SPE 30364

HPHT Drilling and Completion Design for the Erskine Field

Society of Petroleum Engineers
G.S.Elliott SPE, R.A.Brockman, Texaco North Sea UK Co, R.M.Shivers III, SPE, Texaco Limited.
Cop'yright 1995, society of Petroleum Engineers, Inc.
This paper was prepared for presentation at Offshore Europe 95 held
in Aberdeen 5-8 September 1995.
This paper was selected for presentation by an SPE Program
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Abstract
This paper summarises the factors influencing the well
design for a high pressure high temperature (HPHT)* field
development using a Not Normally Manned Installation
(NNMI) in the UK sector of the Central North Sea (CNS).
Introduction
The Erskine gas condensate field is a 50% Texaco / 50% BP
venture and will be the first HPHT field developed in the
North Sea with frrst gas scheduled for 1997 (Fig. 1). The
field development concept is to install a not normally
manned installation (NNMI) with multiphase export of
produced fluids to the Lomond platform from six platform
wells. Drilling and completion operations will be carried out
using a harsh environment jack-up rig in cantilever mode.
Primary functional requirements for the wells include high
reliability, high productivity and the ability to perform
through tubing plug-backs. Reserves in the core area are
found in three separate but generally overlying Jurassic
sandstone producing horizons, the Kimmeridge, Erskine, and
Pentland sands.
A multi-discipline project team consisting of reservoir,
production, drilling and facilities engineers was set up to
progress the development concept. Specific well design
principles were adopted and an iterative approach was used
to produce a robust and reliable drilling and completion
design that is compatible with the overall development
concept and provides reliability on a NNMI in HPHT service
conditions.
Jackup drilling will commence over the platform jacket
which will be installed over an existing sub-sea appraisal
103
well in the spring of 1996 (Fig.2). Two wells will be
predrilled through the jacket structure and suspended prior to
the platform topsides deck being lifted into place in 1997.
The appraisal well will be tied back and wells will then be
completed ready for commercial gas export in late 1997.
Further wells will then be drilled and completed as required.
* Defined by United Kingdom Continental Shelf Operations Notice as any
well where the undisturbed bottom hole temperature is 300F or greater and
either the pore pressure exceedr 0.8 psilft or pressure control equipment
greater than 10, 000 psi rated working pressure is required.
PlatfOl'm Concept Outline
By North Sea standards Erskine is a marginal field (335
MMSCF gas, 66.5 MMBBL oil). The resultant development
has revolved around this in order to make development
economic. The following lists the main features of the
development.
1) Simple NNMI 12 slot wellhead platform providing
unprocessed multiphase fluids export to host platform
with a projected field life of 15-20 years.
2) Platform design and slot layout which enables access to
all slots for cantilevered jack-up drilling in the 300 ft
water depth.
Well Design Considerations
Primary considerations for the well design are:
1) Reservoir fluids containing H
2
S and CO
2
, Reservoir
pressure +/-14.,000 psi, temperature 350Op, initial surface
shut-in pressure 10,600 psi (Table 1).
2) Design flow rates required from each well will be up to
60 mmscf/day of gas.
3) The wells that are initially completed as Pentland sand
producers will water out and require to be plugged back
and re-completed as Erskine sand producers. Due to
availability and cost of large jack-up rigs, this requires to
be a rig-less operation.
4) Possible future production enhancement with fracturing /
2 HPHT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FffiLD .SPE 303M
laterals.
5) Wells must be reliable because of:
a) limited rig availability and high rig cost.
b) NNMI concept allowing very limited personnel access
without support vessels.
c) platform maintenance, inspection and well intervention
only being planned for once yearly.
6) Well and drilling programme features to minimise well
costs.
Well Design Primary Features
Primary well design features to meet these requirements are:
1) Monobore completion for reliable through tubing plug
.backs..
2) Polished Bore Receptacles (PBR) instead of packers.
3) Corrosion Resistant Alloys (CRA) for all flow wetted
surfaces.
5) Standard, field proven materials and technology whenever
possible.
6) Use of API bit sizes which are common in the North Sea
if necessary at the expense of non-standard casing sizes.
Completion Design
The requirement for through tubing plug backs, high
production rates, and wellbore reliability drove the proposed
completion design. The completion design (Fig.3) is based
on a PBR. It consists of a seal mandrel run on 4.112" CRA
tubing with a full bore tubing retrievable surface controlled
subsurface safety valve (TRSCSSSV). Landing nipple ID's
have been selected to allow through tubing plug backs using
cast iron bridge plugs (CIBP). The production string will be
run in a non kill weight packer fluid prior to perforation of
the wells on wireline.
Tubing Design. A 4.112" tubing string satisfies both the
production requirements and provides a workable overall
well design. Nodal analysis indicated that 3.1/2" tubing
would not achieve the required production rates of 60
mmscf/d. 5.112" tubing would provide a modest increase in
flow capacity, but would greatly increase the cost and
complexity of the casing programme. It would cause the
Pentland wells to water out prematurely due to the effect of
high liquid loadings in the tubing. Even with high flow rates
the number of wells could not be reduced due to reservoir
recovery considerations.
The production string will consist of 4.112" x 0.320" WT,
104
130 ksi tubing below the safety valve with 5" x 0.400" WT,
130 ksi tubing above to accommodate wireline insert safety
valve installation.
The tubing has been designed for burst loads based on initial
shutin wellhead pressures of 10,600 psi and flowing
wellhead temperatures of 325 deg F. The collapse load has
been based on minimum bottom hole pressure with a 18.0
ppg packer fluid. Triaxial analysis has been performed to
confirm the tubing design together with tubing movement
calculations for various operational load cases.
Metallurgy. The combination of high temperatures, CO
2
and
H
2
S partial pressures, formation water salinity, and
multiphase flow requires the use of CRA materials for the
tubing and production liner to ensure reliable corrosion
control (Table.l). A 28%Cr-31%Ni CRA has been selected
as the base case material with a yield strength of 130 ksi
which has been derated for use at elevated temperatures
(0.85) and for material anisotropy (0.9)1 (Fig 4).
Environmental testing of 13%Cr, "Super" 13%Cr and duplex
stainless steels has been conducted in an effort to qualify
lower cost materials for the tubing string. Preliminary results
indicate that 13%Cr and "Super" 13%Cr materials are not
suitable, whereas 25%Cr can be used, but with limitations on
the ability to acidize wells.
PBRvs Packer. Isolation of the reservoir from the
production casing annulus is achieved by use of a PBR
system. The PBR is installed as an integral part of the
production liner, directly below the liner hanger with the
seal mandrel and stack run with the completion string. A
PBR style completion was selected over a packer style
completion because it provides:
1) Simpler workovers (no deep milling operations required
that could lead to loss of a platform well).
2) Lower tubing stresses.
3) Simpler completion design.
4) Successful experience in US HPHT wells and recently on
the Strathspey field in the North Sea.
To maximise completion reliability and reduce the chances
of a workover, the seal stack will be maintained in a static
position during all production operations. Sufficient weight
will be set down together with annulus pressure to prevent
seal movement during hot producing and cold shutin periods.
The stack is positioned in the PBR to accommodate upward
movement during well kill operations or stimulation
treatment. Seal stack testing at simulated bottom hole
conditions is ongoing to determine the best available
configuration.
TRSCSSSV. The running of tandem tubing retrievable
SPE 30364 G.S.ELLIOTI, R.A.BROCKMAN, R.M.SHIVERS III 3
surface controlled subsurface safety valve's was considered.
However the increase in the overall completion reliability
and workover cost benefit was not significant when
compared to the added complexity and increased cost of the
completion design. Hence a single safety valve with a
communication nipple was selected as the base case. Mean
time to failure of the safety valve have been estimated as 20
years based on available North Sea data.
A single piston non-equalising flapper type valve with all
metal to metal seals will be used. To maintain the through
tubing workover ability a 4.112" full bore safety valve will
be run. The valve is rated to 15,000 psi at an operating
temperature of 350 deg F. It will be manufactured from
Inconel 718 material with a 7.875" aD and a 3.813" bore.
Skimming the valve aD to 7.750" at the expense of a
reduction in working pressure to 14,000 psi is being
considered. Fluid velocities across the valve are well below
100 ftlsec which should ensure no erosion for sand free
production
2

A separate communication nipple will be run above the valve

to allow wireline retrievable subsurface safety valves
(WRSSV) to be run should the primary valve faiL Separate
control lines will be run for the primary valve and the
communication nipple. In the event of control line failure to
the primary valve a full tubing workover would not be
required as a WRSSV will be run to maintain production.
Packer Fluid Selection. Packer fluid selection has been
driven by:
1) Improving tubing workover ability.
2) Minimising tubing movement.
3) Passive to production tubing and tieback materials.
4) Cost effectiveness.
On unperforated wells the completion string will be run in
11.3 ppg calcium chloride brine giving an initial pressure
differential across the seal stack of 5,500 psi. Seawater has
been disregarded as a suitable fluid due to the high
differential pressure and excessive tubing movement
occurring during production operations for a small reduction
in cost. low solubility of oxygen in a saturated calcium
chloride brine will ensure that only low general corrosion
occurs.
Work is ongoing to try to establish safe, efficient, reliable
means of completing perforated wells with underbalanced
clean packer fluids. If necessary perforated wells will be
completed using kill weight fluids with weights up to 18.0
ppg. Pseudo oil based muds will be used for the heavier
weight fluids as opposed to zinc bromide and formate
brines.
105
Annulus Heatup
This has been analyzed on a global systems basis with
various well designs. In all cases, pressure build-up in a
sealed annulus due to thermal expansion from production
conditions results in unacceptable loads on casings. This
will be prevented by the following measures.
1) Pressure will be bled off from all annuli at the surface
wellhead on initial production start-up.
2) For drilling casings below 20" conductor, cement tops
may be left below the previous casing shoe, thus
providing a natural relief valve to the formation.
3) For the tubing to production tieback annulus, pressure
will initially be bled off. In addition, remote pressure
monitoring will be provided on the host platform for this
annulus. In addition application of a pressurised nitrogen
cushion is being considered for this annulus.
Workover/Intervention Philosophy
Workovers and well interventions will be minimised by high
well reliability and only carrying out data gathering required
to maximise hydrocarbon recovery. Major workover and
well interventions will be carried out where possible during
the summer months. Typical through tubing operations are
expected to be:
1) Plug back and re-perforation of 2 Pentland wells as
Erskine producers.
2) Production logging on all wells on a yearly basis.
3) Installation of wireline retrievable safety valves.
Full tubing workovers are likely to be caused by PBR seal,
tubing hanger, tubing or TRSCSSSV failure. It is estimated
that at least 2 full tubing workovers will be required over the
life of field based on the overall reliability of the completion.
Shutin wellhead pressures decline sharply (Fig.5) to allow
through tubing plug backs to be carried out using
conventional wireline and coiled tubing techniques with
through tubing CIBP's. The platform has been designed to
allow wireline, coiled tubing, and snubbing / hydraulic
workover unit operations. However, logistical support must
be provided by a bridge linked Mobile Support Vessel. Full
tubing workovers can be conducted at any time by a harsh
environment jackup or a medium size (CEFM 2005-C)
jackup in summer. Modular workover rigs can also be
utilised by the addition of capping beams to the platform
thus enabling full tubing workovers to be accomplished
without using a jackup rig.
Enhanced Recovery
The deliverability of the wells completed in the Erskine sand
decline with the sharp drop in reservoir pressure which is a
characteristic of this low permeability reservoir. A number
4 RPHT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FIELD SPE 30364
of enhanced recovery techniques have been considered and
their impact on well design identified.
The technical feasibility and design of fracturing the Erskine
Sand to improve recovery has been investigated. Both
technology and equipment exist to enable fracture stimulation
to be carried out. However, erosion of production equipment
caused by proppant flowback over time is a major problem
especially when associated with high flow rates and wellhead
pressures. This stimulation technique will not be used
initially due to the increased risk of equipment failure which
will impact on the platform reliability and safety.
High angle wells have also been considered as a means of
improving well deliverability. There are however a number
of technical problems that have yet to be solved:
1) Limitations of current down hole tools (especially
slim-hole Measurement While Drilling tools at high
temperatures).
2) Bore hole stability in depleted reservoirs limits the
maximum hole angle that can be successfully drilled.
3) At initial reservoir conditions, fracture gradient decreases
with increasing hole angle, thus narrowing further the
margin between fracture gradient and pore pressure.
Studies are ongoing and it is possible that the production
liner design on the two later Erskine sand producers may be
modified to allow a future short radius horizontal sidetrack
to be performed within the Erskine sand.
Drilling Design
Platform I Rig Interfaces. The field development plan
provides for cantilever Jack-up drilling over the NNMI
platform. Advantages of this are simplified platform design
and elimination of skidoff equipment requirements. The
disadvantage is relative motion of the platform and jacket
structures and possible limits on operability in severe
weather. Field data suggests that actual movements will not
be as large as the theoretical movements predicted by
structural analyses. It is estimated that down time due to
excessive relative motion will be limited to 1 year storm
conditions or similar. Following selection of the Santa Fe
'Monitor' for the development drilling campaign, an
operability study is underway to identify means of
minimising downtime. For example a flex-connect system
is planned to be installed in the riser between the rig and
BOP.
Other platform rig interfaces include provision and tie-in of
ESD, alarms, fire and gas, firewater, kill manifold,
navigation lights, power, telecomms / PA, air, water, and
access bridges. Early selection of the jack-up rig has
allowed the platform design to suit the jack-up to reduce rig
modification cost wherever possible.
106
Lithology / Pressure Regime. Erskine lies in the Central
Graben area of the CNS. The lithology / pore pressure /
mud weight diagram is shown in Figure 6. Tertiary
formations extend to approximately 11,500 ftss. These
formations are primarily normally pressured, but reactive
unstable / overpressured shales of the Eocene age have
required oilbased mud of 12.5 ppg to maintain good hole
conditions.
Upper Cretaceous chalk and calcareous limestone then
continue to around 14,500 ftss. In most of the CNS, Lower
Cretaceous shales and marls then continue to the Late
Jurassic Kimmeridge formation which is often overpressured
due to compaction. The pressure transition zone is usually
over this Lower Cretaceous interval. Most CNS wells
targeted for the Jurassic formation set intermediate casing in
the Lower Cretaceous pressure transition zone. In the core
area of the Erskine field however, the Lower Cretaceous is
virtually absent. This results in a rapid pressure transition
towards the base of the Upper Cretaceous calcareous
limestone. Intermediate casing has to be set in the base of
the Upper Cretaceous formation. Although there are useful
formation markers such as the 'Black Limestone Marker',
picking this casing point has always been a problematic part
of the Erskine appraisal wells. Correct placement of the
intermediate casing shoe is essential to ensure sufficient
fracture stren,gth to weight up the mud and drill the
overpressured reservoir
3

The Jurassic, reservoir. sequence consists of Late Jurassic

Kimmeridge formation containing limited Kimmeridgian
hydrocarbon bearing sandstones, then Mid Jurassic sequences
that contain the Erskine and underlying Pentland sand
sequence. Pentland sands are anticipated to exhibit a strong
water drive, whereas the Erskine and Kimmeridgian sands
are depletion drive. Jurassic pore pressure at Erskine ranges
from ca. 17.8 ppg EMW in the Kimmeridge sands to 17.2
ppg EMW in the Pentland sands. Fracture pressure is in the
range 18.5 to 20 ppg EMW. Thus there is a very limited
window in which to operate allowing for mud ECD's etc.
In addition, overbalance of mudweight over pore pressure
increases through the sequence, and mud losses particularly
to the more permeable Pentland sands have caused a drilling
liner to be required to reach TD on several appraisal wells.
Significant time has been spent controlling influxes and
losses to these formations during appraisal drilling, and the
differentiation of influxes from kicks and formation
ballooning has been difficult.
Casing Setting Depths. The generic development well
design is shown in figure 7.
30" Structural Casing provides sufficient formation
integrity to support loads and drill 26" hole for the 20"
conductor.
20" Conductor is set at 2,500 fiss in order to case off
initial build section and obtain a formation strength in the
SPE 30364' G.S.ELLIOIT, R.A.BROCKMAN, R.M.smVERS III 5
15-16 ppg EMW range.
Suiface Casing is set in the top of the Upper Cretaceous
chalk to case off the unstable shales of the Eocene age and
the penneable Palaeocene sands.
Intennediate Casing is set in the pressure transition zone
towards the base of the Upper Cretaceous fonnation as
described above.
Drilling Liner is contingent to be set during the drilling
of the reservoir sequence if required.
Production Liner is set at TD and cases off the reservoir
sands and drilling liner if run.
Production Tieback String is cemented in place in the
tieback PBR on top of the production liner, and ties back to
surface as the production string.
Directional Drilling. Wells will be'S' shaped. This is
possible with quite low tangent angles due to the relatively
small areal extent of the field. The furthest stepout well
requires a tangent angle in the region of 35. 'S' shaped
wells enable the well to be vertical from intermediate casing
point to TD thus eliminating the need for MWD tools in the
highest temperature part of the well. The drillstring will also
be kept simple in the reservoir section, simplifying well
control and minimising circulating pressure losses.
Build rates will be limited to a planned rate of 1.5/l00ftin
the 26" hole and Arnco 200XT or Armacor M drillpipe
hardbanding will be used in order to minimise casing wear.
Well Design Philosophy. The following lists the general
principles used in the development of the Erskine well
design in addition to the considerations for completion
design previously discussed.
1) Use of API bit sizes common in the North Sea hole sizes,
if necessary at the expense of non-standard casing sizes.
2) Tapered casing strings to accommodate the TRSCSSSV.
3) Allowances made for casing wear, casing yield strength
reduction with temperature (Fig.4) and tri-axial stress
analysis.
4) Specification of 'extreme' and 'expected' load cases
where appropriate, with differing safety factors for the
two cases. Lame's casing burst strength equation was
used for uniaxial design calculations rather than API
Barlow equation.
5) Optimisation of running clearances on completion, casing
in casing, and casing in open hole. Consideration of
fishing capabilities of well cleanout strings and tubing.
107
6) Provision of one contingency drilling liner for the
reservoir interval and acceptance of reaching TD in a
6.1/4" equivalent hole size.
7) Isolation of the liner lap to remove the risk of liner top
leakage from completion with an underbalanced packer
fluid.
The design considerations specific to each casing string are
discussed in more detail below. This has been laid out in
the order of ascending casing size as well design is primarily
driven by completion design and TD hole size. Table 2
shows a summary drilling and production string load criteria
used in the well design.
Metallurgy. Due to the casing clearance requirements, it was
desirable to use high strength sour service casing for
intermediate and production string applications. A
qualification testing programme commenced in 1991 and
NACE TM0177 method A coupons and full scale casing
joint testing have both taken place. Notable differences were
seen in results from coupons and full scale casing. Full
scale casing qualification testing is preferred because 1) a
full scale test sample has an area equal to approximately
200,000 coupons thus increasing statistical confidence, 2) the
internal surface of the full scale sample is that which must
prevent initiation of SSC and contains imperfections
remaining from the manufacturing process. These
presumably account for the differences seen in coupon and
full scale results.
NACE TM 0175 method A high-end ClOO coupons were
found to have 90% threshold of SMYS in standard NACE
solution, but full scale joints failed this environment at 80%.
Low end C90 was used as a control and passed full scale
testing at 90% of SMYS in this environment.
Further full scale joint testing took place using a 1.5 psi HzS
partial pressure modified NACEenvironment (conservative
Erskine environment). This qualified high end yield strength
ClOO at 90% SMYS, a dramatic rise from the testing at
NACE environment conditions. Confirmatory ClOO testing
is underway, and ClIO sample testing is planned.
Selection of surface and drilling casing grades follow NACE
MR 0175 temperature and service exposure criterion, using
the production casing test full scale qualification as the initial
reference at surface conditions (Table.3).
Thus, for production applications on Erskine ClOO has been
qualified, and ClIO is planned to be used for intermediate
casing in pseudo oil based mud drilling environments.
Further testing may also qualify C110 for production
applications on Erskine
4

PrOduction Liner. A 4.1/2", 28%Cr-31%Ni production liner

will be used. The corrosive nature of the fluids requires the
use of CRA' s and the selection of this material for the
6 HPIIT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FIELD sl:>E 30364"
production liner is based on the absolute requirement for
longevity from the liner. This size provides monobore
features to the well for ease of plugback with cast iron
bridge plugs and simplified workover operations. 3.118"
wireline perforating guns can be run for sufficient
perforating performance and 2.7/8" cleanout strings can be
used.
The driving load considered is collapse load of full
undepleted formation pressure externally with depleted
production pressure at the end of field life internally.
Reservoir compaction was calculated, and connections will
be selected to maximise resistance to compression.
Zonal isolation is critical when plugging back the Pentland
producers to Erskine producers after watering out. Thus
cementation quality including anti migration properties will
be important.
With the tubingPBR below the liner hanger, hanger and
tieback equipment can be of 140 ksi carbon steel at these
temperatures (+300Op). The hydraulically actuated hanger
will be above the tieback receptacle and hence isolated from
the production wellbore fluids and pressure. therefore it is
designed only for hanging loads. The liner lap will be behind
the tieback casing, and thus overbalanced by kill weight
mud.
Production Tieback String. The production tieback string
is run to provide protection against possible production
loads. Primarily a surface tubing leak at initial shut-in
pressure on top of the brine packer fluid with degraded mud
backup was taken as the expected load case. In the extreme
case a tubing leak on top of kill weight mud packer fluid has
also been considered. The intermediate casing provides a
degree of redundancy in the event of a breach of the
production tieback string. This is considered of benefit for
the first HPHT field in the North Sea environment. Other
benefits provided by the production tieback include isolation
of the liner top behind the production casing and elimination
of casing wear concerns on the production string.
The tieback's internal size is driven by the completion
components. The 15M 4.112" TRCSSSV's available have
OD's in the region of 7.7/8", although it is expected that
Erskine valves will be skimmed to 7.3/4" at the expense of
a slight drop in pressure rating. Thus 9.5/8" ClOO sour
service casing provides the required strength capabilities with
a 7.95" drift. This provides a minimum running clearance in
the completion brine of 0.2". Increasing this clearance may
be possible if C110 casing is qualified for Erskine production
conditions.
In order to be able to meet the requirement to washover and
fish 4.112" tubing with 5" T&C couplings, a 6.3/8" minimum
drift diameter is required below the TRCSSSV. The tieback
casing selected is therefore 8" ClOO from the TRCSSSV to
200F and 7.5/8" Q125 below this to the production liner
108
top. Running clearances for the tieback string inside the
intermediate string are a minimum of 0.5" on couplings and
are around I" on pipe.
The tieback string will be tacked in place with cement in
order to prevent tieback seal movement. Following
cementation, it is necessary to pull tension in the production
tieback string to prevent high axial compressive loads from
temperature deep in the string which could exceed triaxial
stress safety factors in the event of a tubing leak during
production.
Drilling Liner. This will serve the function of a drilling
liner only, as the production liner top will straddle and
isolate this liner. Thus loads will be limited to losses to the
formation for collapse and pressure testing and gas
evacuation for extreme burst loads. The liner selected for
this application in 8.112" hole is 7", 23 ppf which provides
good clearance for cementing and allows drilling to TD in
6.1/4" hole for the production liner.
It is anticipated that this liner will be required on between 2
and 4 of the 5 new wells.
Intermediate Casing. The setting depth for the intermediate
casing in 12.114" hole is in the pressure transition zone as
already described. This hole section will continue the use of
the pseudo oilbased mud system to be used for the 17.112"
hole. It is planned that Gamma Ray-Resistivity LWDand
VSP's will be used to assist in picking the intermediate
casing point, as there are some identifiable features for.
reference in this interval. Following running and cementing
of the intermediate casing, the reservoir is drilled in 8.112"
/ 6.114" hole to TD of the well through this casing string.
Design criteria for this casing string are an 'extreme' burst
load defined as gas evacuation to surface from the reservoir.
'Expected' load is that of partial gas evacuation. In any
event sour service casing is required. Collapse loads
considered are that of mud level dropping to minimum
formation pressure. In addition, the lowermost section of the
intermediate casing is designed for production loads as a
contingency against failure to land or seal the production
tieback in the liner tieback PBR.
In order to accommodate the 9.5/8" casing at the top of the
tieback string, and be compatible with a 13.5/8" wellhead /
BOP, a 12.1/8", 90 ppf, ClIO, casing with Marubeni ULT
connections was selected for the top of the intermediate
casingS. The remainder ofthe intermediate casing is 10.3/4",
73ppf, ClIO down to 200F inside the surface casing, and
10", 72ppf, Q125 in 12.114" open hole. The 10" casing has
an 8.112" drift. Clearances for running and cementing this
string inside the surface casing are a minimum of around I"
diameter on the 10.3/4" couplings. This provides acceptable
running surge pressures and cementing ECD's.
Surface Casing. The surface casing string is required to 1)
SPE 30364 G.S.ELLIOTI, R.A.BROCKMAN, R.M.SHIVERS III 7
case off the Tertiary and Palaeocene sequence, 2)
accommodate the 12.118" casing at the top of the
intermediate casing, 3) provide a 12.114" drift for drilling to
intermediate casing point. Design criteria is based on a
limited kick due to knowledge of the area from 8 previous
exploration and appraisal wells. Sour service is not required
for this string. Losses considered are mudweight dropping to
balance pore pressure. It is planned that 17.112" or 16" open
hole will be drilled with a pseudo oil based mud system to
inhibit the reactive and unstable Tertiary formation. Surface
casing will be set in 12.5 ppg mud. The mudweight may
then be reduced for the 12.1/4" hole section to drill the
Upper Cretaceous chalk in order to increase penetration rate
and assist in detection of the pressure transition zone.
A 16" x 13.3/8" tapered casing string has been selected as
the surface casing. 16" will be run inside the 20" conductor
and 13.3/8" run below the TRSCSSSV depth and across the
open hole. A modified buttress thread has been selected for
this application on both casing sizes.
Conductor. The conductor will be set at 2,500 ftss to
provide a 15+ppg EMW formation strength, and to case off
the build section of the well. 26" hole will be drilled with
seawater and viscous sweeps, with returns to the platform
deck elevation. 20", 133 ppf, X56 casing will then be run
and cemented. Design criteria are based on kick loads
limited to the 20" shoe formation strength. Due to siting of
the platform over an existing well and site survey results,
shallow gas is considered to be extremely unlikely.
Structural Casing. Structural casing is 30" diameter. Pre-
installing the jacket allowed omission of a mudline
suspension system. Full hanging weight of all casings will be
supported by the 30"/20" casings. Structural analysis
showed 30" xl" wall, X52 material is suitable for wells
drilled through the platform jacket. A proviso on this is that
in severe storms it will be necessary to release the jackup
from the conductorlBOP if relative motion of the two
structures approaches 3 ft. Operations analysis is underway
to determine maximum relative movements that will be
allowed for continuing operations. The 30" casing from
seabed to wellhead will be coated with flame sprayed
aluminium for corrosion protection.
Analysis early in the project planning showed that if wells
were to be drilled from a jackup without the jacket in place,
30" structural casing would have required significant
redesign from the above sizes.
36" hole will be drilled vertically with seawater and viscous
sweeps and the 30" casing will be run and cemented.
Driving the 30" was discounted due to firm shallow
formations and the need to eliminate doglegs and maximise
directional control.
Casing Connections. 30" and 20" use established threaded
connectors. The surface casing uses the Dalmine ATS
109
modified buttress thread. Intermediate and smaller casings
will all utilise premium connections.
Due to the small annular clearance between some casing
strings, there are requirements for slimline couplings on
relevant casing sizes. For example the 12.118" casing at the
top of the intermediate string has a coupling OD restriction
due to 13.5/8" wellhead design constraints, however this is
also an area of high tensile loads. The Marubeni ULT
connection was selected due to it's high tensile efficiency,
full drift and restricted connection OD features. Connection
design also lends itself to this application, being customised
for specific pipe sizes. Qualification testing is also planned.
The remainder of the intermediate string utilises
Mannesmann HPC connections.
Tieback and production liner connections have not yet been
selected, but similar criteria exist.
WeUheadslXmas Trees
The heavy duty jack-ups considered for Erskine are generally
equipped with 21.1/4" I 13.5/8" BOP systems. Use of a
single 18.314" 15M BOP was considered to reduce BOP
handling and possibly simplify casing hanger configuration
for the Erskine casing programme. However, the savings do
not justify the considerable expense of supply and fitting of
such a BOP and handling system for a 6 well development.
The wellhead system is designed for the 21.114 5M x 13.5/8"
15M BOP configuration and consists of stacked casing
spools. Drilling casings will normally be suspended by
mandrel hangers with contingency hanger systems will be
provided for all casing strings. Metal to metal seals will be
provided for intermediate and tieback casing strings.
Because it is necessary to pull tension in the production
tieback string to prevent high compressive loads deep in the
string during production, a slip and seal is required.
As jackup drilling will take place through the platformjacket
casings can be hung at surface and a mudline suspension
system is not required.
To facilitate safe and efficient BOP I wellhead handling,
'quick connect' type connections will be utilised on all
wellhead and riser connections that are routinely made up
and broken.
The tubing hanger will be 11" nominal to facilitate the
possible use of 11" BOP's during future workover or well
intervention that requires only manipulation of the tubing.
The x-mas tree will be nominal 4.1116"API 15M to be
compatible with the tubing bore, and will be a stacked valve
configuration to facilitate ease of component valve
replacement. The tree is of split design consisting of a tubing
bonnet and upper valve assembly. The upper valve assembly
consists of a solid block cross containing an actuated master
valve and manual swab valve. An actuated flow wing valve
8 HPHT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FIELD SPE 30364
and a manual service wing are bolted to thier respective 90
outlets. A connection for methanol injection is provided
between the service wing and upper master valve. This
configuration has been adopted to facilitate ease of change
out of component parts of the tree assembly. Trees will be
fire resistant to maximise well security in the event of fire
on the platform. Production bore valves are not required to
cut wireline, as this feature will be provided by the block
valve assembly that will be utilised during the wireline
operations. This will minimise the chance of removing a
tree valve that may have been used to cut wire.
Conclusions
I. HPHT development wells can be designed to be safe, cost
effective. and reliable using current field proven
technology.
2. Well design requirements and considerations should be
thoroghly evaluated. The design process should start with
the completion string and work outwards. An iterative
approach allows optimisation of well design.
3. An integrated team approach enables drilling and well
design issues to be considered in the overall field
development concept.
Acknowledgements
The authors wish to thank Texaco and BP for their support
and permission to publish this paper, and all parties who
contributed to the well design and project progression.
References
1. J.B.Greer, Greer Engineering Co. " Yield Strength Reduction at
Elevated Temperatures and Anisotropy of Yield Strength in
Performance Design for OCTO" unpublished proprietary report.
2. S.J.Svedeman, K.E.Arnold. " Criteria for Sizing Multiphase
Flowlines for Erosive/Corrosive Service" SPE Production &
Facilities journal, February 1994.
3. S.D.Cassidy, Texaco E&P Technology. "Solutions to Problems
Drilling a High Pressure, High Temperature Well" SPE 24603
presented at 67th Annual Technical Conference and Exhibition
of the SPE in Washington, DC, 4-7 October 1992.
4. J.B.Greer, Greer Engineering Co." Test Programme for 110 ksi
Sour Service Casing" unpublished proprietary report.
5. E.F.Klementich, S.C.Morey, M.L.Payne, W.T.Asbill,
E.O.Banker, J.K.Bouche. "Development and Acceptance Testing
of a Flush Joint Casing Connection with Improved Performance
Properties" SPE 26320 presented at the 68th Annual Technical
Conference and Exhibition of the SPE in Houston 3-6th
October 1993.
6. The Institute of Petroleum. "Well Control During the Drilling
and Testing of High Pressure Offshore Wells".
110
7. S.A.Cruser, Texaco E&P Technology. "HPHT Production
Experience in the United States" unpublished proprietary report.
8. R.M.Shivers,J.P.Brubaker, Texaco Ltd. "Development Planning
for the HPHT Erskine Field" SPE 30370 presented at
Offshore Europe Conference in Aberdeen, Scotland, 5 ~ 8
September 1995.
SPE 30364 G.S.ELLIOIT, R.A.BROCKMAN, R.M.SmVERS III
Table 1 - Reservoir Characteristics
9
Reservoir Pressure (psia)
Reservoir Temperature (OF)
Reservoir Depth (tvd,ft)
CITHP (psia)
FWHT (OF)
Well Fluid
H
2
S (ppmv)
CO
2
(mol %)
Formation Water Ct- (ppm)
14,000
345
15,000
10,600
325
Gas/condensate
18 - 33
3.5 - 5.5
up to 160,000
Table 2 - Drilling/Production String Load Criteria
LOAD CRITERIA BURST COLLAPSE TENSION
Drilling 1. 20" casing. Gas evacuation not to exceed fracture Limited losses while drilling:- Pressure test on bumping
Casings gradient at shoe. plug.
Fluid level drops to balance or
2. Surface casing. Limited kick. formation pressure. Mud weight String weight plus
(16" /13 3/8") behind casing string. 100,000 Ibs over pull.
or
3. Intermediate casing. Full gas evacuation from pore pressure Dynamic slip loading.
(12 1/8"/10 3/4"/10") at TD of next hole section.
Mud weight behind casing string as
backup (All strings)
Production 1. Tieback string. Tubing leak at surface acting on 11.3 Below PBR:- Pore pressure outside Pressure test on bumping
Casings (9 S/8"/8"n 5/8") ppg packer fluid. with minimum bottom hole plug.
pressure. or
Degraded mud outside casing string as String weight plus
backup. Above PBR:- Mud weight outside. 100,000 Ibs over pull.
Seawater inside drops to equalise or
pore pressure of depleted reservoir. Dynamic slip loading.
Production 1. Tubing string. Maximum shutin tubing pressure plus Kill weight fluid outside with Seals seize in PBR
Tubing (5"/4 1/2") excess pressure required to start minimum pressure inside string due preventing movement of
bullhead kill. to depleted reservoir. the string during well kill
operations.
Seawater as backup. or
String weight plus
100,000 Ibs overpull.
Table 3 - OCTG Grade Selection vs Temperature and HzS Exposure
Vertical Depth Minimum Drilling Casing Production
(ft) Temperature (deg F)
Casing Liner Tubing
0-9,000 50 ClIO CIOO - CRA
~ 7,500 175 Q125 Q125
-
CRA
~ 13,500 300 140 140 CRA CRA
111
10
HPHT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FIELD
SPE 30364
II
1II
I
\ 1I1
I
I
Erskine
,
,
,
,
,
,
,
,

Lomond
I
,
,
,
,
,
ETA
,
,
\ NORWAY
UK\

L-_.L.-_.L.-_..a..;;.......BIU---
,
.---y----.._-.., ,
,
,
,
,
Fig.l -Erskine Field Location Map.
Fig.2-JackuplPlatform Interface During Operations
Fig.3.Erskine Completion
String Schematic.
9 5/8" / 8" /7 5(8"
Production
String
-
;::;
U
....
.....

r-
....
,,-
E
lU(
Ij1ii'iO:ll
.......
..
tn
1M
..
'"
...
I ...
I
5" Tubing
Flow Coupling
4 1/2" TR-SCSSSV c/Y
W1m1lne Insert Nipple
Flow Coupling
4 1/2" Tubing
Locator Sub
Seal StackI PBR
WIr8Ilne Nipple
Perforated ):Sup Joint
Wlrellne Nipple clw
gUide shoe
41(r Production liner
112
SPE30364 G.S.ELLIOTI, R.A.BROCKMAN, R.M.SIUVERS 1lI 11
...
'.
".
..
...
Low Alloy Steels
28 Cr (NI-Cr-Mo)
22/25 Cr Cold Worked
" " ..
" '
+(,lIlo ....
...... lo.'Io ........ + ..........
0.9 .. ..--+----j-----+-----1
'. .
13 Cr ISuper 13 Cr (Q & T) ""'+"""'=:::-:-+__--1
".. -... ...
j
c
:B
-Ill 0.8
i
fl
....
,
...
0.7 +----t----I----1-----t----+----'+;-:.,-...
....
.. ..
".
'.
0.6 +----t----iI----1-----t-----l-----l-----t----i----l
o 100 200
Temperature (dog F)
300 400
Fig.4-Yield Strength Degradation Factors with Temperature
12,000
10,000
<'
8,000
w
a:
:::l
m
6.000
If

::I:
:l
4,000

2,000
0
Max initial shutln
pressure 10,600 PSI
.
'\. I
j
"
"
I ."',
, .
: .., .....
"
It'''lt,, \! !
It" I !
...
! " \. /1
, \....!
" " - - .. j
.1

\!: .... L

APllOMUmft
____ J
!
Erskine
Pentland
KimmAlpha
-';
!
6
CONTRACT YEARS
'0
12
Fig.S-WelUlead Pressure Over Life of Field
113
12 RPHT DRILLING AND COMPLETION DESIGN FOR THE ERSKINE FffiLD SPE 30364
9518" /8" /7 5/1t'
Production -----............
Tlebeck String
- Frl!dlJre Grlldlflll1
- - Mud WOight
......, Pore PressL18
& 8 10 11 12 13 14 16 18 17 1& 18 :lO 21
EMW(ppQ)
Fig.6.Generalised LithologylPore PressurelMud
Weight Plot
SHlevei 140 ft
Seabed at 436 ft
30" Csg 600 ft
20" Csg .. 2,150
ft
16" /13 3/8" SurfaCe Csg
at +/-11,!iOOft tvd
TieBack
Stem
Sleeve
12 1/8" /10 3/1f' /10"
Intermediate Csg +/- 14,850ft tvd
7" Drilling Liner - contingency for
Erskine Sand wells. Expected
for Pentland sand wells.
41/2" Liner to +/-15,500 ft tvd
L
114
Fig.7-Generic Erskine Well Design