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Platform Rig Design Platform Rig Design, ,: Daisy Field Development, ABC Oil Daisy Field Development, ABC Oil
Platform Rig Design Platform Rig Design, ,: Daisy Field Development, ABC Oil Daisy Field Development, ABC Oil
Summary
Lifting capacity of draw works : Calculations enclosed illustrate that a 3000Hp draw works working at 85% mechanical efficiency will provide sufficient lifting capacity to take an over pull of 150,000lbs on the heaviest stuck casing or drillstring. In this case the heaviest string is the 9 5/8 casing. (see figures enclosed.) Derrick load capacity to accommodate a dynamic derrick load in excess of 825,750lbs Substructure and setback load in excess of 1,000,000lbs BOP sizes and ratings : 18 5000 BOPs, 3000psi annulars. Annular, Blind/shear ram, two sets of pipe rams. (choke and kill lines located below shear rams.) Drillstring capacities (critical design sections are 12 and 8 @ sections) Drillstring summary for 12 section
Component Connection Length Cum length Air wt (lbs) Buoyed wt (lbs) 49K Cum buoyed wt (lbs) 49K Overpull (pa-Cum Bw) -
Drill collars
120m
120m
59K
HWDP
5 x 3 NC-50
200m
320m
35K
29K
78K
Drill pipe 1
19.50 G NC-50
2148m
131K
109K
187K
166K
Drill pipe 2
19.50 S NC-50
3000m
61K
51K
238K
217K
Drill collars
6 x 2 13/16 4 IF
120m
120m
30K
HWDP
5 x 3 NC-50
200m
320m
35K
29K
54K
Drill pipe 1
19.50 G NC-50
2148m
131K
109K
163K
190K
Drill pipe 2
19.50 S NC-50
4300m
159K
132K
295K
160K
Summary (continued.) Mud pump output and pressure / power ratings. Mud pumps rates to 4500psi, providing 3000hp (i.e. sufficient to drill at 4350psi @ 950GPM at 12 section TD, at 85% mechanical efficiency and 95% volumetric efficiency.) See summaries in appendix 3. Mud pit capacity : Minimum of 3000bls required. This however is unlikely to be accommodated on a platform rig design due to loading conditions. (Note: In reality, Platform design may only allow approx. 2000bbls that add constraints to many operational aspects.) Solids treatment and mixing equipment. Shale shakers to handle circulation volumes 1100-1200GPM, with redundancy for one shakers to be taken out of service using as fine as screens as possible maintaining high solids removal efficiency. E.g. High capacity , fine screen shale shakers such as thule VSM 100s) Built in scalping screen, quick change screen facility, easy to operate and maintin, repairable screens. Efficient centrifuges to remove fine solids generated during drilling. Shallow header tanks entry to shakers and proper flowline division to ensure flow can be equally controlled and divided to each shakers as required. Poor boy de-gasser to be fitted with minimum 8 vent line. Vacuum de-gasser to be able to handle max. operating rate of charge pumps i.e. 1200GPM. Gumbo box fitted to flowline. Flowline access platform for fitting and maintaining flow shows, gas detectors etc. 2 weco flushing connections fitted at strategic points for flowline cleaning. References: Homco technical handbook. Ds-1 ( Terrance Hill & associates.) Drillstring desgin notes, Msc notes and Shell training notes. Halliburton red-book.
Casing Scheme 30 conductor 20 surface casing 13 3/8 intermediate csg. 9 5/8 intermediate casing
Depths (m) 300m TVD BDF 800m TVD BDF 900m TVD BDF 1400m TVD BDF 1650M AHD BDF 1900m TVD BDF 3000m AHD BDF
Comments
Maximum anticipated angle 27degrees Maximum anticipated angle 32degrees Note: Required to isolate long Salt section. Tangent and build section to almost horizontal. Shale stability required, >mud weight of 0.5ppg per 30deg required for wellbore stability. Set 150m inside 9 5/8 casing Mud weight to represent minimum safe overbalance to limit formation damage. Normal pore pressure assumed = 8.33ppg Reservoir pressure assumed to be 1.5ppg above normal i.e. 9.83ppg.
7 production liner
Design Notes 26 section drilled with seawater and displaced to 1.2sg mud prior to running casing 17 section, mud weight to reflect 300psi working overbalance and 0.53ppg for 32 degrees hole angle. (10.12pg) 9 5/8 section, mud weight to reflect 300psi working overbalance and 1.5ppg for hole angle (10.8ppg) 7 section mud weight to reflect 300psi working overbalance over reservoir pressure (10.73ppg) Design Factors Tension design 1.33 Tension calculations assume that the drillstring is hanging vertically. For high angle wells this would be accounted for in design as too conservative, hence a higher design factor has been used. In reality in high angle wells, each section should be considered at an average hole angle. Drag is also not accounted for in design calculations. In reality torque and drag simulations would have to be conducted modeling field data friction factors known etc. Collapse design factor: 1.15 Burst design factor: 1.15, 1.25 for 13 3/8 section due to requirement for salt section isolation. BHA design factor: 1.1 Margin of overpull, 120,000lbs drillstring Margin of overpull, 150,000lbs casing. The operator would like to trip with a minimum speed of 90ft/min at highest loading conditions. Draw works Wire rope safety factors, minimum of 2.0 for drilling / casing. Maximum operating torque = 25,000ftlbs (safe working value for top drive system e.g. TDS-2.) Solids Control : Enough shakers to have one redundant at required section flowrate. System to be designed such that shakers and centrifuges provide required solids control efficiency.
Ref: see wellbore stratigraphy in appendix 1. 2.) Burst : No pressure tests to be conducted before cementing, burst loads not considered. 3.) Max collapse pressures. (Design factor 1.15, & 1.25) Note: Worst case (total evacuation) has been used in collapse for platform design i.e. heaviest casing strings. In reality based on platform experience, lost circulation aspects etc, total evacuation not likely to be used in design.
Collapse 17 section For 13 3/8 casing Collapse 12 section For 9 5/8 casing Collapse 8 section For 7 liner 0.052 x 10.73ppg x (1950m x 3.281) x1.15 = 4105psi 0.052 x 10.12ppg x (1400m x 3.281) x1.25 = 3021psi 1.25 design used due to isolating salt section. 0.052 x 10.8ppg x (1900m x 3.281) x1.15 = 4026psi
Note: Surface equipment, BOP equipment, casing and drillstring component requirements would be based upon likely maximum injection pressure into the reservoir of 4335psi. This may have to executed
during some operational stages in the life of a well via drilling equipment Bops etc. ( e.g. Injectivity test, well stimulation etc.) 5000psi equipment would therefore be chosen and selected if it can fulfill other requirements. I.e Drilling (Pumping /pressure) requirements. Choke manifold. SWP of 5000psi valves before chokes. SWP of 3000psi valves downstream of chokes. (one remote and one manual choke.) Standpipe manifold. : SWP of 5000psi for all valves, lines and fitments. BOPs : SWP : 3000psi annular, SWP : 5000psi rams, kill and choke line valves, HCR valve fitted as first outlet v/v on choke line. Rams : Solid ram block consisting of Pipe ram, Shear ram, and two pipe rams . Kill and choke lines fitted below shear rams. Rams fitted with variables from 3 to 5 and 4 to 7. IBOP eqpt. : All kellycocks, IBOPs , Grey valves etc rated to SWP of 5000psi.
Casing selection
Casing selection
Casing was selected for burst and collapse criteria based on maximum anticipated pressures given on the previous pages. Note: A premium gas tight connection would have to be chosen for the 9 5/8 casing and 7 liner e.g. Vam Size Grade Lbs/ft Yield strength (psi) 80,000 80,000 Burst (psi) Collapse (psi) Body strength (Klbs)
13 3/8 13 3/8
P110 N80
72 77*
7400 6390
2880 3170
2596 1773
*Heavier casing may be required over salt section. 9 5/8 7 N80 N80 47 29 80,000 80,000 6870 8160 4750 7020 1086 676
Casing weights
Based on casing weight above, the highest casing load would be running the 9 5/8 casing. Note: All tension calculations assume that the casing is hanging vertically and in air. For high angle wells, this would be accounted as too conservative in design. A design factor of 1.2 has been for hole angle and wellbore profile to be taken into account. In this design, a value of 150,000lbs over-pull has also been used to account for casing being stuck prior to landing at TD. Size 30 * 13 3/8 9 5/8 7 7 ** Grade X-56 X-52 P110 N80 N80 N80 G&S N80 Lbs/ft 310 133 72 77 47 29 21.8 29 Length (m) 300 900 1300 350 3000 1450 2850 4300 Dry Weight (klbs) 305K 393K 307K 88K 463K 138K 203K 409K
* Assuming all ran at once. ** Contingency string if required to run to surface, e.g. if leak in 9 5/8 string.
Drill collar and BHA requirements. Drill collar, BHA, and drillstring component lengths have been determined as follows: Length of Drill collars + BHA components required to drill with max 45000lbs WOB in 12 @ section.
Wob Df Wdc Kb Cos 45,000 1.1 151 0.83 Cos32 = 465 ft (142m)
Based on the above 12 drill collars would be required in addition to other BHA components, e.g. mud motor, MWD collar, stabilisers etc. that would make up the additional length required. The operator prefers however in the directional sections of the well, to run a DS1, BHA type 3. I.e. utilising HWDP for available WOB. This is to minimise BHA handling time, reduce stuck pipe likeliness, and run drill collars required for directional control and BHA design.
HWDP required. Based on a drill collar and BHA component length of 120m, the following calculation determines the amount of HWDP required for 35,000WOB (Upper limit of 12 PDC), at an angle of 60degrees (i.e. where cos. = 0.5). Note: A t higher angles BHA has a diminishing effect for WOB requirements.
1 Wob Df Kb cos (Ldc Wdc ) W ( hwdp ) 35000 1.1 1 0.83 cos 60 (120m 3.281 148) 53.7 1 = [92,771 58,270] 53.7 = 642 ft (21 jts.)
If buckling was the limiting factor appendix 4 illustrates that at 60degrees, drill-pipe could also be used to apply WOB up to 53,000lbs before buckling would occur. (available weight from BHA components is only 31,000lbs at 60degrees inclination.) Initial tubular selection Size Grade Lbs/ft * Yield strength (psi) 135,000 105.000 -Burst (psi) Collapse (psi) Body strength (Klbs) 560,764 436,150 691,185
5 5 5HWDP
S G --
15,640 12,090 --
10,050 8,765 --
HWDP dimensions: 5 OD x 3 ID *Adjusted weights. Burst, collapse and body strengths given for premium pipe.
Drillstring design ABC oil companies require that drill strings have at least a quality of API inspection " Premium " grade for the drill string and depth of well required and that drill string are inspected to a minimum DS1 class 4 standard. Note : For a specification of the various API inspection classifications see API standard 7 : Rotary Drilling Equipment or the recently released DS-1 Drill stem Design and Inspection specification.
Notes :
1.) Von Mises triaxial equation, fatigue and jar placement considerations are not considered in design 2.) Due to the complexities involved vibrational analysis is not considered and accounted for in this brief. 3.) Corrosion and erosion are not loads, but they both reduce the strength of tubulars. Accounting for a measure of wall thickness (e.g. 80%) to account for anticipated erosion and corrosion is considered acceptable in this case. e.g. A long extended reach well where drillpipe wear may be severe. The fundamental approach to drill string design is to calculate the loads individually to determine if the strength of the drill string is exceeded by each individual load. Then combine all loads in the Von Mises general stress and fatigue endurance equations to ascertain if general or fatigue failure will occur. (see appendix2)
1.) calculate the lengths of various 5" 19.50 lbs/ft G105 and S135 drillstrings for drilling the hole. 2.) Using maximum lengths of all drillstrings , what is the maximum depth obtainable. 3.) Design the strings to account for slip crushing, safety factor for accelerating loads. Margin of over pull allowed = 120,000 lbs. Depth of along hole depths required = 12 section 9843ft (3000m.), 8 section 14,108ft (4300m) Use maximum lengths for G and S. Drill collars = 8" x 2.813" x 120m, 200m HWDP, 5 x 3 6 x 2.813 x 120m in 8 @ hole. Mud in use = 10.8ppg. From API section B3 page 3 = 5" 19.50 lbs/ft G = 553,833 lbs, minimum yield strength., S = 712,070 lbs a.) "G" pipe Maximum allowable static load ( for acceleration forces ) = 553,833 x 0.85 1.33 Similarly "G" = 353,953 lbs.
"S" =
455,082 lbs
b.) Margin of overpull, maximum allowable static load. "G" = (min Ys x 0.85)/1.33 - M.O.P = (553,833 x 0.85)/1.33 - 120,000 "G" = Similarly "S" = 233,953 lbs 335,082lbs.
c ) Slip crushing. ( Assume normally lubricated slips, coefficient of friction = 0.08 ) from table provided : 16 slips, friction factor K = 0.08
Maximum allowable static load = Min Ys x 0.85 1.42 "G" = 553,833 x 0.85 1.42 Similarly = 331,520 lbs.
"S" =
331,518 lbs.
6
203,953 lbs.
( From the M.O.P. calculations, i.e.lowest loadings) Maximum allowable depth of "G" pipe. = Max allowable static load Wdp * Kb ( Wdc x Ldc) + (Whwdp x Lhwdp) Wdp Wdp = 86,992lbs
BHA = (2.67 ( 8 - 2.813 ) x 120m + ( 2.67( 5 - 3 ) x 200m) x 3.281 x 0.83 Buoyancy factor ( Kb ) = 0.83 = 233,953 21.80 x 0.83 86,992 21.80 = 8939ft
Maximum length "G" and "S" = max all static load "S" - ( Wbha x Lbha ) + ( Wdp1 x Ldp1) Wdp2 x Kb Wdp2 335,082 22.50 x 0.83 ( 86,992 ) + ( 21.80 x 9839ft) 22.50 = Maximum depth G and S = 8939ft + 4544ft = 13,483ft 4544ft.
12 section 3000m (9843ft) & 8 section TD 4300m (14,108ft) a combination of G and S would be required. Maximum depth we can drill to with G & S pipe. =13,483t + 120m (drill collars) + 200m HWDP = 14,532ft (TD of well is 4300m (14,108ft.) For additional safety 6000ft of G will be run with the remainder S. Summary sheets and spreadsheet calculations have been based on these figures. A design spreadsheet was run (courtesy of Mitchell engineering) to ensure all design criteria are met. ( See Appendix 2.)
Stiffness ratios Drill collars to HWDP ( section modulus figures taken from DS-1.) Drill collars 8 x 2 13/16, HWDP 5 x 3 SR = Z below / Z above = 54.382 / 10.682 = 5.09 Drill collars 6 x 2 13/16, HWDP 5 x 3 SR = Z below / Z above = 20.181 / 10.682 = 1.89 HWDP to G drillpipe ( section modulus figures taken from DS-1.) HWDP 5 x 3, G pipe 5 x 4.276 SR = Z below / Z above = 10.682 / 5.708 = 1.87 Stiffness ratios are within acceptable ranges
Torsional check (* values from DS-1) Connection G NC-50 S NC-50 O.D. (in) 6 5/8 6 5/8 I.D. (in) 3 3 *Make up torque (ftlbs) 27,080 31,020 *Torsional strength (ftlbs) 45,130 51,700 Max operating torque (ftlbs) 25,000 25,000
Cum length
Air wt (lbs)
Drill collars
120m
120m
59K
HWDP
5 x 3 NC-50
200m
320m
35K
29K
78K
Drill pipe 1
19.50 G NC-50
2148m
131K
109K
187K
166K
Drill pipe 2
19.50 S NC-50
3000m
61K
51K
238K
217K
Pa = maximum allowable load for drillpipe from design calculation Drillstring summary for 8 section.
Cum length Air wt (lbs) Buoyed wt (lbs) 25K Cum buoyed wt (lbs) 25K Overpull (pa-Cum Bw) -
Drill collars
6 x 2 13/16 4 IF
120m
120m
30K
HWDP
5 x 3 NC-50
200m
320m
35K
29K
54K
Drill pipe 1
19.50 G NC-50
2148m
131K
109K
163K
190K
Drill pipe 2
19.50 S NC-50
4300m
159K
132K
295K
160K
Note: In reality as inclinations increase, less BHA components are required and more drillpipe can be used for WOB before buckling will occur. (see appendix 4) To permit drillstring to slide, HWDP may have to be placed in the build section, drags and buckling would have to be determined using a torque and drag simulator.
Derrick loading
Derrick loading worst case
1.) Worst case would be running heaviest casing string (95/8 casing 463K), getting stuck at section TD and applying maximum overpull i.e. 150,000lbs. 2.) Assuming all 5 drillpipe has been picked up to drill to TD Block weight + top drive and hoisting equipment = 80,000lbs. No account taken for other equipment and fixtures in derrick. E.g. Pipe handling system. Pipe in derrick 5 drillpipe required for well 1828m x 21.8 lbs/ft x 3.281 2152m x 22.50 x 3.281 120m BHA (Dcs + BHA) 21 joints of HWDP 1.) 120m x 99lbs/ft x 3.281 200m x 53.7lbs/ft x 3.281 Pipe weight in derrick 130,749lbs 158,866lbs 58,270lbs 35,238lbs 383,123lbs set back load.
Casing stuck Over pull applied Block and travelling eqpt. weight 2.) 1.) + 2.)
3000m x 47lbs/ft x 3.281 Design for 150,000lbs 80,000lbs Stuck casing load on derrick Worst case derrick loading
Blockline selection
1 3/8 Extra improved plough steel block line has a breaking strength of 192,000lbs. Safety factor on maximum fast line load (75,000lbs) from previous page. Sf = (192,000lbs / 75,000lbs)
Draworks requirements
The operator would like to trip with a minimum speed of 90ft/min at the highest loading conditions. Fast line speed = (n) x speed required ft/min = 12 lines x 90ft/min = 1080 ft/min. For a 60 drum ( 1.25ft radius = (r) ) Velocity of the fast line (Vf) = 2 x x r x N 1080 = 2 x 3.14 x 1.25 x N N = 138 revs /min. Horse power of the drum (HP) = ( Fl x 2 x x r x N ) / (33,0000) Where 33,000 = ftlbs / rev/min / per HP. HP = (75,000lbs x 2 x 3.14 x 1.25ft x 138revs/min) / (33,000) Horse power of drum = 2462 HP.
HP of draw works (assuming mechanical efficiency of 85%) = 2462 / 0.85 Horse power of draworks = 2896 Hp. A 3000hp draw works would therefore be most suited for the Daisy platform.
Appendix 3