IADC/SPE 62773 THE DRILLING AND COMPLETION OF THE FIRST MONOBORE WELL IN PENINSULAR MALAYSIA

Aminuddin Mohammad & U Mya Maung, PETRONAS CARIGALI SDN. BHD.

Copyright 2000, IADC/SPE Asia Pacific Drilling Technology This paper was prepared for presentation at the 2000 IADC/SPE Asia Pacific Drilling Technology held in Kuala Lumpur, Malaysia, 1113 September 2000. This paper was selected for presentation by an IADC/SPE Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the International Association of Drilling Contractors or the Society of Petroleum Engineers and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the IADC or SPE, their officers, or members. Papers presented at the IADC/SPE meetings are subject to publication review by Editorial Committees of the IADC and SPE. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.

Abstract During a recent revisit (October 1999) to Duyong Field, Offshore Peninsular Malaysia, the operator Petronas Carigali Sdn Bhd (PCSB) was able to drill through the troublesome Terengganu Shale and successfully completed a well in the productive Tapis Gas Sands. The well, Duyong A-4 STR4D (DYA4STR4D) was drilled and completed under approved budget with minimal lost time. DYA-4STR4D was the first 3-1/2 monobore completion by PCSB in Peninsular Malaysia, paving the way for future application of the technology especially for the development of marginal oil and gas fields. This paper will summarize the design, planning and execution of this milestone achievement for PCSB. Background Duyong Gas Field located about 236 km southeast of Kuala Terengganu in Block PM-12 and was discovered by Conoco in 1970. The field development was started in 1983 by PCSB and a total of 13 wells were drilled by 1985 from the 3 platforms; DYDP-A, B and C using the jack-up rig Parameswara in water depths of about 76-78 meters (Fig.1, 2, 3). All these wells were completed in the S reservoir sands located between 1650 to 1827 mss.

Out of these 13 wells, well DY-A4 was initially planned to develop the T reservoir sands which require penetrating the approximately 250 meters thick highly reactive Terengganu Shale overlying it. This well was drilled down to the top of the Terengganu Shale without problems and the 9-5/8" production casing was set and cemented casing-off the S sands. Several attempts were made below the 9-5/8" casing to pass the Terengganu Shale failed. Severe bore hole problems were encountered resulting the well to be sidetracked three times without success. A water based sea water polymer mud used failed to inhibit the Terengganu Shale. Finally, further drilling into the T sands was terminated and the well was completed as a single gas producer in the S sands. A new 9-5/8 inches casing string had to be run inside a sidetrack hole due to a leak in the old casing string resulting from extended drilling below it. In 1995, during the Revisit-I Campaign, another attempt was made to develop the "T" sands from a new well DY-A7 drilled from the Duyong-A platform. This well also failed to be drilled to the objective T sands. This time the failure was due to the differential pipe sticking problems encountered in the depleted "S" sands which was further aggravated by the higher equivalent mud weight required to drill through the shallower "R" sands ("R" sands are being produced from the Duyong B & C platforms). Like in the DY-A4 well, a water based mud was used. This well failed even to penetrate the Terengganu Shale. After premature running of the 133/8" casing set at shallower depth, the well was plugged and abandoned. Further attempts to make progress in drilling to the S sands failed, due to the repeated differential pipe stuck problems encountered. With potential viable reserves still remaining untapped at this location, a third attempt was planned to develop the "T sands during the Revisit-II Campaign from Duyong-A platform in Q4, 1999. For this Revisit-II campaign, the jack-up rig Harvey H. Ward owned and operated by R & B Falcon was contracted for the project.

AMINUDDIN MOHAMMAD & U MYA MAUNG, PETRONAS CARIGALI SDN. BHD.

IADC/SPE 62773

Operation Planning Side-scan Sonar. Suspecting poor primary cementing as observed from the high annuli pressures in all the wells, a shallow seismic survey was conducted prior to the Revisit - I campaign in 1993 / 1994. The results showed severe gas migration resulting from channeling effects in most of the shallow unconsolidated sandy layers beneath the platforms to be gas charged. For safety in using the jack-up rig, a shallow seismic survey was run again prior to this campaign.. As part of the procedure in positioning a jack-up at a platform, a ROV survey will be conducted to check for any seabed construction debris. An opportunity will be taken to check for any gas breaking to the seabed which also indicated no active gas bubbling at the seabed. In addition, to check for shallow gas a dedicated pilot hole drilling will be carried out in each of the foot print areas by drilling 8-1/2 inches pilot holes to 18 meters below the seabed. Swiss Cheesing. As stated earlier, the jack-up Parameswara, a BMC 300C independent leg type jack up rig was used during the initial development stage in 1983 / 1985. For the Revisit - I campaign in 1994/1995, the rig Randolph Yost a MLT 116 C also an independent leg jack-up design was used. Thus, these campaigns left two different foot -prints having different spud can diameters as well as spud can center distances. Thus to alleviate this foot print in-compatibility problem when bringing in the jackup rig Harvey H. Ward (Friede & Goldman L 780 - MOD II C design) this time, the rig owner R & B Falcon formulated a novel procedure called Swiss Cheesing drilling (Fig. 4). Basically this involves drilling a number of 26 inches diameter pilot holes in each of the foot print overlapping areas of the three spud cans to soften and disturb the soils significantly so that the leg of Harvey H. Ward rig will not slide into the old spud can holes left behind in the previous campaigns. This will be carried out with the rig in floating mode with the rotary table positioned 1.5 feet off from the transom of the rig hull. Well Planning Well Plan Change. Initial planning called for drilling a new well DY-A8 from an empty conductor on the Duyong-A platform. However, after thorough re-study taking into account the deterioration in the shallow gas situation, the need to pass through the highly depleted "S" sands (as low as 3.79 ppg EMW) and lessons learnt from the previous two failures, the team decided to abort drilling the new well DY-A8 and instead of decided into the option of sidetracking and deepening the existing DY-A4 well from below the existing 9-5/8" production casing to the prospective "T" sands. The existing 5-1/2

by 5 single completion string need to be pulled out including the permanent packer. After remedial squeezing and establishing the integrity of the S sand perforations in this 9-5/8 casing, the 8-1/2 hole to be drilled from below this 9-5/8" casing shoe and 7" liner to be run to case-off the Terengganu Shale. This entails drilling a 6" hole below the 7" liner penetrating the prospective "T" reservoir sands. At total depth, a small 3-1/2 liner to be run, cemented, tieback and completed as monobore (Fig. 5). Deepening of the DY - A4 will not only save well cost but also it will increase the chance of successful drilling as all the shallow hazards are already isolated behind this casing. This decision eliminated most of the problems present in the upper hole sections above the Terengganu Shale. Since there was no contingent hole size available, the drilling operation was very carefully planned and executed. Synthetic Oil Based Mud. Terengganu Shale is a stressed swelling shale that is sensitive to water based mud system with an exposure time window of 3-1/2 to 5 days. This evidence not only happened in Duyong but also in other fields e.g. Bekok. In these fields the shale is about 250 meters thick and situated 1700 meters below vertical depth. In this campaign, the team used the newly formulated synthetic LTOBM to tackle this swelling shale. Prior to the Duyong revisit campaign, the new synthetic mud was tried in a nearby Bekok-B10 where it proved very effective in mitigating the troublesome Terengganu Shale. The mud system used was Ancovert 2000 (LowToxic Oil Based Mud) with Escaid 110 as the base oil. The advantages observed in using this system comparing to the previous campaign which used Salt polymer and KCI/PHPA polymer muds are: LTOBM provided better hole stability. One of the main cause of shale (K-shale) instability in Malay Basin is water absorption. LTOBM utilizes oil as the external phase, thereby eliminating the effect of shale swelling. Moreover, increased inhibition is obtained by balancing the internal brine phase with that of the formation water, thus preventing waters transfer. LTOBM provided better lubricity while drilling. Low torque and drags were observed while drilling using LTOBM compared to the Salt and KCI / PHPA polymer muds that were used in the previous campaign. The base oil as well as the extremely tough, thin and slick filter cake formed by the LTOBM provided the lubricating properties which would help in drilling DY-A4STR4D which is a 68 well.

IADC/SPE 62773

THE DRILLING AND COMPLETION OF THE FIRST MONOBORE WELLS IN PENINSULAR MALAYSIA

High Pressure Tapis Sand. Based on pressure data from exploration well, the "T" sand (Tapis sand) is overpressured with an anticipated maximum surface pressures exceeding 6000 psi with a dry gas column from the T-10.2 and T-11 sands. The drilling and completion of this sand require high mud weight up to 14.3 ppg and wellhead equipment was subsequently rated to 10,000 psi WP. During the DY-A4 original well drilling program, the drill string got stuck several times and at TD, it failed to be freed. The string was cut above free point and abandoned without cement plugs leaving the T sands in potential communication with each other. As such, cross flow was anticipated and determining the mud weight became a critical planning factor. Completion Strategies

to ensure annular pack-off above the liner. The wet flow parts of the packer were enhanced to accommodate any potential erosion or corrosion problems that may occur downhole. A key driver in the DY-A4STR4D completion strategy was to minimize well intervention and maintenance. This was done in the individual component designs. An example of this, was the using of standard Halliburton (Otis) X line flow control equipment with a 2.813 inch bore which is commonly available. This allows the use of Petroleum Engineering Services (PSE) plugs and straddles which was designed to pass through a 2.813 inch bore ID. Further, both wireline and coiled tubing set retrievable bridge plugs are available to pass through a 2.813 inch seal bore. Three locations were chosen for landing nipples: Above the formation liner, which allows for work to be done on the upper wellbore components without a dynamic kill and for setting the hydraulic packer. Above the retrievable hydraulic, which allows work to done on the upper wellbore without a dynamic kill. Below the safety valves, which allows for leak detection, and work to be done on the SSSVs, tubing hanger and Christmas Tree components.

Well DY-A4STR4D will access new production from the prolific Northern Tapis T-sand at about 2870 to 3400 meters. Based on data obtained from exploration and appraisal wells, the team determined that the reservoir was composed of heterogeneous sandstone layers with some of the layers having potential for water breakthrough. It was necessary that the completion be designed to allow eventual segregating the different zones as they water-out in order to maximize production and recovery. It was determined that the well life for DYA4STR4D would be 4 - 5 years. Production from the T sands is expected to be highly corrosive (CO2 content of 6 to 10 mole percent and no H2S). Because of this, the team chose to go with 13% chrome tubulars and accessories to minimize sweet corrosion that may occur after water breakthrough. Premium connections were selected for all tubulars to minimize potential leak paths. In deepening the well, the hole size is limited by the drilling interval from the kick-off point to reach target reservoir. After setting the 7 liner at base of Terengganu Shale, the next available hole size is 6 inches. This limits the size of liner available to complete the well. Completing with standard 4-1/2" liner cannot alleviate the problem of potential early water cut from the upper "T" sands (T2, T4 sands). The last and best option is to complete well inside the 3-1/2" monobore set across the "T" sands. This would not only achieve effective co-mingled production from the different sand members namely ; T-2 , T-4, T-10, T-11.1 and T-11.2 but most importantly will minimize cost well intervention and maintenance during the producing life (Fig. 7). Future wellbore intervention, if required for zone charge, water shut-off etc., could be easily achieved at minimal cost using wireline only. Completion Components. The liner hanger will include integral pack-off packer. A polished bore receptacle (PBR) and retrievable hydraulic packer are included in the monobore completion. The hydraulic packer is used

The use of a monobore completion design for DY-A4STR4D was driven to minimize well installation times and costs. This is in line with PCSBs drive for application of slim well engineering to achieve cost optimization Deepening The Well Positioning The Rig. As planned, the shallow seismic survey conducted confirmed that the shallow gas situation had deteriorated and has encroached underneath the platform area at three different layers : 36 meters, 26 meters and as shallow as 13 meters below the sea bed. The boundary of this shallow layer being close to the rigs bow leg spud-can needed further confirmation due to safety implication. A confirmation with a dedicated pilot hole drilled using a soil boring vessel before the rig move in and an earlier ROV survey showed it has not effected the spud can foot print area. The planned swiss cheesing was also conducted with the Harvey H. Ward in floating mode. A total of 101 numbers of 26 diameter pilot holes were drilled in the three (3) spud can foot print areas to weaken and to disturb the soils in the foot print overlapping area. The rig was then pulled into positioned. After successfully preloading to full 40.7MN (9132 kips) it was jacked up to operating air gap and rigged up for operations.

AMINUDDIN MOHAMMAD & U MYA MAUNG, PETRONAS CARIGALI SDN. BHD.

IADC/SPE 62773

Drilling of DYA-4STR4D. After retrieveing the old 5 x 5 completion assembly, the inside of the casing was cleaned down past the S sand perforations to PBTD. The well was displaced to 12.0 ppg LTOBM mud. Then the mud weight was increased to 13.9 ppg required to drill the next 8 hole section penetrating the Terengganu Shale. There were no losses of mud confirming the integrity of the squeeze cementing across the perforations. A 14.3 ppg PIT was performed after drilling 3 meters of new formation to 2365m, below the shoe. This 14.6 ppg PIT was considered more than sufficient to drill the next hole section. An 8-1/2 rock bit with directional BHA was ran and successfully steered the well away from the old fish left behind in the initial campaign. This section was continued drilled through the Terengganu Shale without problems to the section TD of 2726 m MD. The 13.9 ppg Escaid-110 synthetic based drilling fluid system proved very successful in mitigating the shale. There was no shale breakout observed at 13.9 ppg mud weight. No borehole problems were also encountered. At TD, no logging was carried out to reduce time exposure of the mud to the shale. The 7 liner was set and cemented as planned. For the production section, a 6 BHA was run and the well displaced with 15.6 ppg mud. The 15.6 ppg mud weight was used in anticipation of cross flow and and potential charging of the shallower T sands i.e. T-1, T-2, and T-4 from the deeper T-11.2, T-11.1 sands. However, the drill string got differentially stuck at 2940 m while setting the tool face. The pipe was freed by slowly reducing the mud weight in stages down to 14.3 ppg confirming that the pressure charging of the upper T sands were not as severe as earlier predicted. The well was drilled ahead without anymore problem reaching TD at 3480m. Drilling was slow probably due to the heavy mud weight and low GPM limited by the small nozzle flow area attainable even with the jets removed for the 6 bit selected. At total depth, two wiper trips were made and the hole cleaned but failed to log the hole successfully from TD. TLC run also failed and further attempts to log the hole was terminated. The hole was conditioned and the planned 3-1/2 monobore was run and cemented. The ESCAID 110 based OBM also proved quite successful and there was no major mud related problems encountered. Overall drilling of this hole section went quite well with only minor problems only. The well was completed by running the 3 completion assembly as planned. A 1 Coil Tubing Unit ( CTU ) was rigged up and the 3 monobore was cleaned down to PBTD and the well was perforated in the T-10 Sands. Estimated savings in well cost was about 30% as compared to drilling a new well.

Conclusion Team work and proper planning was the main contribution factor in the successful drilling of this complicated well. Use of this monobore technology also helped in the successful drilling by allowing the well to be drilled to TD in a small 6 hole interval. However, due to small hole size, no more contingent hole size will be available in case of any problem prior to reach TD. Monobore completion has proven successful in this well and can be recommended for consideration in the development of marginal oil and gas fields in the future. Most importantly, it paves the way for the application of slim well design for future field development. The Escaid 110 based LTOBM proved very successful in mitigating the borehole stability problems in the Terengganu Shale Acknowledgement The authors wish to express out thanks to the management of Petroliam Nasional Berhad and Petronas Carigali Sdn Bhd for giving their permission to publish this paper, and those who have contributed to this paper.

IADC/SPE 62773

THE DRILLING AND COMPLETION OF THE FIRST MONOBORE WELLS IN PENINSULAR MALAYSIA

DAMAR

PM 2

PM 3
BINTANG JERNEH JERNEH BARAT LAWIT

BUNDI

MESAH S. BUNDI PIATU NORTH LARUT LARUT-LIKU

NORING 700,000 N

SEPAT LAHO

PM 5
MELOR

LARUT

EAST LARUT NORTH LUKUT

700,000 N

GULING

INAS

PENARA BEDONG TUJOH KAPAL Pulau Perhentian Besar TANGGA DULANG Pulau Redang LABA BARAT SEROK TELOK BARAT LABA RABUNG TANGGA BARAT

ABU KECIL ABU BUBU DIWANGSA LEREK

BUJANG

PM 8

JKT-A
Proposed A4 Sdtr

SERUDON

PM 306

MERANTI

1976 PSC
TELOK TABU GUNTONG

LAWANG PANTAI BERUANG PALUH

BANGGOL YONG NORTH RAYA PETA KIRI EAST RAYA PETA CHERMINGAT

SEMANGKOK
JAMBU 1 JAMBU 2

IRONG BARAT IRONG

TAPIS
TIONG BARAT

PALAS TIONG

BERANANG 600,000 N KETUMBAR

LIANG

KEPONG
N.W SELIGI

CAHAYA SOUTH RAYA BELUMUT W.BELUMUT TINGGI 600,000 N BELANGA PULAI LEDANG LEDANG BARAT

KUALA TERENGGANU

PM 10
TEMBIKAI ANGSI

BERANTAI

BEKOK

SELIGI OPHR
BAYONG

Marang

BESAR

SOTONG

DUYONG BARAT

1: 1,000,000
0 0 10 20Miles 50KM 400,000 E
Kuala Dungun

PM 307
500,000 E

ANDING

DUYONG
DELAH

MALONG

FIGURE 1 : LOCATION MAP

FIGURE 2 : TOP T RESERVOIR MAP

Duyong Drilling Platform (DDP-A) o 9 slots o 3 production wells o current prod @ 60 MMscf/d o 1 emergency generator o 1 firewater pump o 1 12 ton crane

Flare tripod o capacity @ 250 MMscf/d

Duyong Drilling Platform (DDP-C) o 9 slots o current production @ 155 MMscf/d o 8 producing strings o 1 emergency generator o 1 fire water pump o 1 12 ton crane 5 km (14") Living Quarters Platform (LQ) o 122 men living quarters o 1 emergency generator o 1 fire water pump o 1 12 ton crane Central Processing Platform (CPP) o 3 trains capacity @ 300 MMscf/d o 4 gas (solar saturn) turbines for generation o 1 fire water pump o 1 18 ton crane o 2 screw air compressor

5.6 KM (14 " 0)

Duyong Drilling Platform (DDP-B) o 9 slots o 8 production strings o current prod @ 140 MMscf/d o 1 12 ton crane Gas/condensate from EPMI operated Bekok field

80 K M

(18 "

0)

48.7 km (24 "0) Sotong Collector Platform (SCP) o Pig receiving/launching facilities o 4 men living quarters o 2 generator sets for power generation o 1 fire water pump o 1 19 ton crane o 1 32 men survival craft Gas Compressor Platform (GCP) o 3 unit Dresser Rand compressor o Compression @ 300 MMscf/d o 1 30 ton crane

(3 0 " 0 ) 156 KM
Gas/condensate to Onshore Gas Terminal

FIGURE 3 : DUYONG FACILITIES

Drill 8-1/2" pilot hole to 18 m below seabed Swiss cheesing with 26" bit to 15 m below seabed Individual leg pre-loading procedure
old footprint depression 50 NOs X 26"hole X 15m area to swiss cheese footprint area after swiss cheesing seabed

DUYONG DP-A

8-1/2" pilothole to check on shallow gas

Harvey H.Ward footprint

Shallow gas layer @ 26m BSB

Old footprint depressions left over from previous campaign

FIGURE 4 : PILOT HOLE DRILLING AND SWISS CHEESING

18 m

15 m

AMINUDDIN MOHAMMAD & U MYA MAUNG, PETRONAS CARIGALI SDN. BHD.

IADC/SPE 62773

B E F O R E A N D A F T E R R E V ISIT

mTVD

mMD

26"conductor 20" ca sing

158 3 9 0 .1

158 391

1 3 -3/8" ca sing

1 1 7 5 .9

1529

9 -5/8" ca sing TERENGGANU SHALE 7" liner estim a ted base a t 2 0 2 9 m TVD

1777

2361

1993

2725

TAPIS S ANDS

3 -1/2" liner FIG U R E 5 : D YA-A TR4D C A S I N G SCHEME SCHEME DYA -S 4STR4D CASING

2330

3480

NO.
1. 2. 3. 4. 5. 6.

ACTIVITIES
SKID RIG TO DYA-4 KILL WELL/ CUT TBG INSTALL BPV, R/U, TEST BOP POOH COMPLETION ND BOP, C/OUT THS MILL & RETRIEVE PKR PRESSURE TEST BOP CLEAN-OUT & LOT DRILL 8-1/2" HOLE TO 2726M RUN, CMT & TEST 7"LINER DRILL 6"HOLE TO T-4 SAND RUN INT.LOG DRILL 6"HOLE TO TD LOGGING & WIPER TRIP RUN, CMT & TEST 3-1/2" LINER RUN COMPLETION N/D BOP, N/U XMAS TREE RIG DOWN

PLAN DAY # C M . D A Y
0.50 1.00 1.00 1.00 1.00 2.00 1.50 2.00 2.25 1.50 2.25 1.50 2.25 3.00 1.75 3.00 1.00 1.50 0.50 1.50 2.50 3.50 4.50 6.50 8.00 10.00 12.25 13.75 16.00 17.50 19.75 22.75 24.50 27.50 28.50 30.00

ACTUAL CUM.DAY DAY #

0.27 0.44 0.39 0.42 0.31 2.13 0.69 1.35 6.21 1.87 0.27 0.71 1.10 1.52 1.83 3.96 4.65 6.00 12.21 14.08

MEASURED DEPTH (M-RKB)

(500)
2

(1,000)

7. 8. 9. 10. 11. 12. 13. 14. 15.

(1,500)
3 4 5 6 8 7 8 9 9 10 10 11 12

10.00 2.46 3.21 1.86 1.30 2.15

24.08 26.54 29.86 31.72 33.02 35.17

(2,000)

16. 17. 18.

(2,500)

(3,000)

11-13 13

14

15

16

17

18

(3,500) 0 2 4 6 8 10 12 14 16 18 DAYS 20 22 24 26 28 30 32 34 36

FIG U R E 6 : D Y - A 4 S T R 4 D - D E P T H v s D A Y S
PLAN ACTUAL

IADC/SPE 62773

THE DRILLING AND COMPLETION OF THE FIRST MONOBORE WELLS IN PENINSULAR MALAYSIA

FIGURE 7 : COMPLETION DIAGRAM BEFORE AND AFTER REVISIT - II

AMINUDDIN MOHAMMAD & U MYA MAUNG, PETRONAS CARIGALI SDN. BHD.

IADC/SPE 62773

FIGURE 8 : DYA-A4STR4D WELL PROFILE