In order for capital-intensive deepwater prospects to remain at investment grade potential, it is important the industry achieve meaningful improvement in capital efficiency. Achieving this goal will require a multi-faceted strategy in which advanced new technology and digital transformation will play a determining role. This paper will address the optimization of rig operations through deployment of an advanced Remotely Operated Vehicle (ROV) system that leverages precision robotics and automation technologies; reducing total cost of ownership (TCO) through increased rig productivity, operational certainty and overall utilization. Current ROV technology faces several key limitations which contribute to both schedule and cost variation. These inefficiencies are a combination of human skill variance, ROV system limitations and reliability. Advanced ROV systems have been deployed on two deepwater rigs to demonstrate that machine vision and precision robotics technologies will radically improve the predictability and efficiency of operations. Comprehensive metrics addressing safety, budget impact, cost avoidance & reduction, inventory reduction & non price TCO have been developed to capture the efficiencies and identify the net improvement to drilling and completion operations and yield outcome-based performance. An overview of the key deficiencies and limitations of legacy ROV operations will be conveyed, focusing on; i) High dependency on ROV pilot subsea task skills, ii) Worksite efficiency and ROV availability, iii) Restricted tooling capabilities per dive, iv) Rental tooling logistics and cost, v) Equipment reliability at depth, vi) Inefficient tooling changes, and vii) Dive duration and lost time efficiency launch/recovery time. An overview of how the advanced ROV system resolves these issues will be explained. In addition, an explanation of the productivity metrics will be conveyed, supported with data from the active offshore projects. Key conclusions from the data identify that enhanced robotics will achieve the objectives of i) Reducing schedule and cost risks which improve total cost of ownership, ii) Enhancing capability and improved wellsite efficiency, and iii) Increasing subsea data. The performance issues of legacy ROV operations and associated project cost impact is currently not widely recognized by the offshore drilling community. The realized limitations of such ROV operations and lack of useful performance metrics to identify non-productive time will be explained. The progression in robotic design that drives a new era of subsea robotic efficiency will be conveyed with results from offshore operations, combined with robust metrics that enable significant operational value and cost savings to be attained.
There is an increasing need for higher pressure and higher temperature rated equipment as wells are being drilled in such reservoirs in deep water subsea fields. This paper presents the development of the first 18–3/4" - 20,000 psi subsea wellhead system rated for 0°F to 350°F temperature applications utilizing high capacity running and specialty running tools. Included are details of the three year development project including component design, reliability analysis, and prototype testing of the equipment in the laboratory with simulated field conditions. With this technology, operators can explore fields while further completion technology is developed. This 20ksi subsea wellhead technology will enable operators to drill wells using 15ksi BOP stacks while the 20ksi BOP stack is under development. The wellhead system includes special provisions to enable annulus seal assemblies to be tested to 20ksi while isolating the BOP stack. Drilling into high pressure zones for logging or testing can be performed through a 13–5/8" -20ksi BOP stack which latches directly to the subsea wellhead. In synopsis, this paper highlights the wellhead system details utilized for extreme environments up to 350°F and up to 20,000psi working pressure. The goal of this paper is to open the industry's horizons to production fields and reservoirs that operators previously could not develop due to technological constraints such as the higher bottom hole pressures or greater well temperatures with existing subsea mudline wellhead equipment. Introduction Operator requirements for subsea drilling and completions systems continue to push the boundary of known, proven, and delivered technology and equipment. As these boundaries get pushed further and further, the need for a new higher pressure, higher temperature, and higher casing capacity subsea wellhead system grows as modifications to existing technology can only be used in fewer and fewer applications. Additionally, as drilling in the Gulf of Mexico continues to push into deeper and higher pressure formations, the need for increased casing suspension capacity is of equal importance. The development of this system was performed to eliminate barriers for operators that current industry developed systems could not handle, including pressure ratings in excess of 15ksi working pressure, casing loads in excess of 1.5million lbs per casing string, and producing temperatures in excess of 300°F. System Requirements The 18–3/4" - 20ksi wellhead system is designed around the maximum logical requirements of the industry for the next 10 years. Those requirements include producing temperature ranges of 0°F to 350°F and a working bore pressures of 20ksi. Additionally, as required by API, the high pressure wellhead was designed to be tested to 30ksi for an API factory acceptance shell test and is preloaded to the LP Housing for increased fatigue resistance. The casing string weights for both the intermediate and production casing strings are 2.0 million lbs each, while the associated running tools have capacities that are 10% higher than those figures (2.2 million lbs) to include enough overpull allowance for emergency operations should casing get stuck. The production casing hanger and wear bushing (2nd hanger position) can both support a full 20ksi BOP test and the intermediate casing hanger and wear bushing (1st hanger position) can support a 15ksi BOP Test with the same tool in both cases. The 18–3/4" - 20ksi metal-to-metal annulus seal assembly was designed for the full temperature range of 0°F to 350°F with 20ksi bore pressure, despite the temperature effects from the wellhead being subsea (showing that the seal region is much cooler than 350°F). Finally, the production casing hanger could see potential thermal growth in the field approaching 3.2 million lbs, so a Lockdown Bushing is provided to positively prevent the casing hanger from moving back and forth during start-up/shut-in operations. Figure 1 shows the system details.
There is an increasing need for higher pressure and higher temperature rated equipment as wells are being drilled in such reservoirs in deep water subsea fields. This paper presents the development of the first 18-3/4" - 20,000 psi subsea wellhead system rated for 0°F to 350°F temperature applications utilizing high capacity running and specialty running tools. Included are details of the three year development project including component design, reliability analysis, and prototype testing of the equipment in the laboratory with simulated field conditions. With this technology, operators can explore fields while further completion technology is developed. This 20ksi subsea wellhead technology will enable operators to drill wells using 15ksi BOP stacks while the 20ksi BOP stack is under development. The wellhead system includes special provisions to enable annulus seal assemblies to be tested to 20ksi while isolating the BOP stack. Drilling into high pressure zones for logging or testing can be performed through a 13-5/8"-20ksi BOP stack which latches directly to the subsea wellhead. In synopsis, this paper highlights the wellhead system details utilized for extreme environments up to 350°F and up to 20,000psi working pressure. The goal of this paper is to open the industry's horizons to production fields and reservoirs that operators previously could not develop due to technological constraints such as the higher bottom hole pressures or greater well temperatures with existing subsea mudline wellhead equipment. Introduction Operator requirements for subsea drilling and completions systems continue to push the boundary of known, proven, and delivered technology and equipment. As these boundaries get pushed further and further, the need for a new higher pressure, higher temperature, and higher casing capacity subsea wellhead system grows as modifications to existing technology can only be used in fewer and fewer applications. Additionally, as drilling in the Gulf of Mexico continues to push into deeper and higher pressure formations, the need for increased casing suspension capacity is of equal importance. The development of this system was performed to eliminate barriers for operators that current industry developed systems could not handle, including pressure ratings in excess of 15ksi working pressure, casing loads in excess of 1.5million lbs per casing string, and producing temperatures in excess of 300°F. System Requirements The 18-3/4?? - 20ksi wellhead system is designed around the maximum logical requirements of the industry for the next 10 years. Those requirements include producing temperature ranges of 0°F to 350°F and a working bore pressures of 20ksi. Additionally, as required by API, the high pressure wellhead was designed to be tested to 30ksi for an API factory acceptance shell test and is preloaded to the LP Housing for increased fatigue resistance. The casing string weights for both the intermediate and production casing strings are 2.0 million lbs each, while the associated running tools have capacities that are 10% higher than those figures (2.2 million lbs) to include enough overpull allowance for emergency operations should casing get stuck. The production casing hanger and wear bushing (2nd hanger position) can both support a full 20ksi BOP test and the intermediate casing hanger and wear bushing (1st hanger position) can support a 15ksi BOP Test with the same tool in both cases. The 18-3/4?? - 20ksi metal-to-metal annulus seal assembly was designed for the full temperature range of 0°F to 350°F with 20ksi bore pressure, despite the temperature effects from the wellhead being subsea (showing that the seal region is much cooler than 350°F). Finally, the production casing hanger could see potential thermal growth in the field approaching 3.2 million lbs, so a Lockdown Bushing is provided to positively prevent the casing hanger from moving back and forth during start-up/shut-in operations. Figure 1 shows the system details.
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