1 Casing / Conductor Design, BOP & Wellhead

1 Casing / Conductor Design, BOP & Wellhead ................................................... 1

1.1 Casing setting depths and justification...........................................................................................2
1.1.1 Introduction.........................................................................................................................................2
1.1.2 30” Foundation Pile...........................................................................................................................2
1.1.3 20” Conductor Casing.......................................................................................................................2
1.1.4 16” Drilling Liner (contingency)........................................................................................................2
1.1.5 133/8” Surface Casing........................................................................................................................3
1.1.6 95/8” Production casing.....................................................................................................................3
1.1.7 7” Production liner (contingency) ....................................................................................................3
1.2 Casing Design Criteria......................................................................................................................5
1.3 Minimum EMG and Kick Tolerance................................................................................................5
1.3.1 Kick Detection....................................................................................................................................7
1.4 Casing Test Pressure........................................................................................................................8
1.5 Casing Specification..........................................................................................................................9
1.6 Wellhead.......................................................................................................................................... 10
1.6.1 Wellhead Running Procedures..................................................................................................... 10
1.7 Casing Centralisers........................................................................................................................ 10
1.1 Casing setting depths and justification.
1.1.1 Introduction
The Example deepwater exploration well can be classified as a wildcat well. The
nearest offset well, was 16 km away and was drilled in only 450 ft of water.

Therefore a large uncertainty in the pore-pressure and formation strength is

predicted. In that, and based on a more conservative design, d eepwater wells
require usually more casing strings than similar wells in shallower water.

The Example well design is therefore rather flexible and comprehensive

(maximum of 6 casing strings in just 5900 ft below seabed). Casing setting
depths are flexible and should be selected during the drilling process. Close
monitoring of drilling parameters and other available information from MWD/LWD
and PWD should be used to select the optimum casing point before drilling
further. Casing points should be selected in close consultation between on and
offshore staff.
Note Casing setting depths have been selected based on the expected pore pressures. It is possible that
a casing string has to be set shallower (or deeper) if pore pressures require a higher (or lower)
mud weight than planned.
1.1.2 30” Foundation Pile
The setting depth of the 30” conductor is dependent on the 8½” soil investigation
hole. Based on the experience it will be decided to either jet the 30” foundation
pile or drill a 36” hole and to run either 4, 5 or 6 joints. A main criteria is to have
sufficient support for the 30” foundation pile and the 20” Conductor in the soft and
unconsolidated seabed.

1.1.3 20” Conductor Casing

The objective is to set the 20” casing as deep as possible, to ensure sufficient
formation strength and to minimize the need for the 16” drilling liner. However, it
should be realized that many wells have been lost in deepwater due to pushing
the 20” casing too deep. Drilling parameters and MWD/LWD and PWD data
should be monitored closely to decide if hole conditions require a higher mud
weight than seawater.

1.1.4 16” Drilling Liner (contingency)

Will only be run if the 20” conductor has to be set early, resulting in a insufficient
leak-off. The same criteria apply as for the 20” conductor. If the 16” is required it
might be decided to set it somewhat deeper than the original planned 20”
conductor setting depth, this to be better prepared for a pressure increase in the
trust wedge.
1.1.5 133/8” Surface Casing
The 133 /8 ” casing will be set just above the Yellow horizon. It is expected that
formation pressures will be hydrostatic until this formation. Although it is possible
that the pore pressure could be inflated if the trust wedge is penetrated. Setting
the 133/8” as close as possible above the Yellow horizon will be optimum if there
is a pore pressure increase in the Yellow horizon.

1.1.6 95/8” Production casing

The 95 /8 ” casing will be set as close as possible above the Example objective.
Setting the 95 /8 ” casing as close as possible above the Example objective will be
optimum for penetrating the main reservoir(s) and minimizes the open hole
length before coring.

1.1.7 7” Production liner (contingency)

There are no plans to run a 7” Liner but a liner will be available as a contingency.
 WELL SCHEMATIC

Note : Casing setting depths will be adjusted based on actual formation pressures and hole
conditions. 0 ft RKB

73 ft Mean Sea Level

2484 ft bdf
(2411 ft ss )
Mud Line
Lithology 2843 ft bdf Drilling Fluid
(2660 ft ss ) 30” x 310# X-52 Quik-Stab Structural pipe

Predominantly
soft clay / shale /
silt Sea water
26” Hole

3873 ft bdf
(3800 ft ss ) TOL
4073 ft bdf 20” 133# X-56 RL-4S Conductor Casing
(4000 ft ss ) 17 1/2” Hole or 22” underream
Gumbo ??
4373 ft bdf
(4300 ft ss ) TOC 0.46 psi/ft

4873 ft bdf 20” 133# X-56 RL-4S Conductor Casing

(4800 ft ss )
16” 84.0# K55 BTC Liner (Contingency)
Sand / shale
sequence PHPA
17 1/2” Hole or 20% NaCl
3% Glycol
14 3/4” hole & 171/2” underream
5373 ft bdf
(5300 ft ss) TOC 0.50 psi/ft
5873 ft bdf 13 3/8” 54.5# K55 BTC Surface Casing
(5800 ft ss )

12 1/4” Hole 0.6 - 0.65psi/ft

7573 ft bdf
(7500 ft ss ) 9 5/8” 43.5# N80 BTC Production Casing
Mainly sand
interbedded 0.6 - 0.70 psi/ft
w/ shales 8 1/2”Hole

8391 ft bdf 7” 26# L80 NSCC Production Liner

(8318 ft ss ) (Contingency)

Figure 1 Well Schematic

1.2 Casing Design Criteria
The casing design is performed using the design program STRESSCHECK. The
casing design takes into consideration the collapse, burst, axial and tri-axial
criteria as used by Stress check for the planned and maximum casing setting
depth. Worst case scenario’s, using the highest expected pore pressures have
been used for the design and the casing selection.

1.3 Minimum EMG and Kick Tolerance.

The minimum EMG required at the casing shoe is calculated based on the
following criteria:
♦ The minimum influx is set at 100 bbls for each hole.
♦ The Well Control Module of Well Plan for windows is used to calculate
maximum kick volumes. This module takes gas compressibility, temperature
effects and well trajectory into consideration.
♦ The influx is either a swab kick or a drill kick, depending on the mud weight.
♦ Expected pore pressures are used.

Refer to Table 1 Kick Tolerance as a function of formation strength and pore-

pressure.
1)
means top of influx already inside the shoe.
Casing Shoe Leak- Hole Pore Mud- Height Volume Max Pore
(bbl)
size depth off TD Pressure weight of influx Pressure w/
(ft tvss) (psi/ft) (ft tvss) gradient (psi/ft) (ft) gas to shoe
1)
20" 4000 0.528 4800 0.435 0.450 800 350 0.457
20" 4000 0.528 4800 0.435 0.435 800 1) 350 0.457
20" 4000 0.502 4800 0.435 0.450 795 348 0.435
20" 4000 0.477 4800 0.435 0.450 509 220 0.414
16" 4800 0.575 5800 0.435 0.500 1000 1) 267 0.493
16" 4800 0.575 5800 0.435 0.435 1000 1) 267 0.493
16" 4800 0.546 5800 0.435 0.500 1000 1) 267 0.469
16" 4800 0.519 5800 0.435 0.500 1000 1) 267 0.447
20" 4800 0.575 5800 0.435 0.500 1000 1) 267 0.493
20" 4800 0.546 5800 0.435 0.500 1000 1) 267 0.469
20" 4800 0.519 5800 0.435 0.500 1000 1) 267 0.447
20" 4800 0.575 5800 0.435 0.435 1000 1) 267 0.493
133/8" 5800 0.628 7500 0.555 0.600 1000 115 0.508
133/8" 5800 0.628 7500 0.555 0.555 931 106 0.508
133/8" 5800 0.628 7500 0.555 0.600 1000 115 0.508
133/8" 5800 0.597 7500 0.555 0.600 636 70 0.484
133/8" 5800 0.567 7500 0.555 0.600 290 28 0.461
95/8" 7500 0.709 8318 0.543 0.600 818 1) 36 0.649
95/8" 7500 0.709 8318 0.543 0.543 818 1) 36 0.649
95/8" 7500 0.674 8318 0.543 0.600 818 1) 36 0.617
95/8" 7500 0.640 8318 0.543 0.600 818 1) 36 0.587
Table 1 Kick Tolerance as a function of formation strength and pore-pressure.
1.3.1 Kick Detection
As mentioned earlier, pore pressures and formation strengths are difficult to
predict for this wildcat well. This pore pressure uncertainty will pose higher
responsibility upon drilling crews. To ensure timely detection for kicks, the
following should be implemented/adhered to:
♦ Continuously monitor relevant drilling parameters, and gas shows with utmost
care.
♦ Carefully watch indications for pore pressure chances such as drill cutting
shape, hole fill, torque and drag, D-exponent, formation resistivity if available,
etc.
♦ Mud logging unit required as an additional independent monitoring system. A
comprehensive mud logging unit with e xperienced crew has been contracted
for the job.
♦ Keep active system small to ensure sensitive pit level measurements. Monitor
relevant pits as part of the active system during mud transfers. All pits should
be equipped with sensors.
♦ Perform a daily calibration check of a pit level and return flow rate
measurement system.
♦ Implement a weekly maintenance check of the above equipment.
♦ Pump out of hole if any signs of swabbing.
♦ Avoid excessive ROP’s when drilling potential hydrocarbon bearing sections.
♦ Monitor PWD closely when available to detect changes in ECD’s
♦ Perform frequent kick drills to ensure fast reaction time.
1.4 Casing Test Pressure
Please find below the casing test pressure calculation and selection:

Casing Test Pressure Calculation

Casing size 20" 16" 133/8" 95/8" 7" Inch
Burst strength 3060 2978 2735 6327 7240 Psi
Deep Well Option
Top of casing/Liner 2411 3800 2411 2411 7000 ft
Casing shoe at 4800 4800 5800 7500 8300 ft
Formation gradient at shoe 0.575 0.575 0.628 0.709 0.744 Psi
Max TD next section 5800 5800 7500 8500 8500 ft
Max Pore-pressure gradient 0.583 0.583 0.667 0.744 0.744 Psi
at TD
Max pressure at shoe 2760 2760 3642 5317 6175 Psi
Max burst at top joint 2521 2660 3304 4809 6045 Psi
Min mud inside 0.46 0.5 0.5 0.5 0.55 psi/ft
Test Pressure 1412 760 2098 3603 2195 Psi
Max Test Pressure
75 % of burst 2295 2234 2051 4745 5430 Psi
Selected Casing Test Pressure
Selected Test Pressure 1300 1000 2000 3600 2500 Psi
Table 2 Casing Test Pressures
 1.5 Casing Specification
Table 3 presents the available data of each casing to be used for the example
well.

Casing Technical Data

Size Weight/Wall Grade Burst Collapse Yield ID Coupling Drift Bending
Thickness (psi) (psi) (kips) (inch) OD (inch) (kip-ft)
(Lbs / in) (inch)
30" 457 / 1 ½” X-52 4550 3890 6984 27 - 3950
H-90/MT - 6700 - 4440 28 32.25 - 4380
30" 310 / 1” X-52 3030 1630 4738 28 - 2770
S-60/MT - 4200 - 2630 28 32 - 2600
20" 133 / X-56 3060 1450 2130 18.73 - 18.543 834
0.625
RL-4S - 4100 - 1800 18.63 21.5 - 850
16" 84 K-55 2978 1407 1326 15.01 - 14.823
BTC - 3063 1410 1499 15 17 - 420
133/8" 54.5 K-55 2735 1131 853 12.615 - 12.459
BTC - 2730 1130 853 12.615 14.375 12.459
133/8" 48 NT- 2510 1030 744 - 12.599
55HE
BTC - 2510 904 14.375 12.599
95/8" 43.5 N-80 6327 3810 1006 8.755 - 8.625
BTC - 6330 3810 1074 8.755 10.625 8.599
7" 26 N-80 7240 5411 604 6.276 - 6.151
NSCC - 7240 5410 519 6.276 7.656 6.151
Table 3 Casing technical Data
1.6 Wellhead
A Dril-Quip SS-10C 18¾” wellhead system is selected for this well. The system is
rated to 10,000 psi working pressure and is equipped with an ABB Vetco Gray H-
4 wellhead connector profile. The high pressure housing has 3 casing ha nger
positions, alternatively, the upper position can accommodate a tubing hanger in
the event of a subsea completion. The 30” housing extension (full joint) is fitted
with a Dril-Quip H-90D/MT box-down and the 18¾” housing has a 20 feet
extension with an ABB Vetco Gray RL-4 pin connector.
The wellhead system has been modified to suit the Example deepwater
operations (see section xxxxx)The SS-10C wellhead package has the following
equipment:

♦ Temporary guide base (200 ft2 mud-mat).

♦ Gymbal system to support and land on TGB.
♦ Permanent guide base complete with 4 of 10’ posts c/w Regan post top
profile and brackets for slope indicators.
♦ 30” wellhead housing and extension.
♦ 18¾” high pressure housing, left hand thread running profile, H-4 connector
profile up and RL-4 pin connector down on wellhead extension.
♦ 133/8” and 9 5 /8 casing hangers.
♦ All necessary wear bushings (inclusive the extended type), running tools and
spare parts to support a 1 + 1 well program.
♦ 100 % back up for all equipment to be available on the rig.

1.6.1 Wellhead Running Procedures

- Refer to Manufacturers Manual.

1.7 Casing Centralisers.

Refer to cementing section for the casing centralisers.