Institute of Petroleum Studies by 2013 o PDF
Institute of Petroleum Studies by 2013 o PDF
Institute of Petroleum Studies by 2013 o PDF
OPERATIONAL
DRILLING AND
COMPLETION
PROGRAMME FOR COD
S-E FIELD
BY
2013
EXECUTIVE SUMMARY
The report contains an elaborate and detailed design and specifications for a
vertical well which aims to produce 1,200,000 STm3 of gas per day in the COD
S-E field in the North Sea, Norway. The water depth is 72meters and the rig
proposed and eventually selected as adequate for the purpose is the Maersk
Gallant Jackup Rig.
The phases designed are a jetted 30” Conductor pipe at 160m MSL, 20”
Surface Casing at 800m MSL, 13 3/8” Intermediate Casing at 1400m MSL, 9
5/8” Intermediate Casing at 2500m MSL and a 7” Production Casing at 3355m
MSL. For each of these phases, the Drillstring design, Casing design, Drilling
Fluid design, Cementing Programme, Cement Design, Logging Programme,
Coring Programme, Well Control and Safety procedure, Equipment Design &
Selection and Rig Power required are all outlined.
Page | 2
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
ACKNOWLEDGEMENT
The group will like to thank Monsieur Francis Fusier (IFP) for his incredible
patience when dealing with our numerous questions and suggestions, and for
his wonderful class on Well Completions.
We would also love to send our appreciation to Monsieur Didier Brigant (IFP),
who educated us thoroughly on Drillstring Design, Casing Design, Rig
Equipment and other pertinent topics.
Page | 3
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
TABLE OF CONTENTS
ACKNOWLEDGEMENT .................................................................................................................. 3
LIST OF FIGURES......................................................................................................................... 10
Page | 4
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 5
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 6
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
8 APPENDIX ............................................................................................................................ 76
Page | 7
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
LIST OF TABLES
Table 2-3: Leak off Test Result .............................................................................................................. 17
Table 4-2: Casing Selection: .................................................................................................................. 21
Table 4-3: Casing Selection ................................................................................................................... 23
Table 4-4 : Casing Properties ................................................................................................................ 24
Table 4-5: Casing properties ................................................................................................................. 25
Table 5-1String configuration ............................................................................................................... 26
Table 5-2: Drill string summary ............................................................................................................. 27
Table 5-3:Drillstring Tension Study ....................................................................................................... 27
Table 5-5: Drilling parameters .............................................................................................................. 29
Table 5-6: Phase II Drilling fluid (WBM) Properties .............................................................................. 29
Table 5-7: Surface Zone Mud Volume Calculation................................................................................ 29
Table 5-8: Surface phase Mud Composition ......................................................................................... 30
Table 5-9: Drill String summary ............................................................................................................ 32
Table 5-10: Drill String Tension Study ................................................................................................... 33
Table 5-11: Bit Selection ....................................................................................................................... 33
Table 5-12: Summary of drilling parameters ........................................................................................ 34
Table 5-13: Pressure Losses ................................................................................................................. 34
Table 5-14: 17"1/2 Drilling Fluid (WBM) Properties ............................................................................. 35
Table 5-15: Total Circulation Volume ................................................................................................... 36
Table 5-16: Mud Composition .............................................................................................................. 36
Table 5-17: Casing Requirements ......................................................................................................... 40
Table 5-18: Cement Volume Calculation .............................................................................................. 41
Table 5-19: Power Requirements ......................................................................................................... 42
Table 5-20: Drill String Summary .......................................................................................................... 43
Table 5-21: Drill string Tension Study ................................................................................................ 44
Table 5-22: Bit Selection ....................................................................................................................... 44
Table 5-23: Phase IV Drilling Parameters .............................................................................................. 45
Table 5-24: Phase IV Pressure Losses ................................................................................................... 46
Table 5-25: Summary of Power Requirements ..................................................................................... 46
Table 5-26: Drilling Fluid (WBM) Properties ......................................................................................... 47
Table 5-27: Total Circulation volume .................................................................................................... 47
Table 5-28: Phase IV Mud Composition ................................................................................................ 48
Table 5-29: Casing String....................................................................................................................... 50
Table 5-30: Cement volume Calculation ............................................................................................... 50
Table 5-31: Cement Composition: ........................................................................................................ 51
Table 5-32: Drilling summary ................................................................................................................ 52
Table 5-33: Coring summary ................................................................................................................. 53
Table 5-34: Bit selection........................................................................................................................ 53
Table 5-35: Drilling Parameters ............................................................................................................ 53
Table 5-36: Table 5-37: Summary of Power Requirements. ................................................................. 53
Table 5-38: Summary Of The Mud Properties ..................................................................................... 54
Table 5-39: Drill String and Hole Volume Calculations ........................................................................ 54
Table 5-40: Mud Composition .............................................................................................................. 55
Page | 8
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 9
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
LIST OF FIGURES
Figure 2-1:Well Stratigraphy ................................................................................................................. 14
Figure 2-2: Pressure Prognosis.............................................................................................................. 15
Figure 4-1: Well Architecture: Casing Sizes and Casing Shoe Depths ................................................... 19
Figure 5-4: Bit Selection ........................................................................................................................ 28
Figure 6-1: A sketch of the completion string ...................................................................................... 61
Figure 6-4: A Cameron Christmas Tree. ................................................................................................ 68
Figure 6-5: Completion Diagram ........................................................................................................... 71
Figure 8-7: Schematic of the Drill string. Depths are given in MSL. Recall MSL + 55m = RKB .............. 93
Figure 8-11a: Hoisting & Drawworks system ........................................................................................ 95
Figure 8-11b: Top Drive and Kelly Bushing system ............................................................................... 95
Page | 10
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 11
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
2.2 Objectives
The appraisal wells drilled to analyse the COD S-E Field and determine the
Reservoir extent
Two DST were performed and DST 2 flowed at a rate of 1.500 000 Sm3/d of gas associated with 153
Sm3/d of condensate through a 40/64" choke. The reservoir pressure is 376 bars at 2 912 m MSL,
giving a gradient of 1.30 EMW. This gradient is considered constant on all the structure.
The reservoir consists of thin sand bodies (1 to 3 m) inter-bedded with thin shale stringers (0,5 to 1
m). Some of the reservoir layers are stacked and constitute more massive sandy units (up to 12 m).
Electrical logging shows that the so-called "thin beds" effect is influencing the reading of the tools,
particularly for the resistivity measurement. Those sands are fine to medium grained, and well
sorted. Core descriptions and electrical log patterns, where typical fining upward Bouma sequences
can be seen, clearly indicate that the reservoir bodies have been deposited as distal lobes of a
turbiditic system. The petrophysical characteristics show relatively low average porosity (16 %) and
permeability (20 to 30 mD) associated with a 50 % net/gross. Both N/G and porosity are in the range
of what is usually found in very distal turbidites. This is consistent with the location of the well close
to the pinch-out area where the reservoir starts.
The well COD S-E 1A is a vertical well to produce gas from the forties formation. It should be
optimized to produce 1,200,000 stm3/D of gas. The Basic PVT parameters obtained include, Gas
Gravity: 0.74, Reservoir temperature: 98 degC, Estimated top of reservoir: 3080 m MSL , Estimated
reservoir thickness: 115 m (Gross)
From the results of the site survey performed by Britsurvey, shallow gas accumulations have not
been interpreted from the seismic data at the proposed location. However high concentrations of
background gas may be present in the uppermost 1 000 – 1 200 m sediments. The sand units in the
section between 600 and 800 m MSL may form potential layers for this gas. Caution must therefore
be shown while drilling the uppermost section of the well to the setting depth of the 13"3/8 at
approximately 1 200 / 1 400 m RKB.
Page | 12
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Coarser material coarse sand-grave may be expected at the base of the Intra Pleistocene channel at
approximately 533 m RKB.
Expected undercompacted shale section between approximately 1 410 m and 2 410 m. The
expected pressure gradient range will be 1.45 – 1.6 g/cc EMW.
High gas readings can be expected when entering the Fortie Formation. Reservoir. However,
problems related to gain / losses are not expected at this point. A maximum pressure gradient of
1.31 g/cc EMW is expected at the top of the reservoir.
H2S have not been encountered during exploration and appraisal. C02 level is expected to be very
low (Less than 0.2% vol).
Page | 13
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 14
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Pressure bars
0 100 200 300 400 500 600
0
500
LOT
1000
1500
Depth MSL
2000
2500
3000
3500
4000
Page | 15
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The proposed lithology is based on data from wells in the surrounding area.
The lithological prognosis for the shallow part of the wells will be adjusted / corrected in accordance
with the results of the site survey.
The prognosis is based on results from the discovery well 10/30-6. The prognosed gradients are
quoted in SG units of EMW. Reference level is Mean Sea Level.
Soft silty clay overlain by thin sand layer of less than 1 meter; Fine sand interbedded with stiff to firm
clay; Stiff clay; Consolidated stiff clay with minor sand layers. Possible coarser material at the base of
the unit (base of channel); Hard sandy clay with layers of sand and silt; Sandy clay with interbeds of
sand; Claystone with minor sand interbeds;Clay, silty-sandy; Claystone, greenish, slightly silty, thin
stringers of limestones, traces of pyrite.
From seabed down to approximately 1420 m normal pressure conditions are expected. The lower
part of Nordland Group, from approx. 1420 – 1615 m is most likely representing the upper part of an
approximately 1 000 m thick undercompacted zone. The pressure gradient at base Nordland is
prognosed to be 1.40 g.cc EMW.
The undercompacted zone, starting at approximately 1 466 m in Nordland Group, extends down to
about 2424 m. Maximum of undercompaction is expected between 1760 and 1860 m. In this
interval, the pressure gradient is prognosed to be in the range 1.50 – 1.55 g/cc EMW (maximum
pressure gradient: 1.60 g/cc EMW, minimum pressure gradient: 1.45 g/cc EMW).
From 1860 m down to base Hordaland, the pressure gradient should gradually drop to 1.30 – 1.35
g/cc EMW.
Balder Formation. Claystone, varicoloured, dominantly medium – dark grey greenish and brownish,
silty, traces of tuff; Sele Formation. Claystone, grey - greenish grey, stringers of limestone, traces of
sandstone; Forties Formation. Sandstone, light grey – light brown, very fine-fine, subangular, well
sorted, thin beds/stringers of shale, light grey, silty, sandy traces of lignite; Lista Formation.
Claystone, grey – becoming green - greenish grey, occasionally brick red, stringers of sandstone; Vâle
Formation. Interbedded limestone, muddy, chalky, locally silty, claystone, grey, very calcareous and
marl grey.
Maximum pressure gradient at the top of the Forties reservoir should be 1.30 g/cc EMW (1.33 g/cc
EMW subsea), assuming a water gradient through the reservoir. Minimum pressure gradient at top
reservoir should be 1.30 g/cc EMW (1.31 g/cc EMW subsea) assuming the same gas-condensate
gradient as in well 10/30-6; 0.038 bar/m.
At base Rogaland Group, the pressure gradient is expected to be in the range 1.29 –
1.32 g/cc EMW.
Page | 16
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Pressure gradient is expected to be same as for base of Rogaland Group: 1.29 – 1.30 g/cc EM
Page | 17
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
3.5 H2S
H2S have not been encountered during exploration and appraisal. C02 level is expected to be very
low (Less than 0.2% vol).
Page | 18
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Using the pressure profile and the stratigraphic prognosis of the formation and taking into account
the size of tubing required to achieve the target production rate, starting from bottom to top, the
proposed well architecture (casing shoe depth) is shown in the diagram below:
Figure 4-1: Well Architecture: Casing Sizes and Casing Shoe Depths
Page | 19
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Surface casing shall be set before entering the first shallow hydrocarbon structure which requires a
blow-out-preventer (BOP); in such case, surface casing shall be designed like a technical casing.
Rule 2: With the exception of deep water wells, the casing point on intermediate casings shall be
designed for the following assumptions:
On exploration/appraisal wells as fluid, pressures, and formation weak points are not well
known.
on development gas wells which can be temporarily abandoned with possible alteration of
hydraulic barrier ( for example, subsea wells or wells drilled from jack-up of platform rigs
with possible crew evacuation due to hurricanes): over time, fluid could replace mud in the
hole leading to a cross flow situation.
On shallow development gas wells: open hole volumes are small and no more compatible
with standard admissible kick volume.
Limited kick
On all development wells except those mentioned above
Rule 3: Minimum limited lick to be considered for casing design shall be 10m 3 on fixed intallations
and 15 m3 on floating rigs; these minimum values should be increased in the event of downgraded
conditions or in sensitive areas.
Rule 4: With respect to the above, the burst and collapse design factor is set at 1.2 while the tension
safety factor is set at 1.6.
Rule 5:The collapse design factor is set at 1.2.
Rule 6: The tension safety factor is set at 1.6.
Calculations and selection for this casing were not done because this casing was placed by Civil
works.
Fracture Pressure at casing shoe,Pe= 134 bar (based on leak off test)
Page | 20
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Pi - Pe =121.6-110=11.6bar=1.16MPa
Page | 21
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
For this collapse study a mud loss to low pressure zone (EMD = 1.0) at the end of the next phase
is considered.
Collapse = 64 – 0
= 64bar = 6.4 MPa
Pi = PP – HP gas + Bullhead
Pi = 366.69bar
Pe @ Surface = 0 bar
Burst = 366.69 – 0
= 366.69 bar = 36.669 MPa
Page | 22
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
For this collapse study a mud loss to low pressure zone (EMD = 1.0) at the end of the next phase is
considered.
Collapse = 110 – 0
= 110bar = 11 MPa
Page | 23
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Pi = PP – HP gas + Bullhead
Pi = 366.69bar
Pe @ Surface = 0 bar
Burst = 366.69 – 0
= 366.69 bar = 36.669 MPa
ΔP = Pe - Pi
ΔP = 430 – 0
= 430 Bar
PC = 43 MPa
All safety factors exceed the minimum acceptable values. The tensile safety factor is calculated using
a buoyancy factor of 0.821, particular to the mud weight of 1.41 SG used for this phase.
Since this is a gas well, a tight sealing is preferred for the connections. We have then selected a VAM
Top coupling with 1566dan.M make-up torque and a drift of 153.9mm. The efficiency of this
coupling is 102% meaning that it can withstand a bit more tensile stress than the casing string and
thus a 3.54 safety factor in tension.
Page | 25
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
5.2.3 Barriers
Inside: Float valve, Drilling mud
Annulus: Drilling mud and Diverter
BOP not needed.
Page | 26
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
For soft formation, Weight on Bit (WOB) is one ton per inch of bit.
100 % of the drill collar weight will be used to apply weight on bit
Bit - 1 26 26 - - -
Bit Sub - 1 - - - - -
Float Valve - 1 - - - - -
Stabilizer - 3 - - - - -
Jar - 1 - - - - -
DC - 14 9½ 9½ 3 124.30 124.3
Linear Weight Length Buoyancy Total Weight (kg) Total Weight (T)
(Kg/m) (m) Factor
Drill Collar 323.18 99 0.809 25883.8 25.9
HWDP 73.4 99 0.809 5878.7 5.9
Drill Pipe 42.08 602 0.809 20493.7 20.5
Page | 27
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
MARGIN OF OVERPULL
Weight of Drill String in mud = (DC weight + HWDP weight + DP weight) * buoyancy factor
Safety factor,FS=0.9
Maximum tension on DP
Page | 28
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
WOB (tons) 26
RPM 150
Inclination will be maintained below 1 degree up to 800m. This will be done by carrying out survey
every single stand until magnetic interference is not negligible after which MWD survey every stand
drilled.
Plastic Viscosity, cp 15 15 12
Solids Content, %
pH 8 8 8
Page | 29
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Annular Volume
Allowance for mud losses e.g resulting from swabbing, etc = 20%
5.2.9 Logging
No logging will be performed on this interval during drilling. But CBL or CET will be run to check
cement integrity.
Page | 30
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Casing String
Page | 31
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
5.3.3 Barriers
Drilling mud
Cameron 15,000psi 18 3/4" Bop stack
Hydril 10,000 psi 18 3/4" Annular BOP
I-Bop
Float Valve
Gray Valve and DICV on RF
For soft formation, Weight on Bit (WOB) is one ton per inch of bit.
Only 80% of the drill collar weight will be used to apply weight on bit
Page | 32
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Q = 3500 l/m
Page | 33
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
TFA
=5 days
FLOWRATE (Q)
Considering the hole size (17.5’’), moderate flow rate is required to ensure proper hole cleaning.
Page | 34
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 35
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 36
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Since the maximum speed of each pump is 120 strokes/ min, then I need 2 pumps of similar
capacity.
From the rig option of the Maersk Gallant, two out of the 3 Continental Emsco pumps (each rated
2200hp and 7500psi) available on the rig are sufficient for pumping this phase.
PUMP NO 1 PUMP NO 2
DISPLACEMENT DISPLACEMENT
lit/strok
15 lit/stroke 15 e
Page | 37
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
11481.1
DRILL STRING VOLUME (D) 8 (E) 765.41 25.51
DC 1 * OPEN HOLE 18.2 133.8 2435.16
DC 2 * OPEN HOLE 80.2 109.4 8773.88
13934.5
HW * OPEN HOLE 98.2 141.9 8
43336.2
DP * OPEN HOLE 305.4 141.9 6
68479.8
OPEN HOLE VOLUME (F) 8 4565.33 152.18
133520.
DP * CASING (G) 800 166.9 00
201999. 14666.6
TOTAL ANNULUS VOLUME ( F+G) = (H) 88 6 448.89
213481. 14232.0
TOTAL VOLUME OF WELL (D + H) = (I) 06 7 474.40
53370.2
ACTIVE SURFACE VOLUME (J) 5
266851.
TOTAL ACTIVE FLUID SYSTEM (I + J) 31
SIDPP 35 Bar
SICP 51 Bar
350
PIT GAIN 0 Lit
Page | 38
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
KMW 1.81
KMG 0.177
ICP (bar) 70
0 70
765.41 40.76
Page | 39
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
With cement with specific gravity of 1.9 and mud weight of 1.55, the height required to give 190 bar
68.3
Slurry Yield = 1.9 1 = 75.8 liter slurry/ 100kg
SPACER VOLUME
Page | 40
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Hole Size = 17 ½”
Volume = 10 000litres
Cement Volume = 54 m3
With cement with specific gravity of 1.9 and mud weight 3076 kg
of 1.55, the height required to give 190 bar
1025 kg
Page | 41
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Class G cementrecommended
Procedure
Cement Composition: Class G cement, Antifoam, retarder, Dispersant. Proportion will be adjusted by
the cementing company.
POWER REQUIREMENT
Pumping Power 2677 hP
Hoisting Power 1544 hP
Rotational Power 1905.7 hP
From the rig option of the Maersk Gallant, two out of the 3 Continental Emsco pumps (each rated
2200hp and 7500psi) available on the rig are sufficient for pumping this phase.
Page | 42
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
5.4.3 Barriers
Drilling Mud
Cameron 15,000psi 18 ¾” BOP stack
Hydril 10,000psi 18 ¾” Annular BOP
I-BOP
Float Valve (especially for the cementing operation)
Gray valve and DICV (drop-in check valve) on rig floor
For soft formation, Weight on Bit (WOB) is one ton per inch of bit.
Only 80% of the drill collar weight will be used to apply weight on bit
Page | 43
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 44
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Vb = 120 m/s
TFA = 0.4049
This is within the range (2-5hp/sq.in) of sufficient hole cleaning without wearing the bit prematurely.
FLOWRATE (Q)
Considering the hole size (12.25’’), moderate flow rate is required to ensure proper hole
cleaning.
Page | 45
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Viscosity = 24.5cp,
Density = 1.63
1.63 * 10785.02
POWER REQUIREMENT
Pumping Power 1403.64 hP
Hoisting Power 1433 hP
Rotational Power 1042 hP
From the rig option of the Maersk Gallant, one out of the 3 Continental Emsco pumps (each rated
2200hp and 7500psi) available on the rig are sufficient for pumping this phase.
Page | 46
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 47
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 48
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
- Run pumps at pre-defined slow circulation rate (SCR). Pressure losses at this rate are
pre-recorded and known.
- Circulate kill mud at SCR and check the gauge to ensure that the Initial circulating
pressure (ICP) is not exceeded.
ICP = Dynamic Pressure Losses + SIDPP
- After a known number of strokes of the pump, the pressure at the gauge will reduce to
the final circulating pressure (FCP) when the kill mud has got to the bottom of the drill
string.
FCP = (Dynamic Pressure Losses * K.M.W/1.41)
- Based on the straight line between ICP and FCP on a graph of Dynamic drill pipe
pressure DPP (from the gauge) against strokes of the pump (read from the pump stroke
counter), the corresponding DPP per stroke is known. Tabulate values of stroke and
corresponding drill pipe pressures. If the read value is higher than the calculated value,
the choke should be opened (pressure relieved). For a lower read value, choke should be
closed.
- For instance, assuming a liner configuration that yields 16litres/stroke, then to fill up
the drill string of 27904litres capacity with kill mud will take 1744 strokes and 58
minutes at this slow circulating rate. From the ICP reading at the gauge till the FCP, there
should be 1744 strokes.
All of this data will be captured in a kill sheet.
Safety Barriers
Barriers required are:
Drilling Mud
Cameron 15,000psi 18 ¾” BOP stack
Hydril 10,000psi 18 ¾” Annular BOP
I-BOP
Float Valve (especially for the cementing operation)
Gray valve and DICV (drop-in check valve) on rig floor
5.4.10 Logging
There will be no coring and logging operation in this hole section duriing drilling. CBT or CET
log is to be run after cememting to check the cementing integrity.
Page | 49
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Casing String
Page | 50
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
CEMENT SLURRY
Density 1.95
Yield 30.59 litres/sx
Volume 39226.5 litres
Composition Specific Gravity Quantity Volume
(litres)
Class G Cement 3.15 489 sx -
Sea Water (40.1 1.03 - 37304
ltr/100kg)
Bentonite 2.60 --- -
(20% BWOC)
SPACER (Mud Push)
Volume 563.3 litres
Density 1.4
Viscosity 30cp
Procedure
After running the 9"5/8 casing:
Mud circulation and conditioning for proper hole cleaning
Pressure test cementing and pumping lines
Pump spacer 0.6 m3 at 1000l/min
Drop Bottom plug
Pump 37.3 m3cement slurry
Drop top plug
Pump displacement fluid (completion fluid) not more than 1.2SG.
Bleed off and check returns
Run Cement Logs tests: CBL and VDL to confirm cement integrity and proper isolation
Cement composition: Class G cement, Antifoam, retarder. The proportions are to be adjusted
by the cementing servicing company.
Page | 51
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
5.5.3 Barriers
Drilling Mud
Cameron 15,000psi 18 ¾” BOP stack
Hydril 10,000psi 18 ¾” Annular BOP
I-BOP
Float Valve (especially for the cementing operation)
Gray valve and DICV (drop-in check valve) on rig floor
For soft formation, Weight on Bit (WOB) is one ton per inch of bit.
Only 80% of the drill collar weight will be used to apply weight on bit
Page | 52
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Stabilizer - 3 8¾ 8¾ 6¾ - -
DC - 27 6¾ 6¾ 2¼ 251 251
Jar 1 - - - 9.3 260
HWDP 26 6.5 5 3 238 498
DP IEU S135 324 6.626 5 4.276 2912 3410
MWD 1 6 6 - - -
Measurement While Drilling (MWD) tools will also be assembled to the BHA with K-monel alloy
based drill collars used. These drill collars will still provide the WOB required and will ensure no
metallic interference with the MWD measurement readings. The 3 bottommost drill collars will
make up the MWD unit.
WOB (T) 26
RPM 100
FLOW RATE (l/m) 1020
SPP (Bars) 224
POWER REQUIREMENT
Pumping Power 583 hP
Hoisting Power 3000 hP
Page | 53
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
From the rig option of the Maersk Gallant, one out of the 3 Continental Emsco pumps (each rated
2200hp and 7500psi) available on the rig is sufficient for pumping this phase.
The mud volume was estimated from drill string, annular capacities and estimated losses. The
summary is shown in the table below.
Total 108566.38
+1% Surface Circuit, +9% Hole Irregularities 119423
Page | 54
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Laboratory quality checks will be carried out on mud samples to ensure conformance of mixture to
specifications. Extra additives will be added where necessary.
Page | 55
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Run pumps at pre-defined slow circulation rate (SCR). Pressure losses at this rate are pre-
recorded and known.
Circulate kill mud at SCR and check the gauge to ensure that the Initial circulating pressure
(ICP) is not exceeded.
ICP = Dynamic Pressure Losses + SIDPP
After a known number of strokes of the pump, the pressure at the gauge will reduce to the
final circulating pressure (FCP) when the kill mud has got to the bottom of the drill string.
FCP = (Dynamic Pressure Losses * K.M.W/1.41)
Based on the straight line between ICP and FCP on a graph of Dynamic drill pipe pressure
DPP (from the gauge) against strokes of the pump (read from the pump stroke counter), the
corresponding DPP per stroke is known. Tabulate values of stroke and corresponding drill
pipe pressures. If the read value is higher than the calculated value, the choke should be
opened (pressure relieved). For a lower read value, choke should be closed.
For instance, assuming a liner configuration that yields 16litres/stroke, then to fill up the drill
string of 27904litres capacity with kill mud will take 1744 strokes and 58 minutes at this slow
circulating rate. From the ICP reading at the gauge till the FCP, there should be 1744 strokes.
All of this data will be captured in a kill sheet.
Safety Barriers
Barriers required are:
Drilling Mud
Cameron 15,000psi 18 ¾” BOP stack
Hydril 10,000psi 18 ¾” Annular BOP
I-BOP
Float Valve (especially for the cementing operation)
Gray valve and DICV (drop-in check valve) on rig floor
5.5.10 Logging
The work done in coring from 2500m to 3355m MSL in stages of 90m (standard core length) was
estimated as 415000daN.km from the relationship shown below
Tc12 2Tm1 Tm 2
where Tm1 is work done during a round trip at 3355m MSL and Tm2 is work done during a round
trip at 2500m MSL.
Coring will be done throughout this phase to augment the data obtained from the first exploratory
well and also to be able to obtain a better description of the subsurface. The coring activities will be
more critical from the beginning of the reservoir section (3135m RKB).
Wireline logging will also be done in addition to the MWD (for resistivity and GR) attached to the
drill string. Logging parameters shall be: Resistivity (Shallow and Deep laterologs), GR, Caliper,
Neutron (NPHI), Density, Sonic, Induction, Dipole and Dipmeter logs. An Imaging Tool can also be
deployed in the reservoir section. In the payzone, a Schlumberger RFT (Repeat formation Tester) will
Page | 56
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
be deployed to sample the formation fluids at different intervals. It shall also be used to measure
permeability of the formation which will be compared to the values later obtained from coring.
Page | 57
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
CEMENT SLURRY
Density 1.95
Yield 30.59 litres/sx
Volume 14959 litres
Composition Specific Gravity Quantity Volume
(litres)
Class G Cement 3.15 489 sx -
Sea Water (40.1 1.03 - 37304
ltr/100kg)
Bentonite 2.60 --- -
(20% BWOC)
SPACER (Mud Push)
Volume 298 litres
Density 1.4
Viscosity 30cp
Procedures:
Page | 58
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Run Cement Logs tests: CBL and VDL to confirm cement integrity and proper
isolation
Cement composition: Class G cement, Antifoam, Dispersant, Retarder, Betonite, Gas Block
Page | 59
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The pay zone in question is a gas and condensate reservoir. The well is completed as a single string
cased-hole completion with 5½’’ production tubing string to enable production capacity to reach up
to 1,200,000STm3/D. The well will be equipped with a vertical Xmas Tree. The 7” Production casing
shall be cemented and perforated in the upper part of the payzone above the GWC in the gas zone
as observed from the logs. This is to achieve selectivity of fluids, and ensure that water production is
delayed and can be controlled in future by plugging and re-perforating. Cased-hole completion will
be used. The completion procedure is detailed here in phases.
Page | 60
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Gun Type: A 4-1/2",6SPF (shots per foot), phasing angle 600 weatherford TCP gun with part
number TAG-3375-3311 is to be used.
Perforation Interval: top half of reservoir to prevent early water coning. 3145 – 3200 m
RKB.
The accessories to be used with the TCP include;
Packer selection:
Page | 62
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Because TCP services perforate long intervals in a single trip, substantial rig cost
savings are realized. Also maximum perforation cleaning—when perforating
underbalanced—can only be achieved by perforating the entire zone at one time.
TCP guns enable maximum potential to be obtained from a perforation, decreasing
stimulation costs. Because pressure-control equipment can be installed before
perforating, kill fluid costs are reduced.
TCP assemblies—essentially large casing guns—safely and efficiently protect
personnel and equipment. With TCP guns there are no electronically detonated
blasting caps in the system, which means no premature or accidental firing because
of stray electrical currents. TCP guns also can be run regardless of temperature, H2S,
or CO2 levels
Large diameter guns can be run in
They can also be fired with underbalanced pressure and with the permanent well
equipment in place.
The efire electronic firing head system for TCP is used. This gives a safer, more efficient and
economical method for a wide range of down hole explosive operations. The firing process
is automatic inside the preset operating window. Efire is more advanced than other systems
giving the operator total control of the operations. With total control, the operator can aim,
fire or abort the operation at any time. This more flexible technology lets the operator
perforate under less rigid conditions.
Gun Release
The Tubing-Conveyed Gun Release enables TCP guns to be dropped off the end of the
running string, allowing access to the perforated zone for stimulation, production logging,
squeezing or additional perforating. After the guns have been dropped, the release housing
acts as a tubing re-entry guide.
Configuration:
The TCP can be configured two ways:
For slick-line release, an Otis Type B (or equivalent) shifting tool is run and engages
the release sleeve. By jarring up, the sleeve moves, releasing the locking dogs and
dropping the guns. The release profile automatically releases the shifting tool from
the release sleeve.
For pressure release, a ball or test tool is dropped into the TCR, sealing on the ball
seat. When pressure is applied, the release sleeve is shifted down, releasing the
locking dogs.
Page | 63
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The fish remaining in the well consists of only one assembly that can be easily fished. After
dropping the guns, the release housing provides a tubing re-entry guide with an ID that is at
least as large as the tubing it is attached to. For H2S and other hostile environments, the TCR
release housing can be made with corrosion-resistant alloys. The TCR can also be supplied
with premium threads, if required. These options are available on special request.
TCP Accessories:
The radioactive marker sub is run in line with the work string above the packer. It serves as a
tubing collar or drill pipe tool joint, with one or two small cavities drilled and threaded to
receive a sealing plug. A radioactive pip tag is installed in each cavity. A pip tag is a weak
gamma ray source (1 -µCi of cobalt-60). All radioactive material is fully recovered when the
string is pulled.
A through-tubing gamma ray log is used for depth correlation of the pip tag with the earlier
open hole gamma ray log. Because the distance from the pip tag to the top shot was
measured previously, the gun can be accurately positioned on depth.
It is typically run between the packer and the firing head of a tubing-conveyed perforating
system. This valve keeps the tubing string closed until it is time to open the valve and
establish an underbalanced condition. The valve pressures up internally until the value of
the shear pins is exceeded and the sleeve is pushed upward, exposing the ports.
A wireline retrievable surface controlled subsurface safety valve (WLRSCSSV) is used. This
selection makes installation and well maintenance easier, considering offshore operations
andIt can be removed easily without unsetting the packer. The WLRSCSSV is a flapper type
and self-equalizing.
Model: Baker VDES – the “V” Series employs a modular concept that allows flexibility and
adaptability to existing and new completions. It is fail-safe and it is used for deep set
applications incorporating self-equalizing system.
Page | 64
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Kill Fluid: To be used when permanent string is to be installed. Oil based fluid, compatible
with formation, filtered CaCO3 as weighting agent, density greater than pore pressure (ℓ =
1.35).
TUBING CALCULATIONS
Compression Force
= 3670 lbs
This is a compression force acting on the tubing due to upthrust from the produced fluid.
Page | 65
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The fluid density is arithmetically averaged from packer fluid density, oil density and gas density.
This a tension force acting on the tubing during a pressure test on plug at 5000psi
Inside Effect =
This is a compression force acting on the tubing due to pressure differential across the tubing from
inside the tubing.
This is a tension force acting on the tubing due to pressure differential across the tubing from
outside the tubing.
Page | 66
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
This is a compression force acting on the tubing due to the well fluid temperature.
This will put some additional length of the tubing in compression but this is negligible as the neutral
point will still be within the tubing far away from the tubing hanger.
Other tubing stresses such as fluid drag, buckling and bending stress are negligible as their
contributions are minimal.
For buckling the tubing is designed to be in tension, as neutral point is at the packer level.
For fluid drag, the tubing size is large enough, so pressure loss due to friction is minimal.
For bending stress, the well is a vertical well, so there are no bends.
Page | 67
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 68
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 69
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Max OD 4.82”
11 Sliding sleeve Baker Model L, Size 4.56 Helps to establish tubing to annular
5 ½” Tubing OD communication for such operation as:
Displacing tubing or annular fluid after
4.562” Sealbore diameter Xmas tree is installed,
OD 6.05” Killing a well,
Gas lifting,
Circulating inhibitors for corrosion
control, etc.
12 Wing valve As per Xmas tree selected Used for shutting and opening of the well.
13 Choke bean As per Xmas tree selected For controlling and adjusting the flow rate
of the well effluent.
14 Master valve As per Xmas tree selected Helps in providing safety for the well
against incidents.
15 Swab valve As per Xmas tree selected Serves as access for running in equipment
into the well.
16 Expansion It reduces the strain on tubing through its
joint movements in case of high tubing
movement.
17 Flow Baker Pdt. No. 819-20 Short heavy-walled tubular to prevent
Couplings erosion of the inner surface of the tubing
5½” tubing: Size 6.050OD x
(inserted 4.950ID Box and Pin as a result of turbulent flow.
before and
after SCSSV,
landing
nipples, and
crossover sub
18 Perforated Serves as alternate entrance point for the
tube fluid in case there is a measuring
instrument in the tubing shoe.
Allows pressure measurements to be made
during production without further
pressure losses due to recorder.
19 Top No Go Baker Model AF, Pdt. Plug landing for pressure testing tubing
Landing No.801-85 and for workover operations
nipple
Sealbore Dia. 4.562”
Max OD 4.65”
20 Crossover sub Allows transition between different tubing
(5"x 41/2") sizes
21 Bottom no go Baker Model AF., Pdt. No. Used to land a plug or other equipment.
Landing 801-78
Page | 70
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Page | 71
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
This operation is carried out just after the excess cement has been drilled out of the casing string
and the debris circulated out of the well. It also involves scraping the casing and liner in the position
of the packer. This phase is completed by displacing the mud from the well with the completion
fluid.
This phase includes all the operations necessary to run the production tubing with all its accessories
into the well. The tubing installed in this well is a 5”1/2 tubing with a retrievable packer in the 7”
liner.
The completion is made up of the tubing with the WLRSCSSV, SSD, and temperature and pressure
gauges on the bottom no go. Side Pocket Mandrels are also installed for the purpose of future gas
lift operations
A GE D15 compact dry wellhead is used. This phase involves removing the BOP and replacing it with
the Christmas tree assembly. The steps involved include;
This phase involves perforating the producing interval at the production liner. The Perforation
should be carried out underbalanced using a through tubing gun after the completion equipment
have been run, the Christmas tree installed and the well is filled with inhibited water. Retrievable
carrier guns should be run into the well by means of an electric cable run through a lubricator.
SAFETY PRECAUTIONS:
Shaped charges are dangerous so compliance with safety practices is compulsory while using
them.
Electrical systems should be checked before perforation to prevent any risks of eddy
currents.
Page | 72
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Opening the Christmas tree valves and allowing the well to flow through the choke manifold
and a flow line connected to a flare. (All test ports must be fully opened)
Flow the well until the effluent is considered clean enough.
Put the well back in safe condition by closing the subsurface safety valve and the Christmas tree
valves.
Page | 73
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Leaks at valves,
Tubing hanger or tie down screws
Back Pressure Valve (BPV) seat
SCSSV control line outlet
It is required to shut-in prior to work-over with an internal safety valve in place in the tubing string.
Remove faulty part for repairs or replace.
For the replacement of equipment beneath the wellhead but above the packer:
The rig and all its equipment can be set up in accordance with safety distances, rules and
regulations.
Kill the well with CaCl2 brine solution
Dismantle the Christmas tree at the tubing head spool with a SCSSV and BPV in place.
Mount BOP and pressure-test.
Pull out down-hole equipment after retrieving BPV. (There should be a Gray valve on the rig
floor ready for use. Care must be taken to avoid swabbing while tripping out).
Page | 74
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Prior to carrying out this operation, the well will be killed and cleaned.
Page | 75
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
8 APPENDIX
8.1 CALCULATIONS
For soft formation, Weight on Bit (WOB) is one ton per inch of bit.
100% of the drill collar weight will be used to apply weight on bit
Drill Pipe Specification = 5” OD, G105, 25.60 lb/ft, Premium Class, NC50(XH), TJ 6-1/2”
IEU
Pumping Power
Pumping Power
Page | 76
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Hoisting Power
Maximum Drill string Tension = weight of string + overpull = 305 kdaN = 310.9 tons
1 stand = 27m
Rotating Power
Page | 77
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Maximum Torque = 7691 daN.m (for a 5’’ G105, 25.60 lb/ft, premium DP)
The total power required to efficiently drill this phase is the sum of the pumping power, hoisting
power and rotary power.
= + + 900.1 = 4405.58 hp
The worst collapse scenario for the intermediate casing is loss of mud to a low pressure
Page | 78
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
For this collapse study a mud loss to low pressure zone (EMD = 1.0) at the end of the next phase
is considered.
Collapse = 64 – 0
= 64bar = 6.4 MPa
BURST STUDY
Well full of gas and bull heading (35bars) is the worst burst condition for the intermediate
casing. The gas comes from a depth of 3195m at specific gravity of 0.25. Pore pressure of gas is
410 bar.
Pi = PP – HP gas + Bullhead
Pi = 366.69bar
Pe @ Surface = 0 bar
Burst = 366.69 – 0
= 366.69 bar = 36.669 MPa
Page | 79
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
TENSION STUDY
Component Rigidity
9.5”x3” and 6.5”x2.8125” 4.67 < 5.5 Acceptable
6.5”x2.8125” and 5”x3” HWDP 3.19 < 5.5 Acceptable
5”x3” HWDP and 5” Drill Pipe 1.87 < 5.5 Acceptable
Page | 80
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
To ensure smooth transition from the rigid and compressed DC’s to the flexible and in tension
DPs, HWDP are used. This also ensures that the DP’s are never in compression, by keeping the
neutral point within the HWDP.
DRILLSTRING (DP)
Estimated phase length = 1400m RKB, BHA Length = 216m, DP Length = 1184m
One DP length = 9.144m =30ft, Number of DP’s = 130 pcs
Page | 81
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
SPP = 309.77bar
HOISTING POWER
Page | 82
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
S 71.1
Drilling line Safety factor, f = = = 2.00
T 34.1
Fastline Speed = Speed of Drum (rpm) x p x
60
80 xx25 31.25x0.3
Vc =
60 x12
Vc = 3.06 m/s
3.06
Travelling Block Speed= = 0.31 m/s
10
Force(kg) xVc (m / s)
Power developed at the hook =
76
276560x0.31
Pc (hp) =
76
1128
With Reeving Efficiency of 0.811, the power required at the draw work =
0.811
= 1390 hp
Page | 83
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
1390
With Efficiency of 0.9, Power Input of Draw work = = 1544 hp
0.9
0.9 0.811
HOISTING POWER
ROTATION POWER
CxRPMx1 CxRPMx1
P (HP) = =
712 x 712 x
= 0.811x 0.9
955x1037.04
C= =990.38 daN. M
1000
990.38 x1000
P= = 1905.7 hP
712 x0.811x0.9
Page | 84
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The worst collapse scenario for the intermediate casing is loss of mud to a low pressure
formation while drilling the next phase.
For this collapse study a mud loss to low pressure zone (EMD = 1.0) at the end of the next phase
is considered.
Collapse = 110 – 0
= 110bar = 11 MPa
BURST STUDY
Well full of gas and bull heading (35bars) is the worst burst condition for the intermediate
casing.
Page | 85
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Pi = PP – HP gas + Bullhead
Pi = 366.69bar
Pe @ Surface = 0 bar
Burst = 366.69 – 0
= 366.69 bar = 36.669 MPa
TENSION STUDY
Page | 86
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
To ensure smooth transition from the rigid and compressed DC’s to the flexible and in
tension DPs, HWDP are used. This also ensures that the DP’s are never in compression,
by keeping the neutral point within the HWDP.
DRILLSTRING (DP)
Estimated phase length = 2555m RKB, BHA Length = 164m, DP Length = 2391m
Page | 87
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
SPP = 302.22bar
HOISTING POWER
Page | 88
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
S 63.68
Drilling line Safety factor, f = = = 2.00
T 31.84
Fastline Speed = Speed of Drum (rpm) x p x
60
80 xx25 31.25x0.3
Vc =
60 x12
Vc = 3.06 m/s
3.06
Travelling Block Speed= = 0.31 m/s
10
Force(kg) xVc (m / s)
Power developed at the hook =
76
258200x0.31
Pc (hp) =
76
Page | 89
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
1053.2
With Reeving Efficiency of 0.811, the power required at the draw work =
0.811
= 1299 hp
1299
With Efficiency of 0.9, Power Input of Draw work = = 1443 hp
0.9
0.9 0.811
Motor Drawwork
Drawwork Hook
Hook
Motor
s (11285112
8)
ROTATION POWER
Page | 90
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Burst Calculation Pb
Worst Case: Well full of Gas and Bullheading at surface
Pi = Ppore - Phgas + bullheading
Where Ppore is taken at reservoir bottom 3195m MSl as 410 bars
Pi = 410 - (0.25*3195)/10.2 + 35
= 367 Bar
Pe = 0 at surface level
ΔP = Pi - Pe
ΔP = 367 - 0
= 367 Bar
Pb = 36.7 MPa
The casing choice properties are tabulated in table 10 below
Table 8-6: Casing properties
Page | 91
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
All safety factors exceed the minimum acceptable values. The tensile safety factor is
calculated using a buoyancy factor of 0.821, particular to the mud weight of 1.41 SG used
for this phase.
Since this is a gas well, a tight sealing is preferred for the connections. We have then
selected a VAM Top coupling with 1566dan.M make-up torque and a drift of 153.9mm. The
efficiency of this coupling is 102% meaning that it can withstand a bit more tensile stress
than the casing string and thus a 3.54 safety factor in tension.
From charts, appropriate drill collar is a 6¾” outer diameter (OD) drill collar. We need 27
drill collars in all as 80% of the drill collar weight in mud will provide the weight on bit
required.
The length of HWDP required to prevent buckling will be 247m which is obtained from 27
HWDPs of 9.14m each. The length of HWDPs is roughly the same as the DC length for
stability and to prevent buckling. The sectional modulus ratios of drill collar to HWDP to drill
pipes were checked to be below 5.5 in order to prevent buckling.
The drill pipes will be the same as that used for earlier phases; 5”, 19.5 Ib/ft grade S drill
pipe with NC50 tool joint will be used. The grade S used allows a margin of overpull (MOP)
of 100 tons which is suitable.
Measurement While Drilling (MWD) tools will also be assembled to the BHA with K-monel
alloy based drill collars used. These drill collars will still provide the WOB required and will
ensure no metallic interference with the MWD measurement readings. The 3 bottommost
drill collars will make up the MWD unit.
A 9.3m wireline-triggered hydraulic Jar will be mounted just above the DCs and before the
HWDP with re-checks to ensure that the jar is not located at the neutral point so it can
perform meaningfully. We shall also use 3 integral blade stabilizers as was used in earlier
phases. The stabilizers (with OD of 8¾”, same as hole size) will be positioned (spaced) near-
bit, mid-body and far away from the bit. These stabilizers will help to maintain the vertical
trajectory and will also aid the drill string to get out of sticky zones if they are encountered.
There will also be a shcok absorber screwed onto the bit to dampen the vibrations
generated during the operation of the bit. The schematic of the drill string is shown below.
Page | 92
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
Figure 8-7: Schematic of the Drill string. Depths are given in MSL. Recall MSL + 55m = RKB
Related formulae:
WOB DCweight
DCweight DClength
0.8 * BF No min alWeight
Page | 93
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
From the rig option of the Maersk Gallant, one out of the 3 Continental Emsco pumps (each
rated 2200hp and 7500psi) available on the rig are sufficient for pumping this phase.
Related formulae:
Q
Q[l / min] AnnularVol ume[l / m] * AnnularVel ocity [m / min] T .F . A[in 2 ]
38.71 * VR
SPP N1 L2 N 2 L3 N 3 L4 N 4 L5 N 5 B Pd d
dQ 2
Pd
2959.41 * 0.95 2 TFA 2
Here we sought to obtained power requirements for drilling, tripping and the general rig
operation. We also calculated and designed minimum acceptable values for hoisting
parameters like hook load, mast load, number of reeving lines, tension in fast and dead
lines, minimum breaking load for the rope, design factor, rotational speeds and efficiencies.
Page | 94
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The drawworks is like a wire spool for the drilling line and powers the line via rotation of its
drums. It receives power from an electrical motor and is connected with different gear
connections for achieving different speeds based on gear ratio. The schematic of the
drawworks and hoisting system is shown in figure 8.11a while the top drive system is shown
beside an older Kelly bushing derrick type in figure 8.11b
Figure 8-11a: Hoisting & Drawworks system Figure 8-11b: Top Drive and Kelly Bushing
system
We would prefer a top drive rotational system because it saves time by handling stands of 3
drill pipes in one trip. Also, the top drive system allows drilling fluid to still be pumped into
the string during tripping out, unlike the Kelly system. This minimizes hydrostatic pressure
losses due to fluid level drop when tripping out.
We assumed a travelling block weight of 10.5 tons. The weight of the entire drill string in
mud is 128tons. Thus the total weight on hook is 138.5tons. We also assumed that the
Page | 95
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
drilling line of the top drive system has 10 lines (N = 10). For roller bearings, the reeving
efficiency of this system is obtained from a chart as 0.811. With this, the fast line tension
was calculated as 17 tons while the static tension was 14 tons. With an MOP of 100 tons,
the maximum force on the hook would be 238.5 tons, fast line tension will be 29.4 tons and
static tension would be 24 tons. With a 1¼ inch 6x19 steel core IWRC-EIPS line, minimum
breaking force is 617kN and thus the design (safety factor) would be 2.14 which is above the
limit of 2, allowable for pulling-on-stuck-pipe operations. In other operations where the
MOP will not be applied, the design factor will be much higher. Thus the selected line is
acceptable for the drawworks.
We also estimated the average work done by the drilling line for a round trip down to
3355m MSL to be 618000daN.km while the work done to drill from 2500m to 3355m MSL is
622500daN.km.
If we assume a tripping velocity of 600m/hr (of this, 20mins per hour is actual pulling out
time) or a hook speed of 0.5m/sec, then the hoisting power required for the round trip
would be 307kW (411hp).
The hoisting power is maximum at the lowest speed ratio and takes into account the pulling
force (MOP) on the drawworks. We assumed a 36in drum with 3 lays of 1¾in line. The
lowest speed ratio is 0.082, corresponding to a hook speed of 0.46m/s. The hoisting power
was then calculated as 2629hp (2630hp). The motor input power is therefore estimated
with a drawworks efficiency of 90% to be 2922hp or 3000hp approximately.
For the rotational power required for the drill string, this will be provided by the topdrive.
The maximum torque the drill string can take is 7874daN.m and applying a safety factor of
0.5, the maximum torque that will be applied to the string will be 3937daN.m to prevent
string twisting. If we take this torque at 100rpm maximum speed and with a rotary
efficiency of 0.9, then the rotary power needed would be 614hp.
Page | 96
Well Design Project - Design of An Optimised Well
Institute of Petroleum Studies
The total power required to efficiently drill this phase is the sum of the maximum pumping
power, hoisting power and rotary power.
Related formulae:
* Vd V fl Fmax * Vh
V fl Vh DwrksPower[ HP]
60 N 77.5 *
DworksPower C * rpm
Motor[ HP] RotaryPowe r[hp]
dwrks 712 *
Page | 97
Well Design Project - Design of An Optimised Well