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Deepwater Drilling Issues
Deepwater Drilling Issues
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INDEX
An anchored semi-submersible.
An anchored drillship.
A dynamically positioned semi-submersible.
A dynamically positioned drillship.
VESSEL SELECTION
As the water depth increases beyond 2,000 ft, the need to utilize a dynamically
positioned semi-submersible and ultimately a drillship increases.
It is recommended that the operator inspects the drilling vessel at the earliest
stage. If possible this should be performed before contracts have been
finalized and well planning has commenced.
This will allow the operator to recommend improvements to the drilling vessel,
which may allow an improved standard of service during drilling operations.
VESSEL SELECTION [ THRUSTERS ]
A dynamically positioned drilling vessel does not use the traditional anchoring
system, but utilizes a set of computer controlled thrusters that are linked to
sensors on the wellhead and a global positioning system that maintains the
drilling vessel’s position above the wellhead.
VESSEL SELECTION [ DRILLING ISSUES ]
It is important that key drilling persons are involved during the selection of the
drilling vessel.
The planning for drilling operations would require with checks for the
following:
The ability of the drilling vessel to remain on location, above the wellhead
with minimal lateral movement.
The ability of the subsea equipment operations in terms of deck space
areas, moonpool facilities, BOP stack configuration’s etc.
The motion of the drilling vessel (heave, roll etc.) and the resulting
operating parameters during all drilling operations.
The ability of the drilling vessel to remain above the wellhead during the
drilling test is particularly important.
Too much lateral movement will eventually result in a need to unlatch the
marine riser hence the drilling vessel that can remain above the wellhead
under severe weather conditions and /or current velocities will be the
preferred choice.
VESSEL SELECTION [ OPERATING ENVELOPE ]
No matter what systems however if they are not properly managed, the
consequence of time, cost, process and environmental loss can be significant
and must be prevented.
[ DP ] OPERATIONAL RULES OF THUMB
Hang-off operations for Dynamic positioning (DP) rigs/vessels and moored rigs
in deep water require more time than in shallower depths.
The lower set designed to cut and the upper set to provide a pressure seal.
Alternatively, the BOP stack may be a "five ram“ configuration.
The BOP stack’s design will vary from location to location, depending on the
drilling contractor and /or local guidelines – it is not possible to standardise the
BOP stack configuration.
MARINE RISER
In deeper water, the extra weight of the long riser requires inclusion of
buoyancy material to reduce load on the riser support and running equipment.
For these reasons, the extra weight and deck storage requirements of a
deepwater drilling riser must also be considered.
MARINE RISER
The running and pulling times for a riser and BOP installed in deep water is
also considerable.
Any routines, maintenance, checks or tests must be given high attention and
an alternative back-up function in case one should fail is highly recommended.
Pulling and running the stack for repair is expensive and investing in back-up
equipment is therefore an attractive alternative.
MARINE RISER
One of the major problems encountered on a deepwater well can be the marine
riser movement due to the local tides and currents.
In particular, the effect of variable currents on the marine riser and hence the
landing string should have been investigated.
If the marine riser has been designed correctly these types of movements will
be minimal or will not occur.
However, care should be taken as the acceptable limits for the drill string may
not be acceptable for the landing string where these movements can create
problems for the subsea equipment, clamps and the control umbilical inside
the marine riser.
RISER CONFIGURATION
Both syntactic foam and air can buoyancy systems have been used for
deepwater riser systems, either individually or in combination.
Thus for a required net lift, not only is more foam needed, but usually at higher
cost per unit weight.
Mounting floating modules (buoyancy) can reduce the extra loads generated by
a long riser.
However, forces from waves and current will increase as result of the increased
riser diameter.
Due to the slow annular speed of drilling fluid in a large bore riser, it is prudent
to have a dedicated riser boost line.
RISER FILL UP VALVE
These measurements should ideally include the lower flex joint angle. Due to
length of rise, it’s reaction in subsurface conditions, and the fact that a much
longer drillstring length may be continuously rotated in it.
Tools run inside the marine risers and subsea wellheads should be confirmed
that there are no reduced bore items inside the marine riser that may prevent
the subsea equipment from landing or passing inside or through the BOP stack
or welheads.
The presence of the water column above the shallow formations reduces the
equivalent fracture density. Lacking regional data, the fracture gradient for
shallow formations can only be approximated.
A small pilot hole, typically 9 7/8 – 12 ¼”, is drilled to a depth which is below
the planned setting depth of the surface casing.
Pump rate is held constant while drilling the pilot hole and pump and annular
pressure measurements are utilized as the primary indicator of well flow.
If changes in pump pressures are observed while drilling the pilot hole, drilling
is ceased and the ROV camera or drilling measurement tools will be used to
determine If well flow is detected. If flow is observed, dynamic well killing
operations are then immediately initiated by pumping kill mud at a pre-
determined modeled kill rate with the rig pumps until the well is killed.
PILOT HOLES IN DEEPWATER
If no well flow occurs after reaching total depth of the pilot hole, the hole is
displaced with mud before pulling out with the drilling assembly.
Once it has been determined that the well can be safely drilled without the
riser, the well is drilled riser less to the setting depth of the surface casing
string(s).
PILOT HOLES IN DEEPWATER
The two basic reasons for sacrificial riser-less pilot holes in deepwater
operations are:
If a gas or shallow water flow does occur while drilling in deep water, flow is
deflected down current and will safely surface away from the rig.
DEEP WATER PILOT HOLE [ CONCERNS ]
Drilling a pilot hole for shallow hazards must allow for the additional
associated hazards:
swabbing
higher risk of mud losses due to higher ECD
faster hole unloading
hole stability
By no means should one believe that the pilot holes therefore guarantees blow
out free drilling.
The pilot hole might be considered for evaluating the hole section until the
next casing shoe, to improve the ability of successful dynamic killing of the
well in the event of a flow.
DEEP WATER PILOT HOLE [ CONCERNS ]
The dynamic kill is however questioned to be effective for many reasons [1]:
Studies and experiences confirm that standard pilot hole sizes do not
allow a significant frictional component while pumping at rates obtainable
with rig equipment.
The length of the borehole is too short to obtain significant friction
pressure.
Should the hole size be drilled in soft sediments they will quickly erode to
larger diameters.
Shallow gas zones are very prolific with near infinite deliverability
DEEP WATER PILOT HOLE [ CONCERNS ]
The dynamic kill is however questioned to be effective for many reasons [2]:
The rig pumping capability may not cope with the pumping power
requirements to attain a dynamic kill.
Additionally most field examples report fast expulsion by gas from the
wellbore in a matter of seconds.
Dynamic killing of a shallow gas blow out might succeed as long as the
well has not yet unloaded and flow is controllable: However the response
time, based on field experiences, is short, and does not permit sufficient
time in most cases to recognise the situation, and initiate the kill
operation in an orderly manner before the flow becomes uncontrollable.
Few rigs if any have remote controlled valve capability from drilling fluid
to kill mud.
An alternative option is to pump the heaviest mud (that formations can handle)
at high rates. Field experiences have shown that this has worked, provided
that pumping starts within second after the flow has been detected and prior
to wellbore unloading.
DESCRIPTION
Also where deepwater mud-line is soft and unconsolidated, jetting benefits vs.
conventional drilling and cementing pipe, can result, especially if there is a risk
of hole collapse.
In that, the length of the foundation pile should be long enough to provide
sufficient skin friction between the pipe and the formation for support of the
BOP and subsequent casing strings.
DESCRIPTION
Another consideration is that jetting ROP will slow down and eventually stop.
The foundation pile should thus not also be designed too long or operational
loss will result.
A pilot hole to 200 to 300 ft. below the mudline. Based on information gained, it
would be determined how many joints of foundation pile to be jetted. If the
sediments below the seafloor was too hard, to inhibit jetting, conventional
drilling and cementing would be used.
A mud mat may also be utilized to provide additional support once a pile had
been jetted to its required depth.
Jetting bit position in relation to the foundation pile shoe is critical and its
exact positioning is very formation dependent in order to optimize .
DESCRIPTION
The deployment of casing and sub sea equipment during all open water work
can be inhibited by the maximum sea-states and surrounding conditions. This
varies considerably from region to region.
Working limits and operating windows therefore have to be defined for drilling,
especially open water operations.
DESCRIPTION
In this case the BOP must be closed prior to removing the riser and on re-
connection it must be circulated to the same gradient of drilling fluid prior to
opening up the well.
With the possibility of gas being trapped below the BOP the well should be
monitored on either the kill or choke line before opening the BOP.
DESCRIPTION
Combined with the riser volume and surface system, the active volumes
required are much larger circulating systems at comparable depths in other
drilling conditions.
In addition, large diameter holes are drilled to accommodate the many casing
strings needed to achieve a given total depth.
Mud velocity alone can adequately clean any practical size annuli. However,
due to the open-hole, casing and riser diameters needed for deep water drilling,
providing the required circulating rate to clean all the annuli by fluid velocity
alone is not practical.
This requires adequate mud pumping capability. In that, three or even four
large (2,200HP) mud pumps are now standard requirements to clean the
wellbore and the 21” marine riser.
Cementing in deep water can be different from normal conditions in the top
hole sections.
The fracture gradient may be considerably lower than normal. This can be valid
from seabed and include the whole interval with normal hydrostatic pore
pressure.
These conditions may limit the maximum densities of cement slurries, which in
turn may lead to slow strength development and a delay in operations.
Slurry selection may require use of special extenders and even special cement.
Consideration should be given to using gas tight slurries in top hole sections
where in-situ hydrates may exist. The exothermic reaction of the slurry as it
sets may melt any hydrates and release gas into the cement column.
Finally, in deep water the seabed temperature may be as low as –2°C (Voring
Plateau, Norwegian Sea) and hydrostatic pressure at high as 5000psi. This will
again affect cement slurry design and strengthening characteristics.
DURING ANCHOR HANDLING [ OPEN WATER WORK ]
Longer handling times are experienced when the rig does not carry all chain
and anchor wire.
Concurrent operations in the derrick while running and pulling anchors can
therefore result in a considerable time/cost saving.
Additional rig crew members are required, either by working overtime for the
rig crews already on board or mobilize additional crewmembers during anchor
handling.
Shut in procedures must minimize inflow from the formation and prevent gas
entry above the BOP’s.
Additionally the Driller must quickly determine space out of the drillstring for
closing rams.
SHUT IN PROCEDURES
There are certain benefits with the ‘driller’s’ method that are appropriate to
deep water wells:
In deepwater pressure losses in these lines are relatively high even at low
circulation rates.
In some instances the margin to circulate out the kick becomes so low that it
may be impossible to kill the well by conventional methods without exceeding
the MAASP.
BULLHEADING INFLUX
It is common practice to bullhead the influx back into the formation as soon as
the well has been closed in.
After the influx has been squeezed back into the formation the well can be
killed with LCM treated kill mud.
CIRCULATING PRESSURES
Slow pump rate tests must be carried out. It is therefore important to pre-
determine the system pressure loss with the components used during killing
operations.
down the drill pipe and up the marine riser - BOP open.
down the drill pipe and up the kill and choke lines both separately and
together - BOP closed.
The pressure losses can be established by comparing the pump pressures with
the BOP open and closed.
In a well control situation with long choke lines, the MAASP is reduced by the
amount of the choke line pressure drop while pumping.
If no allowance is made then the formations below the shoe will be over
pressured by this additional back pressure which could induce mud losses.
Once the well has been closed in, displace the choke & kill lines to the
current drilling fluid.
When commencing the kill operation reduce the choke pressure by the
choke line frictional loss with current mud weight. Use kill line as pressure
monitor.
BOP STACK AND CONTROL SYSTEM
The selection of BOP stack and control system is mainly governed by two
factors:
The BOP may ideally be fitted with intervention stabs to operate any or all of
the following functions from the ROV:
A key issues for a deepwater BOP is response time and hence the BOP will
likely be electronically controlled, with a large capacity of sub sea
accumulators.
The response time is defined as the time required from initiating a command on
the operation panel(s) to the time when the function is completely executed on
the BOP stack. The maximum allowable response time for closing any annular
preventer or ram is 45 sec.
BOP / WELLHEAD CONNECTOR
Install a hydrate lip seal that seals around 18¾” Wellhead housing.
Install flush ports in the top of the H-4 connector as per wellhead
manufacturer and flush the connector cavity above the cam ring on a
regular basis with a few barrels of glycol
DEEPWATER WELLHEAD MODIFICATIONS
In deepwater areas "shallow water flows" have been encountered from over-
pressured water reservoirs, at relatively shallow depths as deep as +/- 2500 ft
below the seabed.
Furthermore, when these reservoirs are penetrated the soil strength around the
casing can be compromised which can cause additional problems as:
Buckling of casing
BOP sinking below mud line and ultimately
Loss of well
DESCRIPTION
In deepwater areas "shallow water flows" have been encountered from over-
pressured water reservoirs, at relatively shallow depths as deep as +/- 2500 ft
below the seabed.
Furthermore, when these reservoirs are penetrated the soil strength around
the casing can be compromised which can cause additional problems as:
Buckling of casing
BOP sinking below mud line and ultimately
Loss of well
DESCRIPTION
Evidence of gas from gas chimneys and “bumps” can be seen, however above
a number of fault blocks however in deepwater regions, where shallow high
amplitude reflections and pull down effects can be seen over the crest of the
fault blocks.
To enable monitoring of the riser fluid level in the event of total losses, and to
determine if the bottom hole pressure has dropped sufficiently to allow gas
into the wellbore, the following procedure can be followed:
Plugging of choke and kill lines preventing their use in well circulation;
Formation of a plug at or below the BOPs, that prevents monitoring well
pressures below the BOPs.
Formation of a plug around the drillstring in the riser, BOP's or casing that
will restrict drillstring movement.
Formation of a plug between the drillstring and the BOPs to prevents
closure.
Formation of a plug in the ram cavity of a closed BOP preventing full
opening.
PREVENT THE FORMATION OF HYDRATES AT THE WELLHEAD/BOP.
A secondary means is achieved by having the kill line full of a glycol/mud mix,
that would be circulated into the BOP’s and wellhead to prevent hydrates
forming.
This is done by circulating methanol down the kill line and up the choke line,
first through the lower choke valve on the BOP.
The methanol should be given time to “soak” and dissolve the hydrates. Some
patience expended can save the need to round-trip the BOP/LMRP.
Once the hydrates have been dissolved, the gas may be either bullheaded back
to the formation via the drillstring and annulus or circulated out.
DESCRIPTION
In deepwater by the time the gas has reached the BOP’s very little expansion
takes place, If undetected and then allowed to enter the riser undetected it may
not be possible to contain and control expansion where a dangerous gas
breakout situation and/or unloading of the riser can develop when the gas
reaches the surface.
Every effort and precaution, through good pit management, must be taken to
detect and prevent any the influx entering the marine riser where it can
percolate up and expand in an uncontrolled manner.
DESCRIPTION
In the instance when a rapid increase in pit level is observed (gas expansion in
the riser) drilling will cease immediately and the following procedure adopted: