page 6 of 28 Fracture Pressure Prediction and LOT Data Proper care has to be taken to correct measured temperatures where necessary and to evaluate the formation strength relationship with depth and lithology. Careful analysis of leak off test data and drilling records (losses) in nearby wells can establish a relation between fracture propagation pressure and depth. In the absence of tensile rock strength and tectonic stresses, the leak off test is a measure of the minimum horizontal stress. This in turn will be a measure of the maximum possible fluid pressure, which would reduce the effective stress to zero. Due to the correlation between fluid pressure and formation strength via effective stress (effective stress is the fracture pressure, minus the pore pressure), the LOT database should make a distinction between normal and overpressured wells. Regional trends should be carefully evaluated and an assessment should be made on how applicable they are to the well under consideration (eg local tectonic stresses). An SPE Paper 28710 ‘A Simple Method to Estimate Fracture Pressure Gradient’ by Rocha LA, Bourgoyne AT, discusses the issues associated with estimating fracture pressure gradient. The proposed method has the advantage of: 1) using only the knowledge of leak off test data and 2) being independent of the pore pressure. Holbrook P, SPE Drilling and Completion, March 1997 ‘Discussion of A New Simple Method to Estimate Fracture Pressure Gradients’, discusses the accuracy of both the Terghazi effective stress law and the Rocha and Bourgoyne fracture pressure method (SPE Paper 28710). This examines their individual linkage to mechanical first principles, stress and strain definitions. These definitions are linked with two fundamental stress/strain relationships applicable to porous granular solids in biaxial normal fault regime basins. Failure to thoroughly analyse the fracture strength of formations can lead to formation breakdown during well control, as outlined in SPE Paper 38478 by Element DJ, van der Vossen, Diamond S, Hamilton TAP ‘Consequences of Formation Breakdown During Well Control: A Study of Underground Crossflow While Drilling an HPHT Well’. This discusses the underground flow between the kicking formation and a loss zone. Almost all modelling methods assume overpressure is directly related to anomalous claystone porosity. This does not work for the case of fluid expansion overpressure methods. With fluid expansion the critical factor is the seal strength. This can be with a strong seal that gives rise to a very rapid overpressure, for a short length in the transition zone. DRILLING ENGINEERING CONSIDERATIONS 5.2 Page 7 of 28 DRILLING FLUIDS The wellbore fluid utilised for an HPHT well plays an important critical role in terms of the drilling, wellbore integrity and maintenance for the life of the well. This is due to not only the narrow safety margins between the pore/fracture gradients but also the very high temperatures and a third equally important variable, time spent within the well. Therefore, in terms of designing and maintaining an HPHT fluid system, the statement should really read as: HPHT/T (high pressure, high temperature and time). The key parameter for any fluid system used on an HPHT well is: ‘stability’ at elevated pressures and temperatures over a defined time period. The small difference between the pore and fracture pressures in the overpressured HPHT section requires a drilling fluid system with a stable and robust rheology that minimises equivalent circulating densities (ECDs), losses and maintains the required overbalance, to reduce the risk of a well control incident. The issues addressed in this document for drilling fluids, apply equally to the completion and workover fluids, except for exposure to the geological formations. 5.2.1 Types of Systems There are two generic systems to consider for HPHT wells: Oil based muds (OBMs) and water based muds (WBMs). Both have their respective positive and negative points to consider. 5.2.1.1 Oil Based Muds These cover a wide range of systems that have evolved over a number of years, to the current most widely used synthetic oil based muds (SOBMs). Other systems that have been developed include esters (which are less stable at high temperatures) and low toxic oil based muds (LTOBMs - which can be problematic under HPHT conditions, due to the viscosity of the base oil). The reader also needs to be aware that many areas around the world do not allow unrestricted cuttings discharge with a SOBM. This influences the choice of drilling fluid and the logistics/treatment of the cuttings, as many areas is now moving toward a restricted discharge policy. It is quite common for an HPHT well to utilise WBMs for the top half of the well and then switch over to OBMs for the latter, deeper, hotter, higher pressure regimes. This is because WBMs are sensitive to temperature and the SOBMs are inherently more stable for longer, at higher temperatures. DRILLING ENGINEERING CONSIDERATIONS Page 8 of 28 Other benefits of using an SOBM are: Good lubricity Formulated to minimise sag Ability to achieve more desirable YP/PV ratios, resulting in lower ECDs (YP/PV > 1) Formation protection – Low fluid loss, all oil filtrate, no swelling of clays Control of fine solids less problematic at high mud densities Issues requiring consideration for using a SOBM are: Surfactants in emulsifiers may cause formation damage Rheology and density of SOBMs are sensitive to temperature and pressure Requires corrections to the surface measured mud weight, for downhole conditions Environmental or logistical considerations may severely restrict, or prohibit their use Flash point of the SOBM base oil, relative to the maximum anticipated flowline temperatures while drilling 5.2.1.2 Water Based Muds A typical WBM formulated system for an HPHT well may be based on a bentonite/synthetic filtration polymer, with lime to treat out the carbonates from the barytes impurities. The benefits of using a WBM can be summarised as follows: Less problems associated with environmental legislation for drilling in sensitive areas Formulated to prevent sag Can be formulated for stability, for an estimated temperature and pressure Can achieve low ECDs, if the rheology is maintained for a stable environment Can be considered for reservoir protection Issues requiring consideration for using a WBM are: Not as stable as an SOBM under the same HPHT conditions. WBM polymers can break down at high temperatures and thus can be more difficult to control and maintain. (SOBM are more stable and simpler to maintain, hence more reliable for drilling) Requires additives to improve lubricity DRILLING ENGINEERING CONSIDERATIONS Page 9 of 28 May not be suitable for water sensitive reservoirs Concern regards long-term robustness and stability, compared to an SOBM (from a production point of view) 5.2.2 Drilling Fluid Planning and Operations There are a number of areas to consider for drilling fluids during the planning and drilling of the well. Effort and time spent in assessing and identifying a suitable system at an early stage, will prove beneficial during the operational phase of the well. 5.2.2.1 Planning The following points should be resolved at an early stage of the HPHT project, assuming an SOBM system is used. (This is based on a conceptual casing design being in place, with a clear policy on the use of either a weighted, or un-weighted packer fluid for DST/completion purposes.): Track record of HPHT wells drilled to date (exploration and development) Detailed laboratory tests, (including hot rolling and thermal modelling), as part of the well design. The casing design thermal modelling requires the mud system and properties to be identified, in order to estimate the maximum flowline temperatures for each hole size. This is then fed back to the fluids company, to validate the performance of the mud system for maximum conditions Stability tests for various system formulations, to determine long-term stability and robustness, including well control simulations Rheology modelling for the identified hole sizes and BHAs to determine flowrates, ECDs, swab/surge pressures, optimum PV/YP and gels Well simulations using a rheology model that is integrated with an advanced pressure and temperature simulator. This should include rheology measurements under downhole Fann 70 conditions, as the data is used to predict accurate ECDs and ESDs (Equivalent Static Density) Testing stability and rheology of the system at high deviations for development wells DRILLING ENGINEERING CONSIDERATIONS 5.2.2.2 Page 10 of 28 Operations The following subjects are listed as issues to consider during the operational drilling phase of an HPHT well. This assumes the system is an SOBM. Use of an HPHT pressurised mud balance to measure the mud properties relative to downhole conditions Measurement of the mud density at a 120F reference temperature. This is used because it represents a practical value of the average circulating temperature for a mud system. Estimation of the correct mud weight at temperature can be achieved, by using data supplied by the fluids company Mud property modification requires careful planning. Two examples are: Shearing the mud system properties within the casing, prior to drill-out and restricting direct chemical additions to the active system while drilling Efforts to keep the mud weight as low as possible while maintaining an overbalance, during the drilling of the high pressure zones, with narrow pore and fracture margins Flowline temperature control through mud flowrate adjustment: Monitoring of mud returns at the flowline as a function of flowrates to establish the limits on equipment and the flash point of the SOBM. Small reductions in flowrate can be sufficient to bring down the flowline temperature. (This would have been assessed during the planning phase, as part of the wellbore thermal modelling and assessment of hole cleaning efficiency) Measurement of gains and losses in the circulating system at surface in the mud pits, due to the expansion and cooling effects of the SOBM. The fluids company should have software for this analysis, and its use should be incorporated as part of the drilling fluid checks Downhole rheology behaviour of the mud system should be monitored frequently, utilising the Fann 70 viscometer. Data from this analysis can be used to assist in the prediction of ECD and ESD Conducting swab and surge pressure tests in cased hole, prior to drilling out the casing to act as a reference while drilling the section Prior to pulling out of hole (POOH), the string should be pulled wet to obtain information regarding the behaviour of the hole/formations and at the same time to avoid disturbing the well by pumping a slug. Particular attention should be paid to selecting the correct tripping speed, which will vary with bit depth. Pumping while pulling out of hole can prevent the bottom hole pressure from falling below static pressure due to swabbing effects Running into the hole with the pumps on can cause significant surge pressures. This is most important when considering washing down to bottom before drilling, running to bottom with pumps on after a connection and when reaming into the hole DRILLING ENGINEERING CONSIDERATIONS 5.2.2.3 Page 11 of 28 Drilling Fluids: Well Control The choice of drilling fluid for an HPHT well can impact the control of a well incident. Some of the differences to note for SOBM and WBM systems are: a. SOBM A flow check in SOBM may require longer to assess a potential influx, due to temperature induced volume changes The influx stays in solution and can mask the kick. As a result, the final influx volume may be larger before it is recognised If the well is shut in for a long period, the influx may stay in suspension for longer with less migration, than a WBM system The influx can spread out within the annulus while performing the well kill, resulting in more manageable volumes to process and easier handling capacities for the MGS. This can result in slightly lower pressures than a WBM Note: An SOBM system is generally regarded as a more desirable system for HPHT well control purposes. b. WBM Influx does not stay in solution, so can migrate to surface Influx stays in place as a cohesive volume, thus producing higher peak pressures and larger volumes for the MGS to handle at surface All of the above issues should be addressed by performing well control simulations, as part of the well control bridging document, in conjunction with the drilling contractor. 5.3 CASING RUNNING OPERATIONS The casing running operations for HPHT wells require assessment at the well design stage. This is due to the weight of the casing strings, the casing axial loads and to confirm the capability of the drilling rig (mast, substructure, travelling block, compensator if the rig is a semi and rating of drawworks). Preliminary casing weights should be identified as part of the initial rig pre-tender audit, to check the capability of the drilling rig. Involvement of the drilling contractor at an early stage will ensure that the team defines the safest, optimum method of casing running. The well design should assess the minimum and maximum mud weights, together with the risk of lost circulation (loss of buoyancy leading to higher axial loads). The method of pressure testing the casing will also have an impact on the equipment required for the casing string, relative to the pressure components of the drilling rig (eg full pressure test as part of cementation, or after waiting on cement). DRILLING ENGINEERING CONSIDERATIONS Page 12 of 28 If the maximum axial Von Mises Ellipse (VME) and minimum API load capacity is close to the limits of the operating envelope of the connector and pipe, a revised method of casing running may be required to limit the axial load. For example, not filling the pipe completely to a predetermined level and floating the casing into the well. 5.3.1 Equipment Selection All casing tools and equipment should be identified, inspected and assessed with the drilling contractor and casing running company for anticipated maximum load conditions. The assessment should identify the weakest component in the system and the sizing and fitting to the top drive (eg water bushings and crossovers for well control, limitations of elevators: 500 or 750 ton, compatibility of elevator links, circulating swage). The drilling line may also need to be strung with additional lines to cope with the increased load. This has an impact on the casing running speed (slower) and should be used to estimate the total time required for the job, from the pick up of the first joint, to landing and final cementing (relevant for a semi-submersible weather prediction and emergency hang-off). Additionally, if using a semi-submersible, the compensator may need to be locked due to limitations on its maximum rating. Casing slip type elevators should be assessed to determine sizing, tolerances and to ensure the elevator slip point contact area does not create concentrated stresses, through the system onto the pipe. This could introduce localised yield hardening making the casing more susceptible to stress corrosion cracking, if exposed to sour well fluids. The strength and handling of the landing string will depend on the cementing system adopted: full-bore surface launch, or high strength drillpipe with a subsea launch system. All equipment should be checked for dimensional accuracy and fit. Important if using non-standard API oversize casing and also for combination strings such as 10-3/4in x 9-7/8in. The complete process of casing running operations and equipment selection for deep, heavy HPHT wells requires a thorough assessment including, detailed involvement of the drilling contractor and the casing running company. DRILLING ENGINEERING CONSIDERATIONS 5.4 Page 13 of 28 CEMENTING OPERATIONS The design and planning for HPHT cementation operations require higher levels of technical resource over and above the criteria for a standard well. It is important to appreciate that all of the cementing requirements should be a seamless part of the well design, at an early stage of the project. This section focuses on the equipment, slurry design, spacers, simulations and contingency planning, for HPHT wells. Cements for HPHT applications should be good quality API Class G or H with an emphasis on quality and consistency. For deeper sections of the well, it is normal practice to use high content levels of Silica Flour to cope with the higher temperatures. An example of the planning required is selection of the final liner size eg 5in in 6in hole, or 5in in 5-7/8in hole, or 4-1/2in in 5-7/8in hole. The preliminary design and drift sizes may indicate a 5-7/8in bit is required to pass through the 7in drilling/production liner. However, cementing hydraulic simulations will probably fail using a 5in liner, resulting in the need to change to a 4-1/2in liner. This has an immediate impact in well testing access for DST tools and productivity of the well. Hence the need to resolve cementation issues early at a conceptual stage. 5.4.1 Equipment The following equipment issues should be taken into consideration on HPHT wells: Specification and selection of float equipment, including the plugs. In particular, temperature and pressure rating of the components of the production string. This is critical if planning to conduct the full casing pressure test, immediately after cement plug bump Length of casing shoe tracks. Important due to the risk of contamination at the casing shoe, for the combination production casing (10-3/4 to 9-7/8in) and the impact of small volumes on liners. It is not unusual to utilise a significant shoe track length (240 to 400ft) on the combination production casing, to reduce risk of contamination and over displacement Centralisation, in terms of achieving the minimum standoff and identifying planned top of cements If offshore, assessments of surface launch versus a subsea launch plug system. This will also be linked to the method of installing the wellhead casing seal assembly Identifying adequate HPHT cement heads and swedges, including inspection, work history and QA/QC of components for high pressure use Identifying liner hanger systems in terms of mechanical strength and sealing ability, eg mechanical versus hydraulic. Collapse, burst ratings and limitations of components, if using an hydraulic hanger DRILLING ENGINEERING CONSIDERATIONS Page 14 of 28 Defining accurate downhole parameters such as pressure, temperature and drilling/completion fluid systems, to check for ratings and sealing compatibility, for cementing packers, liner hanger packers etc Allowing adequate time to design, specify, procure and manufacture non-standard equipment 5.4.2 Slurry Designs Slurry stability and retarder responses are the two most important issues. The higher temperatures along with the higher retarder concentrations will tend to thin the slurry to such an extent, that the slurry may become unstable. Thus any testing will need to simulate downhole conditions. The retarder system is critical. Important to ensure that variations in retarder concentrations and variations in temperature will not harm the slurry’s thickening time, compressive strength and other properties. Compatibility with the drilling fluid systems is a key area requiring attention. Particularly, if using synthetic oil based mud systems (SOBMs). In addition, if the well is planned as a long-term producer, silica flour slurry designs may also be required for the surface casing strings (due to long-term temperature effects and breakdown on standard cement). Some of the cementing additives that require assessment for an HPHT slurry design are: Fluid loss additives Retarders Weighting agents Anti gas migration stabilisers 5.4.2.1 Slurry Testing When testing slurry designs for HPHT applications, it is critical to ensure that realistic tests are performed. For example, curing the freewater at atmospheric conditions on the lab bench cannot represent the behaviour of the slurry at HPHT conditions. The areas that require close attention in the laboratory are: Temperature: Temperature data should not rely on the API schedules but take into account downhole temperature gauge measurements, simulations of bottom hole circulating temperature (BHCT) and actual well offset data Pressure: The thickening time test should be performed at the actual BHP applied by the hydrostatic mud weight and column of spacer and cement. Also to obtain an accurate compressive strength development, the test pressure used should be close to the actual pressure that the cement will experience at downhole conditions DRILLING ENGINEERING CONSIDERATIONS Page 15 of 28 Fluid Loss: The temperature typically affects the fluid loss control of a cement slurry. The fluid loss value will normally increase as the temperature rises, although with some fluid loss additives it seems that the higher the temperature, the lower the fluid loss value. There are two different test procedures for testing fluid loss control; API FL test (maximum to 190F) or the Stirring Fluid Loss (at actual BHCT). The stirring fluid loss test is the most realistic test for HPHT conditions Thickening Time: This test should simulate as close as possible the job execution offshore. This should include the time the mixwater takes to prepare, if mixed in a pit, or other tank. A mixwater aging test should also be performed to ensure physical properties of the slurry, as prepared to API, would not change. A safety margin should be allocated to batch mix the slurry (if batch mixed, 60 to 120 minutes is generally acceptable). In addition, retarder sensitivity tests should be performed to determine the effect of ‘more or less’ retarder added to the slurry and the effect that a lower, or higher BHCT can have on the design Sensitivity Testing: The slurry design should be tested for thickening time at temperatures +20 and -20F on the estimated BHCT. At the higher BHCT the thickening time should still be long enough to account for placement plus two hours of safety. The reason for testing at 20F lower than estimated BHCT is that in some cases there is a so called ‘S’ curve effect ie at lower temperatures the slurry pumping time may be less than at higher temperatures. Assuming that there is no ‘S’ curve effect, if the slurry pumping time is extremely long at the lower temperatures, it may be required to test the compressive strength at the lower temperatures. In some cases the tests are performed at different slurry densities (eg +/-0.25ppg). These tests determine the robustness of the slurry Rheology: There is an optimum balance to achieve for HPHT slurries: To remain stable under downhole temperatures and pressures To be mixed readily by the equipment offshore and to be easily pumped downhole These two objectives may not be easily achievable. Testing should be done at the mix temperature and at 190F and where in cases the BHCT is greater than 190F, the slurry should be conditioned in the HPHT consistometer to the BHCT prior to taking the rheology and freewater. Alternatively the HPHT rheometer should be utilised to determine the rheology profile of the slurry at downhole conditions. The HPHT rheometer should be used only on the final design DRILLING ENGINEERING CONSIDERATIONS Page 16 of 28 Freewater: This test needs to be performed beyond APIs recommendations to ensure that the freewater value is zero at downhole conditions. The slurry should be conditioned in the HPHT consistometer. Once it has reached the BHCT and conditioned for a time at BHCT/BHP, it should then be cooled to 190F, prior to being placed in the cylinder. The cylinder is then placed into a water bath at 190F for 120 minutes. If the well is deviated, the cylinder should be inclined at 45. At the end of the curing period measure the freewater, and by inserting a rod into the cylinder, determine if any settling is present. This will give an initial appreciation of the slurry’s stability, or settling tendencies Static Gel Strength: A test for this property (SGS) is recommended for two reasons: To determine the transition time and confirm if the slurry is gas tight. As a guide the transition time for a gas tight slurry should be around 30 minutes To determine the zero gel time which would indicate the time available to retrieve the liner running tool. For a safe operation, the zero gel time would typically exceed 60 minutes Pilot Tests: Prior to submitting the cementing programme, the HPHT liner slurry and plug designs will need to be pilot tested. This can be waived only if a similar design (additives and slurry weight) at almost identical conditions have been previously tested. Extrapolating or interpolating from given slurry designs to meet a new set of conditions and requirements can be inaccurate and is not advised. During the pilot testing a full set of tests will need to be performed including sensitivity testing, especially if the slurry design is new with no previous data Lab tests with Rig Samples: Confirmation with rig samples is a must. Cement samples must be tested to confirm the required level of Silica Flour prior to slurry testing. It is important that tests are performed with a representative rig sample. Small Silica Flour content variations can have a big effect on slurry properties. Similarly, rig chemical samples must be used for the final testing. If more than one lot of each retarder exists on the rig, make sure that tests are performed with each one unless one lot number can be isolated for the job. The equality of additives should be checked and drillwater should be tested for chloride levels DRILLING ENGINEERING CONSIDERATIONS 5.4.3 Page 17 of 28 Spacers Spacer designs should ensure stability at downhole conditions, especially since the spacer is likely to be heavily weighted with solids. The spacer volume should ensure good separation of the cement/mud and usually higher amounts are recommended than a standard well, especially if the weight difference between the mud and slurry is close. It is important to identify additives that are stable at high temperatures and can also maintain suspension of the weighting agent. The spacer system should be tested for stability with the same emphasis as a cement slurry. This should include compatibility tests, for both mud and cement. For example, for an HPHT liner, it is recommended to confirm the compatibility with an actual rig mud sample, prior to the job, as there may be differences between a lab prepared mud and actual rig sample. 5.4.4 Simulations Wellbore simulations should be conducted with software that takes into account the rheology, hydraulics, pore/fracture pressures, LOT data, temperatures, casing design and mud system. Simulations should be performed to determine optimum pumping and displacement rates. Accurate rheology is needed not only for the cement slurry but also for the spacer and the mud. It is recommended to use Fann 70 rheologies for the mud. For the spacer and cement the HPHT rheometer can be used for critical slurries. In cases where there is a long cement column, perform simulations to ensure the cement at the top of the column will set within a reasonable time (due to the change from a maximum BHCT, to a much lower value higher up). Issues to consider for cementation simulation are: Displacement rates and pressures Losses during displacement/breakdown of fracture gradient over the narrow pore and fracture regimes, for the HPHT transition zone Mud properties and conditioning of the system to obtain the required PV/YP and gels prior to and during cementing (checking for sensitivity of the mud properties on displacement) Hydraulics and pressure losses, including ECD effect in the annulus on identified weak zones Defining the optimum displacement rates for the spacer, to displace the mud from the casing/formation in the annulus Estimation of total job time to ensure cement does not set prior to end of job, with an adequate safety margin (part of the sensitivity testing in the laboratory) Impact of cementing liners in small hole sizes, to obtain a realistic concentric cement sheath DRILLING ENGINEERING CONSIDERATIONS 5.4.5 Page 18 of 28 Temperature Estimation Obtaining an accurate BHCT is critical for HPHT slurry design. API schedules for these extreme conditions may be inaccurate, generally by overestimating temperatures. This is better in terms of placing a safe slurry as it provides a safety factor in terms of available pumping time. However, other properties such as compressive strength may be affected. It is therefore recommended to run a temperature simulation programme and/or run a (BHCT) temperature gauge. MWD temperatures will not give an accurate estimated temperature profile for BHCT. 5.4.6 Contingency Planning Prior to the start of the well, various cementing contingencies should be defined and assessed and put in place ready for use as part of the well design programme. They include the following issues for consideration: Squeeze plugs with cementing string (low LOTs, loss zones) Tieback strings Plug and abandonment/suspension with cementing strings. (Design of plugs to minimise risk of communication from HPHT zones to normally pressured zones may require substantial cement volumes) Balanced plugs (loss zones) Squeeze plugs by cementing through the bit A plug may have to be used for losses, or well control purposes. It is therefore important that emergency cement plugs are designed that they can be pumped and displaced through BHAs with adequate bypass. Bits should thus be run without nozzles (if hydraulic simulations permit this), in order to allow pumping of the lost circulating material (LCM) and cement to the zone of concern. For small diameter holes such as 5-7/8in, the volumes of slurries for cement plugs will be small (eg 500ft plug in open hole will be 17bbl). If conducting abandonment or suspension operations, contamination requires consideration, (plus use of wiper darts through the combination drillstring), to provide control over cement placement and pressures. Dedicated cement strings should be available for the various hole sizes (especially small hole), together with adequate materials and up to date slurry designs to perform emergency cement plugs at short notice. DRILLING ENGINEERING CONSIDERATIONS 5.5 Page 19 of 28 TEMPERATURE PROFILES An accurate temperature profile is a must for an HPHT project. The influence and impact on using good quality data has a significant impact on all aspects of the well. This will include the following subjects: Casing design DST/completion design Fluid programmes (drilling, DST and completions) Cementation programmes Capability and operating envelope for the drilling rig Surface equipment such as DSTs Design, operating envelope and limitations on equipment. eg Safety critical systems such as BOPs, wellheads, packers, connections, seals, de-rating of tubulars NACE requirements for H2S and CO2 Logging tools, MWD, logging while drilling (LWD) 5.5.1 Temperature Hazards The influence of high temperatures and thermal effects can also amplify wellbore hazards. Thermal modelling should typically consider the following subjects at an early stage: Loss of casing integrity Loss of surface equipment seal integrity Overpressuring of annuli De-rating effect on equipment Instability of fluid column Effect on the drilling fluid Poor cementation DRILLING ENGINEERING CONSIDERATIONS 5.5.2 Page 20 of 28 Temperature Sources Temperature data should be obtained from as many sources as possible and will generally include the following: Maximum recorded logging temperatures Extrapolated formation temperatures from logs DST temperatures Maximum recorded RFT temperatures A profile of the undisturbed formation temperature is then constructed from all of the data sources, as part of the HPHT datapack. 5.5.3 Modelling Temperature Profiles It is usual practice to utilise a temperature prediction and thermal modelling programme for HPHT wells during the planning and operational phase. There will be different requirements depending on the assessment topic. For example, for cementation analysis, the most important criteria is BHCT (bottom hole circulating temperature). For casing design we need to know the temperature profile for the complete wellbore including the BHST (bottom hole static temperature). Temperature predictions, analysis and assessment would typically be performed for the following subjects at the design phase: Maximum drilling fluid temperatures Maximum temperature of produced fluids Circulating temperature profiles for all hole sections Circulating temperature profiles for running/cementing casing strings Influence of annular fluid on the maximum wellhead flowing temperatures (heat transfer issues to outer casings) eg unweighted water packer fluid will be lower than a weighted SOBM Maximum/minimum casing and annulus temperatures during the life of the well. eg hottest during long-term production and coldest during injection Minimum temperature downstream of choke when circulating out a well influx (required for the well control bridging document) DRILLING ENGINEERING CONSIDERATIONS Page 21 of 28 All of the above cases are influenced by: The drilling circulating rates and reservoir production flowrates, fluid types, weights, rheologies, time and limitations on the operating envelope of the equipment. Changing one of the variables for a particular case, will impact all subsequent assessments. This requires a detailed iterative approach when conducting thermal modelling. Additionally, the well should be monitored during its construction phase to check assumptions and data do not exceed the boundary limits of the temperature model. If the well is planned offshore, the temperature profile should also take into consideration the water depth and temperature from the seabed to surface. The actual temperature profile for the well from TD to surface may produce a series of gradients, which could be above or below, the average geothermal gradient. Information obtained from thermal modelling studies is important, as it provides a datum for identifying suitable equipment and sealing systems, for the HPHT well. 5.6 WELLBORE EVALUATION Wellbore evaluation includes formation evaluation, casing wear and cement integrity monitoring. This section also includes MWD tools for surveying purposes, as many of the electronic issues apply equally to the MWD as well as LWD equipment. 5.6.1 Formation Evaluation Formation evaluation data can be obtained from LWD and Wireline logging, at the end of the hole section. The LWD tools will generally be run with the MWD survey equipment. Wireline equipment may be utilised to either verify the LWD data, or provide the main data due to the LWD limitations. When preparing a logging programme, attempt to reduce the complexity of wireline and LWD equipment designs for HPHT wells. The following issues should be considered for HPHT wells when assessing and utilising LWD/MWD systems: Allow adequate time to plan for HPHT equipment. Although they are becoming more widely available, the planning and timeframe required is greater than conventional equipment Once the LWD objectives have been identified (including additional modular requirements such as pressure while drilling) check that all systems are compatible. For example, it may be necessary to utilise two systems from different vendors. Check that the links to the mud logging systems and data files are also compatible to allow downloading and processing direct at the rigsite eg ASCII file formats. Minimise and avoid if possible, processing away from the rigsite DRILLING ENGINEERING CONSIDERATIONS Page 22 of 28 The biggest single issue affecting the performance, operation and reliability of these systems is the temperature of the well. Pressure does not appear to be a major issue regarding performance. By definition, HPHT wells are hot and this has a dramatic impact on the electrical components and the life of the battery systems. (However, temperature degrades the seals which then collapse under high hydrostatic pressure.) Standard equipment is usually rated up to a maximum temperature range of 300F (150C). HPHT equipment is generally rated up to c.350F although they have been run at higher temperatures with success. The technology is evolving and systems are under development to improve on the temperature limit up to 400F. Use of heat shields are a must and the technology is evolving constantly to improve reliability and operational performance. For example, the electronic chassis now include new developments, such as ‘surface mount technology’ with additional heat sinks, to disperse the heat away from critical components As the wells are drilled deeper, the formations become increasingly harder, leading to dramatic increases in shock and vibration. This has an impact on reliability and so requires additional sensors to monitor downhole parameters, such as vibration, torque and weight on bit. This also requires the systems to be optimised in conjunction with the bit, to minimise bit whirl and vibration Tool availability will also depend on the size required. For example, LWD systems are available and capable of drilling HPHT wells down to 5-7/8 to 6in hole, for most requirements (eg 4-3/4in diameter tools for Resistivity, Density, Gamma Ray and directional MWD). Systems are constantly under development for smaller tools to allow use in smaller hole sizes When specifying and assessing systems for HPHT wells, spend time to consider and discuss with the vendors issues such as, QA/QC and the resulting MTBFs (mean time between failures) of the system sensors, including onshore and rigsite use of calibration procedures. Keep the systems simple ie avoid complex combinations Operational planning requires that LWD/MWD systems are designed to allow as much flexibility for contingency operations as possible. For example, adequate bypass areas to allow pumping of LCM material and conducting emergency cementing operations through the BHA and bit To minimise risk of LWD component damage, it would be a normal practice to perform a number of intermediate circulation’s while running in the hole. The purpose would be to reduce the delta temperature prior to reaching bottom eg the components do not experience extreme temperature changes. However, too many temperature cycles can have a detrimental affect on the electrical components Compatibility and calibration (resistivity) requirements to the mud system (eg SOBM or WBM) DRILLING ENGINEERING CONSIDERATIONS Page 23 of 28 The pressure while drilling (PWD) tool (also known as the annular pressure while drilling tool - APWD), has replaced calculations with direct, real time downhole measurements and in doing so has exposed the limitations of conventional surface measurement techniques for estimating annular ECDs. These types of tools are becoming much more widely used in HPHT applications and are essential to obtain a much more accurate real-time assessment of downhole pressures. This assists decision making for mud flowrates, overbalance/underbalance and verification of LOT data, at previous casing shoes Pulser systems are also highly susceptible to failure in an HPHT environment, although it is possible to still have the downhole recorded data but lose real time transmission. Developments are ongoing to increase the MTBF of components for pulser systems LWD/GR/Resistivity may assist the wellsite geologist in recognising the stratigraphy associated with the high pressure transition zone The pore pressure/fracture gradient (PPFG) tool and software model calculates pore and fracture pressures on a foot by foot basis through mixtures of all major lithologies (shale, sandstone, limestone, salt anhydrite) in normally compacted sedimentary sequences. The information is obtained in real time and downhole memory mode. The overburden pressure determination requires initial calibration to a leak off test, which is updated using a calculated porosity, matrix density and formation fluid density. The tool can assist in identifying changes in the pore pressure trend, along with traditional wellsite methods (cuttings, background gas, drilling breaks) while drilling through the high pressure transition zone The following issues should be considered for HPHT wells when utilising wireline logging tools: Keep the wireline logging tool runs as simplistic as possible, even if it means multiple runs Detailed preparation, planning and communication with the wireline company is critical, at an early stage Wireline logging objectives will also require samples to be taken at specific points in the well. This may include RFT (repeat formation tester), MDT (modular dynamic formation tester), or CST (chronological sample tester). Obtaining and verifying maximum static temperatures will also be required to assist with the final design of the DST programme If the wireline logging programme is extensive over a number of days, additional wiper trips may be required to ensure the wellbore temperatures do not degrade the mud system and to check that the well is not deteriorating, or masking an influx Cable strength is downgraded due to the high temperatures, resulting in a reduced overpull capability. This can influence the maximum weight of the tools if considering combination runs DRILLING ENGINEERING CONSIDERATIONS Page 24 of 28 Consider a fusible weak point within the cable system (activated electrically) as this allows greater pulling strength to free the cable, eg a mechanical weak link may be limited to 70% of the cable strength. 5.6.2 Casing/Cement Integrity Monitoring Wireline logging programmes will not only run tools to obtain well objectives but also to obtain and confirm the hole size, casing condition and cement integrity. For example, use of the correct hole calipers (single, 4 or 6 arm) will have an influence on the cement volumes pumped and the eventual top of cement (TOC). This has an impact on the casing design and backup gradients for assessing external loads and providing a thermal bleed-off capability for the well annuli. Casing wear wireline tools may require benchmark calipers prior to drillout of the main production casing, followed by casing wear assessment caliper surveys, before testing/completing the well (MFCT/USIT). However, the attenuation may be too high to use the USIT in high density mud, in order to provide realistic data. Cementation integrity tools will typically include a CBL/VDL/GR/CCL. An imaging evaluation tool such as a CET may also be used. However, in high density mud the attenuation may be too high, to provide realistic data. For example, they will confirm isolation of weak zones/sandstones behind the production casing. The CBL is still the main tool to use in assessing cement integrity for high temperatures and high mud weights. 5.7 IDENTIFICATION OF TRANSITION ZONE Identifying the high pressure transition zone is a critical issue, for picking the production casing (10-3/4 x 9-7/8in) shoe depth. Time spent in identifying the depth for the production casing could save a contingency drilling liner and avoid drilling small hole sizes. The transition zone formations may not be readily visible by conventional logging and wellsite analysis techniques. However, in order to identify the pressure transition zone, the methods used will depend upon the dominant overpressured generating mechanism. For example: Porosity reduction by use of porosity tools, such as resistivity, sonic, neutron porosity and density Fluid expansion overpressure If the above techniques are not as reliable, then it is critical to identify the formation and stratigraphy, which is acting as the seal, to the underlying overpressure regime. Page 25 of 28 DRILLING ENGINEERING CONSIDERATIONS The following two techniques have been used successfully in certain instances to identify seismic reflectors, which are apparently associated with the pressure transition zone: Vertical seismic profile (VSP) Seismic while drilling (SWD) Use of such techniques requires extensive research and understanding of the overpressure system for the geological regional basin under assessment. 5.8 SLIMHOLE DRILLING The design and complexity of HPHT wells requires contingencies to be planned at an early stage if a casing string has to be committed early. Hence, the well design is a continuous circular approach, to identify minimum hole sizes and drift diameters. The casing design may be planned with additional liners for the lower portion of the well. Slimhole drilling can generally be considered to start from 6in and below. The following example demonstrates the need to discuss casing options and issues at the planning stage, with members of the multi-discipline team. String Casing Size (inches) Hole Size (inches) Conductor 30 36 Surface Casing 20 26 Intermediate Casing 13-3/8 17-1/2 Production Casing 10-3/4 x 9-7/8 12-1/4 Drilling/Production Liner 7 8-3/8 Drilling/Production Liner 4-1/2 5-7/8 Drilling/Production Liner ---- 3-3/4 The above example illustrates the importance of placing the production string in the right place and having additional casing strings available in the event of the following: Hole problems such as loss/gains, or stuck pipe Requirement to sidetrack the well due to hole problems Well control incident Poor LOT at the intermediate casing, requiring commitment of production casing early within the high pressure transition zone Poor LOT at production casing, requiring commitment of a drilling liner DRILLING ENGINEERING CONSIDERATIONS Page 26 of 28 All of the above issues and sizes need to be assessed, modelled and reviewed in terms of: Hydraulics/high ECDs Limitations of drilling equipment, such as the drillpipe strength Ability to perform fishing operations Specialised float equipment to allow drillout with PDC bits Obtaining a satisfactory cement sheath for the hole size/pipe combination Availability and supply of equipment such as bits, turbines, mud motors, survey tools, LWD/logging tools. (LWD/MWD equipment would probably not be available for 3-3/4in hole) Sensitivity of small kick tolerances and the ability of the rig to identify the influx (in particular, on a semi-submersible) Ability to achieve the DST/completion objectives (eg possible need to test in open hole) The example illustrated is only one example. There are many casing permutations and hole sizes that could be considered to achieve slightly larger hole sizes. However, the issues requiring assessment are the same. 5.9 WELL MANAGEMENT This section is focused toward HPHT developments and highlights areas relating to the management of the reservoir. A significant number of issues can be eliminated at the planning stage, by spending time and resources to design the completion for a ‘zero workover’ strategy. Although this is a planned objective, HPHT wells may require intervention to address: Equipment failure, eg sub-surface safety valves Sand/scale problems Reservoir management Sand production may lead to tunnel perforation failure, which cannot be handled by production measures such as reducing the drawdown. This may then require a suitable rig to access the well. Production decline due to depositional problems (scale and/or salt deposit, permeability reduction, perforation plugging) may be treatable by pumping fluid down the tubing and/or through a wireline unit, coiled tubing or snubbing unit. DRILLING ENGINEERING CONSIDERATIONS Page 27 of 28 The reservoirs are characterised by high salinity formation brines. As a result, scaling problems may be more severe than standard reservoirs and so requires a strategy for dealing with the problems. Scale inhibitors should therefore be modelled and tested to check for thermal instability and brine incompatibility. Reservoir management in terms of pressure decline has an impact on the Net Asset Value (NAV) of the project. The development drilling schedule may require all wells to be drilled prior to producing the reservoir, because of the risk of drilling into a depleted reservoir with an overpressured seal above. This can lead to extreme cases of losses coupled with well control problems. 5.10 EMERGING TECHNOLOGY Many of the issues that originally affected HPHT developments have been resolved eg capability of wellheads, xmas trees, downhole safety valves and packers. However, the biggest challenge that needs to be improved upon is the ability of equipment to cope with deeper, hotter, higher pressure wells. This has an impact on well designs, as it may mean drilling smaller hole sizes, with the use of the contingency strings to achieve the well depth. In particular, LWD/MWD systems need to be developed further, to provide smaller tools and electronics that can withstand the higher temperatures and pressures. Elastomer technology will need to ensure longer life and reliability, to cope with higher temperatures for the new tools under development. Examples of emerging technology for HPHT wells are summarised below. 5.10.1 Expandable Solid Tubular Technology This system uses pressure and an internal mandrel, to expand the casing diameter and so allow full bore access for drilling out. The potential benefit of the technology could allow casing shoes to be extended after the original casing has been installed. For example if a loss/weak zone is encountered, or a critical LOT is lower than the minimum required (intermediate casing) to drill through the transition zone. The system could be utilised on a production casing or liner and thus save a casing string and hole size. If the system were to be utilised, contingency planning would be required, to install a modified float shoe in advance, as part of the well design. DRILLING ENGINEERING CONSIDERATIONS 5.10.2 Page 28 of 28 Mud Pulse Telemetry An HPHT packer can be set using a pulse based communication technique, similar to that used in MWD and well testing applications, which actuates and manipulates downhole completion tools equipped with onboard electronics. Downhole tools programmed at the surface to recognise one of a series of discrete commands from a portable terminal unit, are actuated using a computerised supervisory control and data acquisition (SCADA) system to control pressure wave pulse frequency. The tools are equipped with a downhole power source, a smart (programmable) board and an actuating device. This promotes more efficient operations and removes a potential wireline run for installing a plug to set and test the packer. 5.10.3 Coil Tubing Perforating Perforating systems are now using coil tubing as the means of pacing the guns at the reservoir. A development of this technology for correlating the guns on depth with the GR and casing collars is by a wireless system, ie the coil tubing does not require an electric line to be run through the reel as part of the perforating system. This is beneficial from a safety and cost perspective, as it removes a cable inside the coil for closing the BOP system. SECTION 6 Drilling and Production Operations Ref: HPHT 06 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 MANAGEMENT AND CONTROL Page 1 of 26 TABLE OF CONTENTS 6. MANAGEMENT AND CONTROL .......................................................................... 3 6.1 DRILLING RIG SPECIFICATIONS AND CONTRACTUAL CONSIDERATIONS ......................................................................................... 3 6.1.1 Pre-hire Acceptance Inspection.................................................................. 3 6.1.2 Pre-hire Environmental Inspection.............................................................. 4 6.1.3 Rigsite Personnel ....................................................................................... 5 6.1.4 Operational History..................................................................................... 5 6.1.5 Maintenance ............................................................................................... 6 6.1.6 Office Based Personnel .............................................................................. 6 6.1.7 Variable Deck Load Capacity...................................................................... 6 6.1.7.1 Prior to Running 13-3/8in Casing ............................................................... 7 6.1.7.2 Prior to Running 10-3/4 x 9-7/8in Casing.................................................... 7 6.1.7.3 During Transit ............................................................................................ 7 6.1.8 Dynamic Response and Station Keeping.................................................... 8 6.1.9 Bulk Storage Facilities .............................................................................. 10 6.1.10 Subsea Package Handling System........................................................... 10 6.1.11 Marine Riser System ................................................................................ 10 6.1.12 Well Control Equipment............................................................................ 11 6.1.13 Drilling Fluid Circulation System ............................................................... 12 6.1.14 Mud Cleaning and Solids Control Equipment............................................ 13 6.1.15 Cementing System ................................................................................... 13 6.1.16 Well Test Facilities ................................................................................... 14 6.1.17 Drainage System ...................................................................................... 15 6.1.18 Sewage System........................................................................................ 15 6.1.19 Gas Detection System.............................................................................. 15 6.1.20 Third Party Equipment .............................................................................. 16 6.1.21 Derrick/Hoisting Equipment ...................................................................... 16 MANAGEMENT AND CONTROL Page 2 of 26 6.2 RESPONSIBILITIES OF RIGSITE PERSONNEL .......................................... 16 6.3 MEETINGS..................................................................................................... 17 6.3.1 Pre-spud Meetings ................................................................................... 17 6.3.2 Mid-well Meeting....................................................................................... 18 6.3.3 Daily Meetings .......................................................................................... 18 6.3.4 Pre-tour Meetings ..................................................................................... 18 6.3.5 Prior to Non-standard Operations ............................................................. 19 6.4 TRAINING ...................................................................................................... 19 6.4.1 Well Control Drills..................................................................................... 19 6.4.2 HPHT Well Control ................................................................................... 20 6.5 HYDROGEN SULPHIDE................................................................................ 21 6.6 BLOWOUT CONTINGENCY PLAN ............................................................... 22 6.7 RELIEF WELL PLAN ..................................................................................... 22 6.8 RISK ANALYSIS............................................................................................ 23 6.8.1 Hazard Assessments................................................................................ 23 6.8.2 Suspension of Operations ........................................................................ 25 MANAGEMENT AND CONTROL 6. Page 3 of 26 MANAGEMENT AND CONTROL This section includes issues to consider for the management and control of: high pressure, high temperature (HPHT) drilling rigs, personnel responsibilities, training, well control, H2S, blowout contingency planning and risk quantification. Most of the subjects listed here require good audit, hazard identification and training systems, not only to remove risk during the well design but also to be able to control the hazards, if they occur. 6.1 DRILLING RIG SPECIFICATIONS AND CONTRACTUAL CONSIDERATIONS The drilling of HPHT wells requires a drilling unit that is not only capable from a technical perspective but also has a strong track record of drilling these types of wells. For example, having available in house technical backup for subjects such as riser analysis, engineering equipment limitations and well control training. This requires the operator to allow sufficient time to work with the drilling contractor and main service companies, at an early stage of the project. The timing and commencement of an HPHT project will be driven by the availability of a suitable drilling unit, especially if drilling offshore. Resources spent at this phase of the project in identifying a suitable rig can save considerable expense in hidden costs at a later date, such as rig upgrades and operating efficiency. For example, conceptual planning will have to be carried out in house by the operator, plus additional third party studies, to identify if a jack-up or semi-submersible is required and suitable for the location site. The following subjects summarised below assume an offshore semi-submersible rig has been identified as the preferred choice. 6.1.1 Pre-hire Acceptance Inspection Most rig tender documents are now based on a standard IADC (International Association of Drilling Contractors) template and modified to suit additional requirements. It is recommended this approach is adopted for specifying the requirements for an HPHT bid invitation and technical assessment. Prior to a formal contract award, the operator and an independent surveyor should perform a pre-hire inspection of the rig. The inspection should include an examination of equipment condition and standards of maintenance, in accordance with API Standards, IP 17, NACE, local legislation relating to health and safety, and the equipment manufacturer’s original specifications and recommendations. The inspection should typically include the following subjects: Internal examination of safety critical equipment, eg blowout preventer (BOP) system, drilling chokes and marine equipment Examination of maintenance records and calibration tests, performed on critical well control components and load carrying equipment MANAGEMENT AND CONTROL Page 4 of 26 Oil sampling from equipment for analysis Function testing, load testing, pressure testing and insulation resistance checks on equipment where considered necessary Note: A good inspection assessment criteria is the ability of the rig to satisfy the minimum requirements of the IP 17 document. Rig acceptance should be conditional upon a satisfactory inspection report of the rig. The drilling contractor should carry out for example, any maintenance work or repairs deemed necessary by the inspection team for the project, prior to contract commencement. It is wise to establish outstanding issues between the drilling contractor and regulatory authorities on safety incidents or safety record, which may impact the rig contract, or start date of the project. If rig modifications are required to satisfy the required standards of documents such as IP 17, they should be assessed and discussed with the drilling contractor, to determine payment responsibilities and the potential impact on the timing of the project (eg shipyard booking schedules). 6.1.2 Pre-hire Environmental Inspection Prior to a formal contract award, the operator and an independent survey team should perform a pre-hire environmental inspection of the rig. The inspection should include examination of procedures, equipment condition and standard of maintenance in accordance with the manufacturer’s original specifications and recommendations. The audit should pay particular attention to personnel awareness of procedures and the measures in place to reduce the risk of an environmental incident. An environmental inspection would typically include the following subjects and should be performed at the same time as the pre-hire inspection: Capability of the Shipboard Oil Pollution Emergency Plan Rig drainage systems Oil spill clean up equipment Fuel bunkering equipment and procedures Note: It is important to understand that the degree of environmental compliance required for the rig, will vary based on local rules and legislation. Establish if there are issues outstanding between the drilling contractor and regulatory authorities on environmental compliance, which may impact the rig contract or start date of the project. MANAGEMENT AND CONTROL 6.1.3 Page 5 of 26 Rigsite Personnel The safe and efficient success of all projects is down to the quality and experience of the personnel. It is important to ensure the key personnel for the rig have adequate knowledge and experience of HPHT wells. The operator should obtain from the drilling contractor the resumes of personnel during the planning and operational phases of the project. It is important to assess the overall stability of the rig crew and onshore support team. Examples of key personnel are: Rig Manager Engineering support (onshore technical support in the planning phases with the operator) Rig Superintendents Toolpushers Drillers Assistant Drillers Derrickmen Master/Barge Engineers Subsea Engineers Emphasis should be placed on the training and work history related to experience of HPHT operations. 6.1.4 Operational History The operational history of the rig should be assessed to determine the types of HPHT wells and areas in which the wells were drilled. For example, is the rig currently working on an HPHT well, or has it been some time since an HPHT well was drilled? This has an impact on drilling contractor efficiency for an HPHT project. Is the rig a new drilling unit, with no work history to date? A situation such as this should be avoided for an HPHT project. However, if rig availability is very limited, what options exist for a drilling campaign to include basic low risk wells, prior to a critical well? The above issues may even result in the project being delayed or deferred, until a suitable unit with a previous work history is available. MANAGEMENT AND CONTROL 6.1.5 Page 6 of 26 Maintenance The operator should include as part of the pre-hire surveys, clear evidence of maintenance systems in place. This should include records of all maintenance performed on the rig, with a clear focus on critical equipment, such as BOP systems, pressure integrity of pipework and links to the rig survey programme, by the rig class certification authority. 6.1.6 Office Based Personnel The operator should obtain a current organisation structure from the drilling contractor, for both onshore and offshore management structures. In particular, how onshore technical backup supports the offshore operation for subjects such as: Engineering problems Equipment assessment Ensuring systems are up to date and complied with, by internal audit 6.1.7 Variable Deck Load Capacity This is a critical subject as it can have an influence on the ability to drill and test the well to a specific depth. It can also have an impact on operational logistic costs, due to weather constraints, well location and space/capacity on the rig. The operator should obtain engineering dimensional drawings of the complete rig deck area. This should show the typical positions of equipment packages, tubulars, and third party equipment and well test surface packages for drilling, testing and completion operations. The ideal situation is high variable deck load (VDL)/space that is more than the minimum requirements. This will depend on the age and generation of rig. For example, new design heavy duty HPHT rigs are now fifth generation units which have a high specification. However, there are a number of older drilling units which are more than capable of drilling HPHT wells, provided the operator has a clear understanding of the well design and issues, to address with contractors at an early planning stage. The drilling contractor should provide VDL calculations to confirm the rig can operate with the maximum anticipated VDL requirements. Examples include: MANAGEMENT AND CONTROL 6.1.7.1 Page 7 of 26 Prior to Running 13-3/8in Casing All standard deck loads due to anchoring, bulks, permanent rig equipment, standard third party equipment should consider issues such as: Maximum length and weight of the intermediate 13-3/8in casing including the casing contingency How much 5in, 6-5/8in drillpipe and BHA can be racked back in the derrick All of the barytes and cement silos full The maximum surface mud volume and mud weight The maximum volume of base oil in storage assuming an SOBM or OBM system 6.1.7.2 Prior to Running 10-3/4 x 9-7/8in Casing All standard deck loads due to anchoring, bulks, permanent rig equipment, standard third party equipment should consider issues such as: Maximum length and weight of the production 10-3/4 x 9-7/8in casing including the contingency How much 5in, 6-5/8in drillpipe and BHA can be racked back in the derrick All of the barytes and cement silos full The maximum surface mud volume and mud weight The maximum volume of base oil in storage assuming an SOBM or OBM system 6.1.7.3 During Transit Provide confirmation that with the maximum VDLs indicated, it is possible to accommodate the maximum well mud weight in the pits, with the rig at survival draft. The operator should obtain confirmation that the rig meets certified stability requirements for the various VDL combinations. The operator should also obtain the maximum mud weights that the rig can transfer and hold in terms of load strength/sq. foot for the pits and pontoons if stored away from the mud pits. MANAGEMENT AND CONTROL 6.1.8 Page 8 of 26 Dynamic Response and Station Keeping Dynamic response and station keeping capability should also be confirmed for the well location, based on the time of year and water depth. Issues requiring consideration are: Confirmation of the details and capability of the rig position/riser angle monitoring system, using transponder beacons on the BOP/lower marine riser package (LMRP) Procedures for rapid disconnect of riser and emergency move off location in any direction Details of the rig motion characteristics including graphs of the following: Heave to wave height ratio versus wave period Pitch to wave height ratio versus wave period Roll to wave height ratio versus wave period The drilling contractor should provide the following matrix, with the operating limits for the rig. Note: This is important, as it has a direct influence on the rig riser analysis and capability of the wellhead connector/conductor design. MANAGEMENT AND CONTROL Page 9 of 26 OPERATING LIMITS ACTIVITY Crane Operations Vessel loading/ offloading. Deck equipment handling. Heavy lifts. Equipment Handling Through moonpool. Deploy subsea equipment. Recover subsea equipment. Drilling Drilling Ahead. Tripping. Circulating at shoe. Well Testing Run tubing. Wireline ops. Coil tubing ops. Marine Riser Disconnect/ reconnect criteria. SIGNIFICANT WAVE HEIGHT (FT) WIND SPEED (FT/S) SIGNIFICANT HEAVE (FT) PITCH ROLL (DEGREES) (DEGREES) MANAGEMENT AND CONTROL Page 10 of 26 The drilling contractor should provide details and history of waiting on weather (WOW) time for wells drilled in similar areas and operations in progress, at the time of suspending operations. Details of mooring equipment failures should be included with recommended tensions and a basic API riser analysis for the area proposed. Note: This should link if required, to the IP Guidelines for ‘Routine’ and ‘Non-Routine’ Subsea Operations from Floating Vessels for a riser analysis. 6.1.9 Bulk Storage Facilities The rig bulk storage facilities should be assessed and confirmed for the well design together with the maximum volumes that may be required for drilling and testing the well. This should include assessments of the following: Barytes Base oil Cement Fuel oil Brine Marine loading points for all of the above should be available on both the port and starboard sides of the rig. 6.1.10 Subsea Package Handling System The drilling contractor should provide confirmation on the ability to perform a pressure test of the complete BOP system, to full working pressure on a test stump, while performing routine rig floor activities. Ability to handle, move and provide sufficient deck area for subsea xmas trees and drill stem testing (DST) equipment. 6.1.11 Marine Riser System The drilling contractor should provide confirmation that the marine riser system includes a riser booster line hooked into a centrifugal pump from the mud system, for circulating at higher rate up the marine riser to clear cuttings. This is of particular importance when drilling 16/17-1/2in hole. Additionally, confirmation from the riser analysis that the complete system is capable of working at various operating conditions with maximum mud weights and pressures at the wellhead/BOP (high mud weights and pressures mean more rigid and hence stiffer systems). MANAGEMENT AND CONTROL 6.1.12 Page 11 of 26 Well Control Equipment Well control equipment and requirements will depend on the well control policies of the operator and should also refer to the IP 17 document. Such issues have been discussed in earlier sections of this manual and the reader should refer to these. However, additional issues to consider may include: Size and operating envelope of wellhead connector. (Important as this is related to the riser analysis and the limitations of the gasket types for temperature, peak and continuous performance) Facility for fitting ‘bullseye’ inclination measuring devices on the BOP and/or the LMRP Availability of a tool for drifting the BOP stack and LMRP to full bore Details of ram configuration if using 6-5/8in drillpipe Capability of the pipe rams for hanging off the complete drillstring weight with the blind/shear rams, shearing pipe above the hung off tool joint Optimising the BOP ram configuration for drilling and testing requirements, with the correct variable bore rams In addition to satisfying the requirements of IP 17, the contractor should provide confirmation of certification, by providing up to date copies of certificates for all safety critical BOP components. Examples include but are not limited to: Flexible hoses on choke and kill lines, detailing continuous and short temperature and pressure ratings. Also age of the hoses and replacement criteria policy BOP ram face seals detailing continuous and short term temperature and pressure ratings Elastomer seals within the well control system detailing continuous and short-term temperature and pressure ratings Well control equipment conformity for sour service under NACE Details of any exposure of well control equipment to H2S over a timeframe, including exposure time, pressures and temperatures experienced and H2S concentration A dimensional engineering drawing and schematic drawing showing the complete surface well control circulating and venting system Records of all well control incidents over a timeframe, including maximum pressures, temperatures, well complications, equipment failures and servicing after the well control incident Details of downtime on the BOP system over a timeframe MANAGEMENT AND CONTROL Page 12 of 26 Details of maintenance programme including wall thickness checking, internal examination and seal replacement of the well control system Details on the use and wear of the rams and annulars, to determine the available life for stripping operations Details of the calibration programme performed on all pressure gauges operating within the well control system An engineering dimensional and schematic drawing of the LMRP and BOP stack showing the positions of all main components with dimensions between the rams and other relevant space out dimensions 6.1.13 Drilling Fluid Circulation System The operator should discuss the requirements of the fluids circulation system with the drilling contractor for the well design, maximum weights and fluid types to be used. Examples include but are not limited to: The total available surface mud volume The total capacity of the slug pits with a defined minimum volume that can be pumped (eg 50bbl) Capability to take mud pumps suction directly from any pit A minimum of two mixing lines, to allow independent simultaneous operations, eg mixing reserve pit pre-mix, while transferring, or mixing into the active system Equipment for the high rate addition of barytes to the mud system, for fast weight up operations Return flowline, flow metering device with output to the drillers console Minimum of two pit level sensors on all active pits. A combination of both mechanical and acoustic sensors is recommended. (Sensors should be positioned to allow for rig movement) Mechanical and electronic trip tank level sensor, with output visible from the driller’s console Three mud pumps with the ability to circulate with a total horsepower output equivalent to 1,000gpm at 5,000psi In addition to the above items, the drilling contractor should provide details of the following: An up to date schematic drawing, detailing the rig low and high pressure circulating systems MANAGEMENT AND CONTROL Page 13 of 26 Specifications of all standard pump liners available, including size, pressure rating, volume output and pressure relief valve settings Pressure ratings of the mud pump well control/kill system, ie mud pumps, standpipe manifold and top drive system 6.1.14 Mud Cleaning and Solids Control Equipment The operator should discuss the requirements of the fluids circulation system with the drilling contractor for the well design, maximum weights and fluid types to be used. Examples include but are not limited to: Rig floor drainage system to collect all drilling fluid from the drill floor, with a facility to return to the mud system All liquids from the rig drainage system to go to the oil water separator, to ensure minimal dumping of oily liquids Totally enclosed/sealed mud bucket with line to the trip tank Suitable ventilation from the shaker room to allow use of SOBM Minimum of 4 shale shakers suitable for cuttings volume generation with an SOBM Centrifuge package for control of mud weight and drilled solids. This package should consist of a minimum of two centrifuges, which can be run either in parallel for solids dump, or in series for barytes recovery In addition to the above items, the drilling contractor should provide details of the following: Details of any cuttings wash/treatment equipment installed on the rig An engineering dimensional drawing showing the proposed location of the cuttings wash/treatment system 6.1.15 Cementing System In addition to the issues raised in IP 17, the operator should obtain confirmation of the following: Maximum delivery rate of the bulk system to the cement unit The ability to accommodate a full 100bbl batch tank (assuming a slurry density of 18ppg), including location, hook up and communication links to the main cement unit and rig floor MANAGEMENT AND CONTROL 6.1.16 Page 14 of 26 Well Test Facilities The operator should obtain confirmation of the capability to perform a wide range of DST/completion activities and should link to at least one, or more, well test service vendors. Many of the issues to consider should be addressed by the use of IP 17. However, items that should be assessed in conjunction with IP 17 include but are not limited to: A 15,000psi rated standpipe to the test flowline, used for connecting coflexip flowline hose from the flowhead. (A second standpipe for the kill line coflexip would be advantageous but not mandatory) A 15,000psi rated production test line, which runs from the drill floor to the nominated test area Permanent pipework, which connects the test area to the burner, booms, including date of installation, material specification, ID, OD, certification, maintenance records and end connections A method of relieving pressure from the hydrocarbon vessel relief valves. This is normally in the form of a relief line header block. The relief lines shall be a minimum nominated ID and rated to an agreed pressure with the operator. The relief lines should include details of installation date, material specification, certification, and maintenance records and end connections A plan view of the test area on the rig showing hazardous areas during the test. A surface equipment layout of a previous HPHT test should be included as a reference guide Details of the burner boom rig up, including: King post certification Length of booms Drawing outlining boom type Details of the following utilities, which are required for testing equipment: Rig air Diesel fuel Potable water Electricity for data systems Sufficient firewater for deluge during flaring Steam supply (if available) Lighting to illuminate the test area Temporary communication facilities in a well test lab cabin MANAGEMENT AND CONTROL 6.1.17 Page 15 of 26 Drainage System The drilling contractor should confirm the facilities and systems for: The facilities in designated ‘open deck drainage areas’ or ‘clean areas’ which normally discharge directly overboard, that can re-direct all deck liquid flow into the ‘contaminated area’ or ‘closed drainage system’ for treatment in an oily water separator if required Oil water separator facilities for treating the bilge and machinery space drainage system, each with a capacity of treating a defined volume per hour. The facilities shall include waste oil holding tanks, prior to transportation ashore for suitable disposal and/or recycling of the separated oil. The facilities shall also include an on line oil content metering system, capable of monitoring that the oil content is less than a defined value (eg 15ppm). This should automatically close the overboard discharge line for the treated water and re-route the oily waters back to the oily water collection tank Procedures and sampling/testing regime to ensure that the on line oil content metering system does not exceed an oil content level of more than a defined value (eg 15ppm) 6.1.18 Sewage System The drilling contractor should confirm the facilities for: Treatment of raw sewage and domestic water, prior to disposal with the digested effluent being cleaned and disinfected by chlorination, before being discharged to the sea. The discharge point shall be located below water level, while the rig is at normal drilling draft The effluent from the sewage system shall produce effluent that is free of suspended solids, with chlorine content to a certain level of so many mg/litre and a defined faecal level per ml Drilling contractor should provide procedures and a sampling/testing regime, to ensure that the effluent from the sewage system is free from suspended solids 6.1.19 Gas Detection System The drilling contractor should confirm the following: Details and location of gas detectors, including drawings of locations and layouts Details of the maintenance and calibration performed on the gas detection system MANAGEMENT AND CONTROL 6.1.20 Page 16 of 26 Third Party Equipment The drilling contractor should provide details for the following: Engineering dimensional drawings showing the typical locations of the standard third party equipment packages, ie mud logging unit, wireline unit and tool cabin, MWD/LWD containers and H2S cascade system containers Details of any third party equipment currently installed on the rig 6.1.21 Derrick/Hoisting Equipment The drilling contractor should provide details for the following: The minimum derrick load handling capacity Note: This should be checked against the maximum anticipated weight of the casing strings. The top drive system, including service history and details of failures and downtime Details of the casing string maximum loads run by the rig Details of the pipe handling system and the ability to rack back an estimated length of 6-5/8in drillpipe (this will have to be estimated, as part of the initial proposed BHA/hydraulics planning) 6.2 RESPONSIBILITIES OF RIGSITE PERSONNEL The responsibilities of the rigsite personnel should be addressed as part of the well control bridging document; in order to define lines of communication and actions required, for a well control emergency situation. The exact details of the roles and responsibilities will depend upon the well control document used as the primary system (operator, or drilling contractor). Once this has been agreed, specific roles can be expanded within the document. Additionally, IP 17 (Section 3.4) provides a good guide for the duties of individual personnel, for a typical well control situation. The chain of command and reporting relationships should be prepared as flowcharts for onshore and offshore. Other issues to consider for the HPHT well control bridging document include, but are not limited to: The operator should have two drilling supervisors at all times for 24 hour coverage The drilling fluids company should provide two Mud Engineers to give 24 hour coverage of the well MANAGEMENT AND CONTROL Page 17 of 26 The operator should provide a Geologist on the rig to supervise the mud logging contractor and to provide the operator Drilling Supervisor/drilling contractor adequate data, on the formations and pore/fracture pressure regimes Assuming the rig is an offshore unit and depending upon the local legislation, the drilling contractor OIM (Offshore Installation Manager) will be the person in charge of the installation at all times Section 3 of IP 17 provides a guide on ‘Responsibilities and Administration’ and discusses issues such as, communications, operator supervision, level of supervision, duties of individual personnel and recommended crew for emergency well control situation. 6.3 MEETINGS The success of an HPHT project depends upon all team members attending and contributing to regular meetings, to ensure well objectives and safety of the well are maintained at all times. This should include onshore and offshore personnel during the planning and operational phases of the project and include the operator, drilling contractor and all service companies. The following safety meetings should be held and recorded, at various phases of the project. 6.3.1 Pre-spud Meetings These should be held onshore at the operator’s office and include all relevant personnel associated with the HPHT project: drilling contractor, service company managerial and supervisory staff prior to the spudding the well. The purpose of the meeting should be to explain and communicate the well design and programme, including hazards and areas of concern. A separate more detailed onshore meeting should also be held for well testing operations. A similar pre-spud meeting should be held offshore to communicate the well programme to the supervisory and service company personnel on the rig. Issues requiring action should be allocated to specific personnel and recorded in the minutes of the meeting. Subjects to present should typically include: Background information Well objectives Geology Safety policies Well design Drilling programme MANAGEMENT AND CONTROL Risk assessment Logistics and materials Safety 6.3.2 Page 18 of 26 Mid-well Meeting Due to the long duration of HPHT wells, a second programme should be held onshore and at the rigsite. This should be conducted prior to drilling out the intermediate casing string or prior to entering the high pressure transition zone. The main purpose of the meeting should be to re-emphasise the special procedures that are required, when drilling into HPHT formations. 6.3.3 Daily Meetings A safety meeting should be held and minuted at the start of each day, to discuss the current and planned operations. The meeting should be attended by: The OIM, Toolpushers, operator Drilling Supervisors, Driller, Geologist, MWD/LWD Engineers, Barge Engineer, Mud Engineers and Mud Loggers. The meeting minutes and actions arising should be sent to the operator Drilling Superintendent and drilling contractor Rig Manager. 6.3.4 Pre-tour Meetings Meetings should be held prior to the start of each tour, to co-ordinate the handover between the drilling crews. The meeting should be run by the OIM, or Toolpusher and include the following personnel: OIM Toolpushers Driller Assistant Driller Derrickman Floormen Mud Engineer Mud Logger MANAGEMENT AND CONTROL 6.3.5 Page 19 of 26 Prior to Non-standard Operations Safety meetings should be held for special operations and prior to testing the well. The meetings should be designed to explain operations that are non standard, or unfamiliar. All personnel associated with the operation should be present and made fully aware of the procedures to be adopted and possible hazards that might occur during the operation. These type of meetings should be held offshore and would be separate and additional to any hazops performed previously. 6.4 TRAINING Training forms a critical part of an HPHT project, therefore adequate time and resources should be allocated to ensure all of the rig crews are trained in the correct drilling practices, well control, H2S and emergency procedures to be adopted for the well. Drills should be used on a regular basis to ensure the drill crews are fully familiar with the procedures and techniques, that may be required when drilling a HPHT well. The toolpusher should ensure that the drills are performed regularly and in accordance with the written procedures. 6.4.1 Well Control Drills For specific details on drills, please refer to the Repsol Well Control Manual. These would include the following standard drills: D1 Kick While Tripping Kick While Drilling (including hanging off the drillstring) Diverter Drill Accumulator Drill Well Kill Drill In addition to the standard drills, special well control techniques which may be employed on HPHT wells should also be carried out. These include: Stripping Drill (Annular and Ram) Bullheading Emergency Disconnect Procedure (semi-submersible). Prior to spudding, or when the rig is disconnected from the wellhead, a drill should be performed to simulate an emergency winch off from the location MANAGEMENT AND CONTROL 6.4.2 Page 20 of 26 HPHT Well Control Adequate time and resources should be allocated to ensure all personnel, both onshore and offshore involved in decision making and/or supervisory capacity, attend a specific HPHT well control course. The following personnel should typically attend these types of courses: OIM Toolpushers Operator Drilling Superintendent Operator Drilling Supervisors Operator Geologists Operator Drilling Engineers Rig Manager Drillers Assistant Drillers Derrickmen Mud Engineers Mud Loggers MWD/LWD Engineers Cementing Engineers The course should be prepared jointly by the operator and drilling contractor and should cover the following topics: Overview of the well Standard well control sections Detection of the transition zone, mud weights and properties, swab/surge pressures How to utilise the well objectives to minimise the use of the contingency liner Contingency planning The course should discuss HPHT issues based on the following subjects: Past experiences and practices Gas behaviour and implications Review of rig equipment MANAGEMENT AND CONTROL Well specific decision trees Surface gas handling equipment capacities and limitations Hydrates formation and corrective actions Effects of pressure and temperature on mud properties Well scenario Practical drills applying procedures and practices Human factors and well control mistakes 6.5 HYDROGEN SULPHIDE Page 21 of 26 There are many aspects of an HPHT well to consider in terms of the wellbore fluids. One of the critical issues is the potential hazard arising from H2S. Therefore, unless it can be conclusively proven that H2S will not be present, all high pressure surface equipment that could potentially be exposed to well fluids should be designed and specified as sour service. The same criteria should be applied to the casing, DST and completion designs and all well programmes. Well test programmes should be defined to ensure safety from the effects of H2S. As it is colourless, highly toxic, flammable and heavier than air, the precautions that apply to any operation where it may appear as a component of the gas must be taken into account, as testing brings the wellbore fluids onto the installation. Areas where the atmosphere can contain toxic H2S fumes in concentrations that could endanger personnel shall be hazardous area classified. This should include planning, monitoring systems, personnel protective equipment and systems, training and drills. If the rig is not installed with a complete H2S system, a third party service specialising in this type of equipment should provide a full H2S cascade detection system, breathing apparatus and training, prior to drilling into any formations of known, or expected H2S presence. Performing operations such as coring recovery at surface, DST sampling, blowing down DST surface equipment pressures, breaking chicksans and/or lubricators, shall be performed according to special safety precautions and procedures. MANAGEMENT AND CONTROL 6.6 Page 22 of 26 BLOWOUT CONTINGENCY PLAN A blowout study and contingency plan should be prepared for the HPHT well as part of the well design and also the well control bridging document. The blowout study should link to Appendix 2 of IP 17 ‘Worst Case Scenario for the Drilling of High Pressure Wells’. By performing this type of study, it allows the maximum temperature of the wellhead system to be calculated and confirm if the minimum period of one hour for rig evacuation is adequate, in terms of equipment and elastomer ratings. It also allows the thermal load to be determined and utilised, as part of the casing design for the thermal loads. The blowout contingency plan may be a generic document that is already in place and modified for HPHT purposes. It would involve the drilling contractor and some of the main service companies, such as cementing, fluids and directional/surveying. Issues requiring consideration may include the following: Emergency organisation and location of key personnel Well control procedures (agreed and finalised with drilling contractor at an early stage of the project) Specialised well control equipment and services based on a call-out contract Assessment of hazardous fluids, such as H2S and CO2 Logistics and ability to supply critical equipment and bulk products at short notice (materials and transport) Relief well planning for an independent well kill, if the well is unable to be killed and capped 6.7 RELIEF WELL PLAN The relief well plan should consider the following issues: Relief well target selection Surface location selection (if offshore, potential availability of a suitable semisubmersible or jack-up. If on land, access and size of existing pad for additional rig) Relief well trajectory design, directional and surveying. This demands an accurate survey programme for the original well design, in order to have a high confidence level of intersecting the original well ie survey error radius of uncertainty Casing shoe selection and design Kill fluid design (well will be deviated and probably longer in terms of measured depth) Dynamic kill modelling (use of a specific well control modelling programme) MANAGEMENT AND CONTROL Page 23 of 26 Kill equipment specification and availability Kill operations including a proposed programme Gas dispersion modelling of the existing well under blowout conditions and impact on drilling rig and surrounding area Subsea plume modelling (if drilling from a floating vessel and blowout is at the wellhead/BOP) The dynamic kill model should assess an underground as well as a surface blowout. Reservoir data is critical to the generation of the relief well plan, so that the blowout model is as accurate as possible. As the drilling programme progresses, the data obtained should be reviewed and compared to the data used in the relief well plan. If substantial differences exist, the relief well plan should be modified as required, in order to ensure it remains valid. 6.8 RISK ANALYSIS The whole process of HPHT well planning and programmes should be based on identifying the hazards and the risk reduction measures, for all stages of the project. It is becoming routine to conduct well operations on this basis by using these types of techniques and requires the involvement of a wide range of personnel, at each respective stage of the assessment. 6.8.1 Hazard Assessments Well designs such as HPHT will require the use of HAZOP/HAZAN techniques as part of the well planning and design process, due to the close design margins and the consequences of failure. To assist the members of the team, HAZOP comes first by identifying the hazards from the design and means Hazard and Operability study. It is qualitative and is performed by a team from a cross-section of various disciplines, not just drilling personnel. The hazards are identified and the team then decide how to address them. The HAZAN process then follows, by analysing the hazards, it is quantitative and may include techniques such as risk assessment, or quantified risk assessment (QRA) (ie what is the likelihood that an incident, or failure will occur and the consequence should it occur). The hazard assessments should break the project down into modular packages, eg subjects such as well design, drilling operations, well control, rig moves (if offshore), DST/completion operations, well suspension/abandonment operations. The various subjects may link to specific studies and outputs, which have been generated by different members of the project team. Page 24 of 26 MANAGEMENT AND CONTROL A table is generally produced, based on the following format or similar, with some examples on how it could be used: OPERATION ITEM Drilling Operations A Well Control Procedures B INHERENT HAZARD POTENTIAL CONSEQUENCES RISK REDUCTION MEASURES Pressure overload of casing Burst or collapse of casing Casing strings are designed to withstand expected shut-in surface pressures for burst and collapse. Production casing designed to withstand expected shut-in maximum surface pressures Loss of primary well control Potential influx of hydrocarbons into wellbore, possibly resulting in blowout Primary control maintained using a fluid of sufficient density to overcome predicted formation pressures with an overbalance by: Ensuring rheology properties of the fluid are such that the density can be increased as necessary by adding material. Ensuring sufficient volume of fluid is available at surface, including a specified volume and weight of ‘kill fluid’. Maintaining sufficient stocks of: Barytes (weighting material). Cement. Lost circulation materials. Mud chemicals. MANAGEMENT AND CONTROL 6.8.2 Page 25 of 26 Suspension of Operations It is normal practice for HPHT well programmes to include, as part of the contingency policies and plans, requirements for the suspension of operations. This is defined within IP 17 Section 6.1.1 (d) as: ‘The criteria for the suspension of operations, or abandonment of the well, or of that section of the hole giving rise to continuing problems, where the safety margin of operations in progress is deteriorating, should be stated.’ Drilling operations should be suspended as soon as safely practical if any of the following situations occur (which are not listed in terms of priority). The situation will be investigated and remedied, or deemed no longer hazardous, prior to any drilling operations recommencing. Note: All of these issues should have been discussed as part of the hazard assessment process. Well conditions, or well integrity dependent equipment, are subjected to conditions outside its operating envelope. Examples are: pressure, temperature, H2S and CO2, excessive casing wear or dynamic losses exceeding a predetermined value) Vital safety equipment, including its backup becoming inoperable (pressure/ temperature/H2S/hydrocarbon monitoring equipment, life saving appliances, kill weight and mixing equipment if no kill mud in reserve, cement unit not operational, mud logging gas detection system not operational) Stock levels of barytes, whole mud, mud chemicals, cement, cement chemicals, base oil and hydrate suppressant volumes fall below their identified minimum stock levels Weather conditions deteriorate outside the operating envelope of the drilling rig (eg semi-submersible riser analysis, bending moment limits of the wellhead connector/BOP) Well directional survey plan approaches upon the ‘minimum distance of separation’ for existing wells if drilling from a platform, subsea cluster or land drilling well slot pad In addition, drilling ahead should be temporarily stopped, if any of the following examples occur: Temperature of drilling fluid returns exceeds a pre-determined maximum The difference between the LOT and maximum mud weight in use falls below a pre-determined value (eg 0.5ppg) Background gas rises to an unacceptable level MANAGEMENT AND CONTROL Page 26 of 26 Any kick indication, drilling break, increased returns, flowrate, pit gain, hole not taking correct volume during trip, change in properties of returned mud, increase in hookload, pump pressure decrease/pump stroke increase All of the above subjects should be addressed as part of the well control bridging document, during the planning phase. SECTION 7 Drilling and Production Operations Ref: HPHT 07 SPECIAL WELLS MANUAL, VOLUME I: HIGH PRESSURE, HIGH TEMPERATURE Issue: Feb 2000 REFERENCES AND FURTHER READING Page 1 of 7 TABLE OF CONTENTS 7. REFERENCES AND FURTHER READING ........................................................... 2 REFERENCES AND FURTHER READING 7. Page 2 of 7 REFERENCES AND FURTHER READING (1) Institute of Petroleum: Model Code of Safe Practice Part 17 ‘Well Control during the Drilling and Testing of High Pressure Offshore Wells’, May 1992. (2) Institute of Petroleum: Guidelines for ‘Routine’ and ‘Non-routine’ Subsea Operations from Floating Vessels, August 1995. (3) NACE Standard MR0175-99. (4) API: Specification 6A, Wellhead and Xmas Tree Equipment. (5) API: Specification 6FA, Fire Test for Valves. (6) API: Specification 6FB, Fire Test for End Connections. (7) API: Specification 6FC, Fire Test for Valve with Automatic Backseats. (8) API: Specification 16A, Drill Through Equipment. (9) API: Specification 16C, Choke and Kill Systems. (10) API: Specification 16D, Control Systems for Drilling Well Control Equipment. (11) API: RP 16E, Design of Control Systems for Drilling Well Control Equipment. (12) API: RP 16Q, Design, Selection, Operation and Maintenance of Marine Drilling Riser Systems. (13) API: Specification 17D, Subsea Wellhead and Xmas Tree Equipment. (14) API: RP 53, Blowout Prevention Equipment Systems for Drilling Operations. (15) ISO: 13628-4, Petroleum and Natural Gas Industries Drilling and Production Equipment Design and Operations of Subsea Production Systems Part 4 Subsea Wellhead and Tree Equipment (Based on API Specification 17D). (16) ISO: 10423, Petroleum and Natural Gas Industries Drilling and Production Equipment Specification for Valves, Wellhead and Xmas Tree Equipment. Note: Check that the API documents and other standards/codes are the most up to date edition, prior to use. The web address for the most up to date listing of all API documents is: http://www.api.org/cat/pubcat.cgi The various codes and API standards can be obtained from: TSSL (Technical Standards Services Limited), Hitchin, England Tel +44 1462 453211 Fax +44 1462 457714 Web http://www.techstandards.co.uk Email sales@techstandards.co.uk REFERENCES AND FURTHER READING Page 3 of 7 (17) Economides MJ, Watters LT, Dunn NS Petroleum Well Construction, Wiley 1998. (18) Articles Reference Author Article Journal Euroil, October 1997 Under Pressure: HPHT could be the place to be Journal Hart’s Petroleum Engineer International. Jeanne P Perdue, Technology Editor Predicting and Preventing Casing Wear While Drilling JPT JPT June 98. Thomson K, Adamek FC High Pressure, High Temperature Platform Wellheads and Xmas Trees OTC Paper 8742 JPT Hilts RL, Kilgore MD, Turner WH (JPT June 97) Development of a High Pressure, High Temperature Retrievable Production Packer (SPE Paper 36128) Journal Hart’s Petroleum Engineer International August 96 Pulse Wave Actuates Downhole Tools JPT JPT June 97. Samuelson ML, Constein VG Effects of High Temperature on Polymer Degradation and Cleanup (SPE Paper 36495) JPT Ray TW (JPT June 98) High Pressure, High Temperature (HPHT) Seals for Oil and Gas Production (SPE Paper 39573) Journal von Flatern R (Offshore Engineer June 99) Pressure to Complete Journal Holbrook P (SPEDC March 97) Discussion of A New Simple Method to Estimate Fracture Pressure Gradients JPT Element DJ, van der Vossen, Diamond S, Hamilton TAP (JPT June 98) Consequences of Formation Breakdown During Well Control: A Study of Underground Crossflow While Drilling an HPHT Well (SPE Paper 38478) REFERENCES AND FURTHER READING Page 4 of 7 JPT Sundermann R, Bungert D Potassium-Formate Based Fluid Solves High-Temperature Drill-in Problem JPT Van Oort E, Bland RG, Howard SK, Wiersma RJ, Roberson L Improving High Pressure, HighTemperature Stability of Water Based Drilling Fluids JPT Harrison JR, Stansbury M, Patel J, Todd Cross A, Kilburn M Novel Lime-Free Drilling Fluid System Applied Successfully in Gulf of Thailand Halliburton Aberdeen Engineering HPHT Cementing Guidelines JPT Patel AD, Wilson JM, Loughbridge BW Impact of Synthetic Based Drilling Fluids on Oilwell Cementing Operations Journal Hunt E, Pursell D (World Oil September 96) Fundamentals of Log Analysis JPT Gardner D, Fallet T, Nyhavn F (JPT March 97) Production Logging Tool Developments for Horizontal Wells and Hostile Environments (SPE Paper 36564) Journal Tollefsen E, Everett M (World Oil December 96) Logging while fishing technique results in substantial savings JPT Technology Digest Addressable Release Tool for Electric-Line Use Journal von Flatern R (Offshore Engineer August 98) A better feel for formations Journal Hart’s Petroleum Engineer International May 98 MWD/LWD Comparison Tables Journal Jackson M, Einchomb C (World Oil March 97) Seismic While Drilling: Operational experiences in Vietnam Journal Kamata M, Underhill W, Meehan R, Nutt L (Harts Petroleum Engineer International October 97) Real-Time Seismic-While Drilling Offers Savings, Improves Safety Journal Holm, G (Oil and Gas Journal January 98) How abnormal pressures affect hydrocarbon exploration, exploitation REFERENCES AND FURTHER READING (19) Page 5 of 7 JPT Graham GM, Jordan MM, Graham GC, Sablerolle W, Sorbie KS, Hill P, Bunney J (JPT June 97) Implication of High-Pressure/ High-Temperature Reservoir Conditions on Selection and Application of Conventional Scale Inhibitors: Thermal Stability Studies (SPE Paper 37274) Journal Harts Petroleum Engineer International August 96 Mud Pulse Telemetry: Pulse Wave Actuates Downhole Tools Journal Grow, JJ (World Oil April 99) Expandable Casing Update Ward, Dr CD (Sperry-Sun Drilling Services) A new approach to Pore and Fracture Pressure evaluation Journal Goins Jr, WC (World Oil October 96) Learning from well control mistakes can help prevent future blowouts Journal Eby, DF (Offshore January 97) Precautions in planning HPHT well control SPE Papers. The web address for the Society of Petroleum Engineers is: http://www.spe.org Paper Number Author(s) Title 35076 Smith JR, Cade RS, Gatte RD Integrating Engineering and Operations for Successful HPHT Exploratory Drilling, SPEDC Dec 1997 55052 Jellison MJ, Eckroth JJ, Fulton J, Ogren LA, Moore PW, Barber V, Vesely D Teamwork Results in World Record Length Casing Run 20900 Krus H, Prieur JM High Pressure Well Design 52884 Miska SZ, Samuel GR, Azar JJ Modelling of Pressure Buildup on a Kicking Well and its Practical Application 56853 Watson, RJ Discussion of Modelling of Pressure Buildup on a Kicking Well and its Practical Application 24603 Cassidy S Solutions to Problems Drilling a High Temperature, High Pressure Well REFERENCES AND FURTHER READING Page 6 of 7 26874 Seymour K, MacAndrew R Design, Drilling and Testing of a Deviated HTHP Exploration Well in the North Sea 26738 Oudeman P, Bacarreza LJ Field Trial results of Annular Pressure Behaviour in a High pressure, high temperature Well 36583 Stewart RB, Gill DS, Lohbeck WCM, Baajens MN An Expandable Slotted-Tubing, Fiber Cement Wellbore Lining System 56921 Hinton, A An Analysis of OSD’s Well Incident Database; Results can Improve Well Design and Target Well Control Training 23120 Davidson A R, Prise G, French C Successful High Temperature/High Pressure Well Testing from a Semisubmersible Drilling Rig 26874 Seymour K, MacAndrew R Design, Drilling and Testing of a Deviated HTHP Exploration Well in the North Sea 28297 Ward CD, Coghill K, Broussard, MD The Application of Petrophysical Data to Improve Pore and Fracture Pressure Determination in North Sea Central Graben HPHT Wells 27488 Bowers GL Pore Pressure Estimation from Velocity Data: Accounting for Overpressure Mechanisms Besides Undercompaction 22557 Morita N, Fuh GH, Boyd PA Safety of Casing Shoe Test and Casing Shoe Integrity After Testing 24603 Cassidy S Solutions to Problems Drilling a High Temperature, High Pressure Well 28710 Rocha LA, Bourgoyne AT A Simple Method to Estimate Fracture Pressure Gradient 18036 Peters EJ, Chenevert ME, Zhang C A Model for Predicting the Density of OilBased Muds at High Pressures and Temperatures 24589 Edward-Berry J, Darby JB Rheologically Stable, Nontoxic, High Temperature, Water-Based Drilling Fluid REFERENCES AND FURTHER READING Page 7 of 7 29071 Growcock FB, Frederick TP Operational Limits of Synthetic Drilling Fluids 28305 Miano F, Carminati S, Lockhart TP, Burrafato G Zirconium Additives for High Temperature Rheology Control of Dispersed Muds 39282 Rommetveit R, Bjorkevell KS Temperature and Pressure Effects on Drilling Rheology and ECD in Very Deep Wells 38480 Swanson BW, Elliott GS, Meier JL, Easton MDJ Measurement of Hydrostatic and Hydraulic Pressure Changes During HPHT Drilling on Erskine Field 19939 Tilghman SE, Benge OG, George CR Temperature Data for Optimising Cementing Operations 24581 Kabir CS, Hasan AR, Kouba GE, Ameen MM Determining Circulating Fluid Temperature in Drilling, Workover and Well Control Operations