Wellheads and Casing

Drilling with a Riser

Temporary and Permanent Guide Bases
Fracture Gradients
Subsea Cementing
Casing Seals
Drilling Procedures - An Example
1

Conventional Riser Drilling

FLOATER

DRILLING RISER
CHOKE LINE

SEA WATER
HYDROSTATIC
MUD HYDROSTATIC

DEPTH

BOP

SEAFLOOR

PRESSURE

Conventional Riser Drilling

- Install 30-in Conductor FLOATER

DRILLPIPE

~200

30

Jet 30-in Conductor to ~ 200 ft below mudline

No riser - Mud returns to seafloor
No annulus - no cementing (in GOM)
3

Conventional Riser Drilling

- Install 20-in Conductor
FLOATER

DRILLING RISER
CHOKE LINE

30

~1,050
20
Drill 26-in hole to 1,050 ft below mudline
Riser optional - Mud returns to surface or
seafloor
Run 20-in Conductor to ~ 1,000 ft below mudline
Cement to mudline

Conventional Riser Drilling

- Install 13 3/8-in Surface Csg.
FLOATER

DRILLING RISER
CHOKE LINE

BOP
Run Riser and BOP Stack
Drill 17 1/2-in hole to 4,050 ft BML
Drill with Mud returns to surface
Run 13 3/8-in Surface Casing
to ~ 4,000 ft below mudline
Cement to mudline

13 3/8

Now, finally, we can close the BOP if necessary

Wellheads and Casing

A subsea wellhead, like a land wellhead:
Must support the BOPs while drilling
Must support the suspended casing
while cementing, and
Must seal off between casing strings
during drilling and production
operations.
6

Wellheads and Casing, cont.

In floating drilling, the casing hangers,
casing seals and cementing heads
differ
from land and platform operations
in the following manner:

Wellheads and Casing

1. The first and second casing strings
are cemented with returns to the
seabed.
2. Casing is run with the last joint madeup on a casing hanger and
permanently suspended prior to
cementing. Mud returns flow
through fluting in the hanger.
8

Wellheads and Casing

3. Usually, cementing plugs are
located at the wellhead and
released remotely. The
cementing string from the vessel
to the wellhead is drill pipe.
4. Casing seals are run and set
remotely.
9

Wellheads and Casing

5. Special test tools are required for
remotely testing the casing seals.
6. Wear bushings are essential for
protecting the wellhead.

10

Fig.4-10.
Typical
sealing
arrangement
for subsea
wells.

11

12

Depth BML
240 ft
1,100 ft
4,100 ft

8,600 ft
10,100 ft

13

14

Permanent
Guide
Structure.

Temporary
Guide Base

15

16

Utility
Guide Frame

Hole Opener
Temporary
Guide Base

17

Procedure for Starting a Well

1. To get the well started, place a heavy
steel template on the seafloor.
Run on drillpipe.
2. Four guidelines guide bit, casing, etc to
the right location on the seafloor.
3. Run 36 hole opener (with guide frame)
and drill 36 hole to ~240 ft BML
with returns to the seafloor.
18

Procedure for Starting a Well

4. Run 30 casing and cement with returns
to the seafloor. With the 30 casing
also run the permanent guide
structure and the wellhead housing.
(3 & 4 alt. Sometimes the 30 casing is
jetted or driven in. - instead of
drilling).
5. Drill 26 hole to 1,050 ft below mudline.
19

Procedure for Starting a Well

6. Run 20 conductor casing.
With the 20 casing, run the high
pressure wellhead. Cement the casing.
NOTE: The 26 hole may be drilled with
returns to the seafloor, or with returns
to the surface using the marine riser.
Note the guide posts on the permanent
guide structure. These are for the BOP stack
20

Fig. 4-5. Estimated Fracture gradients at

100 ft below seabed (Santa Barbara Channel).
21

Fracture gradient at

100 ft. below seabed

(Santa Barbara
Channel).

Why drill with returns to the seafloor?

With this low fracture gradient it is difficult
to drill with returns to the surface.
No shallow gas would be expected at this
depth below the mudline.
22

Drill with Diverter to the

Surface Casing Point

Fig. 4-5. Estimated Fracture gradients at

1000 ft below seabed (Santa Barbara Channel).
23

Shallow
Gas
Blowout

Gas
reduces
buoyancy!

24

Gas in the
Water Column

Typical specific gravity variations in a

blowout boil have increasing effect nearer
the waters surface.
Fortunately for a semi-submersible, the
rigs primary flotation members are
situated below the zones where specific
gravity has been reduced the most.
25

26

Gas in the
Water Column

If there is sufficient length to the mooring

system cables/ chains, the rig will be
pushed off location and out of harms way.
However, the plume can also cause the rig
to list, which reduces its freeboard and
makes it more susceptible to capsizing.
27

Fracture Gradients in Deep Water

Increasing the water depth reduces
the total overburden gradient and
consequently the formation fracture
gradient. This can be expressed as:

g f (g ob g p )F g p
28

g f (g ob g p )F g p
Where:

g f fracture gradient, psi/ft

g p formation pressure gradient, psi/ft
g ob overburden pressure gradient, psi/ft
F horizontal / vertical stress ratio
29

For offshore drilling:

g ob

1
d KB

0.44 d 0.4335 pff (d KB d d F )

Where:
d KB depth measured from the kelly bushing, ft
d

water depth, ft

d F height of flowline above the water, ft

f formation bulk density, g/cm3
30

g ob

1
d KB

0.44 d 0.4335 pff (d KB d d F )

0.44 d is the overburden due to water,

or simply the hydrostatic pressure at the
seafloor.
(dKB - d - dF) is merely the penetration
into the seafloor.
31

Get f from
density log.
Get F from
this plot.
Get gp
Calculate gf
Formation bulk density vs. horizontal to vertical
stress ratios for the Santa Barbara Channel.
32

Fig. 4-7. An example of onshore and

offshore fracture gradients.
33

J. W. Barker and T. D. Woods

Estimating Shallow Below Mudline Deepwater
Gulf of Mexico Fracture Gradients
Presented at the 1997 Houston AADE Chapter
Annual Technical Forum, April 2-3, 1997.

Cumulative average (BML)

formation bulk density

= 5.3 * (TVDBML)0.1356
e.g. = 5.3 * (3,000)0.1356 = 15.70 lb/gal
34

J. W. Barker and T. D. Woods contd

At 1,000 ft below mudline, avg. OB. Density,

= 5.3 * (TVDBML)0.1356
gob = 5.3 * (1,000)0.1356 = 13.52 lb/gal
gf = 0.9 * ob= 12.17 lb/gal= 0.663 psi/ft
gp = 0.8 * ob = 10.82 lb/gal= 0.563 psi/ft
NOTE: These are gradients relative to
the mudline!

35

J. W. Barker and T. D. Woods contd

At 1,000 ft below mudline, in 1,500 ft water:
Total overburden = 0.44 * 1,500
+ 0.052 * 13.52 * 1,000 psi
gob = 1,363/2,500 psi/ft = 10.48 lb/gal !!
pf = 0.44 *1,500+ 0.052 * 12.17 * 1,000 psi
gf = 1,293/2,500 psi/ft = 9.94 lb/gal
gp = 0.44 * 1,500+0.052 * 10.82 * 1,000 psi
= 1,223/2,500 psi/ft = 9.40 lb/gal
NOTE: These are gradients relative to SURFACE!
36

Ben A. Eaton and Travis L. Eaton

Fracture Gradient Prediction for the new
generation
World Oil, October 1997, pp. 93-100.
Fracture gradient equation:
p

1 D

=
Poissons
Ratio

g f (g ob g p )F g p

from Text

F S p

D D D

37

Fig. 4-8. Plot of a leak-off test.

38

Fracture Gradient Calculation

Mud Weight 9.5 PPG
Casing 13 inches
Set to 3,340 ft-KB
Frac. Grad. = ?
Fracture Pressure = 0.052 * 9.5 * 3,340 + 650
= 2,300 psig
Frac. Grad. = 2,300/3,340 = 0.6886 psi/ft
= 0.6886/0.052 = 13.24 ppg
39

Leak-Off Test

BOPs
Casing
Drillpipe

40

Fig. 4-9.
Sub-sea
cementing
system.

41

Fig.4-10.
Typical
sealing
arrangement
for subsea
wells.

42

Metal-to-Metal Casing Annulus Seal

Assures maximum seal over
extended periods, even in highpressure holes
Eliminates dependence on seal
materials that deteriorate or cold
flow.
Available on systems up to 15,000
psi pressure integrity.
43

1. Actuating force is transferred to the

2. Resilient compression element
which expands, forcing the
3. Metal seal lips into contact
with the surface of the
4. Wellhead housing and the
5. Casing hanger
Upper Metal
Seal Lips
Resilient
Compression
Element
Lower Metal
Seal Lips
44

Casing Hanger and Pack-off

Assembly
Single trip installation
The pack-off seal assembly is run
simultaneously with the casing hanger
body. All operations - installing the casing
hanger, cementing the casing string and
actuating and testing the pack-off seal are
performed in a single trip of the running
string.
45

Large Flow-By Areas

Large flow-by areas can handle most
drilling fluid applications with a minimal
drop in pressure.
Deep 2" wide flow-by slots in the casing
hanger body, and ample porting through
the pack-off nut assembly, provide clear
passage for cuttings and mudcake
without plugging.
46

Liquid Compressibility
The volume required to compress a liquid
is defined by the equation:
V = Vi * Cp * P
Where:
Vi = volume of system, bbl
Cp = compressibility = 3 * 10-6 per psi for water
= 6 * 10-6 per psi for mud
P = test pressure, psi
47

Seal Test - Example

Water depth = 500 ft (all depths are KB)
Casing string = 13 3/8 OD
Volume of system above the seal = 11 bbl
Test pressure = 3,000 psi
Test fluid = water
Previous casing string = 20, J-55, 94.0 lb/ft
Previous casing seat = 1,500 ft KB
Cement top = 996 ft
48

Seal Test - Example

V = 11 bbl
500 KB
996
1,500

Mud Line
20
13 3/8
4,000 ft 49

With no leak, the system will require

V = 3 * 10-6 * 11 * 3,000 = 0.1 bbl water
to reach test pressure.

If the seal leaks, the volume will be more,

but how much more?
50

Obviously, 0.1 bbl would be difficult to

measure. The annular volume between the
seal and the cement is
(996 - 500) ft * 0.1815 bbl/ft = 90 bbl of
mud
Now,

V = 6*10 * 90 P + 3*10 * 11 P bbl

= ( 5.4 * 10-4 + 3.3*10-5 ) P bbl
= ( 5.73 * 10-4 ) P bbl
What should the maximum pressure be?
-6

-6

51

Pressure in the annulus must always be

less than the collapse pressure of the inner
casing, and less than the internal yield of
the outer casing.
This will depend on both volume and
pressure. Table 4-2 shows the relationship
for four grades of casing.
Also, the internal yield of the 20-inch casing
is reached at 2,110 psi when V = 1.24 bbl.
52

53

Plug for
testing
casing seal
to full
working
pressure.

54

Test Procedure
1. Set seal
2. Land test plug in wellhead,
sealing off below the seal
3. Displace mud with water for test
4. Close pipe rams
5. Pump slowly down the choke line,
preferably in stages, to protect the
casing in case of leaks
55

Test Evaluation
During the test, if the wellhead system
being tested will not sustain test
pressure, several possible causes
should be considered:
1. Leak in the surface manifold
2. Leak in the test plug (detected by
returns through the drillpipe)
56

Test Evaluation, cont.

3. Leak in the casing seal
4. Leak in the BOPs
5. Leak in the hydraulic wellhead
connector

57

Test Evaluation, cont.

When the well does not sustain
pressure, it is obvious that there is a
problem.
There is also a problem if the well
takes too much fluid to reach test
pressure, just as we have discussed.
58

Drilling Procedures
from a floater
Install 30 Structural Csg.
Install 20 Conductor
Install 13 3/8 Surface Casing
etc.
59

Drilling Procedures
Tentative Hole and Casing Sizes
8 1/2 Pilot Hole to 180 BML
26x36 Hole Opener to 180 BML
Install 30 Structural Csg.
8 1/2 Pilot Hole to 1040 BML
17 1/2 Pilot Hole to 1040 BML
17 1/2x26 Under reamer to 1040
Install 20 Conductor
60

Drilling Procedures
Tentative Hole and Casing Sizes

12 1/4 Pilot Hole to 3,830 BML

12 1/4x17 1/2 Hole Opener to 3,830 BML
Install 13 3/8 Surface Csg.
12 1/4 Hole to TD (8,530 BML)
Install 9 5/8 Production Csg.
8 1/2 Hole if Required7 Contingency
Liner
61

General Rules
1. Do not change the tension on the
anchor lines until the 30 casing
has been run and cemented.
2. Have all the 30 casing and all of the
wellhead equipment on board
prior to spudding.
3. There will be an SLM prior to any
logging or coring run.
62

General Rules
4. All casing strings will be strapped
and drifted prior to running.
5. Casing will not be run until the
hole is in the best possible
condition and a trouble free
wiper trip can be made.
6. Cement densities will be
monitored with a mud balance.
63

General Rules
7. The rig will be moved 50 off location
whenever the riser is being run or
pulled.
8. No smoking or open flames are
permitted on deck whenever the
riser is connected to the well.
9. Welding permits (authorized by the
drilling supervisor and tool pusher)
will be required at all times.
64

General Rules
10. Coring will be at the the discretion of the
well site geologist, but only after
approval from the task force Manager
and the Exploration Coordinator.
11. All information concerning the well will
be kept strictly confidential. Any
discussions will be held in a secure
area in the quarters or on the rig.
65

General Rules
11. Confidentiality - contd.
Only contractors with a need to
know
will be allowed access to well information.
12. All personnel on board and all visitors
will be instructed with the necessary
environmental and safety films and
instructions.
66

General Rules
13. No one will be allowed on the
helicopters, work boats, or drilling
vessel without the proper
authorization or identification.
14. The rotary table must be positioned
within a 200 foot radius of the
proposed location.
67

General Rules
Anchoring

1. Place anchors on sea floor 5800 from

the desired final location.
2. Anchor lines should be equally
deployed around the rig with an
angular spacing of 45 degrees
between adjacent lines.
68

General Rules
Anchoring
3. Pull in opposing lines to set anchors.
An indicated line tension of 125
kips is necessary for the anchor to
receive any load.
4. A tension level of 440-460 kips
should be reached before 600 of
line is taken in with the rig
remaining stationary.
69

General Rules
Anchoring
5. If a line tension of 440-460 kips has
not been reached before 8001000 of line has been retrieved,
then it may be necessary to use
piggy-back anchors.
6. The following Western KDC plan
outlines the mooring procedure.
70

71

Shallow Gas Plan

After the rig is properly anchored the
following steps will be followed as
there is a potential for shallow gas in
this area:

72

Shallow Gas Plan

1. Leave mooring line pawls or stoppels
unset until the 20 casing has been
set and cemented.
2. Mooring winches will be manned while
the 8 1/2 pilot holes for the 30 and
20 casings are being drilled.
73

Shallow Gas Plan

3. Mooring winches will be manned
while the 8 1/2 pilot holes for the
30 and 20 casings are being
opened up or under-reamed.
4. The moonpool and seafloor will be
observed for gas bubbles until the
20 casing is set and cemented.
74

36 Hole Plan
1. Premix 600 barrels of 11.5 ppg kill mud
prior to spudding the well.
2. PU and TIH with an 8 1/2 bit, 6 - 6 1/2
drill collars, 6 jts of 5 Hevi-Wate drill
pipe, and sufficient 5 drill pipe.

75

36 Hole Plan
3. Tag bottom with the pilot bit, and
note and report the following:
a. RKB to water level
b. RKB to mud line
c. Water depth
d. Time of day (tide allowance)
76

36 Hole Plan
4. Lower TV camera, and observe bit
entering guide base. Retrieve
universal guide frame back to surface.
5. Upon spudding, space out drill string with
pup joints so that it will not be
necessary to pull the bit above the
guide base to make the first
connection.
77

36 Hole Plan
6. Drill an 8 1/2 hole to +/- 30 below
the setting depth of the 30
casing (estimated at 180 BML).
Circulate returns to the sea floor,
and monitor returns with the
TV camera.

78

36 Hole Plan
7. If there are no problems with shallow
gas, pull out of hole, PU 26 bit and
36 hole opener, 6-9 1/2 DCs, 6 jts
5 Hevi-Wate DP, and sufficient 5 DP.
Drill 36 hole to set 150 (4 joints) of
30 OD structural casing.

79

36 Hole Plan
Drill with sea water as follows:
a. Circulate viscous sweeps as
required to clean the hole.
b. Survey hole at 30, 60, and
150 BML.
c. At TD of 36 hole, displace
hole to the mud line with
viscous mud.
80

36 Hole Plan
Drill with sea water cont.:
d. Make a wiper trip.
e. Circulate the hole to the
mud
line with viscous mud.
f. Penetration rate should not
exceed 100 ft/hr overall.
81

36 Hole Plan
8. Run 30 structural casing per procedure.
9. If there are problems with shallow gas,
displace the 8 1/2 hole with kill mud
until the gas stops or the hole is full of
kill mud.
Monitor returns with the TV camera for
evidence of gas or flow, and if after
one hour the hole is stable, proceed
as in steps 7 and 8.
82

36 Hole Plan
10. If the kill mud in step 9 does not
stabilize the well and it appears that
heavier mud will not stabilize the well
or will break down the formation, then
prepare to cement.
Mix and pump, sufficient 15.8 ppg
cement slurry to circulate cement to
the mud line, and monitor returns for
gas with the TV camera.
83

36 Hole Plan

10. Make sure that the hole is stable

POH with BHA
Retrieve TGB
Move rig as required

84

26 Hole Plan
1. Have 600 barrels of 11.5 ppg kill mud
prior to drilling out below the 30
casing.
2. PU and TIH with an 8 1/2 bit, 9-6 1/2
DCs, 9 jts of 5 Hevi-Wate DP, and
sufficient 5 DP.
85

26 Hole Plan
3. Drill an 8 1/2 hole to +/- 40 below the
setting depth of the 20 casing
(estimated at 1040 BML).
Circulate returns to the rig shakers, and
monitor returns for indications of gas or
flow.
86

26 Hole Plan

4. Displace the hole with viscous

spud mud, make a wiper trip,
displace the hole with viscous
spud mud, POH, and log well
as required.

87

26 Hole Plan
5. If there are no problems with shallow
gas, pull the riser, PU & TIH with a
17 1/2 bit, 26 hole opener, monel
DC, 6-9 1/2 DCs, 6-8 DCs, 9 jts 5
Hevi-Wate DP, 26 stabilizer at 60,
qand sufficient 5 DP.
Drill a 26 hole to set 1040 of 20 OD
conductor casing as follows:
88

26 Hole Plan
a. Circulate viscous pills as
required to clean the hole.
b. Circulate returns to the sea floor
with sea water.
c. Maintain inclination at less than
three degrees.
d. Spot viscous mud at TD of 26
hole.
89

26 Hole Plan
e. Make a wiper trip.
f. Spot viscous mud as required.
g. Drop multishot and POH.
6. Run 20 OD conductor casing and
cement per procedure.

90

26 Hole Plan
7. If there are problems with shallow gas in
Step 5, circulate the hole with viscous
spud mud and slowly increase the
weight until the flow has stopped or
until the active system is depleted.
If the flow continues, pump the kill
mud at the maximum rate until the
active system is depleted.
91

26 Hole Plan
7. (Cont.) Then pump sea water at the
maximum rate until the hole bridges.
8. If the flow rate is significant, and the hole
will not bridge, prepare to move the rig.
Cement the hole to just below the sea
floor with 15.8 ppg cement. POH with
the BHA. Cut or shoot the 30 casing,
and pull the TGB and PGB. Move rig
as required.
92

26 Hole Plan
9. If the gas in step 7 depletes or the
density is sufficient to control the
well, then casing can be run or the
well can be drilled ahead.
10. Drill 8 1/2 hole to +/- 40 below the
setting depth of the 20 casing
(estimated at 1040 BML).
93

26 Hole Plan
11. Circulate and condition for logs. Pull out
of hole, and log well per procedure.
12. PU & TIH with 17 1/2 bit, Monel DC, 6-9
1/2 DCs, stabilizers at 60 amd 90, 6-8
DCs, jars, 9 jts 5 Hevi-Wate DP.

94

26 Hole Plan
13. Drill a 17 1/2 hole to sufficient depth
to set 1040 of 20 conductor casing.
Drop multishot, and POH.
14. PU & TIH with 17 1/2 bit and 26
underreamer, 6-9 1/2 drill collars, 68 drill collars, 9 jts 5 Hevi-Wate DP,
and 26 stabilizer at 60.
95

26 Hole Plan
15. Underream to sufficient depth to set
1040 of 20 conductor casing.
16. Circulate and condition the hole for
casing. Care must be taken to have a
balanced mud weight all the way
around with no heavy slugs.
96

26 Hole Plan
17. Displace hole from TD to the sea floor
with sufficient weight mud to balance
the hydrostatic when the riser is
removed.
Again, care must be taken to have a
balanced mud weight while displacing,
and the riser may have to be voided
with sea water as the heavier mud is
circulated.
97

26 Hole Plan
18. POH, run the 20 casing and 18 3/4 10,000 psi wellhead housing, and
cement per procedure.
19. If there is evidence that the hole
cannot be drilled deeper safely in
step 9, the well will be underreamed
at the depth reached in step 9 and
20 casing will be set.
98

26 Hole Plan
20. It will then be determined whether
future casing settings need to be
changed.

etc. etc. etc.

99

100

101