Recognised as the first high pressure and high temperature (HPHT) development ever embarked by PETRONAS as well as the first of its kind in Malaysia, KN-UUD Development had also marked a significant step change in well engineering design approach for Asia Pacific region.Learning from experience of HPHT operators in the North Sea and the Gulf of Mexico, a detailed focus on lifecycle well integrity aspect had been thoroughly emphasised throughout the well design phase. Innovative design thoughts, meticulous process in selecting cost effective solutions and strong collaboration between operator and service providers proved to be the key ingredients for success. This paper highlights the sophisticated journey of KN-UUD HPHT development well delivery, covering the initial scoping work, design phase, equipment (and material) planning and testing, execution phase as well as the lessons learnt from the campaign.Challenges and experiences discussed include:1. Depletion on shallow reservoirs, its impact towards pore pressure and fracture gradient profile and subsequently, overall well design. First implementation of big bore well design with liner and cemented tieback philosophy in AsiaPacific. 3. HPHT lifecycle integrity aspect and considerations on worst case scenario i.e. reservoir compaction study, cement stress analysis, tubular connection and material testing. 4. Challenges in dealing with non-availability of equipment (including material) and lack of service capability within the region. 5. Complex process of identifying and procuring fit-for-purpose equipment solutions and unique contracting strategy. 6. Annulus management philosophy for HPHT development. 7. Lessons learnt from the actual well construction phase.The well was successfully delivered to meet all of its objectives, producing from layers close to 16,000 ft. beneath the seabed. The complex process, obstacles and vital experience in overcoming the challenges has pioneered a path for future application of its kind within Malaysia and Asia Pacific region.
The scope of this paper discusses the development of Offshore Wellhead Facilities within PETRONAS Group of Companies to mitigate the development of marginal offshore fields during low and volatile oil prices, as well as a case study of its first implementation at Field T, offshore Peninsular Malaysia. As the oil price plunged from USD 115/barrel to USD 27/barrel (Brent) in 2014, PETRONAS’ flagship marginal field operator, Vestigo Petroleum Sdn Bhd faced challenges to develop fields within its portfolio. It instigated a new way of field development, which includes a portfolio-based view, accelerated monetization, uncertainties reduction and better control of scope and cost. Uncertainties on the facilities design are narrowed and greater focus could be allocated to manage subsurface uncertainties during planning stage. Uncertainties on the facilities design are narrowed and greater focus could be allocated to manage subsurface uncertainties during planning stage. PETRONAS has since adopted this approach for other field development types e.g. near field developments, redevelopment of existing fields and stranded fields.
Petroliam Nasional Berhad (PETRONAS) is embarking on the implementation of the Design One Build Many (D1BM) concept, an integrated approach on design standardization, replication and volume consolidation for light weight fit for purpose wellhead platforms - also known as Lightweight Structure (LWS). The objective of the standardization is to enable monetization of marginal and small fields by improving project economics that are challenged with the high development costs and conventional execution schedules. Traditionally, projects are developed through a "bespoke" design which requires a specific engineering study during the Front End Loading (FEL) phase to cater for the field specific requirements. In addition, once the project has been sanctioned, it is a must to undergo tendering and bidding activities which can increase field monetization duration by four to five months. The current "bespoke" design has resulted in non-standardization, loss of opportunity for volume consolidation and ultimately longer time for field monetization. Although the Design One Build Many principles were known for a long time, but they were rather project oriented. Thus this emerging solution is a result of synthesizing multiple challenges with the goal to establish an end-to-end systematic approach in monetizing marginal and small fields by lowering development cost and monetization duration. There will be standardized sets of Base Design and a flexible Catalogue items to cater for standardized add on items. Lessons learned incorporation upon the repeated design and standardized execution strategy including Engineering, Procurement, Construction, Installation and Commissioning could also help in improving the delivery efficiency for the lightweight structure. The greater collaboration across fields and blocks will give significant added advantage through economies of scale efficiency and eventually increase in the overall project value.
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