TAMU - Pemex

Offshore Drilling

Lesson 3
Wellheads and Casing

1
 Wellheads and Casing

 Drilling with a Riser

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

2
 Conventional Riser Drilling
FLOATER
SEA WATER
DRILLING RISER
HYDROSTATIC
CHOKE LINE
MUD HYDROSTATIC

BOP

DEPTH
SEAFLOOR

PRESSURE 3
 Conventional Riser Drilling
- Install 30-in Conductor -
FLOATER

DRILLPIPE

~200 30”

Jet 30-in Conductor to ~ 200 ft below mudline

No riser - “Mud” returns to seafloor
No annulus - no cementing (in GOM)
4
 Conventional Riser Drilling
- Install 20-in Conductor
FLOATER

DRILLING RISER

CHOKE LINE

D 30”
~1,050
20”
Drill 26-in hole to 1,050 ft below mudline
Riser optional - Mud returns to surface or
seafloor
Run 20-in Conductor to ~ 1,000 ft below mudline
Cement to mudline 5
 Conventional Riser Drilling
- Install 13 3/8-in Surface Csg.
FLOATER

DRILLING RISER

CHOKE LINE

BOP

Run Riser and BOP Stack D

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

Now, finally, we can close the BOP if necessary 6

 Wellheads and Casing

A subsea wellhead, like a land wellhead:

 Must support the BOP’s while drilling

 Must support the suspended casing
while cementing, and
 Must seal off between casing strings
during drilling and production
operations.
7
Wellheads and Casing, cont.

In floating drilling, the casing hangers,

casing seals and cementing heads
differ
from land and platform operations
in the following manner:

8
 Wellheads and Casing

1. The first and second casing strings

are cemented with returns to the
seabed.
2. Casing is run with the last joint made-
up on a casing hanger and
permanently suspended prior to
cementing. Mud returns flow
through fluting in the hanger.

9
 Wellheads and Casing

3. Usually, cementing plugs are

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

10
 Wellheads and Casing

5. Special test tools are required for

remotely testing the casing seals.

6. Wear bushings are essential for

protecting the wellhead.

11
 Fig.4-10.
Typical
sealing
arrangement
for subsea
wells.

12
13
Depth BML
240 ft

1,100 ft
4,100 ft

8,600 ft

10,100 ft

14
15
Permanent
Guide
Structure.

Temporary
Guide Base

16
17
 Utility
Guide Frame

Hole Opener

Temporary
Guide Base

18
 Procedure for Starting a Well

1. To get the well started, place a heavy

steel template on the seafloor.
Run on drillpipe.
2. Four guidelines guide bit, casing, etc to
the right location on the seafloor.
3. Run 36” hole opener (with guide frame)
and drill 36” hole to ~240 ft BML
with returns to the seafloor.
19
 Procedure for Starting a Well

4. Run 30” casing and cement with returns

to the seafloor. With the 30” casing
also run the permanent guide
structure and the wellhead
housing.
(3 & 4 alt. Sometimes the 30” casing is
jetted or driven in. - instead of drilling).

5. Drill 26” hole to 1,050 ft below mudline.

20
 Procedure for Starting a Well

6. Run 20” conductor casing.

With the 20” casing, run the high
pressure wellhead. Cement the casing.
NOTE: The 26” hole may be drilled with
returns to the seafloor, or with
returns to the surface using the marine
riser.
Note the guide posts on the permanent
guide structure. These are for the BOP stack21
Fig. 4-5. Estimated Fracture gradients at
100 ft below seabed (Santa Barbara Channel).
22
Fracture gradient at
100 ft. below seabed
(Santa Barbara
Channel).

Why drill with returns to the seafloor?

With this low fracture gradient it is difficult

to drill with returns to the surface.
No shallow gas would be expected at this
depth below the mudline.
23
 Drill with Diverter to the
Surface Casing Point

Fig. 4-5. Estimated Fracture gradients at

1000 ft below seabed (Santa Barbara Channel).
24
Shallow Gas
Gas reduces
Blowout buoyancy!

25
 Gas in the
Water Column

Typical specific gravity variations in a

blowout boil have increasing effect
nearer the water’s surface.
Fortunately for a semi-submersible, the
rig’s primary flotation members are
situated below the zones where specific
gravity has been reduced the most.
26
27
 Gas in the
Water Column

If there is sufficient length to the mooring

system cables/ chains, the rig will be
pushed off location and out of harm’s way.

However, the plume can also cause the rig

to list, which reduces its freeboard and
makes it more susceptible to capsizing. 28
Fracture Gradients in Deep Water

Increasing the water depth reduces

the total overburden gradient and
consequently the formation fracture
gradient. This can be expressed as:

g f = (g ob − g p )Fσ + g p

29
 g f = (g ob − g p )Fσ + g p

Where:

g f = fracture gradient, psi/ft

g p = formation pressure gradient, psi/ft
g ob = overburden pressure gradient, psi/ft
Fσ = horizontal / vertical stress ratio

30
 For offshore drilling:
1
g ob = [ 0.44 d + 0.4335 ρp f f(d KB − d − d F )]
d KB

Where:
d KB = depth measured from the kelly bushing, ft
d = water depth, ft
d F = height of flowline above the water, ft
3
ρ f = formation bulk density, g/cm
31
 1
g ob = [ 0.44 d + 0.4335 ρp f f(d KB − d − d F )]
d KB

0.44 d is the overburden due to water,

or simply the hydrostatic pressure at the
seafloor.

(dKB - d - dF) is merely the penetration

into the seafloor.

32
 Get ρ f from
density log.

Get Fσ from
this plot.

Get gp

Calculate gf

Formation bulk density vs. horizontal to vertical stress

ratios for the Santa Barbara Channel.
33
Fig. 4-7. An example of onshore and offshore
fracture gradients.
34
J. W. Barker and T. D. Woods
“Estimating Shallow Below Mudline Deepwater
Gulf of Mexico Fracture Gradients”
Presented at the 1997 Houston AADE Chapter
Annual Technical Forum, April 2-3, 1997.

Cumulative average (BML)

formation bulk density

ρ = 5.3 * (TVDBML )0.1356

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

35
J. W. Barker and T. D. Woods cont’d

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

ρ = 5.3 * (TVDBML )0.1356

gob = 5.3 * (1,000)0.1356 = 13.52 lb/gal

gf = 0.9 * ρ ob = 12.17 lb/gal = 0.663 psi/ft
gp = 0.8 * ρ ob = 10.82 lb/gal = 0.563 psi/ft

NOTE: These are gradients relative to

36
J. W. Barker and T. D. Woods cont’d

At 1,000 ft below mudline, in 1,500 ft water:

Total overburden = 0.44 * 1,500
+ 0.052 * 13.52 * 1,000 psi
gob = 1,363/2,500 psi/ft = 10.48 lb/gal !!
pf = 0.44 *1,500 + 0.052 * 12.17 * 1,000 psi
gf = 1,293/2,500 psi/ft = 9.94 lb/gal
gp = 0.44 * 1,500 +0.052 * 10.82 * 1,000 psi
= 1,223/2,500 psi/ft = 9.40 lb/gal

NOTE: These are gradients relative to SURFACE!

37
Ben A. Eaton and Travis L. Eaton
“Fracture Gradient Prediction for the new
generation”
World Oil, October 1997, pp. 93-100.

Fracture gradient equation:

γ =
F S p  γ  p Poisson’s
=  −    +
D  D D   1− γ  D Ratio

g f = (g ob − g p )Fσ + g p from Text

38
Fig. 4-8. Plot of a leak-off test.
39
 Fracture Gradient Calculation

Mud Weight 9.5 PPG

Casing 13 inches
Set to 3,340 ft-KB
Frac. Grad. = ?

Fracture Pressure = 0.052 * 9.5 * 3,340 + 650

= 2,300 psig
Frac. Grad. = 2,300/3,340 = 0.6886 psi/ft
= 0.6886/0.052 = 13.24 ppg
40
Leak-Off Test

BOPs

Casing

Drillpipe

41
 Fig. 4-9.
Sub-sea
cementing
system.

42
 Fig.4-10.
Typical
sealing
arrangement
for subsea
wells.

43
Metal-to-Metal Casing Annulus Seal

 Assures maximum seal over

extended periods, even in high-
pressure holes
 Eliminates dependence on seal
materials that deteriorate or “cold
flow”.
 Available on systems up to 15,000
psi pressure integrity.
44
1. Actuating force is transferred to the
2. Resilient compression element
which expands, forcing the
3. Metal seal lips into contact
with the surface of the
4. Wellhead housing and the
5. Casing hanger

Upper Metal
Seal Lips
Resilient
Compression
Element
Lower Metal
Seal Lips
45
 Casing Hanger and Pack-off
Assembly

Single trip installation

The pack-off seal assembly is run
simultaneously with the casing hanger
body. All operations - installing the casing
hanger, cementing the casing string and
actuating and testing the pack-off seal are
performed in a single trip of the running
string.
46
 Large Flow-By Areas

Large flow-by areas can handle most

drilling fluid applications with a minimal
drop in pressure.

Deep 2" wide flow-by slots in the casing

hanger body, and ample porting through
the pack-off nut assembly, provide clear
passage for cuttings and mudcake
without plugging.
47
 Liquid Compressibility

The volume required to compress a liquid

is defined by the equation:
∆ V = Vi * Cp *
Where:
∆ P
Vi = volume of system, bbl
Cp = compressibility = 3 * 10-6 per psi for water
= 6 * 10-6 per psi for mud
∆ P = test pressure, psi

48
 Seal Test - Example

Water depth = 500 ft (all depths are KB)

Casing string = 13 3/8” OD
Volume of system above the seal = 11 bbl
Test pressure = 3,000 psi
Test fluid = water
Previous casing string = 20”, J-55, 94.0 lb/ft
Previous casing seat = 1,500 ft KB
Cement top = 996 ft
49
 Seal Test - Example

V = 11 bbl

500 ‘ KB Mud Line

996’ 20”
1,500’
13 3/8”

4,000 ft
50
With no leak, the system will require

∆ V = 3 * 10-6 * 11 * 3,000 = 0.1 bbl water

to reach test pressure.

If the seal leaks, the volume will be more,

but how much more?

51
Obviously, 0.1 bbl would be difficult to
measure. The annular volume between the
seal and the cement is
(996 - 500) ft * 0.1815 bbl/ft = 90 bbl of
mud

Now,
?
∆ V = 6*10 * 90 ∆ P + 3*10 * 11 ∆ P bbl
-6 -6

= ( 5.4 * 10-4 + 3.3*10-5 ) ∆ P bbl

= ( 5.73 * 10-4 ) ∆ P bbl
What should the maximum pressure be?
52
Pressure in the annulus must always be
less than the collapse pressure of the inner
casing, and less than the internal yield of
the outer casing.

This will depend on both volume and

pressure. Table 4-2 shows the relationship
for four grades of casing.

Also, the internal yield of the 20-inch casing

is reached at 2,110 psi when V = 1.24 bbl.

53
54
 Plug for
testing
casing seal
to full
working
pressure.

55
 Test Procedure

1. Set seal
2. Land test plug in wellhead,
sealing off below the seal
3. Displace mud with water for test
4. Close pipe rams
5. Pump slowly down the choke line,
preferably in stages, to protect the
casing in case of leaks
56
 Test Evaluation

During the test, if the wellhead system

being tested will not sustain test
pressure, several possible causes
should be considered:

1. Leak in the surface manifold

2. Leak in the test plug (detected by
returns through the drillpipe)
57
 Test Evaluation, cont.

3. Leak in the casing seal

4. Leak in the BOPs
5. Leak in the hydraulic wellhead
connector

58
 Test Evaluation, cont.

When the well does not sustain

pressure, it is obvious that there is a
problem.

There is also a problem if the well

takes too much fluid to reach test
pressure, just as we have discussed.

59
 Drilling Procedures
from a floater

 Install 30” Structural Csg.

 Install 20” Conductor

 Install 13 3/8” Surface Casing

 etc.

60
 Drilling Procedures
Tentative Hole and Casing Sizes

 8 1/2” Pilot Hole to 180’ BML

 26”x36” Hole Opener to 180’ BML
Install 30” Structural Csg.
 8 1/2” Pilot Hole to 1040’ BML
 17 1/2” Pilot Hole to 1040’ BML
 17 1/2”x26” Under reamer to 1040’
Install 20” Conductor

61
 Drilling Procedures
Tentative Hole and Casing Sizes

 12 1/4” Pilot Hole to 3,830’ BML

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

62
 General Rules

1. Do not change the tension on the

anchor lines until the 30” casing
has been run and cemented.
2. Have all the 30” casing and all of the
wellhead equipment on board
prior to spudding.
3. There will be an SLM prior to any
logging or coring run.
63
 General Rules

4. All casing strings will be strapped

and drifted prior to running.
5. Casing will not be run until the
hole is in the best possible
condition and a trouble free
wiper trip can be made.
6. Cement densities will be
monitored with a mud balance.
64
 General Rules

7. The rig will be moved 50’ off location

whenever the riser is being run or
pulled.
8. No smoking or open flames are
permitted on deck whenever the
riser is connected to the well.
9. Welding permits (authorized by the
drilling supervisor and tool pusher)
will be required at all times.
65
 General Rules

10. Coring will be at the the discretion of the

well site geologist, but only after
approval from the task force Manager
and the Exploration Coordinator.
11. All information concerning the well will
be kept strictly confidential. Any
discussions will be held in a secure
area in the quarters or on the rig.
66
 General Rules

11. Confidentiality - cont’d.

Only contractors with “a need to know”
will be allowed access to well information.
12. All personnel on board and all visitors
will be instructed with the necessary
environmental and safety films and
instructions.

67
 General Rules

13. No one will be allowed on the

helicopters, work boats, or drilling
vessel without the proper
authorization or identification.
14. The rotary table must be positioned
within a 200 foot radius of the
proposed location.

68
 General Rules
Anchoring

1. Place anchors on sea floor 5800’ from

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

69
 General Rules
Anchoring

3. Pull in opposing lines to set anchors.

An indicated line tension of 125
kips is necessary for the anchor to
receive any load.
4. A tension level of 440-460 kips
should be reached before 600’ of
line is taken in with the rig
remaining stationary.
70
 General Rules
Anchoring

5. If a line tension of 440-460 kips has

not been reached before 800’-
1000’ of line has been retrieved,
then it may be necessary to use
piggy-back anchors.
6. The following Western KDC plan
outlines the mooring procedure.

71
72
 Shallow Gas Plan

After the rig is properly anchored the

following steps will be followed as
there is a potential for shallow gas in
this area:

73
 Shallow Gas Plan

1. Leave mooring line pawls or stoppels

unset until the 20” casing has been
set and cemented.

2. Mooring winches will be manned while

the 8 1/2” pilot holes for the 30” and
20” casings are being drilled.

74
 Shallow Gas Plan

3. Mooring winches will be manned

while the 8 1/2” pilot holes for the
30” and 20” casings are being
opened up or under-reamed.

4. The moonpool and seafloor will be

observed for gas bubbles until the
20” casing is set and cemented.

75
 36” Hole Plan

1. Premix 600 barrels of 11.5 ppg kill mud

prior to spudding the well.

2. PU and TIH with an 8 1/2” bit, 6 - 6 1/2”

drill collars, 6 jts of 5” Hevi-Wate drill
pipe, and sufficient 5” drill pipe.

76
 36” Hole Plan

3. Tag bottom with the pilot bit, and

note and report the following:

a. RKB to water level

b. RKB to mud line
c. Water depth
d. Time of day (tide allowance)

77
 36” Hole Plan

4. Lower TV camera, and observe bit

entering guide base. Retrieve
universal guide frame back to surface.

5. Upon spudding, space out drill string with

pup joints so that it will not be
necessary to pull the bit above the
guide base to make the first
connection.
78
 36” Hole Plan

6. Drill an 8 1/2” hole to +/- 30’ below

the setting depth of the 30”
casing (estimated at 180’ BML).
Circulate returns to the sea floor,
and monitor returns with the
TV camera.

79
 36” Hole Plan

7. If there are no problems with shallow

gas, pull out of hole, PU 26” bit and
36” hole opener, 6-9 1/2” DC’s, 6 jts
5” Hevi-Wate DP, and sufficient 5” DP.

Drill 36” hole to set 150’ (4 joints) of

30” OD structural casing.

80
 36” Hole Plan

Drill with sea water as follows:

a. Circulate viscous sweeps as
required to clean the hole.
b. Survey hole at 30’, 60’, and
150’ BML.
c. At TD of 36” hole, displace
hole to the mud line with
viscous mud.
81
 36” Hole Plan

Drill with sea water cont.:

d. Make a wiper trip.
e. Circulate the hole to the
mud line with viscous mud.
f. Penetration rate should not
exceed 100 ft/hr overall.

82
 36” Hole Plan

8. Run 30” structural casing per procedure.

9. If there are problems with shallow gas,
displace the 8 1/2” hole with kill mud
until the gas stops or the hole is full of
kill mud.
Monitor returns with the TV camera for
evidence of gas or flow, and if after
one hour the hole is stable, proceed
as in steps 7 and 8.
83
 36” Hole Plan

10. If the kill mud in step 9 does not

stabilize the well and it appears that
heavier mud will not stabilize the well
or will break down the formation, then
prepare to cement.
Mix and pump, sufficient 15.8 ppg
cement slurry to circulate cement to
the mud line, and monitor returns for
gas with the TV camera.
84
 36” Hole Plan

10. Make sure that the hole is stable

POH with BHA

Retrieve TGB
Move rig as required

85
 26” Hole Plan

1. Have 600 barrels of 11.5 ppg kill mud

prior to drilling out below the
30” casing.

2. PU and TIH with an 8 1/2” bit, 9-6 1/2”

DC’s, 9 jts of 5” Hevi-Wate DP, and
sufficient 5” DP.

86
 26” Hole Plan

3. Drill an 8 1/2” hole to +/- 40’ below the

setting depth of the 20” casing
(estimated at 1040’ BML).

Circulate returns to the rig shakers, and

monitor returns for indications of gas or
flow.

87
 26” Hole Plan

4. Displace the hole with viscous

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

88
 26” Hole Plan

5. If there are no problems with shallow

gas, pull the riser, PU & TIH with a
17 1/2” bit, 26” hole opener, monel
DC, 6-9 1/2” DC’s, 6-8” DC’s, 9 jts 5”
Hevi-Wate DP, 26” stabilizer at 60’,
qand sufficient 5” DP.
Drill a 26” hole to set 1040’ of 20” OD
conductor casing as follows:

89
 26” Hole Plan

a. Circulate viscous pills as

required to clean the hole.
b. Circulate returns to the sea floor
with sea water.
c. Maintain inclination at less than
three degrees.
d. Spot viscous mud at TD of 26”
hole.
90
 26” Hole Plan

e. Make a wiper trip.

f. Spot viscous mud as required.
g. Drop multishot and POH.

6. Run 20” OD conductor casing and

cement per procedure.

91
 26” Hole Plan

7. If there are problems with shallow gas in

Step 5, circulate the hole with viscous
spud mud and slowly increase the
weight until the flow has stopped or
until the active system is depleted.
If the flow continues, pump the kill
mud at the maximum rate until the
active system is depleted.
92
 26” Hole Plan

7. (Cont.) Then pump sea water at the

maximum rate until the hole bridges.
8. If the flow rate is significant, and the hole
will not bridge, prepare to move the rig.
Cement the hole to just below the sea
floor with 15.8 ppg cement. POH with
the BHA. Cut or shoot the 30” casing,
and pull the TGB and PGB. Move rig
as required.
93
 26” Hole Plan

9. If the gas in step 7 depletes or the

density is sufficient to control the
well, then casing can be run or the
well can be drilled ahead.

10. Drill 8 1/2” hole to +/- 40’ below the

setting depth of the 20” casing
(estimated at 1040’ BML).
94
 26” Hole Plan

11. Circulate and condition for logs. Pull out

of hole, and log well per procedure.

12. PU & TIH with 17 1/2” bit, Monel DC, 6-9

1/2” DC’s, stabilizers at 60’ amd 90’, 6-8”
DC’s, jars, 9 jts 5” Hevi-Wate DP.

95
 26” Hole Plan

13. Drill a 17 1/2” hole to sufficient depth

to set 1040’ of 20” conductor casing.
Drop multishot, and POH.

14. PU & TIH with 17 1/2” bit and 26”

underreamer, 6-9 1/2” drill collars, 6-
8” drill collars, 9 jts 5” Hevi-Wate DP,
and 26” stabilizer at 60’.
96
 26” Hole Plan

15. Underream to sufficient depth to set

1040’ of 20” conductor casing.

16. Circulate and condition the hole for

casing. Care must be taken to have a
balanced mud weight all the way
around with no heavy slugs.

97
 26” Hole Plan

17. Displace hole from TD to the sea floor

with sufficient weight mud to balance
the hydrostatic when the riser is
removed.
Again, care must be taken to have a
balanced mud weight while displacing,
and the riser may have to be voided
with sea water as the heavier mud is
circulated.
98
 26” Hole Plan

18. POH, run the 20” casing and 18 3/4” -

10,000 psi wellhead housing, and
cement per procedure.

19. If there is evidence that the hole

cannot be drilled deeper safely in
step 9, the well will be underreamed
at the depth reached in step 9 and
20” casing will be set.
99
 26” Hole Plan

20. It will then be determined whether

future casing settings need to be
changed.

etc. etc. etc.

100
101
102