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As deepwater well designs have progressed toward deeper targets, the well integrity risk of surface casing strings has increased. Surface casing strings utilized in deepwater environments are installed before the drilling riser is installed allowing them to be subjected to metocean conditions and difficult to handle and install. Additionally, the exposure from the well has increased the need for advanced connector designs and complex manufacturing processes to ensure well integrity is maintained. To ensure the casing string is fit for duty, a "cradle to grave" approach is utilized to identify and classify the risks created by loads induced on the casing string. Beginning with the handling process, all handling loads, environmental loads resulting from handling, and metocean conditions are identified. Once installed, the well loads resulting from potential well exposure and structural loads resulting from the rig are identified. Finally, the connector and fabrication design process is analyzed to identify requirements needed to satisfy the load conditions and mitigate risk to well integrity. Introducing advanced mechanized tubular running technologies resulted in up to 20% reduction in exposure of the surface casing string to dangerous sea states and ocean currents and a 41% reduction in red zone entries. Exposure of the surface casing string to environmental loads was further reduced by 7% with the use of an innovative hands-free anti-rotation key, which requires no installation on the rig floor during tubular handling operations and lowers red zone entries beyond current mechanized handling solutions. Once set in place, surface casing strings are subjected to a higher classification of well service as structural and well loads increase in severity. To address this, a new weld-on connector qualified to connection assessment level I+ for gas tight service with elevated temperature per API RP 5C5 / ISO 13679 was installed, allowing deeper wells in deeper waters to be achieved.
As deepwater well designs have progressed toward deeper targets, the well integrity risk of surface casing strings has increased. Surface casing strings utilized in deepwater environments are installed before the drilling riser is installed allowing them to be subjected to metocean conditions and difficult to handle and install. Additionally, the exposure from the well has increased the need for advanced connector designs and complex manufacturing processes to ensure well integrity is maintained. To ensure the casing string is fit for duty, a "cradle to grave" approach is utilized to identify and classify the risks created by loads induced on the casing string. Beginning with the handling process, all handling loads, environmental loads resulting from handling, and metocean conditions are identified. Once installed, the well loads resulting from potential well exposure and structural loads resulting from the rig are identified. Finally, the connector and fabrication design process is analyzed to identify requirements needed to satisfy the load conditions and mitigate risk to well integrity. Introducing advanced mechanized tubular running technologies resulted in up to 20% reduction in exposure of the surface casing string to dangerous sea states and ocean currents and a 41% reduction in red zone entries. Exposure of the surface casing string to environmental loads was further reduced by 7% with the use of an innovative hands-free anti-rotation key, which requires no installation on the rig floor during tubular handling operations and lowers red zone entries beyond current mechanized handling solutions. Once set in place, surface casing strings are subjected to a higher classification of well service as structural and well loads increase in severity. To address this, a new weld-on connector qualified to connection assessment level I+ for gas tight service with elevated temperature per API RP 5C5 / ISO 13679 was installed, allowing deeper wells in deeper waters to be achieved.
As well construction progressed into increasingly deeper water depths targeting deeper reservoirs, surface casing strings became exposed to additonal risks during various phases of execution and well design requirements. Beginning with handling and installation, they are subjected to handling and environmental loads from various metocean conditions. Once set in place, they see increased exposure to higher well and structural loads while being subjected to deeper hole sections before additional casing strings are set in place. Deepwater casing strings are installed prior to the drilling riser being installed, which creates additional exposure to loads and risks not seen by other casing strings as well as loads induced by the well. To ensure the casing string is fit for duty, a "cradle to grave" approach is utilized to identify and classify the risks created by loads induced on the casing string. Each risk is analyzed and mitigated with a technological solution or best practice to ensure the design parameters of the well are achieved. Introducing advanced mechanized tubular running technologies resulted in up to 20% reduction in exposure of the surface casing string to dangerous seastates and ocean currents and a 41% reduction in red zone entries. Exposure of the surface casing string to environmental loads was further reduced by 7% with the use of an innovative hands-free anti-rotation key, which requires no installation on the rig floor during tubular handling operations and lowers red zone entries beyond current mechanized handling solutions. Once set in place, surface casing strings are subjected to a higher classification of well service as structural and well loads increase in severity. To address this, a new weld-on connector qualified to connection assessment level I+ for gas tight service with elevated temperature per API RP 5C5 / ISO 13679 was installed, allowing deeper wells in deeper waters to be achieved. It is sometimes necessary to temporarily protect the well with deeper hole sections exposed to the surface casing string. Additional challenges to effectively seal the well are present when the string contains internal weld seams and inside diameter restrictions such as the high-pressure wellhead housing and supplemental casing adapters. To overcome these challenges, a unique retrievable packer system was developed and validated to API 11D1 and ISO 14310, allowing well protection from the surface casing string and below.
The construction of wells in deepwater environments is accelerating toward a common goal of reducing the personnel required to construct wells and reducing or eliminating entry and working in hazardous zones which commonly existing around well center. Due to its repetitive nature, tubular installations are often viewed as an attractive focus to mechanize or automate. Within these operations an area often overlooked is the rig up, change out, and/or rig down of tubular installation equipment. Deepwater well construction requires casing strings to be installed in the well by utilizing a drill pipe landing string. While this is common practice, it is a practice that introduces risk as handling tools are required to be changed out during the switch over from casing to drill pipe which requires multiple personnel operating in the red zone. This risk is also present when casing strings of varying diameters are installed which gives the well architecture additional clearance down hole. Additionally, tripping operations also contain multiple components the BHA and varying diameters of drill pipe requiring multiple slip changes. While tool changeout is common and varies throughout the well construction process, one specific example that is commonly found in deepwater well designs are production tie-backs. They are often tapered with the top section of the casing string being a larger diameter than the bottom section to allow clearance for critical components contained within the completion string such as subsurface safety valves. Currently, to safely execute the installation of a production tie-back string, two slip system changes are needed as operations moved from the bottom section of casing string to the upper section of casing string and then to the drill pipe landing string. In this case, installation requires more equipment present on the rig, increased rig time due to the multiple slip changes, and increased safety risks as additional red zone entries are required to swap out slip systems. Additional examples include drill strings that contain components within the bottom hole assembly (BHA) that vary in diameter. This operation contains the same safety risks and inefficiencies as the previous example. A novel slip system has been implemented that reduces the number of slip changeouts improving safety on the rig floor and decreasing rig time.
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