This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper SPE 202439, “Pushing Malaysia’s Drilling Industry Into a New Frontier: How a Distinctive Wellhead Design Enabled Implementation of a Fully Offline Well Cementing Resulting in a Significant Shift in Operational Efficiency,” by Fauzi Abbas and Azrynizam M. Nor, Vestigo, and Daryl Chang, Cameron, a Schlumberger Company, prepared for the 2020 SPE Asia Pacific Oil and Gas Conference and Exhibition, originally scheduled to be held in Perth, Australia, 20–22 October. The paper has not been peer reviewed.
Traditionally, rigs are positioned over a well from the moment the surface casing is drilled until the installation of the wellhead tree. This results in the loss of precious time as the rig idles during online cementing. However, in mature Field A offshore Terengganu, Malaysia, a new approach eliminated such inefficiency dramatically.
Operational Planning
With oil production in Field A initiated in October 2015, historical data on well lithology, formation pressure, and potential issues during drilling were available and were studied to ensure that wells would not experience lost circulation. This preplanning is crucial to ensure that the offline cementing activity meets the operator’s barrier requirements.
Petronas Procedures and Guidelines for Upstream Activities (PPGUA 4.0) was used for the development of five subject wells in Field A. In this standard, two well barriers are required during all well activities, including for suspended wells, to prevent uncontrolled outflow from the well to the external environment. For Field A, two barrier types, mechanical and fluid, allowed by PPGUA 4.0 were selected to complement the field’s geological conditions. As defined in PPGUA 4.0, the fluid barrier is the hydrostatic column pressure, which exceeds the flow zone pore pressure, while the mechanical barrier is an element that achieves sealing in the wellbore, such as plugs. The fluid barrier was used because the wells in Field A were not known to have circulation losses.
For the development of Field A, the selected rig featured a light-duty crane to assist with equipment spotting on the platform. Once barriers and rig selection are finalized, planning out the drill sequence for rig skidding is imperative. Space required by drillers, cementers, and equipment are among the considerations that affect rig-skid sequence, as well as the necessity of increased manpower.
Offline Cementing Equipment and Application
In Field A, the casing program was 9⅝×7×3½ in. with a slimhole well design. The wellhead used was a monobore wellhead system with quick connectors. The standard 11-in. nominal wellhead design was used for the wells with no modifications required. All three sections of the casing program were offline cemented. They were the 9⅝-in. surface casing, 7-in. production casing, and 3½-in. tubing. The 9⅝-in. surface casing is threaded to the wellhead housing and was run and landed with the last casing joint. Subsequent wellhead 7-in. casing hangers and a 3½-in. tubing hanger then were run and landed into the compact housing.
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