From: Miller,RichardA (Viking) Sent: Wed May 20 13:13:31 2009 To: Hafle,Mark E Cc: Pattillo,David Subject: RE: MacondoCasingDesign-

Finalpre Spuddesigncheckrequest lmportance:Normal Attachments: MacondoProspecl APB Mitigation S-19-09.21p R1

Mark. h$ated my nrodels reflectDe\r$ell design to conditions.Thilgs areslill OK. brt ircreasingtheTD lv1ly lmscut into our safety uurgiu for 9-?/8' collapse.I lure uot alleredthJassunlpliom colrplaior-sprovided tlnt several tnonths ago.butrven'ouldneed revisillhis ifthe 12.8ppgpacker lo fluid brineis changed a iiglrter to densirr-. I-rvas interested changiqg uhole reportto rcflecttlrenervconditions. nd in the particutarly mitigatiouoptioru for thnt the project n'ol't purnre. hxtead.I havererisedthereporlto adda 3 pagesection rvhiclrdiscuises theihauges andimpact. Please rneknorvif this fonnatis clear. let Keepus in theloop. Riclr
Frm: Hrflo-LfrrkF. Mdey. StephnC

Smt: Lluday. I{ry Il,2009 3;17PIrl To: Ce lrlillc, Ridnrd A (Vikins) SubJGct lr{amndo(heing Desig - FinolpreSpuddesign cbL-krspes Steveand Rich.

OK. I belieretre havea {inal plan... please therevised Altached trnd uellbore schematic... ard l3-5/8n nou.deeper... thatdre-u-3/4 16" are so erpandable bea conthgenc,r rvill string( hlt please clreckits design it is likel_"goingto beneeded) as Wellis non slurllouer also.20.2t10'MD/TVI). Updated PPFG on theschemadc. is << File:Macondo_\{C 252_l Sclrenaric >> 051109_Rev{_DEFINE.xls Thedatafrom rny'notein April still applies corrections .. for roo. Please mekuorvifyou lraveanyquestions. let Thanks. Nf:uk
From: Senl: 'l'o: Hafle,ItlrkE ThuNdiv..{pril 09. 2009 9:51 AM Irlre.v. Steptvr C RE:MocondoCosingD*ign

SubJccl:

Good rnonriug Steve. I lravea fervrevisions& correctiorrs lhe Tv{acorrdo for casingdesign: Well naureis Maconrl,o, MC 252 # l, OCS-G-32306 16" rrill really be a '|ircr..." top is at -5121'. lruug iu the 22". 2?7#.x-80 extnjoint just belorvrhe rvellhead.so 22', is exposedto TD. 16" 97# ' P-l l0 is allocatcdto bc uscdon this {asnuningit * i[ pnssrc'isc.ddcsigr) I l-7l8" liner uill actrallylretheEnr.enrrrre sET | 1.75x 13,5/E expandable liner

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ExhibirNo. _ Worldwide Court

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BP-HZN-2 7gMDL00202550 1

Ptoductioucasingnillur'9-718'Q-l25...nolI2Sonthisrrell. (I'mstillnorkingtlreCO2issuc.butdon"texpectit to bea probleur here) Let mekrpw if I'ou needclarificationor additjonal informalion. Regards. Mark llalle Drillir Enginr
tsPDpwatq GoN{ (o) 281-36Gf237 (ur) 28t{87-8216

F|m; To: Ce Mark-

Iuffc.r, StwbcnC H.1Se, I\larli E Sirns.Darid C: lrlill.r, Richrd .{,(Viknrg) [\\':NlocondoCosingDesigr

Sent: Frirhy.Februar-v 200910;19.{M 06.

Subrcct:

BecauseGOM is snch a good crslomcr aud I lilie )'ou guys. I \.vas.ablc conrpleteruy anall'sis of the Macondo to casitrg desiSn this week! (Xcourse since I'll on['be here 3 dals nerl lt'eek and tlroselluee days are packed lrith meetiugs may lrave had sornetling to do raith it. Actually lhis lell rverrtfiridy easilyand the desipan lhis nell sasn'l very complicated.I'ie attached report and for a my r'ersion of the Stressclreckfile. Pleaselet nre klron' if there are ary questious.errors. revisioru. etc. I ruderstand Rich is rvorking tle AFB anall'siscurreillt. << File: MacondoscrnFeb09.doc >> << File: Macouda(lvlC252#2).sck >> David- thanlis for the fast SWO approval. Steve Tubular qucstion? Trv thc BP Tubular Tcchnolog, Wcb Sitc. hltps://epli.bp8lobal.corn/C | O/C?/TubularTo20Techrr,olosr/default.asns

Frum:

HJla lr{arkE Fetrnrry 04.20O9 9:53 AIrl

Sern: rvqhs(lT, Tol l\ttrq',

Steplm C I'dacmdo Casing Design

SubJecl:

Slcve. Here's the latest fast track erdoration nell. . . looking to a possible April spud with Marianas rig. How is yortr schedule to cranli through Stresscheck this one? It's planned as a keeper nell- and Rich is norking on APB mitigation right nolv. Plan Nould be to nur a produclion liner and nrspendfor firturc tieback, or possib\' nrn a firll strin << File. Maoondo-PP-MW-FG-BOD-rer8.ZIP >> of 9-?/8 for production if capital and pipe can be found. <<File: Macxrndo-MC252#2 Schernatic020J09 RevB.ZIP>> <<File: Macondo MC.252#2 Scheuratic >> 020109_RevB.ZIP Regards. \{ark FLdIe
Drilling Enginu BP Dccpurter GoI\l (o) 281-36G.1237

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BP-HZN-21 79MD10020255 1

28t-688216 (m)

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BP-HZN-21 79MDL002A2552

#np

TECHNICAL REPORT

T.rtle: Macondo Prospect ApB Mitigation PrepandBy: RichMiiler- EpTIntegrityManagsment Toam Approved By: P. DavidPattilto - EpTlntegdtyManagement ll Team lssuedTo: MarkHafle Date: May19,2009 Revision: I

Welf parameters the upcoming fg MC 252#1 Macondoprospecthave beenfinalized. A reporton AnnularPressure Buildup(APB)was issuedin February basedon preliminary data. The uiOateO paramelers alterthe analysb but do not changethe overallmessageor concluslons.Ratherthan rcwod( all sectionsof the report,the most relevantchangesare hightighted here. Tie changewith the bigges( impactcomesfrom lncreasing TD mud weighttrom 14.2ppg to 14.6 ppg. the No changeto the flanned-1Z.A.ppS cornpletion brinewas communicated;thbrefore nei cottapse tne prcssureacmssthe 9.718'has increased.The produclion casingTOC is wetl abovethe previousshoe, s9 tLe_B annufus be trappedand subjectto APB. B annulus mitigafron must be rerrisited eimer will if tlre TD mud weight incrcases above 11.6 ppg or fffie packer luia is ress tt an 12.9 ppg. The recommendations remainessentially same: the 1. PrimaryC annulusmitigation achieved new 1,600psi inward-acting is via collapsedisks run in 16"subs. The disksmitigate16' collapseloadsunderthe updated welt design'parameters. 2. PrimaryB annulusmitigation comesfrom 7,500 psi outward-acting burstdisks run in the same 16"subs. The newwell parameters havelowerg-7/8'collapsedesignfactorsthan before. \Mth e worst caseA annulusprofileof hydrostatic melhanolat lhe mudlineand 12.8ppg b,rine below, the higheslAPB thal coulcloccurptiorto dlsk ruptureresultsin a 1.03collapsedeiign factor. This worsl case scenariois marginally acceflable but must be revisited well parameters if change. 3. Secondary annulusmitigation B comesfrom the strengthot lhe 9-7lE". PredictedApB resultsin an unmitigated collapse 1.05 designfadorwith synthetb 14.6ppg mud on the backside and hydrostatic 12.8ppg packerfluirtinside. This secondary mitigation marginal. is 4. SecordaryG annulusmitigation comefrom pumpng a nitrifiedspaceraheadof the 16' can cemenl. This analysishas not beenupdatedfor the newwell parameters. Figure2 is updated showthe new well parameters.Table I is updetedto showWellcat outputfortte to new well parameters-The magnitude APB does not changemuch. Table 2 summarizes of ApB loads and the resulting casingcollapse des(1nfactorswilhoutmitigation.The loadschangedue to different Ruidweightsratherthansubstantially rlifferent ApB levels.

MacandoPtospectAPB Mitigation

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BP-HZN-279MD100202553 1

ifr.@s,oef ppg 11.8

nitifietl spacer

zz @qw
18'@9,900 16',@ 12,5@' 115/A'@ 15,300 contingency expanda ble @ 17,000 9-78'@20200' UPDATEDFigure2 - SmplifiedWellSchematicwithMitigation Altematives Default Mud P\fT APB Volume
0 psi psi 10,098 9 84? nsi u psl 0 psi 6.620 Dsi

Scenario
A annulus vnled A&B annulivented

Annulus
A

ct6ct8 PVT

c
c

APB Volume 13.1bbls 0 psi t\r.1 DDls psi 28.8bbls 30.8 bbls 7,961 19.5bbls 7.865 osi 19.4bbls
13-1 bbls 30.8bbls 19.5bbls 0 psi 0 psi 5.590osi 13.1bbls 28.8 bbls 19.4bbls

A B

Table1 -APB wtthout Mitlgetion

String
9-718'62.80 Q-125 16"97.0P-l10

Collapse Rating
psi 11,140 2,340 psi

Pressure Loads
Pi: hydrostatic 12.8ppg Po:APB on 14.6ppq Pi: hydrostatic 14.6ppg Po:APBon 11.8ppq

Default Mutl APB DFC psi 0.87 10,098 psi 0.38 6,620

cl6Ct8 APB DFC

7,961psi 5,590 psi 1.05 0.46

UPDATED

Loadswithod

Figure5 showsthe corilrolling collapse disk calculations forlhe 16"cesing. Fpure 7 has updatedbursl disk calculations mi{igation 9.7/8"collapseloads. for of

Macondo Prcqerl APB Mitigation

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BP-HZN-279MDL00202554 1

,trr cdLFs rrst

l|fr? ClrF.l l.600l 6,300 qg'J

D.tlh 5,(l1' 6,Gr

R;

l"^rT*'orY*nY'
Fo FI 3,ry 1,612 PG 2,tv 2,O12 DFc

, Ailutaqa./Aqb r2.8m AArtohB rd lc' tf lf Po Pl ft OFo

sfq wrt il.t37 5,5e3 6.5r 7.6t 6s l,gn I,e t.7!2 1,690 1.07 7.17 7.73 t.29 !,117 5,99t 7.6t 8,150

6.&

r.06 Lt5 1.21 tzr

224.3 XJo il7F1.t0

0,0.0 .ttl

8,(D0 lt.t g,qxr 1r.8 9,qxr r2r

7,a69 6.068 1,t37 qG? 6.826 1,7a6 4cg3 7,609 1,004

97.0 P-l t0

m'8t.20Gt25 tB'c cr0atabb

,::
t3,Eto tt,1,t{t

r 6'2'80 Gtat

W
l5,3r 17,W n,mt
Oelh 5.08t

12,500 t!.4

il,7 Drt 2f .6 1,600 Fld.t llmlbAPBb 2666 pra

lil'rdd.ffih$,mAh

o,t
77.E ,600pd drr !nr. ApBto 2.039Ft

- 16" Collapse DiskGalculations OtiginalMud Weights wilh

FG

ArN htt it hyeo sh b Fc ls tlukl tc" 9-7la $78 0-t/8' Fo Po Pi Fc

s.?,8. OFc

MrYP Co!.p!

| tuaoha F 4.7 On.l tln ndrc g-7/8. t6. ,7C S-1te PofuPIPGOR .q.ra r,rov o.sa

*78

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97.0Ftt0

0,3&

qCTO

0,000 1l.t 9,ooo r2.3 '1o,4{rt

a,?8 4632

r2,u7 r1,12E 14,507

5,320 6,5$ 6,9.t6

4O5E qam E,490

t.3t r.33 1.31 6,326 6,632

12,6E? ta,r2r 1{,50?

3,710 a,973 a,305

S,459 g,mt 9,81

t.tl l. l/ t-t:

6,680 ztl| 7,500

'lE EE.m Ot25 Irf d erpc6bb 8" 6200+125

l0,m

48m

t3.6

fi. r40

UPDATED Figure - 16"BurstDisksfor B Annulus APB Attachedis the originalTechnicalReportwilhoutmodiffcation. Descriptlons celculation of methodsand assumptions still conecf. are

W
r7,o0t' 20,2N

le5OO 13.6

16.100

8,312

a,86A

1.26

t6.1dt

6,t02

to.re

15,30tt la.t

t8.22t

io,l7il

9.37t ryt t5.4

1.19

BZ21 8,fi1 i0,ftz o

15.,1 5([) Fl d!* rnlB APB E 6,619 pel

r.q

,3/00psl (lsk ilmE AFE b 6,619 p6l

Macondo Proqect APB Mitigation

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BP-HZN-27gMD 1 100202555

#np

TECHNICAL REPORT

Trtle: Macondo Prospect APBMatigation Preparcd By: RichMiller- EPTIntegrity Management Team Approved By: P. DavidPaflillotl - EPTtntegnty Management Temr lssuedTo: MarkHafle Date: February 6,2009 Revision: 0

1.0 Recommendations AnnularPressureBulldup(APB)duringproduclion generateloadsthat threatenthe Macondocaslng can strings, APB mitigation can be achieved throughthe following ways: 1 . PrimaryC annulusmltlgetion accomplished collapse is with disks in the 16". lf the rig schedule permits10 weeksof lead time,then a newdisk designb recommended with 1,600psi t 5olo collapseratingand a minimumbackpressure 7,000psi. lf disksare requiredsooner,lhen the of efsting HES40624&7 disks are acceptable, with 1,800psi r s% collapse ratingsand a minimumbackpressure 7,000psi. of PrimaryB annulusmitlgation accomplished bursidisksin the 16". HESA06239-3 disks is with are recommended a 7,500 psi * 5olo with burstratingand a minimumbackpressure 5,250psi. of Four 16'subs are recommended. Eachsub shouldcontaintwo burstdisksand two collapse disks. The subsshouldbe loctedapproximately 1,000'belowthe mudline,500'to 800' ibove 'l E' shoe, the and 500' to 700' belowthe 18" shoe. The fourthsub is includedas a back-up. 4. Secondary annulus B mitigation comesfromthe collapse resistance the 9-718'62.80 of e-129. which exceedsthe APB lod predlcted synthelic-based for mud. Boththe flnal casingstring designation and the actualmud baselluid shouldbe confirmed. secondaryc annulusmitigation comefrornpumFxng can anitffied spaceraheedof the 16' cemenl. The spacervolumeshouldbe sizedto place60 bbls of nitrogenat dovnholecondilions 2.0 Background and Input Data The Macondoprospecl MC 252 #2, is one of the possible locations the Marianas drill for rig. lt is a wildcatwell still in the planningsilage, dataon mudweights,casingseats,formaion properties, so and produdionratesis subjectto clange- This well is expected find commercial to pay,so ApB mitigation must be considered part of lhe overallwell engineering as effort. The BP TubularDesignManualstatesthat two mitigators be designed each annulusof concern will for barringextenuating operational circumslances. With lhis objective mind,the stralegyfor Macondois to in designrupturedisksfor primaryAPB mitigation and comeup with back-upmitigation iithin lime ard

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BP-HZN-21 7gMDL00202556

physical conslraints. hasexperience rupture BP wilh disks, nitrified foamspacers, syntacticfoam, and (VlT) vacuum insulated tubing forAPBmitigation. addition, hasviewed ln BP casing strength a as mitigatorwhere loads APB threaten integrity unmitigated well but colapse design fac{ors exceed minimum values.ForAPBloadcases, Tubular the Design Manual recommends a 1.1multiplier uslng on thestandard design factors account lemperature prediction to for uncertainty. Since standard the collgOsg deslgn fadoris 1.0.APBloads involve prediciion that temperature should sati$ a I .1 collapse design fador. Sinp-well.parameters,arebeing siill refined, workuses bestavailable provi<ted January this the dda on geometry proviJed the file Maondo_MC #2 S&qnatic 0129@-RevA.xls, 29'". Wellbo]e was in 252 inO properties contained Mxondo-PP-MW_FG_BoD.xls. production formation were ln parameters The and tubirgassumptiom provided lhe comdetion were by erEineer assigned Macordo.Thewellbore to schematic included lhe endof thisreport reference. is et for 2.1Thermal Model A Wellcatmodel buihto analyze thermal was the characteristics productlon. during Temperatures are calculated for2Skbop<l steady stateproduction 18,816'- bottom conditionsare from The hole 245.Fand psi. 12,350 Production are33"APl 0.6SGgas,anda gas-oil fluids oil, ratioof 1,300 sd/bbt. Figure I shows temperatures forthe produced andtheaffected fluid annuli.

Figure 1 - Predicled Temperatures 25kbopd for 2.2 APB without Mitigation The primarydriverfor APB is the averagetemperalure changein a trappedannulus. Forthis analysis, the initialcondilionis assumed be undis{.urbed to temperatures, the final conditionusesthe and lemperalures shownin Figure1. The highestlevelsof APB are calculated the scenariowhereall for annuliare sealed. Although absolutepressures highesl,dafferential the pressureloadsacrossa are casingare typicallybenign, Worstcese differential pressures occurwhenAPB is relievedfrom onlv one

MacondoPrcsFd APB Mitgdfion

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BP-HZN-279MD 1 100202557

sideof thestdng.Thisanalysis focuses collapse on loadirB, design thus scenarios involve will APB odsidea string a defined pressure and boundary condition inside. Flgure shows slmdltled schematicto 2 a well assi$in disanssing loeds mitigation APB end methods. TableI shows APBlevels forseveral different des[n scenarlos. firstscenario The assumes theA that annulus beUeddovm will production thatpressures during initial such equal hydrostatic gradient the fluid prwides screenirq Thisscenario a forcollapse loads ecross production ths casing.Thesecond scenario assumes boththeA andB annuli that havehydrostatic pressures no ddilionalAPB. This lluid with condition serves a baseline determining as for collapse loads across 16"casing.APBis calculated the fortwodifferenl pressure'volume'temperature cofrelations; is thewellcd default (PVD mud one fluid refleding cliesel,' theother a second and is ordercurue of C16C18 fit synthetic fluiddeta.2 base

B
o o cr q t

ML@ 4,88e' ppg 11.3 nitrified spacer 72'@7,s00', 18"@ 9,300 16',@ 1,s@' 1 13-5/8'@ 13,650' 11-7t8',@fi.A0}', (orexpandaUe) 9-718" 20,600' @

Figure2 - Simplified Well SchematicwithMitigation Altematives Scenario

A annulus vented

Annulus
A

B
A

Default Mud PvT cl6Ct8 PvT APB Volume APB Volume u psl 1 3 . 1 b b l s o psl 13.1bbls psl 31.0bbls 7,876 10,013 psi 31.0bbls
0 84? nEi

18.0bbls 18.0bbls

7 939 osi

A&B annulivented

Opsi 13.1bbls 0 psi 31.0bbls

6.712 Dsi

0 psi 0 psi 5 691 osi

TaUe | -APB without Mitigation

18.0bbls 13.1bbts 31.0bbls 18.0bbls

The APB valuesin Table 1 are usecl createcesingdesignloads. For the firsl scenario, to ApB is superimposed on'l-4.2ppg mud outsidethe 9-718" casing. lnsidethe casingis hydrostatic i2.8 ppg packerfluid,i.e. a fluid columnextending from surface. No gradewas specified the $Z/8", so'c6llapse for calculationsrefleclanAPl ratingof 1'l,140psi forQ-125.Table2summarizesAPBco[apseloads. tire 97/8" collapsedesignfador basedon defaultmud APB is 0.89. The dasignfactor improves a l.0B to
' Sorelle,R.R.,Jardiolin,A., Bucktey,p., and Banic, J,R "Mathemati:d Field ModlPrdictsDotvnhote DensityChengEin Stalic DdllingFluids." SPE t | | 18, 1942. ' Zanpra, M., P.N. Broussarct M.p Stephens, and "The Top 1OMud-Retated Concemsin DeepwaterDrillingOperations.' SpE 59019,2000.

Macondo ProsD'c/ APB Mitigatian

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BP-HZN-2 79MDL002025s8 1

whensynthetic P\/Tis used.These mud design faclors notadequate justify APBmitigation are to no for the B annulus. synthetic The based APBloadindicates the casing that strength bemaryinilfor may consideration seconCary as miligation. String
97/8'62.80G,t25
16',97.0 P-l10

Collapse Rating Pressure Loads

psi 1't,140 psi 2,340
l,l: nyoro$4rc tz.u ppg Po: APB on 14.2 ooo Pl: hydrostdic 14.2ppg Po: APB on 11.3 ooo

Default Mud APB DFG psi 0.89 10,013

cl6Ct8
AFB EIFC psi 1 . 0 8 7,876 0.45

psi 0.38 5,691psi 6,712 Mltigation

Table2 -APB Collapse

The 16' collapse loadswithoutmit$ationare also shownin Table 2. Loadsassumehydroslatic14.2 ppg ' mtd insidethe casingand APB superimposed 11.3ppg mt^doutside. Collapse on designfaciors areInsufiicient regardless whichfluid modelis assumed. Mitigation required of is forthis siring. 3.0 Rupture Disks Rupturedisksprovidea one-timereliefof APB. They are run in engineered subsand providetigltt r S% tolerances the pressure on resistance a casing. Both inwardand outward-acling of ruiture disks may be usefulfor mitigating APB. Outward-acting disltscan providea leak pathfor plessures'lovent to the formation. Inwad-ading diskscan provkJe pressurereliefbetweenadjacentannulipriorto the threat of a mechanical collapse. Bothtypes of diskswere considered mitigaling16"and g7/ti' collapseloads. for Rupluredisk selection does nol dapendon lemperature and APB prediction.Instead,disksare selecied to limitAPB belovtr threshold lhe that threatenscasingcollapseratings. Muchof the uncertainty associated with APB predidioncan be eliminated when designing disks,suchas using worst-case manufaduring tolerances and investigating comtinationsof fluid gradients.Becausemany of the all variables can be determined with certainty, rupturedisksdo not requirelargesafetyfaAors to accountfor the unknown. Aff cafculalions refled worst casedisk tolerances considerhow high ApB6utd rcachpriorto the disk to ventingpressure. 3.1 C Annulus Mitigauon via2a,, Burst Disks 22' burstdisksdo not look feasibtefor mitigating annulus G APB. The 16" collapseratingis only 2,340 psi, e fraciionof the 22'minimum intemalyieldpressuro(MIYP)of 6,360 psi. An outwarO-acfin! oist woufdcut lhe 27 ralirg in half in orderto limitAPB collapseloadsbelowthe 16" collapseratingi Fi,gure 3 showsone designscenario that refleclsa 3,000psi bursl disk. 22'disks are not recommended.

Macondo Ptaspect APB Mitigation

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BP-HZN-2 79MD100202559 1

AonurR W6atb Nd It 2? t5' te Po Fo Pl

4,t89

5,0r z00t
7.5F 6,54

62g,J

a,4A

2,ff1

3,72.

30

q'A72 7.165 7;t52 Em.

5,1U t.t$ !"270 El61

2,07' 2,qt{, t,t33 t,t55

r 2 5 f 0 , 0 c t 1 , t 0 4M r u
ft.7rl"or.)p.d$ | I_VM,

lt3,6s t4.o
Jt7,oo'
DN 2t.a F da* [nlt APg !0 2,753 pd

7n'62loe12o

13.s.0 rlJd

ru

lzo.eo

- 22'Bul9 Dsks for C

3.2C AnnulusMitigation lE" BurstDisks via Similarly, burst 18' diskshave same the shortcoming 22' disks.The18'diskwould as have besetfar to below casing the prior MIYP order rupture to loads in to exceeding 16'collapse the rating.Figure 4 shows calculatlons a 2,600 disk. Thlsmitigetion psi for altemative notrecommended. is
Atntla t8. mlYP CoiaDsd lAl ! | c V, | 4Efj9 5:65 4,'126 5,16{ 8.533 6,?0 2,157 2,060 2,Oti 1,913 1. 1. L k htdnbtft ntcl i6. t6r ,te t6-

dsk 2..3x-go buddbk

rrp-lo

3,000 lll 5,30 3,1701I | 2,600 lll

6 . G 8 o , r r olll z

I W. l?p@ to.z 1 W4 | 1,6@' ro.. I{T I a,56'u.3

s,O(b

6,052 7,145 ?33

1W

ls.3o'ti..

8,202 6,861 1,t35

ez.oP-lro
oE.mqrzs

6.ezoz,3rol I I
f0,o3o I,E&I I f4[V llVfu, --(ft

lW.

lrr.co rz.r
I t3,65o' t..o lrz.om, lm,so
!d dtt

f1-7r8'd.xF.n&bb 7rr.Ga.8oo 120 tt,en nlal

ot
27A Imhr APA b 2,7 Fl

Figure4 - 18"BurstDisksfor C Annulus ApB 3.3 G Annulus Mitigationvia l6" CollapseDisks 16' cofiapse dlskscan be designed equalize pressurepriorto APB loadsexceeding casingrating. to the The disks operaleon differential pressure, lhey are closelytied to collapse so loadsregardless nuiOol gmdienlsand pressurebou.ndary conditions.Figure5 showsdisk calculations fortws differentdesign scenarios.The firt scenarioassumes that the B annuluscontainshydrogath 14.2 ppg rnudwilh nd additional APB. The secondscenarioassumesa leak in the produclion casing,cauiing the 14.2ppg mudto equalize with 12.8 ppg packerfluid. ln eilhercase,an 1,800psi disk rupturespriorto tne AF-A load exceeding casingcollapse ratings.

MaconcloPtospect APB Mitigatian

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BP-HZN-2 79MD100202560 1

dll t'rribFedbx f buddilL r 224.3r.s' t'burtdbt Nr1r7P-1lo

t.ri?

Cdhpl.Eo

o.Fr r,8&t qoo 7,dxt 7.grc q5od qoo

FG

;AM['Aro , ArNtut tt ,ryd,wDtc nttd tlr ta' 16. 16. Po PI Pc DFc

c,g 9,@, z,a1 | I .q

6,316

a,16 5,t8{ 6,53 6?10 6,861

\m8 2,fi0 2,62 1,304 't,8t8

l.|f, .t fi 1.13 1.19 '1.21

3,0OO E,360 3170 2.!00 6.C80 2tt0

to2 to.t fi,3 tl.3

6.m 7,191 7,74 8,266

;; I; :;";:;
| | | 6,5.e 6341 7,42r

tADru,llrqo&s ,16' lf Po Pl

b tZB NA ADld|R 11 1t P6 ItFo

'n* r*

4.Ar8 2.0t5 5,17' 2N q91o rpg6

l"E60 1.2s

r.12 l.i5 t:i

r 97.0 P-ilo

3rt8&met25
1.7,f q qFndrtb .1rt 52.80 CttS

t3,t40

Figure5 - 16"

W
r?,oq 20,$o
DC'BI

rt,50d t2.e

I
I
Dtt 27.4
1,800 pli dH( ltma! APB b a79{ pd UoErdbk ls& n.dnrm APR

t3,660 ta,o

I
with OriginalMudWeights

l*r**#*"**
Atilta 16' Po q6k6 16r Pl b tZO ilg A Atulels t61e Pc OFc

Thecalculations repealed barile are for settling. Figure shows same design 6 the two scenarios with but lo^,r gradients. fluid psi Again, 1,800 dbk ruptures to loads the prior exceeding casing the collapse rating.
; Annulur APB t ArDuhts rs 112 EMWon 7,OpB l6f 16! t6' 16! FO R ft T}Fg

Mudhc l8'@lbpecdbt A'hrnGh tza3\-8 l8'hrstdbk t8'lt? P.110

UIYP Cqlhp* t,8@ q(m 6,360 3,8m 2.6110 6,680 2,1t0

4,6Ee

FG I

5.7

3,607 2,t49

1.09 td? r.6 t.O6 1 (X 1.O3

5,5,6 3.665 2.153 1.o9

I I i 6,0r j zto ,o.

z50o to3 I 8,$0 r r.3 e.oo 1t.! I

5,90f 4,011 2,17a 6.26f 6..f.f6 6.810 7.101 4,371 4,556 4,920 5,211 1201 2,21? ?,214 ?'Tna

5,900 6,000 6,4s 6,74t

,a,Olg .a,200 a,$r 4,&tt

2,179 2,t0a 22't 2239

t-O7 ro7 t.txi 1-06

I
t6" 9?.0F-ilo

l}5,F 88.20 Gr25 q l'1.718 aFndabl $?a" 6280Gt25

W
I
I tosc | ',r-o

1,'.* 'r..
reo
D,t 27.a
1,800pei did( Ioit! APB b a6:U Dol :itEr& .dnt& herlmh APB D't 27.4 t,800 pd dbk linlb APg |F2,nl pd Ffhd dbL @ntrcl9 mrrimum APB

1,o,'n

16! Collapse Disk

Mud Degradation

Hunting/Fike an existing has 1,800pi disk: HES406240-7 1,600psi t 5% collapsepressure 1S0"F at 7,000psi minimumbackpressure The minimumbackpressure ratingexceeds 16" 97.0P-11o MlYp ot 6,920 psi, so this disk will not llnit the casingpressure ralings. Sincethe disk designhas alreadybeenqualified,procuremenl disk sub6 of oouHoccur in 4-6 weeks. Two subsare recommended this application;'one placed1,000'belowthe for mrdline and the other50G'800' abovethe '18'shoe. A lhird sub shouldbe odered as a Dack-up. The preceding calculations reflecta nominalcollapseresistance 2,340psi. The 16"casingwill be all of driled throttgh,so the possibility casingwear shouldbe considerect. of Expeiience has shownlhat collapseresistance decreases linearlywith wear,thus a 1o9o wear groovewill lowerratingsby the same 10%. f the calculations u@atedto includea 10olo are marginfor wear,lhen the irlealdis[ specification would be 1,600psi t 5% collape pressure with the same 7,000psi minimumbackpressure.

CONFIDENTIAL

BP-HZN-279MD10020256 1 1

psi Unfortunately, existing the 1,600 diskdesign a minimum has backpressureorily4,5il) psi. A new of diskdesign maytake&10 weeks design, for te$ing,andfinalmanufaduring. In summary, cdlapse disksinthe 16'casing mitigate againsl APBloads a variety fuid densities for of and pressure boundary conditbns. timepermits, lf ordering newdiskdesign a '1,6fl) collapse psi a with rating anda 7,000psibackpressure provide margin drilingwearin the 16'. lf thewellis scheduled would a for to spudwithin weks, ths exisiing A0624&7is recommen<led. 4-5 then HES 3.4B Annulus Mnigation 16" BurstDisks via jn Outward-acting disks berunin the 16'toventB annulus bursil can APB. Catculations shown are Figure for twodifferent 7 pres$reoutside diskis assumed bethe design scenarios. eachcase, In the to formation gradient. <lesign frac This assumption considers pressur fluid building outside diskto the the pressure highest allovrred theformation. by Using pressure outside diskresults thehphesl this limit the in priorto diskrupturing. annulus is thensuperimposed B annulus APBthatcould occur the B APB on1l.Z ppgmudoutside produclion the casing. Then, difierent two scenarios considered pressure are for inside the 97/6". Thefirstscenario useshydrostatic ppgpacker 12.8 fluid.Thesecond scenario assumes the samepackerfluld density places ppgequivaleril pressure themudline model methanol but 6.7 at to a pressure. either control dictating lovrest annulus line the A psi priorto In case, 7,500 diskwitlrupture a APBloads exceedlng casing the collapGe for97/B"62.90 rating e-i25.
lArdts t! Fo B rytGla'c Po PI +zcr F,ctqlltt|J Pc ,,J6 OFc I o Atouns B 6.7 N ilme ntdhe 16' 9?O' $7/A 9?E Po Po B P. 97/8 DFc

Colbps

l*"-]
| ".'...
| +oa r.o

u21.3X-& r8i 1t7p-1r0 16r hEtdbl( 15'9?.0 P-110

I,tGO 3,8?p q68o etlo 7,5@

12,tt3 a,967
5,7|)l 6,1t2 l3,il71 t3.9r7 ql8,l 6.6C0

7,E6 8,090 8,20t

t3i l3l r.3r

12,143 5,701 t3.atl 6,1',12 t3,9E7

3,43t

9,r5r

1.4 r.it 1.17 1.r4

4,636 9.438 5,tm 9,549 809E 9.7EE

0,9?0 23{B

115/A 86.20 Clt25 t1-7O'q qFnd.bts t7ltf 6280 +r25

i3.c40 il,t,|o

Figure7 - 16' BurslDsks for B Annulus Hunting/Fike an e{sling diskdesignfor thisapplication. hes HES 406239-3 7,500 psi t 5% bur$ pressure 200"F at 5,250psi minimumbackpressure Since 16"collapsedisksare also recommended this string,it is stronglyrecommended burstand for thal collapsedisks are placedin eachsub anrl a total of four subsare orderecl.Two subswouktbe run ln the cased hole;one al 1,fi)0' BML and the other500' to 800' abovethe 18" shoe. A third sub shouldbe run 500'to 700' belowlhe 18" shoein the open hote. The fourthsub is recommended a back-up. as gradewas not specifiedon the provitled The 9-718" wellboreschemalic.This burstdisk is recommended proviJedlhatthe9-7/8''hasacollapseratingthalmeetsorexceedsl'1,'l40psi. lfaweakerproduction casingis specifiedforthis well, thenthe 16'burs| disk calculations needto be revisited. will

W
l24os

I'n'o 12'
lll.no

15.093

7.6{7

6,4'm

1.3

15,(83

l::il'*

t6,6r9

9,077

8.7& M l5.a

,t2

16.679

7,521 10,t30 at 15.4

lJt

f,500 Fl dlst *nn3 APE b q610 FEI h!dmdatuxlw

p8ldbt llrnit APBio 6,610 psl ,5OO

Macondo Pfosped APB Mitigatian

Page 7

CONFIDENTIAL

BP-HZN-21 79MD1002 A2562

4-0 Nitrified Foam Spacer The C annulushas primarymiligation 16"collapsedisl(s. A nitrogenspacerpumpedaheadof the 16' via cemenl is analyzedforconsideratlon secondary of miligation. Nitrogencan be introduced into an annulusto providea compressible medium. The benefttd nihogenis it acts as a prossuroregulator.As lhe mud expands, nitrogencompresses the with a much smaller increasein pressure, therebyreducingoverallAPB. The downsideof nitrogenis a concemfor gas migration.nner ptacement, nitrogenmay coalesoe the and rise. lf the annulusis sealed,then the risingbubblehas no roomto expard, therebymigratingbottom hole pressureback to the mudline. Gas migrationcan negateany benefitprovidedby the compresiHe medium. Calculations made usingtwo differentassumptions ges migration.The first set assumesa wonsl are for casescenariowherethe nitrogenpres$re at placement fully migrates the mudlinein a sealed to annulus. The seconC assumeslhat nnrogen set coalesces and risesagainstthe exposedformation frac gradiental the 18"shoe. A third scenariocouldinvofueno nitrogenmigration, this caseis nol as btlt severeas the two shown. A final scenariorecognizes placement of losingthe nilrogento the lhe risk formationduringcementing.This case reducesto the unmitigated APB shorvnin Table 1. Figure8 showsresullsfor the two primaryscenarios.The graph on the lefl depictsmitigation underlhe rnoreonerousconditionof full gas migration.The line showshow increasing volumeof nitrogen the rssultsin lolverAPB. However,the red line showsthe mudlineequivalenicollapsepnessure, which includesboth gas migration and APB outsidethe string. Addingthe firsi banel of nilrogenlncreases the collapseload by 2,600 psi due to gas migration.This downsideis insurmounlable giventhat the 16" collapseratingis only 2,340 psi. 16" collapse designfectorsare shownby the green tineand remain below 1.0. The graphon the righl of FigureI depicisgas migrationagainstthe 18' frac gradient Here,the gas migrationpenaltyis not prohibitive.60 bblsof nitrogenat placement providesa 1.22collapse condilions designfactor.
APB illfig.Oon wlth C Annr.ilu3 Nttrogen tu[ gas migralion twn th TOC 9,000 8.UI) 7,000 5.tx)o = 5.000
5

APB Mltga$on wlttt c Annutusilttrogen gs migralB agaiBl an opnshoe

1.1 1.0 6.000
|.'l

-\,*rcatAFB
lc' ooltp6o bsign F-r

5.0@ 0.9

1.2

*
!

osg
0.7 I
uo

4.000 +ll

to

E
o

4.ooo 3,000 2,000 1,000 0 20 tiliogen Vollm 40 60 .t Phcemil (bbb)

6
o

I g.om
2,0@ 't.0@
t,*8. AFB Ft.ssC Fcto.

T o.a o
I
06 o
-l^dh...etEG

I 05 0.4 o.3 o2

o4 0.2

1A'CotbtBo bcbn

o
20
Ntrogo Vol!re

40
at Pbccmnl

60
(bbb)

FigureI - C AnnulusMitigation with Nitrogen

Macondo Prospect APB Mitigation

Page I

CONFIDENTIAL

BP-HZN-279MD100202563 1

A nitdfied foamspacer inchded is here illuslrale potential a secondary to ils as mitigatorlt is prefened overoutward-acting disks the 22'or 18'strings; burst in howeverthere a riskthatil maynotbe is effedive nitrogen if migrates to thomudline a closed back in annulus.

Macondo ProspectAPB Mitigation

Page9

CONFIDENTIAL

BP-HZN-2 17sMD100202564

5.0 Appendix

F PfittrB EArawffiEo6fst hi.EAt ,ftA Ofrsroi; ocAlnt Fr"an7s8-o Y4o.(nlt|m IOC(Str r6C

BP GoM DeepwalerExploratlon illacondo (Preilrtnary Prospct EoDtf29t09)

lbEtIBo t [u DA'E t2!/20r-rrl pfD 2o30r0rm FFEAI r0ffi] PErr m tD

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dgO,tpEO

rwD6str@noe

m!

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tl "l'Hffi*
tl

z,zt.w

bTh&

P.t1q|ffitl

w@-10,wwno

tGf

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l+rmt krh'&

115d6, G16

t13- l2t

tt-7rFilflOt?5 ktutueail#,

tz.a. S0gl

rffiz,li'

$76.a2.4,tD DffiC.j!

lJ5-tt2 W

CONFIDENTIAL

BP-HZN-2 79MD 1 L00202565