Overcoming Shallow Hazards in Deepwater Malikai Batch-Set Top-Hole Sections with Engineered Trimodal Particle-Size Distribution Cement

Abstract

The well construction strategy for the Deepwater Malikai project, Malaysia, included 36-in. structural pipe jetting and 13 5/8-in. surface casing riserless cementing for top-hole sections with the objective for further development of lower sections with tension leg platform (TLP). Cementing of the 17 ½-in. surface hole mainly dominated by shale formation and penetrating multiple shallow faults required isolating shallow gas sands by bringing top of cement to the seabed, thus meeting the well integrity requirement stipulated by the Malaysian Petroleum Management (MPM).The cement slurry design for the 13 5/8-in. casing with riserless mud recovery system includes selection of lightweight trimodal particle-size distribution cement blend optimized with a gas migration control agent and low-temperature dispersant. This mitigates dynamic losses in unconsolidated formations and faults having narrow margins between pore and fracture pressures. Cement slurry achieves faster compressive strength and static gel strength development at lower seabed temperature, preventing casing subsidence and providing good shoe strength. The cement job design respects density and friction pressure hierarchies, providing flat fluid interfaces between successive fluids pumped, combined with optimal casing standoff and displacement efficiency ensuring effective mud removal in highly deviated largeannulus top-holes. This paper will discuss the extensive laboratory testing employed to qualify the engineered trimodal lightweight cement slurry design and effective mud removal strategy fit for the applications on the seven batch-set top-hole sections, achieving zonal isolation requirement.

A Low‐Cost and Low‐Density Cement Slurry System Suitable for a Shallow Unconsolidated Stratum

“…e PSD slurry, due to its particle network and corresponding reduction in the water content, inhibits the sedimentation and separation of solid and liquid phases during well cementing, and the fine particles in the mix also play a good role in suspension, ensuring that the slurry maintains a good stability. e porosity of these systems is usually between 35% and 45% [20], and a reduction in slurry porosity ensures the early development of compressive strength. An improvement in fluidity results in a more reasonable particle distribution in the cement slurry system, a smaller contact angle of the hydration film between the particles, and a smaller frictional resistance.…”

Study of the Relationships among the Reverse Torque, Vibration, and Input Parameters of Mud Pumps in Riserless Mud Recovery Drilling

“…In the land and shallow sea environment, the practice of casing drilling has become very mature to improve drilling efficiency and reduce drilling hazards. RMR technology was also applied to achieve the successful cementing of the surface casing in the Malikai deepwater field in Sabah, Malaysia [15]. A model was devised to measure the bottomhole pressure of the RMR system during gas intrusion conditions using the gas-liquid two-phase flow theory [16].…”

Quantitative Analysis of the Stability of a Mud-Return Circulation System in a Riserless Mud-Recovery Drilling System

“…It effectively solved the problems of formation erosion and wellbore collapse in the region [17]. RMR technology was also applied in Sabah, Malaysia, successfully cementing the surface casing for the Malikai deepwater oil field [18]. In the Zumba well in Norway, RMR was utilized in a unique manner to prevent drilling fluid and cuttings from being discharged into the seabed.…”