IADC/SPE Innovative Tubular, Hoisting, and Deepwater Rig Designs Extend Hook Load Envelope to 2,000,000 Pounds

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1 IADC/SPE Innovative Tubular, Hoisting, and Deepwater Rig Designs Extend Hook Load Envelope to 2,000,000 Pounds J. N. Brock, R. B. Chandler, NOV Grant Prideco; C. Selen, Maersk Drilling USA; J. Dugas, W. White, Quail Tools; M. Vasquez, A. Jonnalagadda, Statoil

2 Agenda Well Description Challenges Systems Involved 1. Casing string 2. Drill pipe landing string and cement stand 3. Top drive section, hoisting and casing handling equipment Pre-Job Inspection of Drill Pipe Landing String and Rig Load-Path Components Planning Phases for a 2-Million Pound Hook Load Simulation work and results Design load, landing string configuration, and safety factors Execution Conclusions 2

3 Walker Ridge Blk. 543 #1 Tucker WD = 6,667 ft. (UDW) Sub-salt ~14,000 ft. salt body Directional well = 25º inc. Multiple CSG strings BBII; 6 CSG strings in place 14 x 13-5/8 CSG at 24,893 ft. 18,226 ft. long tapered CSG string 2 million pound hook load 3

4 Challenge Safely Makeup and Run 18,226 ft. of 14 x 13-5/8 Tapered Casing String Ensure drill pipe landing string meets or exceeds load requirements Ensure ALL hoisting and casing running equipment meets or exceeds load requirements 4

5 System I: Casing 5

6 System II: Landing String 6

7 System II: Cement Stand 7

8 System III: Top Drive and Hoisting System 8

9 Performed Load Path Inspection Load Path Inspection to be Conducted On The Critical Path for an Expected 2 Million Pound Load Allocated 76 Hours to Conduct the Inspection Conducted inspection in 48 hours In Addition, ALL Drill Pipe Landing String and Handling Tools Were Inspected, as Well as the Surge Reduction Tool and Cementing Head Brake Test Conducted and Magnetic Particle Inspection of Disc Brake Conducted Right Before Running the 14 X 13-5/8 Casing String Slip & Cut Drill Line Right Before Running the Casing String 9

10 Components Inspected 10

11 Drill Pipe Landing String Configurations Drill Pipe Inspected To 95% RBW For Tension and Slip Crushing Calculations SF in tension = 1.2 SF for slip crushing = 1.3 To account for dynamic loads 11

12 Slip and Elevator System 1,000 ton Hydraulically Actuated Slip Assembly 1,000 ton Hydraulically Actuated Elevator 12

13 6-5/8 OD Wall Slip-Proof Drill Pipe Landing String 13

14 DP Landing String Safety Factors 14

15 Planning Phase Simulation Results (Output) TIH Stretch = 24.6 ft. (Casing Stretch = LS Stretch = 17.3 ) TOH Stretch = 32.2 ft. (Casing Stretch = LS Stretch = 21.1 ) 15

16 14 x 13-5/8 Running Loads 1.98 Million Pound (889 MT) Tripping-in simulation is spot on see the light green line Directional work started at 18,000 ft. 16

17 Execution: Running 14 x 13-5/8 Casing At 24,763 ft. 17

18 Conclusions 1. Tubular Technology Has Advanced Sufficiently to Make Possible the Safe Running of up to 2 MM lbf Hook Load Casing Strings 2. Attaining Greater Than 95% Wall Thickness Drill Pipe Landing String Is Possible Continue tracking of drill pipe wall thickness is critical in order to sort out joints in the landing string 18

19 Conclusions 3. Load-Path Inspection Is Critical to Ensure the Safety of the Operation Careful planning is required as this is done in the well program s critical path prior to drilling this hole section 4. Tracking Drag During the Running of Casing Strings Allows the Forecast of Forces Associated with Heavy Casing String There Is a point (depth) of no return when running heavy casing strings The total of the string weight and drag prevent pulling the casing out of the hole Understanding this point by operations is key to the success or failure of landing the casing string, specifically if it comes earlier than expected 19

20 Conclusions 5. The Challenge Involved with Setting of Larger Diameter and Heavier Casing Strings with Total Setting Hook Loads Approaching 2 MM lbf has been met by Implementing a Total Systems Approach 6. On the First Well Drilled by the New MAERSK DEVELOPER, All Rig Equipment Performed as Designed and the Crews Demonstrated Their Competency by Successfully Managing the World Record Casing Setting Operation 20

21 Thank You The authors wish to thank the management of Statoil ASA, Maersk Drilling USA, Inc., Quail Tools, and NOV Grant Prideco for their support and encouragement in publishing this paper.

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