OTC 5808

Deepwater Drilling
by L.C. Chita and A.L. Cordeiro, Petrobras SA
This paper was presented at the 20th Annual OTe in Houston, Texas, May 2-5, 1988. The material Is subject to correction by the author. Permission
to copy is restricted to an abstract of not more than 300 words.
References and illustrations at end of paper
This paper presents the drilling program
evolution, from the first well up to now,
showing the improvement of efficiency and
costs control as well as the alternatives
selected to overcome the problems faced
during the operations. Among the
achievements, a special attention is given
to a new permanent guide base, designed and
developed by PETROBRAs, which allows to
improve the spud in of exploratory wells
and the subsea completion.
INTRODUCTION
At the end of 1984 PETROBRAs started,
with the drill ship Pelerin, operations
utilising dynamic positioning (DP) rigs.
The first well, 1-RJS-219A, in 853 meters
water discovered a giant oil field named
Marlim. In 1985, six wells were drilled in
water depths between 621 and 942 meters
with two DP ships - Pelerin and Ben Ocean
Lancer. Due to the excellent results
achieved, PETROBRAs managed to operate in
1986 four drill ships, having contracted
the PACNORSE I and the SEDCO 472. During
this period, thirteen wells were drilled in
water depths varying from 550 to 1250
meters. In 1987, eight wells were spudded
in by using the OS SEDCO 472 and the
semi-submersible SEDCO 709. In this period,
the national record of 1565 meters water
was achieved with 1-RJS-367 well, at the
Albacora field.
GENERAL CONDITIONS OF OPERATION SITE
the operation site
restricted to Campos
of the wells were
The description of
conditions will be
Basin area where 90%
carr ied out.
Water Depth - In a first stage, the area in
focus was situated between 400 and 1000m
water, where the impossibility of divers
intervention and resulting necessity of
special equipment had to be considered. The
concentration of wells in these waters
reSUlted in the discovery of fields which
showed good prospects of being extended to
even more deeper waters. As a consequence,
in OCT/86 a second stage initiated with
rigs capable to work in waters up to 1800m.
This large quantity of wells provided
PETROBRAs the informations necessary to
develop new techniques and new equipment
which increasingly proved to be
indispensable for the effective reduction
of the drilling costs and for having these
wells onstream in the future.
The exploration efforts were
concentrated on the southeastern drilling
district in an area located at Campos
BaBin, t ~ n the latitudes of
22 and 23 outh and longitudes of
39,5
0
and 40,5 East, distant 190km from
Macae where the support base
is located. In this strip, large
structures were discovered as Marlim,
Albacora and South of Marlim (yet to be
delimited). In addition to this area, one
dry well (1-BAS-80/978m water) was carried
out in Jequitinhonha Basin and other two
(1-SES-92/1110m water and 1-SES-93/1112m
water) in Sergipe/Alagoas Basin, with
promising results (FIG. 01). Despite the
great depth, the exceptional proximity of
the coast (35km) makes this area to become
of great interest for future development.
end of 87,
wells in deep
using dynamic
ABSTRACT
From Dec/84 until the
PETROBRAs have drilled 28
waters (deeper than 500m)
positioning units.
17
2
DEEPWATER DRtLLING OTC 58 08
- Inadequacy of the equipment available
on the market.
- High currents in the sea bottom.
- High inclinations of the sea bottom.
- Possible disconnections of the riser
system caused by a vessel "drive off".
The combination of long riser columns
exposed to the action of the current, high
traction levels and the "excursion" itself
of the drilling unit, are responsible for
the high stresses on the wellhead, making
necessary a complete knowledge of the soil,
the cementing conditions and the behavior
of casings as structural elements.
In all locations drilled in waters
beyond 600m along the Brazilian coast, the
formations showed low fracture gradient
(FIG. 05), mainly on the surface layers. As
a reSUlt, the cementing operations of the
structural casings (30" and 20") on their
upper sections, which would assure a good
foundation to the wellhead, became a
challenge. The low temperatures at sea
bottom (_4
o
C) and the long length of the
landing string that creates additional
pressures by the free-fall effect, also
contributed with difficulties to the
cementation of those casings.
Although less critical, the low fracture
gradient of the deeper formations causes
modifications on the casings' program,
reducing their lengths in order to attend
the "riser margin" and "kick tolerance"
criteria.
were
the
the
the
- High stresses on the wellheads.
- Diving impossibility.
- Formation of hydrates.
In addition to these ones, there
other existing problems such as
particularities of each area,
limitations of the equipment or
available resources:
Waves and Winds - The oceanometeorological
conditions of the area with occurrence
above 60% are: winds of 13 to 24 knots in
the NE direction and waves of 1,2 to 1,8
meters height, with periods from 7 to 8
seconds. The bad weather conditions,
generally occuring in winter time, are the
result of cold masses coming from the
Southeast, whereas its intensity can be
foreseen 24 hours in advance.
Currents - The current profile is fairly
complex and is closely related to the
movement of water masses in South Atlantic
and to the relief of the sea bottom.
Through current meters installed on the
drilling units, records of the intensities
of the currents were obtained. Although
significant variations from location to
location took place mainly due to the
bottom relief, the typical profile would be
the one showed in figure (02), where a
surface current ranging from 0,5 to 2,5
knots can be observed, which decreases
with depth with an inversion of direction
occuring between 200 and 500 meters and
normally reaching 0,5 knots at the bottom.
Bottom Profile The drilling area
located in the continental slope, a
submarine region extending from 200 to more
than 2000 meters of depth and located
between the shelf and the abyssal zone. The
shelf has a gentle declivity, around 0,2%,
whereas the slope shows a much more
accentuated dip, varying from 3 to 7%.
These values are totally altered by the
presence of canyons and faults which cut
the slope and values up to 84% may occur.
Sea Floor - The typical profiles for the
Marlim and Albacora areas, according to
figures (03) and (04) present a layer of
very soft clay in the first meters and with
increasing resistence with depth. It can be
noted in Marlim the presence of an
abnormally rigid portion between 10 and 40
meters of silty clay. The water content
of up to 70% on the surface layers gives an
indication of the soil fragility.
PROBLEMS FACED DURING WELL DRILLING
The exploration of Campos Basin
required, in the course of time, a drilling
activity in waters increasingly deeper. As
the water depth increased, the greater were
the operating difficulties encountered and,
when it was decided to spud in deep waters
with DP units, it was previously known that
some typical problems would have to be
faced, such as:
- Low fracture gradient of formations,
of the surface layers as well as of
the deeper ones.
- Low temperatures of the sea bottom.
The high declivity of the slope and the
weak soil have been making difficult the
use of anchored rigs and instalation of
subsea structures, like templates, due to
the complexity of the foundations. Although
not confirmed, there are indications of
slidings on the sea bottom, particulary in
the BTeas near the canyons.
The conventional wellhead equipment, in
general, proved to be inadequate to the
characteristics of the operation site. The
gUide systems as the temporary and
permanent guide bases (TGB and PGB) were
responsible for long time losses during the
first wells. Mechanical running tools like
cam-type ones, proved to be simple,
18
OTC 5808
CHITA & CORDEIRO 3
reliable and of easy
pack-offs were in part
clear-sighted methodology
for their landing.
handling. The
modified and a
was established
and different depths.
- Simplify the handling considering
normally restricted areas of
ships.
the
the
PLANNING
WELL SPUD-IN
- Have an installation method which be
effective for the various areas of use
To identify and solve the operational
problems and equipment deficiencies,
PETROBRAs selected an engineering team from
the Drilling Department with the following
incumbencies:
The constant fracturing problems
occuring during cementing of the 30" and
20" casings had to be overcome so as not to
compromise the well structure. Computer
analysis were carried out for simulating
the free-fall effects in order to obtain
the best combination between the slurry
- 1,80 meters in height.
This TGB together with the double J
running tool were responsible for a great
reduction in rig time spent in the start of
the wells.
- Caisson housing for easier handling.
- Running tool closed and with sealing.
- Side outlets for cuttings return,
preventing it from going out through
the upper portion of the base.
To speed up the installation process,
eliminating the necessity of trips and
reentries, a double J system was developed
for the running tool. The TGB was also
equipped with level indicators for
monitoring its inclination during and after
its installation.
With the results of the soil analysis
carried out in laboratories and the data
obtained by the current meters, it was
verified the necessity of changing the
structural casing program so as to ensure
the wellhead stability. In this change,
the option was the use of the caisson
not only as a foundation of the TGB but
also as structural casing, by altering its
6 to 7 meters length into 14 meters and its
42" diameter into 46" or 48". Other changes
were required, such as in the 30" x 1"
B type and 20" x 5/8" X52 type columns,
which became 30" x 1 1/2" B type and 20"
x 1" K55 type in the first 25 meters.
The installation of the TGB caisson is
carried out through jetting with the bit
positioned near the caisson shoe. The "BHA"
is equipped with a bottom motor with the
purpose of facilitating the functionning of
the double J R. Tool and eliminating the
excessive tilt problems which were occuring
in the drilling of the 36" well and which,
inclusively, caused the loss of some well
starts.
As a foundation for the TGB, a caisson
was chosen which would be run in together
with the TGB and would work as a pile.
After experiments with prototypes,
PETROBRAs' new TGB shows the following
features:
the to
operating - Observe contractors'
procedures.
- Verify their suitability
Brazilian coast conditions.
The first step of the group was to
develop a procedure which could ensure the
laying of the TGB at the sea bottom. After
making some attempts with lateral
extensions, greater heights and indicators,
it was verified that the available designs
did not meet. the needs and were not
adequate for the type of soil, making it
necessary to develop a new TGB design in
order to meet the following purposes:
- Minimize the burying effect during
drilling the 36" well.
Have effective foundation ensuring its
stability even in low resistance
soils.
- Point out the shortcomings of each
procedure and to standardize the
positive points.
- Coordinate the adoption of solutions
and of new procedures and equipment,
by avoiding as much as possible the
introduction of more than one novelty
for each operation.
- Normalize the solutions adopted with
success.
After determining the environmental
conditions of the operation site and
knowing the limitations of the drilling
units and equipment, it was able to
establish plans of action to overcome the
di fficul ties.
This group have been coordinating the
studies and designs by working in
conjunction with the Research Center,
Regional Drilling Districts, Production
Department and equipment supplying
companies.
19
4 DEEPWATER DRILLING OTe 5808
characteristics (density x viscosity) and
geometry of the landing string. In order to
better determine the surface fracture
gradient and knowledge of the soil, a cone
penetrometer specially designed for
operating in waters up to 1.500 meters
was developed in conjunction with a
national soil engineering enterprise for
obtaining better data by means of in-situ
tests.
The density of the slurry is the most
important factor for the success of the
operation and this density has been
maintained at 11 to 12 Iblgal through the
use of special additives such as the hollow
glass microspheres and with combinations of
extenders with viscosifiers and
accelerators. The inspection of the success
of the operation is being carried out
through the observation of the return at
the sea bottom with the aid of tracers such
as mica.
USE OF THE ROV'S
Although all the rigs were equipped with
last generation ROV's and the services
rendered by these vehicles are excellent,
it is advisable to reduce as much as
possible their use, at the risk of great
time losses.
One of the main difficulties encountered
by the vehicle at the operation site was
the excessive current at the bottom, which
sometimes prevented its use for various
days. Moreover, the failures of the vehicle
as well as of its cable are relatively
frequent.
Experiments made with kevlar cables
showed that this is not the appropriate
material for working with the umbilical of
vehicles without cage. The vehicles with
cage proved to be more advantageous when
operating under strong currents while the
vehicles without cage proved to be more
flexible and effective in areas of lower
bottom currents.
In order to minimize the use of the
ROV's, the operating procedures and
equipment were adapted or modified to
allow, with greater safety and reliability,
the use of the rig conventional TV's. Among
the modifications and adaptations, there
are:
- Use of rechargeable mini-beacons
positioned on the TV's guide.
- Break-away arms to allow the running
in of the TV to the extremity of the
surface casings and stabilized
drilling strings (Fig. 06).
- Telescope system on the TV's guide.
20
- Compensated guide cables.
- Observation locations positioned at
several angles facilitating the access
of the TV.
- Use of beacons on the TGB.
These resources eliminated the need for
using the ROV's, although they are still
used when the conditions are favorable.
Certainly they make the operations more
simple and increase the yield of the
operation.
WELL DESIGNS
The drilling programs of the wells
mentioned in this paper have a remarkable
similarity, even because their great
majority was drilled in two fields, Marlim
and Albacora, whose hydrocarbon producing
horizons are located at similar depths.
Even the wells spudded in Jequitinhonha and
SergipelAlagoas Basins keep this
uniformity, as they have similar water
depths and stratigraphy with the deep
waters areas of the Campos Basin.
In this way, an abstract of the design
of these wells would be: (Fig. 07)
- 46" or 48" jetted caisson - 12 to
14m.
- Phase I of 36" - 70m - 30" csg.
- Phase II of 26" - 350 to 450m
20"csg.
- Phase III of 17 1/2" -
- 700 to 800m - (Albacora/Sergipe)
- 1000 to 1300m - (Marlim).
13 3/8" csg.
- Phase IV of 12 1/4" - 600 to 800m -
9 5/8" csg.
- Phase V of 8 1/2" - 500 to 700m
7" liner.
Another benefit from the similarity of
the programs was the acquisition of
experience in the area, enabling the
optimization of the various items and
operations which influence the drilling
itself. Among the main modifications, the
adoption of the simultaneous drilling and
reaming can be cited - 14 3/4" bit plus 17
1/2" underreamer - which contributed for a
considerable gain in time. Another major
improvement, was the optimization of the
bit program, mainly during the 8 1/2"
phase, with the introduction of the
PDC-type bits.
OTC 5808
~ t T S CORDEIRO
5
DRILLING FLUID
WELL COMPLETION
These fluids, although of higher cost,
have had success in the drilling of
swelling shales, ensuring wells with good
caliper and good penetration rates.
studies have been carried out at CENPES
PETROBRAS' RESEARCH CENTER - with a view
to inspect the operation conditions and to
minimize the risks of possible formation of
hydrates.
Main features:
Tool for removing the guide funnel.
c) A cap was designed for protection to
the wellhead in addition to work as
a guide system (reversed funnel) for
equipment to be installed after
removal of the funnel.
a) The funnel release takes place
preferably by means of thrust and
shearing of the four attaching bolts
applied through a mechanical tool run
in with the drill string, which
lodges in a profile located at the
upper part of the funnel. Optionally,
the system is provided with a remote
device actuated by ROV, which
collects the shearing bolts,
releasing the funnel (Fig. 09 and
10). With the removal of the funnel,
a free area is promoted for the
running-in of a production base with
or without guide posts or any other
type of guide.
b) The high pressure housings keep
internally the features of each
manufacturer. Externally, however,
the systems will be standardized and
the housings will have the same type
of external profile, that is: the
same support on the 30" housing,
profile for H-4 connector and a
special profile in order that, after
removal of the funnel, it may receive
the production base. This profile
makes unnecessary the use of an
extend adapter, now being used, which
ensures the elevations between the
connections of the flow lines and
those controlling the "WCT"
(positioned at the production base)
and the connection of the "WCT" on
the high pressure housing, both
elements having to be fitted
accurately and simultaneously.
- Standardization of the whole external
profile of the high pressure housing.
- 30" housing.
- Protective cap for the high pressure
housing.
- Tool for installing and removing the
protective cap.
RESULTS
The immediate effect of the application
of the new tecniques and equipment
described in this paper was a considerable
reduction in drilling times and
consequently in the costs involved.
following
removable
avoided due
of polution,
of greater
cases of gas
solubi tili ty
more risks to
presents the
Guide Base with
The system
components:
- Permanent
funnel.
Up to the present, no case of hydrates
formation has been recorded, mainly because
no kick case has taken place. In production
tests it has been occurred formation of
hydrates in the manifold, but that has been
solved with the injection of glycol
upstream the choke.
The confirmation of the discoveries of
large reserves in deep waters imposed a
challenge for the development of new
techniques for their exploitation. The use
of anchored floating units and subsea
completions is the prioritary system chosen
by PETROBRAS in face of the large
experience acquired by the company. Aiming
at the future exploitation of the producing
wells by means of subsea completions, the
engineers of the Drilling Department
devised and developed a wellhead system
showing a high versatility adopted as a
standard for equipping new wells (Fig. 08).
The oil-base fluid has been
to the increase of the risks
in addition to being a fluid
difficulty of operation in
influx where there is a high
of the gas in oil, bringing
the operations.
In the initial phases of the wells, a
fairly viscous fluid with a density between
9,5 and 10 Ib/gal is being used.
For the following phases, the most used
fluid is the salted type treated with
polymers with salinity ranging from 60000
to 70000 PPM. In the last wells, successful
experiments were made, as substituting the
polymers for polyacrilamide, thereby
eliminating problems as the bit balling
during the 17 1/2" phase, mainly
considering the simultaneous reaming
operation. This fluid with salinity between
35000 to 50000 PPM will probably have its
use extended to the other phases of the
well. - -------
21
6 DEEPWATER DRtLLtNG OTe 5808
Figure (11) shows the evolution suffered
in the time spent for the well start
considering from the "spud-in" to the
landing of the 16 3/4" housing. It can be
observed that presently 4 to 5 days are
required, compared with an average of 20
days for the first wells (until the end of
85), therefore a reduction of approximately
80%.
ACKNOWLEDGEMENTS
The authors wish to express their
recognition to their colleagues of
PETROBRAS' Drilling Department who, with
their comments, enriched this work.
REFERENCES
As an effect not yet measured, the use
of PETROBRAS wellhead system as a standard,
will undoubtly result in a significant
operational economy, taking into account
the large number of wells foreseen for the
MarlimlAlbacora fields.
Simultaneous 17 1/2" underreaming while
drilling 14 3/4" phase resulted in a
drilling rate 30% faster than before.
Moreover, the optimization of the well
programs associated with the use of PDC
bits, after JAN/87, resulted in a
remarkable improvement of the drilling
performance in the 8 1/2" phase, as shown
in figure (12).
The average drilling rate has been
annually increasing, even with the average
waterdepth also increasing (Fig. 13).
By its turn,
meter has been
shown in figure
less than in 85
the cost/meter
with equivalent
the average annual cost per
increasingly reducing as
(14) and, in 87, it was 45%
and only 24% higher than
achieved in shallow waters
rigs.
EPIFANIO, Demarco Jorge; RODRIGUES,
Renato Sanches and PILOTO, Paulo Roberto
"The new gUide bases design improve spud
in and sub-sea completion in deep water"
In: DEEP OFFSHORE TECHNOLOGY CONFERENCE,
4, Monaco, 1987.
PETROLEO BRASILEIRO S.A. - DEPARTAMENTO
DE PERFURACAo.: "Manual de Opera95es em
Aguas Profundas". Rio de Janeiro, 1987.
1v.
CHITA, Luiz Carlos and RODRIGUES,
Renato Sanches
"Perfura95es em Aguas Profundas no
Brasil Inicio dos p090S" In:
Congresso-Latino Americano de
Per 5, Buenos Aires, 1986.
COELHO, Osmond and DE LEPELEIRE, Rubens
"Cimenta9go de Condutores em P090S de
Lamina D'agua Profunda Estado da
arte." In: PETROLEO BRASILEIRO S.A.
- Encontro Tecnico Interdepartamental
sobre Explota98o em Aguas Profundas,
Rio de Janeiro, 1987.
CONCLUSION
The maintenance of PETROBRAS
investiments for exploration in deep waters
has resulted in significant successes as
the discoveries in Campos and in
Sergipe/Alagoas Basins. These discoveries
give the necessary support to the
development of the exploratory program.
The difficulties faced have been
systematically bypassed with the
application of new procedures and
development of new equipment, rendering the
operations increasingly simple and
reliable. The standardization of these
solutions results in the reduction of
operation times with the consequent
reduction in costs.
While PETROBRAS goes to a drilling
optimization phase, on the other hand it
makes massive investments in Research and
Development for the exploitation of the
reserves discovered and, in a near future,
it can be foreseen the entering into
production of the Brazilian fields located
in deep waters.
22
CORDEIRO, Andre Lima
"Ensaio de do Cone - CPT".
In: PETROLEO BRASILEIRO S.A. - Encontro
Tecnico Interdepartamental sobre
Explota98o em Aguas Profundas, Rio de
Janeiro, 1987.
3 2
CURRENT (KNOTS)
o 2
- SUMMER
._.- WINTER
E::JTRANSITION
ZONE
200
800
3
000 -l-....-...l--r---I..._.....L.._--L_---J._......j
\\ (
\ I
\ I

I .
: )
I .
: /
I .
: I
I .
: I
I .
: I
I .
! I 1000..J.... ---l.__J......i. ...I
::I:
l-
Q..
UJ
o 600
a::
UJ
!;(

Cii
a::
400
UJ

\
I-BAS-'SF 0

BASIN'
SERGIPE/ALAGOAS / :'
BASIN
oS"
00 0
1;.,:(
,.> <JpOOoS'
(. r... I-SES-93
.,' :.......
... :S;'-SES -92
-=-_ -- \C, l i
- - .. ALBACORA \':'-U :
:3\TLANTIC FIELD -M{;:"Y'I
OCEAN CAMPOS ,',' 0 Ei :
BASIN f d
0 h.1J
Do- 0+'
rvo/ ,;.... t I
d.'MARIMBA ,/; ARUM
FIELD / t FIELD
Fig. 1-Brazlllan deepwater exploration basins.
SW ..... __---... NE
Fig. 2-Campos Basin current profile.
SOFT TO
HARD
SILTY
CLAY,
WITH
LOCALLY
FINE
QUARTZY
SAND
o 100 200 0 40 SO
{
WP
ATTERBERG LIMITS WL
WATER CONTENT - w

E
::I:
l-
Q..
UJ
o
100
I i
II i I
o 100 200 0 40 eo
ATTERBERG LIMITS -[
WATER CONTENT - w
Fig. 3-Albacora field typical soli profile.
Fig. 4-Marllm field typical soli profile.
23
TV CABLE
COM'ENSATED
WIRE ROPE
TV
GUIDE FRAME
/
Flg. 6-R.entry assembly.
DRILL

BREAK AWAY_
ARM SUB
13 14 15
{ Lb/gall
II 12
GRADIENT
9 10
FRACTURE
o S.F.
500
1000+--..::>>k---I....
1500

2500 - .0- j- -- -
3500
E
2000
a..
w
Cl
fig. 5-Fracture gradient xwater depth.
FUNNEL
FUNIL
Fig. 8-Petrobme deepwater wellhead atackup.
13\'
elg
18 95t8'
elg
51'2' In
7 PHASES
attLs
I [ i j , I I
WATER

7"
In
9f
elg
6 PHASES
MUOUNE
h--.-,...,..-1" 1000
r==
"" E l::=-
elg - i= - cag
20" :t: == 20"
elg Ii: MIOCENE elg


'---

Fig. 7-Deepwater casing program and lithology.

Fig. 9-Funnel releasing system details.
46" HSG ,>-l-..-LLI
ALOJ. 46"
Fig. 10-Removing the funnel.
RIGS
50
o PELERIN DS
+BEN O.L
aPACNORSEI
o SEDC0472 DS
@SEDC0709SS
40
en
~ 30
o
20
10
~ ~
!\
: \
: \
+-----+ \. ~
>-
100
c
't:I
.....
E
w
!;r
a:
50
z
0
~
a:
I-
W
z
W
a.
YEARS
Fig. 12-0rllllng performance at BY2-ln. phase.
67 65 66
YEARS
Fig. 11-Alg time from spud In to 6 ~ l n housing setting (by well).
25
>.
.g 75
"-
E
w
!;:( 50
0::
Z
o
25
0::
I-

w
a..
500
E
....
::J:
I-
a.. 1000
w
Cl
0::
w
1500

3f
100
;e
!!-
0::
\.!J
I-
w

"-
50

m
0
()
YEARS
D MAX. a. AVG WATER DEPTH
Fig. 13-0rllllng performance and water depth.
85 86
YEARS
87
Fig. "14-Average costs.
26