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UBD PROGRAM
TABLE OF CONTENTS
1 WELL INFORMATION AND CONTACTS........................................................................................... 2
1.1 1.2 OBJECTIVES .................................................................................................................................................... 3 WELL SCHEMATIC ........................................................................................................................................... 3
APPENDIX II LEASE LAYOUT DIAGRAM ........................................................................................... 25 APPENDIX III PROCESS FLOW DIAGRAM ........................................................................................ 26 APPENDIX IV UBD RIG INTERFACE CHECKLIST ............................................................................. 27
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WELL SUMMARY
SURFACE HOLE:
100 m TVD 311 mm HOLE (12 1/4) 244.5 mm CASING (9 5/8) CEMENTED TO SURFACE 347 m TVD 222 mm HOLE (8 3/4) 177.8 mm CASING (7) CEMENTED TO SURFACE
MAIN HOLE:
INTERMEDIATE HOLE:
OPERATOR PERSONNEL
Drilling Manager: Superintendent: Geologist:
Will Cover Adam Way Julia Feltham
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1.1 Objectives
The primary objective of this well is to underbalanced drill the Grosmont formation to mitigate the potential for lost circulation. The circulating medium used will be dry compressed air to provide the lowest possible circulating pressures.
311 mm
Surface Casing Point
244.5 mm
100
456
VIKING
JOLI FOU
222 mm
GRAND RAPIDS 172 388
177.8 mm
CLEARWATER SAND
271
289
WABISKAW
337
223
159 mm
Preservoir 2400 kPa
Open Hole
GROSMONT
347
213
TOTAL DEPTH
352
208
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Operational Phase:
Hazard
What If ?
Consequences
Controls / Safeguards
Considerations
Actions to be taken
Can not drill UBD Delay in drilling well (lost time and cost) Attempts to try and fit could cause injury to personnel
Raise rig sub height by building up lease around casing bowl. Verify and check equalizing line clearance if built too high. Change BOP equipment. Use different rig. Use different RCD. Add pony sub under rig. RCD supplier go to location to check out rigs sub prior to job. Use hex kelly, square kelly not recommended. Use power swivel instead of kelly. Use top drive instead of kelly. Use Coil Tubing.
Unable to run square kelly through RCD. Delay in drilling well (lost time and cost) RCD leakage. Injury to personnel.
All wellsite supervisors must review the results of this non-exhaustive (i.e., there could be other Hazards that have not been foreseen) assessment, to ensure their awareness and to possibly identify other Hazards that require control and/or mitigation.
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2.1.2
In agreement with regulatory requirements, including Directive 033 and IRP 18, it is safety critical to establish a systematic approach for identifying and managing fire and explosion hazards. This process must involve: Evaluating potential risks with respect to fire and explosion hazards; Determining how to effectively manage these potential risks; Determining the need for specific control measures to prevent fires or explosions; Putting the required control measures in place.
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2.1.3
Underbalanced Equipment
Min Max Consequence Controls / Corrective Action - BHA Non-Return Valves (NRVs) or float valves are required to prevent back flow back up the drill string. - Positioning at least two NRVs in the BHA (normally on top of the mud motor) allows for safe underbalanced tripping. These are to be considered part of the well control equipment. It must be clearly noted that the integrity of the drill string below a float valve is unknown - A Near Surface Non-Return Valves (NRVs) is required during air drilling for operational efficiency reasons only this not to be considered a well control NRV. - For drill string connections, the near surface NRV allows for rapid bleed off of pressure and therefore avoidance of bleeding off the entire drill string. - It must be noted that the integrity of the drill string below this NRV valve is unknown until the drill string can be inflow tested below it (i.e., when the NRV is brought top surface). - To Totco survey the near surface NRV must be removed from the drilling string. - Drill pipe buckling calculations indicate the maximum unsupported stroke length at the maximum potential surface pressure (5,000 kPa) is greater than 9 meters. The push force of the top drive will not buckle the one joint of 101.3mm drill pipe under these surface pressure conditions. - Although torque and drag increases with UBD (no filter cake), previous similar air wells have indicated no torque and drag problems. - See RCD section.
Well Control
n/a
n/a
Uncontrolled flow up the drill string. Harm to personnel. Waste of rig time.
Buckling
Failed drillstring / loss of drill string integrity Loss of containment Injury to personnel
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Controls / Corrective Action Closely monitor standpipe pressure Control ROP to 50 meters / hr maximum
30
45
- Too low will cause hole cleaning problems and potential stuck pipe. - Too high will cause hole washout and too much frictional pressure loss within wellbore (potential formation damage)
- Formation damage - Stuck pipe - Formation damage - Stuck pipe - Poor hole cleaning
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2.1.4
Table 1 below shows the expected air drilling circulation parameters. The minimum air injection rate to fulfill Angels criteria for air drilling of 914 m/min (3000 ft/min) annular velocity is 20 m3/min. In table 2 an annular velocity of 1200 m/min (3936 ft/min) has been used to calculate the optimal hole cleaning velocity. It is recommended therefore to inject between 16 30 m3/min of air to ensure optimal hole cleaning. Puon and Ameri - Simplified Method
n/a
50
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n/a
n/a
Do not dead head or close in well at any time there is potential for air/O2 to be in wellbore. Ensure well is flowed at all times. Continuously observe methane detector to verify when was has displaced to 100% methane gas.
BHA handling
Ensure all BHA components are accurately measured and BOP stack measurements are also accurately recorder (blind ram to base of RCD is critical).
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Well Control Procedure 1. If a loss of drill string integrity is observed while top drive is not connected, immediately install and then close a stabbing valve or re-connect top drive. Monitor pressures and report top supervisors. 2. If risk of a pipe light condition occurs (shallow twist off), then immediately close Rig Annular preventer to maximum closing pressure. Space out drill pipe and close pipe ram. Proceed immediately with Bullhead well killing procedure. 3. Once a drill string integrity failure has been observed, an appropriate corrective action must be determined.
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3.
4.
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5. Pressure test all equipment according to the pressure testing table below. The RCD element must be installed while pressure testing. SAFETY CRITICAL: a) b) c) d) The maximum anticipated shut-in wellhead (WHP) is 363 psi / 2,500 kPa The maximum anticipated injection pressure (SPP) is 1,500 psi / 10,335 kPa RCD is weakest component, ratings: 250 psi / 1,700 kPa dynamic, 750 psi / 5,200 kPa static Pressure Testing Requirements: Low Pressure Test 200 psi / 1400 kPa High Pressure Test 363 psi / 2,500 kPa
Equipment Rotating Control Diverter (RCD) Annular Preventer Pipe/Blind Rams Rig Manifold Stabbing Valves / Kelly Cocks Stand Pipe and Associated Equipment High Pressure Air Injection Associated Valving NRV Bleed Off Tool and Line Float Sub NRVs * Low Pressure Flow Lines
Pressure test according to rig contractor standard operating procedures and practices. 200 psi / 1400 kPa 200 psi / 1400 kPa 200 psi / 1400 kPa 200 psi / 1400 kPa 180 psi / 1250 kPa 1500 psi / 10,335 kPa 1500 psi / 10,335 kPa 363 psi / 2,500 kPa 363 psi / 2,500 kPa N/A
e) For pressure testing the Float Non Return Valves (NRVs) use following testing procedure and safety precautions: i. ii. iii. iv. v. Make up the ported test sub to the bottom of float sub. Install the NRV in the float sub. Make up the keeper portion to the top of the float sub to prevent accidental release of NRV. Pressure test via bottom port to 200 psi (1400 kPa) and 363 psi (2,500 kPa) for 15 minutes each. Bleed off pressure through port on test sub and break out NRV test sub. Note: Once the float NRV has been tested in the float sub, do not remove it prior to installation or else it will need to be pressure tested again.
6.
Make up UBD BHA and drill string as follows (bottom to top): 158.8mm (6-1/4) insert bit Bit sub 2 NRVs (Note: NRVs must be in separate subs in order for the valves to function properly) one 4-3/4 Drill collar (check tool joint OD******) Totco ring for surveys 10 joints of 88.9 mm hevi-weight drillpipe 88.9mm drill pipe to surface Install 1 NRV in the top of the drill string before drilling ahead underbalanced.
7. 8.
Install RCD element on drill string as per SOPs. Close blind ram and RIH to gently tag blind ram and establish tripping out of hole bit position for closing of blind ram (accurately record this tally position). Open blind ram and conduct UBD familiarization period with all crews as follows: a. It is recommended to practice and familiarize all wellsite crews with UB tripping operations. b. Ensure RCD snubbing adapter is onsite in the event a decision is made to log the well underbalanced. c. Conduct a BOP drill and well control shut-in procedure.
9.
RIH and tag float collar / cement. All liquid is to be displaced to UBD flowback tank. Begin circulating with water and drill out float equipment and to within 1 meter of casing guide shoe. Do not drill out into new 14 Compton Thornbury
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formation with water. Use maximum pump rate and string rotation to ensure optimum hole cleaning and removal of shoe debris. 10. Prior to drilling out, conduct a pre-job meeting with all personnel to discuss the procedures for drilling out. It is essential that all rubber components are removed from the well prior to displacing to air. 11. Drill through float equipment slowly with maximum pump rate. Once the float equipment has been drilled, consideration should be given to pumping a high viscosity sweep to ensure all debris has been removed from the hole. 12. Displace the water from the wellbore and integrity test drill string as follows: a) Returns will initially be taken to the cellar via the tubing head and pumped to the mud tanks. b) Line-up rig well control valves for a soft shut-in with an open rig choke and closed HCR. Both drilling spool choke side manual wing valves are to be open. Line up rig pump and kill tanks to annulus for bullhead well killing. Rigs well control flare tank must have igniter turned off and locked out. c) Begin pumping air down drill string. Stage the water displacement from the hole at the following rates 5 minutes with 10m3/min (350 scf/min) air 10 minutes with 25 m3/min (880 scf/min) Ramp up air to full rates of ~ 45 m3/min (1,580 scf/min). Maximize the air volume to allow the casing/hole dry.
d) Monitor the standpipe pressure and do not exceed the maximum pressure rating of the compression equipment - 10,335 kPa (1,500 psi). e) Once the majority of water has been displaced, open the valves on the primary flowline to allow flow to the flowback tank. Close the valve on the tubing head. All returning flow is to be COLD VENTED to atmosphere (no lit flare pilot). Continuously check returns at the flowback tank until there is no water in the air stream.
f)
g) Shut-in well and inflow test to ensure casing integrity and cement bond for at least 15 minutes. Continuously monitor for inflow and if pressure is detected, then report to supervisors. 13. Begin injecting air at 25 m3/min (900 scf/min) rate. The objective of this operation is to drill underbalanced while maintaining BHCP as low as possible. Predicted required injection rates of air are from 20 to 30 m3/min (700 to 1050 scf/min). a) Circulate until bottom hole and standpipe pressures stabilize. b) Record torque and drag values for both up and down pipe movement, with and without pipe rotation. c) Perform familiarization period during actual underbalanced drilling operations. Make sure the rig crews are comfortable and understand their roles and responsibilities for all procedures, including communication. Conduct this separately for each crew. d) From this point and while circulating air, well control procedures require a policy of never letting the well build pressure the well is either continuously flowed to the Sonic separator or via the rig choke to the flare tank. This is required to avoid flammability and explosion risks within the wellbore. Only when the well is confirmed free of air (i.e., displaced to methane) can the well be shut-in and allowed to build pressure. 14. Commence drilling and drill to final TD of 352.2 mKB maintaining prescribed conditions at all times: a) The team Geologist, Drilling Engineer, and the Drilling Superintendent will adjust the final TD if necessary. b) Continuously monitor hole cleaning, borehole stability and drill string integrity by watching for: Increased drag Increased torque Observation of a decrease or increase of cuttings at surface Confidential 15 Compton Thornbury
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Monitor for possible signs of a loss in the drill string integrity (i.e., losses of SPP, drop in ROP, etc). If such indications are observed refer to the Well Control Procedures.
c) Do not exceed 50 meters/hour drill rate of penetration (ROP). d) If it is suspected that a downhole fire has occurred then immediately stop injecting air. Allow well to displace itself to gas. Once well has displaced to gas, slowly bleed off remaining pressure in drill string. Inflow test drill string to confirm integrity. Once integrity confirmed then POOH to inspect BHA. If drill string integrity can not be confirmed then kill well. e) Perform all connections according to detailed Connection Procedure. f) Perform any underbalanced trips according to detailed Tripping Procedures.
g) If the RCD requires servicing, follow RCD Servicing Procedure. 15. At TD, perform a wiper trip, circulate the hole for minimum of two circulations or until returns are free on cuttings. 16. Trip out underbalanced according to detailed Tripping Procedure 17. Rig out air underbalanced drilling equipment.
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5. Strip out until bit is located above blind rams. 6. Open secondary flowline to separator and isolate RCD by closing primary flowline valve adjacent to RCD. 7. Close blind rams and bleed off pressure below RCD via the hose line on the outlet of the RCD. Close bleed off valve. Inflow test blind rams for 15 minutes to ensure a competent seal. 8. Unlatch and remove RCD element. 9. Pull bit to surface and change out required BHA elements or prepare for next well operation As per main program.
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In order to maximize the consumed element life, the wellhead should be centered with the derrick throughout the drilling operations. The consumed element life must be calculated based upon a weighted average of time or meters stripped and wellhead pressure. For an example calculation for a Grant 7368 RCD, with a 1,720 kPa dynamic rating, see table 3. Table 2. Example Passive Rotating Diverter Element Life Calculation Pressure 150 kPa 500 kPa 1000 kPa 1500 kPa Meters Stripped 366 m 488 m 610 m 183 m Calculation 366/3660 = 10% 488/2440 = 20% 610/1525 = 40% 183/610 = 30% Life Remaining 100% - 10% = 90% 90% - 20% = 70% 70% - 40% = 30% 30% - 30% = 0%
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OFFICE TRAILER
Well Center
SAMPLE WELL
Dec, 15th,2006
SCALE NTS
LEE CAMPBELL
SHEET 2 OF 2
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RIG MANAGER (TOOLPUSH) DAY - DRILLER #1 DAY - DRILLER #2 NIGHT - DRILLER #1 NIGHT - DRILLER #2
NOTE: ANY NO ANSWERS MUST HAVE AN EXPLANATION ITEM YES NO COMMENTS / EXPLANATIONS
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Personal Protective Equipment Protective clothing (fire retardant coveralls, etc) Safety helmets & Safety boots Safety glasses or goggles available Gloves incl. barrier creams Hearing protection available Safety harnesses for working at heights. Breathing apparatus requirements met and in good condition.
Warning Signs DANGER-Restricted access to the rig floor and surrounding area. DANGER-No Vehicles or Unauthorized Personnel Beyond This Point DANGER: Poisonous Gas (H2S wells only) DANGER- High pressure Lines in operation or being tested. Designated smoking areas clearly identified
Others Mobile auxiliary Command Center zone rated and positioned for optimal operation. Adequate lighting in planned UBD equipment area and wellhead or marine riser Emergency Kill checked and operational MSDS available for all chemicals used Permit to Work system being used
PIPING
UBD Process Flow Diagram posted in Doghouse All high pressure piping held down and secured Only targeted elbow Tees are in use
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10 internal diameters spacing between Flowline Tees (no double elbow turns!)
High pressure pump lines and elbows Identified for specified pressure rating Free from dents, bends & excessive wrench marks No threaded pipe greater than 50.8mm
Flare Lines and Stack Certified for use by the Certification authorities Free from dents, bends & excessive wrench marks No barriers (valves, blinds, etc) between separator and flare tip.
Liquid Flow Lines Certified or Identified for specified pressure rating Free from dents, bends & excessive wrench marks
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BOP Control Unit and Accumulators Certified in accordance with Certification Authorities regulations or API or Operator minimum standards. Accumulator size Back-up N2 litres / gallons bottles psi / kPa
BOP Controls Unit and remote site identified and readily accessible Appropriate safety devices for blind / shear ram controls available. Hydraulically actuated by-pass valve installed if pipe is sheared. Annular closing pressure regulated from the rig floor BOP Control Unit remote panel. BOP Control Unit routinely tested and maintained in accordance to API recommendations BOP Control Unit malfunction alarms fitted with repeater alarms on drill floor Housekeeping and safety equipment (fire extinguishers etc.) appropriate for BOP Control Unit area. Pressure Remote psi / kPa psi / kPa psi / kPa psi / kPa psi / kPa psi / kPa
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Blow Out Preventers (BOPs) BOP certified in accordance with Certification Authorities regulations or API or Operator minimum standards. BOP routinely tested and maintained in accordance to API recommendations BOP configuration in accordance to drilling contractor or specific Operator requirement Annular Preventer element recently replaced or inspected Hydril GK Annular Preventer? Not to be used in UBD wells with expected shut-in WHPs greater than 14 MPa. Shear rams installed with boosters that enable shearing forces sufficient to cut pipe in use Last overhaul date: BOP manufacturers third party certification is valid, current and available. Full BOP systems maintenance register available on-site for audit purposes.
Pump house or rooms Air-intake will not be affected by any zone change imposed by MPD/UBO rig up Shear relief valve correctly set with a relief line secured and connected to a drain or suction Pulsation dampeners fully charged Shock hoses safety chained and all guards for moving parts of the pump installed. Mud pumps protected by a check valve installed in the discharge pump line Hearing protection sign in pump house or room and hearing protection equipment available
Rig floor Stand pipe injection system Size inches (mm) Pressure psi (kPa)
Kelly hose new or internal visual inspection conducted with a camera and is acceptable for UBD operation - for operations where N2/gas injected down drillpipe ONLY. Stand pipe firmly secured to derrick and Kelly or Top Drive hose secured appropriately. Tie-in point for Stand pipe bleed off available and can be tied into the closed process system Tie-in point for UBD injection and bleed off available as part of the standpipe manifold.
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Each side of the manifold can be isolated and pressure tie-in points are available for monitoring Steam tie-in point for heating the manifold available-if required. Kelly cocks with correct connections for DP and DCs available (including keys) Stabbing valves with fold down handles, handling subs, tools etc are properly racked
To Standpipe
To Standpipe To Standpipe
Cement Manifold
12
6 2 4
11
10
To Choke Manifold
Schematic - Stand Pipe Manifold (Generic) Mark up as required Valve # Description Valve # Description
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INSPECTED BY
DATE
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