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OTC 7422

Captain Extended Well Test Program: Project Management


and Execution
W.L. Lovaas, C,N, Weller, and Wayne Huddleston, Oceaneering Production Systems, and
Brian Wells, Oceaneering Intl. Services Ltd.

Copylght 1994, Offshore Technology Conference

This paper was presented at the 26th Annual OTC in Houston, Texas, U.S.A., 2-5 May 1SS4.

This paper wae selected for presentation by the OTO Prcgram Committee following review of information contfdned In an abstract submitted by the author($). Contents of the paper,
as presented, have not been reviewed by the Offshore Technology Conference and are subject to correclhm by the author(s). The material, as presented, does not necessarily reflect
any posltlon of the Offshore Technology Conference or its officers. Permission to copy is restrlded to an abstract of not more than 300 words, Illustrations may not be copied. The abstract
should contain conspicuous acknowledgment of where and by whom the paper Is presented.

CAPTAIN EXTENDED WELL TEST PROGRAM wells. A well to the north in 1989 found 93 feet of oil
PROJECT MANAGEMENT AND EXECUTION sands and flowed at 740 BOPD using an electric
submersible pump (ESP). It was determined that
horizontal wells were necessary if commercialproduction
ABSTRACT rates were to be achieved. In 1990, one horizontal well
was drilled. Again using an ESP, it produced 6,500
Extended Well ‘hats (EWTs) are gaining increasing BOPD of heavy 19 Degree API gravity oil. From this and
recognition throughout the offshore industry as a useful other data it was theorized that there might be about 200
tool for evaluation of field developmentprospects. These million barrels of recoverable oil in the field.
tests, which can range from a few weeksto several months
in duration, provide valuable data Ibr reservoir evaluation The EWT program was originally scheduledto commence
and design of field development facilities. This paper with the drilling phase in January, 1993, and to conclude
describes how a contractor serving as project manager following a 90day extended well test in September.
supported Texaco North Sea (UK) Company in the During the test phase, the produced crude would be
planning, organization and execution of a fast-track EWT processedby equipmentinstalledaboard a semisubmersible
at the Captain field prospect offshore Scotland. drilling rig and exported to a storage tanker as clean
stabilized crude oil.
INTRODUCTION
The purpose of the extended well test program was to
In November 1992, Texaco North Sea (UK) Co. awarded confii the magnitude and producibility of the Captain
a contract to Oceaneeringto perform project management field. Test results would be used to determine sustainable
services for an extended well test (EWT) of its Captain crude oil flow rates and the probability of early water cuts
prospect. Captain is located in the Moray Firth, Block which would impact field economics. This information
13/22 of the UK sector, 90 kilometers east of Wick, would contribute to design of the eventual field
Scotland, in 107 meters of water, Fig. 1. developmentprogram and facilities. It was very important
to test the oil and water separation techrdquesfor the high
The field was discoveredin 1977when an exploratorywell viscosity crude with the ESP-induced emulsions.
encountered 191 feet of oil-bearing sand. Further
delineation followed in 1989 and 1990 with additional

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2 CAPTAIN EXTENDED WELL TEST PROGRAM: OTC 007422
PROJECT MANAGEMENTAND EXECUTION
>
The main taska fix the EWT program included the force; management approval of authorities and
following: responsibilities-includingmonetary limits; correspondence
and technical document distribution matrixes; and other
● Establish appropriate management systems and QA and Safety documents.
procedures
● Finalize vessel and hardware subcontracts It is desirable to develop realistic budgeta at the initial
● Finalize flowlinedesign and submit it to regulatory bidding point which can then be monitored by an effective
authorities cost control system. All persomel must be aware of
● Direct requisite rig modificationsto accommodate quality requirements, and a quality program which meets
the process facility 1S0-9000 guidelines should be in place. Safety and
● Ensure timely detail process design and environmentalconsiderations are major issuea demanding
fabrication. early and persistent attention. Ultimately the contractor’s
goal is always to deliver value to the customer.
The main EWT system componentsused during execution
of the well test program were: the spread-moored semi- An early Captain EWT technical and economic trade-off
submersiblewhich drilled the wells and later served as the study had concluded that a weathervaning dynamically
test platform for the process equipment; the process positioned tanker was more cost-effective than a
system; the flexible export flowlinty and the dynamically conventional tanker moored to a CALM buoy.
positioned storage tanker, Fig. 2. Preliminary efforts had identified potential subcontractor
sources for the storage tanker and a semisubmersible
Oceaneering’s function was to manage the total program drilling rig for the drilling program and follow-on use as
from planning, system cmtlguration and scheduling to the platform for a crude oil processing system.
subcontracting and timely execution during the summer Negotiationsfollowedto firm up a variety of technicaland
weather window. The critical path was controlled by the financial contract terms on this fast-track, tight schedule.
design and fabrication of the process equipment and
supporting systems. An equally challengingtask was the The process system design was frozen early on to allow
selection and design configuration of the export flowline major componentmanufactureto begin in December 1992.
and submission of the detailed design to the Pipeline In parallel, an accelerated effort was made to select a
Worka Authority before the Chrkmaa holiday to meet flowline concept and get the design submitted to the
their schedule requirements. Pipeline Works Authoritybefore the Christmas Holidayto
meet their lead-time requirement. Final selection of the
drilling rig involved a detailed review of the potentirdly
PROJECT PLANNING AND MANAGEMENT available units, focusing on drilling capacity,
SYSTEMS accommodations, variable deck load, and available deck
space for process system installation.
Project management for a North Sea EWT involves
identi~ing all key project tasks and objectiv~, assembling A managementsystem with documentationtrails, detailed
a team of highly qualifiedpersonnel, developing a realistic scheduling, weekly coordination meetings and associated
but aggressiveschedule, and monitoring project execution project controls was establishedand placed into operation.
to a successfid completion. A basic project organtilon The weekly meetings at Oceaneering’s Aberdeen office
chart is presented in Fig. 3. included the client and all key subcontractors. All
scheduleswere reviewed and updated. Ongoing activities
Early detailed planning is essential for a fast-track project were tracked and specific individuals were assigned to
such as the Captain EWT if the work is to commence follow up and advise no latter than the next progress
immediately on cmtract award. This planning includes meeting. A fill range of system design reviews, safety
such tasks as: preparation of org-lon charts down to audits and quality assurance inspections and controls were
the shop level, with job descriptions for each person; developed and administered.
selection of the personnel who will make up the work

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OTC 007422 WES LOVAAS 3

Though all offshore oil operations are conducted with the The John Shuw was used initially to drill one well for
utmost concern for the environment, supplemental belter delineation of the reservoir boundary. A second
precautionary measures were adopted at the Captain well was drilled for further delineation and preliminary
location. Safety zones of SoO-meter radius were tests to study reservoir characteristicsand better predictthe
establishedaround the rig and the tanker bow. There was potential of water coning in the reservoir and its possible
a nominal separation of 1350 meters between the flowline effects on later production activities. The third well, a
export porch on the rig stem and the zero point about lengthy horizontal completion, was drilled for the EWT.
which the tanker weathervaned.
Installation of process equipment aboard the rig was
At the request of the client, all contractors and scheduled to avoid interference with the ongoing drilling
subcontractors provided information for development of activities and the preliminary testing prior to the actual
a “SafetyCase”. At the time of the test program, a Safety extended well teat program. All equipment skids were
Case was not required, but it was considered prudent in carefullymodularizedto accommodatethe 30-ton working
view of the fact that tier a successful EWT program, limit of the rig crane.
planning would continue for full development and
production of the field. ‘Ihe rig maintained its original Certificate of Fitness. It
retained classification as a Mobile Offshore Drilling Unit
Toward the end of the scheduled test period, the annual (MODU) with no need to change to a Mobile Offshore
flight of the Great Black Auk would occur. The nearby Production Unit (MOPU). After the well test program, the
area was a spawning ground for fish, and sumounding rig returned to its normal drilling activities. All new
areas supported the local fishing industry. It was known equipment was built to DNV requirements, compliedwith
that military maneuverswere performed on occasionin the relevant production rules, and was reviewed and approved
area, so this causedfurther concernfor safetyprecautions. by DNV StSff.

The additional precautions included the availabilityof the Both topdrive and rotary were utilized for better
Smit LZoyd122 and the full-time assignment on station of performanceduring drilling of the horizontal well. Due to
the personnel safety standby boat Star Vega and the relatively low reservoir pressures and high fluid viscosity,
pollution control vessel Sea Spruyo a downhole electric submersible pump (ESP) was used to
pump the oil to the process facility on the rig. For the teat
An Oceaneering Senior Production Superintendent with duration, oil was produced through a seafloor BOP and
extensive floating production experience was assigned to drilling riser assembly instead of a subsea tree. This was
the rig during the process system installationand checkout. considered simpler to accomplish and provided all the
He remained on board as our representative in charge of safety features inherent in a BOP.
the overall operation for the 90day test program.
Required changea to the rig operating manuals were
handled by removable addenda to avoid the unnecessary
EQUIPMENT REQ~ exercise of formally revising the manuals and then
changing them back after the completion of the test
IXULLING AND PRODUCTION PLA~O~ program. Bridging document addenda related to the rig
were approved by DNV.
The drilling rig John Shuw, a spread-moored
semisubmersibleof the Enhanced Pacesetter design, was ~
selectedfor both drilling and production platform support,
Fig. 4. This unit was selected because it had a deck area A major ongoing engineeringeffort was required to design
large enoughto handle the process equipmentand quarters the purpose-builtoil and gas process facility to be installed
large enoughto accommodateboth drilling and production on the rig. Standard industry well testing equipment was
persomel. It also was available in January 1993 for the not available to properly process the Captain crude to
scheduledstart of the drilling program. acceptable sales quality. The crude is low gravity (19°
API) with very high viscosity. Producing the well with an

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4 CAPTAIN EXTENDED WELL TEST PROGRAM: OTC 007422
PROJECT MANAGEMENTAND EXECUTION

ESP also created much tighter emulsions. These fiwtors The process system was designed and built at various
all complicated the oil processing system. The process locations in England and Wales. Upon completion of all
system design required a treating temperature of 200° F, the shop and in-process inspectionsand tests, the skidded
with 50 minutes retention time, electrostatic grid and de- units were shipped to Aberdeen. These skids and
emulsi&ingand defoamingchemicals. Crude stabilidon interconnectingpiping assemblieswere test-fit in a “mock-
for the tanker required an operating pressure of 8 psig in up” of the rig configuration prior to being shipped
conjunctionwith the 200° F temperature. The facility was offshore. This would ensure minimum lost time when
designedtQhandle a throughput of 10,000 BOPD with an performing actual assembly on the rig. The system was
anticipatedhigh percentage of water. designed and built in fill compliancewith API and DnV
standards and the operation manual was approved by
The required process system was composed of the appropriate authorities. Oceaneeringstationed a process
followingpurpose-built main components, Fig. 5: facilities engineer in the process subcontractor’s
engineering office for coordination and design review
● Feed heater (steam-heated shell-and-tube heat during all key phases of the design, fabrication and
exchanger) inspection efforts.
● Fwst stage, three-phase separator
● Interstageheater (steam-heatedshell-and-tubeheat Actual onboard rig piping modifications, deluge system
exchanger) installation, foundation work, blast wall construction, and
● Second stage, three-phase separator (mounted so forth, were done prior to equipment installation by
above the coalescer) marine sub-contractorsunder the supervision of senior rig
● Electrostatic Coalescer personnel. Fig. 6 shows the process system on the rig
● Crude exportpumps (electric-drivenscrewpumps) deck. Installation of the process facility on the rig was
● Export crudecooler (seawate-cooledshell-and-tube accomplished by a coordinated effort to set the main
heat exchanger) components during the well completion phase. This
● Crude metering skid (parallel turbine meters with lengthened the overall offshore hook-up time to two
check meter) weeks, but reduced the waiting time from well completion
● Flare gas scrubber to startup, thus reducing the overall schedule. The entire
● Hydrocycloneproduced water treatment system process facility was installedby the rig crane. The process
● Chemical injection package (four tanks with skids were each set in place and field welds were made to
pumps). complete the piping installation. The system was
completely hydrotested and all welds x-rayed. l%e
A key design goal was to mhdmize offshore hook-up and instrumentationkontrol systems were tied-in and function
commissioningtime while maintainingprocess component tested. The process system was completely teated and
weight within rig crane litling capabilities. The process cm.missioned for start-up. Major installations on board,
facility subcontractor had originally projected 30 weeks including the processing system, were witnessed by
from detail design ixdtistion until system installation Oceaneering’sproductionsuperintendent. He remainedfor
offshore. In retrospect, this estimate was very close to functional checkats, start-up and the test program.
reality.
FLOWLINE
Detailed design began in November 1992, shortly after
award of the program managementcontract. Procurement Indepth engineering analysis was performed on two
activity followed a few days latter. Fabrication of the options for providing a flowline from the rig to the nearby
major componentscommencedin late Decemberin parallel storage tanker. The first option considered was a pliant,
with detailed system design work. Design approvals and reinforced rubber hose system with its own deployment
procurement of buy-out items such as pumps, heaters, and recovery reel and associated handling system. The
controls, instrumentation, pipe spools, valves, etc., second was a more rigid flexible pipe system which would
followed. lle system was subject to a series of safety require time-consuming refurbishment and a suitable
reviews, including an overall “Hazop” study. independentdeployment system.

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OTC 007422 WES LOVMS 5

‘he flowlineto handle throughput of 10,000BOPD of 19° considerations included ease of regulatory approvrds and
API crude oil required a minimum ID of 6 in. Local vessel availability. While the DP tanker requires a higher
regulationsset a 500-meter safety zone around the rig and dayrate than a conventionaltank, this was more than offset
bow loading point, and the tanker owner set a contractual by the additional dayrate of a CALM buoy required with
minimum separation of 1300 meters. ‘l%eline actually a conventionaltanker.
selected was a nominal 1600 meters in length allowing a
separationof 1350meters. Export crude oil was expected l“Ee tanker selected was the 770,000-BBL capacity Tm
to be about 160° F with a pressure of 50-150 psi flowing KM@enwhich was under long-term charter to Stat.oiland
through a 6-ii. -ID line. was sublet to Oceaneering for the test program. It is a
state-of-the-art,dynamicallypositioned,bow-loadingvessel
An acceleratedengineeringanalysis effort revealedthat the of the type developed for offshore loading in harsh North
pliant reinforcedrubber hose system, whichhad previously Sea environmentssuch as Statfjord and Gullfaks. Prior to
been used fir a shorter teat program at Gullfab field, mobilizing to Captain, it was equipped with a helideck to
would meet the criteria of the regulatory agencies, and allow crew changes during the extended assignment.
formaldesign submissionwas completedwithin the limited
remainingtime available. Initial inspectionof the selected When this 1989-builtvessel was converted into a DP bow-
flowline and handling system was conducted in January loading unit in 1992, it waa outfitted with Microfix,
1993, and during March and April the equipment was Artemis and Acoustic position-reference systems. These
refurbished and the material condition verified by the systemsperform quite satisfactorilyfor the vessel’s normal
classification society. Resulting procedures, teat and service, which involves loading from an offshore location
inspection reporta were then submitted to the UK in under 24 hours and then proceeding to a designated
regulatory authorities. offloading port. For the lengthier stay at Captain, the
Microfix system was replacedby differentialGPS (DGPS),
This 6-in. flowline had a design operating pressure of 350 and this system along with the acoustic reference was used
PSI. The rig end of the flowline was equipped with a for station-keeping, with Artemis as backup.
locally controlled hydraulic quickdiscomect coupling
(QDC), while the tanker end used the ship’s normal quick By design, the tanker would weathervaneabout the “zero”
conneddisconnect bow coupling. point near the end of the flowline. The DP system would
electronically signal the bow and stern thrusters to
P N MICALLY POSITIONEDTANKER (STORAGE maintain the bow heading toward the “zero” center point.
& The system would further control the ship’s propeller to
operate ahead or astern to maintain the proper bow
‘he EWT storage vessel required a minimum capacity of dis~ce from the “zero” point. The flexibility of the
500,000 BBL and heating coils to keep the heavy oil t%om flowline and the particular installation configuration
thickening. It had to remain on location for the entire 90- allowed the system to operate within a lo-meter tolerance
day test period with minimal risk of flowline discomect. radius. Exceedingthese values by a pm-set amount would
The capacity requirement was well beyond the capability cause an alarm. Greater deviation would be required
of bargea, so the vessel needed to be a tanker. Safety before initiating any automatic shutdowns or disconnects.
considerations further dictated a full marine crew and
fimctioningpropulsion system. To accommodatethe probable extendedperiod of operation
at relatively low power levels on the main engine,
A trade-off study was performed to compare the provisions were made to add a special additive to the fbel
operational considerations and costs of acquisition and to ensure cleaner combustionand reduce the risk of carbon
installationhemoval of a conventionaltanker moored to a buildup requiriig a premature disconnectduring the EWT.
CALM buoy with those of a dynamically positioned (DP)
tanker. The DP tanker was selected due to its significantly A two-channel telemetry link of a particularly reliable
lower mob/demob costa. In addition, downtime was design was provided between the tanker and the rig tbr
expected to be less with a DP tanker than with a safe control of crude oil flow. A single-channelfailure is
conventional tanker moored to a CALM bouy. Other very rare, but in that event, a second channel is

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6 CAPTAIN EXTENDED WELL TEST PROGIMM: OTC 007422
PROJECT MANAGEMENTAND EXECUTION

immediatelyon line to ensure safe operations. If a total program, they provided the operating personnel fir the
system failure ever occurred, the process system and process facility.
pumps would be immediately shut down and oil flow
stopped. The telemetry system was a “fail safe” design The Statoil crude oil transportation group was contracted
which requires a continuouspositive signal from the tanker to provide the tanker ToveKkufsenwhich they had under
to allow oil production to commence and continue on the long-term contract. All technical support of the vessel as
rig. The system was designed for a rig-end shutdown in it related to the test program was provided by Statoil’s in-
under 20 seconds, followed by tanker-end shutdown house personnel in Stavanger.
secondslater. The process facility safety systems and ESD
would shut down the export pumps and close the The flowlineselectedfor the project was owned by another
emergencyshutdown valve at the export station. division of Statoil. They provided both the flowline and
the reel type installationhtrieval system.
Related safety monitoring systems on the tanker included
a green light indicatorpanel. A number of key parameters Solstad Services, a long-established provider of
were physically checked by electronic sensors. Each sophisticated DP work boats in the Norwegian Sector of
would indicatea safe conditionby an energizedgreen light the North Sea, was selected for installation and eventual
by its designationon the bow-stationsafety panel. Failure removal of the flowline. They provided the dynamically
of any one parameter would prevent a permit-to-pump positioned support vessel Normand Mjolne.
signal from passing to the rig and block any oil export
through the flowline from the rig. By design, the system
was extremely reliable and inherently failsafe, i.e., no oil PROJECT EXECUTION
flow.
The OceaneeringProject Managementteam was lead by a
seasonedoffshore manager with worldwide experienceon
EQUIPMENT SELECTION AND CONTRACTING major projects involvingmany and varied sub-contractors.
He focused on organizing the team and installing
As the Project Manager and Prime Contractor, schedulingsystems and documentationcontrols, preparing
Oceaneering negotiated contracts for all the major items status reports, setting the agenda for weekly review
required for the drilling and test program. Criteria used for meetings and coordinatingthe managementteam and sub-
subcontractor evaluation were capability, availability, contractors. All process equipment and the eventual
industry reputation, price and terms, and compatibility installation on board the rig were under the direct control
with Oceaneering’s project management philosophy. of Oceaneering’sSenior Process Engineer ftmctioning as
Subcontractors’activities were monitored by periodic on- an assistant project manager. Marine aspects, such as the
site visitation, weekly schedule and progress updates and flowline selection and submissions, rig interfaces and all
weekly review meetings. tanker related items, were supervisedby a second assistant
project manager with a very broad marine background.
A contract was negotiated with Sonat Offshore to provide Other activities such as budget control, schedule
the semisubmersibleJohn Maw to drill the wells and later maintenance, safety, quality control, and logistics were
serve as the platform for production equipment. handledby other seasonedcompanystaff. Texaco attended
the weeklyprogress meetings and was apprisedof schedule
Texaco earlier provided the overall process system design. progress and activity status. Fig. 7 presents a milestone
The process subcontractor, Expro, was engaged to detail project schedule.
design the process equipment, fabricate the major new
purpose-built vessels, assemble the equipment, and shop- DM LLING
test major componentsto class society requirements. They
were further contractedto perform final shoresidemockup Due to bad weather at its previous operating location, the
fit tests in Aberdeen befbre taking the system offshore for drilling rig arrived about two weeks later than originally
installation on the rig. During the oftkhore well test

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OTC 007422 WES LOVAAS 7

planned and actuallystarted the first delineationwell at the export station at the stem of the rig onward to the target
beginning of February 1993. location for the tanker about 1350 meters distant. Upon
completionof installation, the flowline was pressure tested
The horizontal well was driiled next, suspended, and later in accordance with the Health and Safety Executive
recentered and completed for the extended test program. requirements, and then the end was laid on the seabed in
Drilling of the horizontal section went relatively smoothly preparation for later hookup to the tanker. Provision had
and daily footage completed was much greater than been made to use the cementing pump to flush the export
originally expected. flowline with diesel and then follow with salt water. llds
capability was made an integral part of all shutdown and
The third well was drilled and @ted fix reservoir water disconnectprocedures.
coning tendencies prior to the main extended well test on
the horizontal well. l%e tanker end of the flowline was adapted from the 6-
inch diameter hose to an 8-inch swivel assembly, and
PROCESS EOUIPMENT thence to the normal 20-inch connection for the tanker
bow-loadingmanifoldassembly. ‘l%etanker’sbow-loading
The criticalpath for the teatprogram paralleled the design, equipment allows both controlled connection and
manufacture and delivery of the process system. disconnection and emergency disconnect.
Oceaneeringstationed its Lead Process Engineer at Expro
to allow on-site monitoring, expediting, and resolution of Use of the bow-loading connection is inherently
any urgent issues. This and a very cooperative attitude by environmentally safe in that an internal valve closes the
Expro personnel kept the job on track and allowed the tanker end of the flowline at all times that the hose
project team to meet a very tight schedule requirement. coupling is not fully mated to the bow-loading manifold
assembly. Even then, it takes activation of a hydraulic
The field mockup in Aberdeen included layout of fitted control in the manifold end of the coupler to cause it to
spool pieces between the various equipment skids and actually open.
testing of the instrumentationand control system. It also
accelerated actual installation and hookup offshore, As A crude oil export manual was prepared to cover all
mentioned earlier, the process system was modularized aspects of the export of oil from the process system on the
into skid sizes and weights to facilitate lifting aboard the rig via the flowline to the storage tanker. This manual
rig with its regular utility cranes and relatively rapid hook- includedprocedures for installation and eventual recovery
up and preparation for final testing. The actual offshore of the flowline, reflecting guidance provided by the
installation of the process facilities took about 12 days. flowlinemanufacturerand the consultantwho analyzedthe
Only minor problems arose, and they were resolvedby the installation and prepared the original submittal to the
on-site superintendentand others. Pipeline Works Authority in late 1992. It further included
a group of flowline flushing and test procedures. For
FLOWLINE INSTWTION convenience of the user, it also included bridging
documents to interface with the standard operating
A contributingfactor to selectionof the EWT flowlinewas procedures used by the tanker during routine oil loading
the availabilityof an installationlevel-wind-and-reelsystem from subsea facilities. This manual was also submitted to
as part of the total package. This compatibility made the the appropriate authorities for approval.
system relatively easy to install on the support vessel
NortnundMjohe. Pre-plarminghad made allowances for TANKER INSTALLATION AND HOOKUP
completingthe final rig-end QDC hookup, laying of line,
conductingpressure tests and positioning the retrieval-end As a final step in flowline installation, the DP reference
on the seafloor. acoustic transponders were placed in position on the
seafloor in a predetermined array pattern. Upon arrival,
The flowline was laid along the seafloor by the Nmnund the tanker conductedDP casualty simulation exercisesand
Mjolne with the assistanceof a Wimpol position survey. telemetry checks and then moved into position. The
The line was laid on a track of 135 degrees true from the flowline end was picked up with the assistance of the

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8 CAPTAIN EXTENDED WELL TEST PROGRAM OTC 007422
PROJECT MANAGEMENTAND EXECUTION

flowline installation vessel and connected to the bow- resolved these in quick order. The full 90day well test
loading manifold. was accomplished in the “summer weather window” as
planned. The EWT program, under the overall guidance
me tanker officiallyarrived on location on 20 June, 1993. of Texaco and Oceaneering’soffshore superintendent,met
An emergencystem tow exercise was conducted with the all testing objectives and ended with extensive well test
Smit Lloyd 122 fir training purposes. A series of tests data and a tanker full of saleable crude oil. lEe well was
was conductedwith the telemetry safetyshutdowndata link plugged and abandoned and the rig was released.
and the voice channel between the tanker and the
semisubmersibleto prove out the system. Refined DGPS During the 90day test, there were extended periods of
and HPR referenceposition data checkswere performedto continuous crude oil flow to the tanker and also periods of
groom the input signals so that all references would no or low flow while Texaco reservoir engineers
simulate the same “zero” point. A variety of DP system performed various downhole teats. During one such
pre-checks and equipment casualty exercises were period of planned shutdown, the tanker disconnectedfrom
conducted prior to auy attempt to move into position or the flowline and departed the field to a safe location to
hook up to the flowline. The tanker then moved into the shut down the main engine and remove internal carlwn
immediate area and began the flowline hawser assembly build-up. This was the result of the engine having run for
pickup with the assistanceof the Normand Mjolnq which many weeks at very low power levels due to relatively
had just completed installing the flowline. calm weather. The tanker then returned to the field and
reconnectedto the flowline in about 2 hours.
SYSTEM TESTING AND COMISSIONING
At the completionof the test program, the tanker departed
All system tests were performed in strict compliancewith the field after carefullypositioning the flowline end on the
approvedprocedures with the classifyingagenciespresent. seabed in accordancewith standard operating procedure,
These procedures included sections as appropriate for
placing the systems into commission. As mentioned SYSTEM DEMOB
earlier, the final process installation, hookup, and startup
were accomplished under the direct supervision of Upon completion of the testing in September 1993, the
Oceaneering’sProduction Field Superintendent. process system was disassembledoffshore and backloaded
to Aberdeen using supply boata. The well was plugged
WELL TEST and abandoned. The flowline and seabed transponder
array were recovered by the Normand Mjolne, thereby
The 90day EWT was perfbrmed on a horizontal well completing the removal of all items originally placed on
drilled to a vertical depth of about 3000 feet and laterally the seabed.
about 6000 feet. The well was completed under the
technical direction of Texaco and put under test after System demobilizationwas accomplishedin essentiallythe
installationof the well test system. The horizontal section reverse order of the original installation. The tanker
was completed with a slotted 7-inchdiameter liner and departed with 570,000 BBL of crude oil. The process
prepacked screens to maintain hole integrity. A downhole skids were removed in a carefidly coordinatedplan which
pump was used to transport the oil from the reservoir to brought one workboat load of drilling support materials
the John Shaw. aboard and then departed with a load of well test
equipment.
The extendedwell test continuedfor the scheduled90 days
with production rates sometimes in excess of the “design”
requirementsand very few stoppages for weather or other CONCLUSIONS
factors.
Oceaneering believes that the benefits of turn-key
There were a few early problems upon startup of well contractingand project managementof extendedwell tests
testing, but a cooperative team effort by all parties have been demonstrated by the success of this tightly

16
OTC 007422 WES LOVAAS 9

scheduled, fast-track project. By appointing a prime


contractor to manage the engineering, procurement,
assembly, installation and performance of the teat program,
the operator requires fewer of its own personnel to be
assigned and can concentrate more fully on the end
objectives of the program.
N. BRAE
PIPER W.Brae
Due to the number of subcontractors, manufacturers, and
suppliers involved in such a project, a first priority is to SALTIRE

choose companiea that display a team mentality. Every HIGHLANDER

company has its own project control methods which will CLAYMORE

require some modifications so that the input from each fits 12 13


SCAPA
the Prime Contractor’s and operator’s requirements. One
CAPTb
example involves eMMshing a uniform method of
correspondence and technical document identification and 2127-I
control. Resolution of these types of details requires a ● 4 IVANHOE ~ ~.. c
spirit of cooperation and a team effort. .
Ettrick GLAMIS
18
e
A prime contractor serving as project manager, with a
dedicated project team, can maintain effective cost and ●
schedule control, and can also be responsible for projwt
documentation, a substantial effort in North Sss EWTS.
St. Fergu%
19 20 I 21

A turnkey contractor can pull together equipment and


subcontractors to complete a project in a timely and cost-
effective manner.

ACKNOWLEDGMENT

Oceaneering is pleased to thank Texaco North Ses (UK)


:J__E?a
Fig. 1 -- Captain Field Location
(BaseMap Courtesy of World Oil)
for permission to publish this paper and all associated
London and Aberdeen staff for their assistance and
cooperation in its preparation. We also want to give well-
de,servedthanks to the sub-contractors whose diligent work
contributed to this project’s success.

-1
... ,
4 .”,.
,~...., # /

Fig. 2 -- Configurationof Major EWT Components


(ProcessSystem on Deck of Semi)

17
10 CAPTAIN EXTENDED WELL TEST PROGRAM
PROJECT MANAGEMENT AND EXECUTION

CAPTAIN PROJFCT OR@JWz,ATQJ.J

rExAm

T“” ‘-
CCEMEE.QING Fig. 3 --
Basic Project
OrganizationChart

r+m5zIPIE&EIE5EIFl
#------- L&--l
RGIT

lJ’lGkl ‘“-
HCREMER
WMNCR

FaIz

Fig. 4 --
The John Shaw
During Testing
Phase

18

.
-—
OTC 007422 WES LOVAAS 11

Fig. 5 --
Captain Process
Flow Diagram

I SSA WATSR

TO SSA
D

CAPTAIN PROCFSS FIOW DIAGRAM

Fig. 6 --
Deck o~ John Shaw
Showing Oil Process
Equipment, Center,
Installed for EWT

—- . — -. –——._ —– _—— -. .—_ ___ _


12 CAPTAIN EXTENDED WELL TEST PROGRAM:
PROJECT MANAGEMENTAND EXECUTION

PROJECT SCH17DUI F

NOV DEC JAN FEB MAR APR MAY JIJN JI.JL A(JG SEP

CONTRACT AWARD A

PROCESS EQUIPMENT

- ENGINEERING

- FABRICATION

- MOCKUP
1-

- lNSTALLATION/TEST

– HOOK UP/COMMUNICATION

FLOWLINE

– ANALYSIS/SUBMllTAL

- PREPARATION

- INSTALLATION .

DRIU 1ST DELINEATION WEU

DRIU HORIZATION WELL

DRILL 2N0 DELINEATION WEU

TEST 2ND DELINEATION WEU

RE/ENTER/COMP
HORIZATION WELL

TANKER ARRIVAL A

I I I
EwT
I I I I I I I
P& AWELl _

DEMOB SYSTEM

Fig . 7 --
Milestone Captain EWT Project Schedule

—>— –——.
_–_— –_ —— -_ .. —___. – _