1 Casing / Conductor Design, BOP & Wellhead

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

1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5
1.1.6
1.1.7
1.2
1.3
1.3.1
1.4
1.5
1.6
1.6.1
1.7

Casing setting depths and justification...........................................................................................2

Introduction.........................................................................................................................................2
30 Foundation Pile...........................................................................................................................2
20 Conductor Casing.......................................................................................................................2
16 Drilling Liner (contingency)........................................................................................................2
133/8 Surface Casing........................................................................................................................3
95/8 Production casing.....................................................................................................................3
7 Production liner (contingency) ....................................................................................................3
Casing Design Criteria......................................................................................................................5
Minimum EMG and Kick Tolerance................................................................................................5
Kick Detection....................................................................................................................................7
Casing Test Pressure........................................................................................................................8
Casing Specification..........................................................................................................................9
Wellhead.......................................................................................................................................... 10
Wellhead Running Procedures..................................................................................................... 10
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 8 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.
RKB
0 ft

Mean Sea Level

73 ft

2484 ft bdf
(2411 ft ss )

Lithology

2843 ft bdf
(2660 ft ss )

Predominantly
soft clay / shale /
silt

Drilling Fluid
30 x 310# X-52 Quik-Stab Structural pipe

26 Hole
3873 ft bdf
(3800 ft ss )

Gumbo ??

Mud Line

4073 ft bdf
(4000 ft ss )
4373 ft bdf
(4300 ft ss )
4873 ft bdf
(4800 ft ss )

Sand / shale
sequence
5373 ft bdf
(5300 ft ss)
5873 ft bdf
(5800 ft ss )

TOL
20 133# X-56 RL-4S Conductor Casing

17 1/2 Hole or 22 underream

TOC

7573 ft bdf
(7500 ft ss )

16 84.0# K55 BTC Liner (Contingency)

17 1/2 Hole or
14 3/4 hole & 171/2 underream
TOC

PHPA
20% NaCl
3% Glycol
0.50 psi/ft

13 3/8 54.5# K55 BTC Surface Casing

0.6 - 0.65psi/ft

9 5/8 43.5# N80 BTC Production Casing

8 1/2Hole
8391 ft bdf
(8318 ft ss )

0.46 psi/ft

20 133# X-56 RL-4S Conductor Casing

12 1/4 Hole

Mainly sand
interbedded
w/ shales

Sea water

7 26# L80 NSCC Production Liner

(Contingency)

Figure 1 Well Schematic

0.6 - 0.70 psi/ft

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 scenarios, 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 porepressure.
1)

means top of influx already inside the shoe.

Casing Shoe Leaksize depth

off

Hole
TD

(ft tvss)

(ft tvss)

20"
20"
20"
20"
16"
16"
16"
16"
20"
20"
20"
20"
133/8"
133/8"
133/8"
133/8"
133/8"
95/8"
95/8"
95/8"
95/8"

4000
4000
4000
4000
4800
4800
4800
4800
4800
4800
4800
4800
5800
5800
5800
5800
5800
7500
7500
7500
7500

(psi/ft)

0.528
0.528
0.502
0.477
0.575
0.575
0.546
0.519
0.575
0.546
0.519
0.575
0.628
0.628
0.628
0.597
0.567
0.709
0.709
0.674
0.640

4800
4800
4800
4800
5800
5800
5800
5800
5800
5800
5800
5800
7500
7500
7500
7500
7500
8318
8318
8318
8318

Pore

Mud- Height Volume Max Pore

(bbl)
Pressure weight of influx
Pressure w/
gradient

0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.435
0.555
0.555
0.555
0.555
0.555
0.543
0.543
0.543
0.543

(psi/ft)

0.450
0.435
0.450
0.450
0.500
0.435
0.500
0.500
0.500
0.500
0.500
0.435
0.600
0.555
0.600
0.600
0.600
0.600
0.543
0.600
0.600

(ft)

gas to shoe

1)

800
800 1)
795
509
1000 1)
1000 1)
1000 1)
1000 1)
1000 1)
1000 1)
1000 1)
1000 1)
1000
931
1000
636
290
818 1)
818 1)
818 1)
818 1)

350
350
348
220
267
267
267
267
267
267
267
267
115
106
115
70
28
36
36
36
36

0.457
0.457
0.435
0.414
0.493
0.493
0.469
0.447
0.493
0.469
0.447
0.493
0.508
0.508
0.508
0.484
0.461
0.649
0.649
0.617
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 ROPs when drilling potential hydrocarbon bearing sections.
Monitor PWD closely when available to detect changes in ECDs
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"
Burst strength
3060
2978
2735
6327
Deep Well Option
Top of casing/Liner
2411
3800
2411
2411
Casing shoe at
4800
4800
5800
7500
Formation gradient at shoe
0.575 0.575 0.628 0.709
Max TD next section
5800
5800
7500
8500
Max Pore-pressure gradient 0.583 0.583 0.667 0.744
at TD
Max pressure at shoe
2760
2760
3642
5317
Max burst at top joint
2521
2660
3304
4809
Min mud inside
0.46
0.5
0.5
0.5
Test Pressure
1412
760
2098
3603
Max Test Pressure
75 % of burst
2295
2234
2051
4745
Selected Casing Test Pressure
Selected Test Pressure
1300
1000
2000
3600
Table 2 Casing Test Pressures

7"
7240

Inch
Psi

7000
8300
0.744
8500
0.744

ft
ft
Psi
ft
Psi

6175
6045
0.55
2195

Psi
Psi
psi/ft
Psi

5430

Psi

2500

Psi

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
Thickness
(Lbs / in)

Grade

Burst
(psi)

Collapse
(psi)

Yield
(kips)

ID
(inch)

Coupling
OD
(inch)

30"

457 / 1
H-90/MT
310 / 1
S-60/MT
133 /
0.625
RL-4S
84
BTC
54.5
BTC
48

X-52
X-52
X-56

4550
6700
3030
4200
3060

3890
1630
1450

6984
4440
4738
2630
2130

27
28
28
28
18.73

32.25
32
-

K-55
K-55
NT55HE
N-80
N-80
-

4100
2978
3063
2735
2730
2510

1407
1410
1131
1130
1030

1800 18.63
21.5
1326 15.01
14.823
1499
15
17
853 12.615
12.459
853 12.615 14.375 12.459
744
12.599

2510
6327
6330
7240
7240

3810
3810
5411
5410

904
1006
1074
604
519

30"
20"
16"
133/8"
133/8"
95/8"
7"

BTC
43.5
BTC
26
NSCC

8.755
8.755
6.276
6.276

Table 3 Casing technical Data

14.375
10.625
7.656

Drift
(inch)

18.543

12.599
8.625
8.599
6.151
6.151

Bending
(kip-ft)

3950
4380
2770
2600
834
850
420

1.6 Wellhead
A Dril-Quip SS-10C 18 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 H4 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 18 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.
18 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.