Kikeh Batch Setting: Case Study
Chris Flannery and Benjamin Choo, Murphy Sabah Oil Company
Summary
The semisubmersible rig Ocean Rover was used by Murphy Sabah
Oil Company to batch-set 23 wellheads in 4,350-ft-deep water
with zero health, safety, and environment (HSE) incidents.
The batch-set team worked to maintain safety and performance
and to overcome numerous logistical and operational challenges.
Implementing lessons learned and development of recommended
practices resulted in continuous improvement throughout the project.
The program was completed in 63 days. The average installa-
tion time for conductor and surface casing was 3.36 days from start
to finish. Total materials used were 50,000 ft of casing, 3,060
tonnes of cement, and 78,000 bbl of 16.6 lbm/gal dynamic kill
drilling (DKD) mud.
Introduction
Kikeh is 75 nautical miles off the west coast of Sabah, Malaysia,
in the South China Sea (Fig. 1). Murphy is the operator of the field,
which is Malaysia’s first deepwater development.
The seafloor arrangement consists of 24 wells in a circular
pattern roughly 150 ft in diameter with 20-ft spacing (Fig. 2). A
spar and semisubmersible tender assist rig will be mobilized to the
batch-set location to finish the drilling and completion operation.
Commonly encountered hazards in the area include shallow
water flows (SWFs) and hydrates. Bottom currents tend to be
almost nonexistent and lead to visibility challenges. Surface cur-
rents have not been a factor.
In April 2005, all 24 well locations were marked with marker
buoys. The buoys were positioned to form a 4-ft box around each
location. Cement blocks (no steel) were used for clump weight,
and a 10-ft rope tether held the flotation buoy to the block.
In May 2005, Slot 1 was drilled to provide additional geologi-
cal data. This well provided important information regarding the
upper soils and hazard confirmation, setting a benchmark for the
remaining 23 wells to be batch set in April 2006.
Six of the 23 wells would have only the conductor installed.
The remaining 17 wells would have both the conductor and surface
casing installed (Fig. 3).
The Ocean Rover has worked for Murphy in Malaysia since
July 2003 and has provided exceptional value. The rig is conven-
tionally moored, and it has a single derrick, trip saver, large pump
capacity, and 6,050-ton variable deck load. More importantly, the
personnel onboard the Ocean Rover have consistently demon-
strated a commitment to safety and a can-do attitude.
Batch Setting—Definition and Benefits
Batch setting (Eaton et al. 2005; Valdez and Fleece 2005) is a
well-construction strategy that reduces overall operational costs by
performing repetitive tasks in sequential mode.
Conductor and surface casing strings were batch-set at Kikeh to:
• Maximize the learning curve through repetitive operations,
thus decreasing time and cost.
• Minimize potential loss of capital in the event that an uncon-
trolled shallow water flow occurs.
• Reduce capital exposure to dropped objects.
• Eliminate drilling mud change-outs from water- to oil-based
fluids on each well.
Copyright © 2008 Society of Petroleum Engineers
This paper (SPE 105027) was accepted for presentation at the 2007 SPE/IADC Drilling
Conference and Exhibition, Amsterdam, 20–22 February, and revised for publication. Origi-
nal manuscript received for review 12 October 2006. Revised manuscript received for
review 20 August 2007. Paper peer approved 12 February 2008.
September 2008 SPE Drilling & Completion
• Take advantage of the availability and efficiencies of a rig
that has operational advantages to handling large-diameter tubulars
(vs. the spar with a tender-assist rig).
Challenges
Logistics. The supply base has a small number of berths available
for the larger deepwater vessels. These berths need to be shared
with other operators. Crane availability, usage, and contingency
requirements were identified. Storage area was required for 50,000
ft of casing.
Boats. Large-capacity boats were required to transport the antici-
pated 8,000 bbl of DKD mud per well required.
Shallow Hazards. A shallow water flow was encountered at 1,800
ft below mudline (BML) on the prebatch set Slot 1.
Wellhead Positioning and Height. Wells were required to be set
within 1 ft of the target, and all wellhead heights were required to
be within 1 ft of one another.
Cement. Additional facilities were required to cut, blend, and store
the cement onshore. Offshore storage was also identified as a point
of concern.
Mud. Additional facilities were required to blend the large vol-
umes of 16.6-lbm/gal DKD mud. Additional storage was identified
for barite.
Seafloor Visibility. Bottom currents are almost nonexistent. Vis-
ibility can take up to 5 hours to be restored.
Anticollision. All surface holes are directional, with several of
them in close proximity to one another.
Directional Control. Jet 36 in. with directional assembly, then
release the cam-actuated drill-ahead (CADA) tool and drill direc-
tionally. The maximum planned inclination was 35°.
Fatigue/Complacency. One concern was that repetitive operations
may lead to personnel becoming complacent and losing focus on
the task at hand.
Water Supply. One concern was that a dry season or drought
would result in an inadequate supply of water for the DKD mud.
Planning
Objectives.
• Zero HSE incidents
• Meet or beat planned authority for expenditure (AFE) costs
and time
• No rig downtime because of logistics or material supply
• Wellheads located within the target buoys
• Wellheads located within height restraints
• All wells drilled to target
• Zero wellbore collisions
Tubulars. The maximum pipe length that could be easily stored in
the riser bay was identified as 82 ft.
36-in. conductor was ordered in 80-ft lengths. This pushed the
first connection farther below mudline and increased the fatigue
resistance of the conductor. In addition, this reduced the number of
connections, thus increasing the running speed.
275

Fig. 1—Kikeh field location.
A casing cutter was provided so the conductor could be cut to
fit the bottomhole assembly (BHA) length (as opposed to adjusting
each BHA to fit the conductor length). The conductor string com-
prised an 80-ft wellhead joint, two 80-ft intermediate joints, and a
40-ft jet joint.
The 20-in. extension joint on the 183⁄4-in. wellhead was ordered
at 65 ft. This allowed the crossover (to 16 or 133⁄8 in.) to be bucked
up in town and still be under the 82-ft design limit.
The surface casing was either 16 or 133⁄8 in. and ordered in
40-ft lengths. The 16-in. casing (thread and coupled connection)
was bucked into doubles onshore. The 133⁄8-in. casing was semi-
flush and left in singles. Testing with the rig identified no time
benefit to bucking the semiflush pipe into doubles.
Logistics. Attempts to secure additional berths for deepwater ves-
sels were unsuccessful. Additional lines were run, and a mooring
dolphin was constructed that enabled mud to be pumped to boats
not tied up at a berth. A fuel line was constructed at a nearby port
to help relieve some congestion at the jetty. Attempts to build an
additional water storage tank were unsuccessful.
Additional land was secured to provide storage for the large
volume of tubulars. Extralong trailers were obtained to transport
the 80-ft pipe lengths from the supply base to the jetty. A casing-
bucking machine was installed and set up. Modifications were
made to some of the fencing and roads to streamline and reduce the
amount of turning required by the 80-ft pipe transports.
Fig. 2—Wellhead pattern and as-drilled well paths.
276
The level of communication between the shore base, rig, ce-
ment, and mud contractors was increased. Reports were distributed
so that all parties were made aware of boat movements, storage
levels on vessels, and storage capacity at the shore base.
Cement. A low-density (13 lbm/gal), controlled-particle-size-
distribution cement was designed for the project. Cement returns to
the seafloor were planned.
A drill-the-well-on-paper exercise was held, specific to cement.
A much greater awareness of the scope of the project was instantly
realized by all participants: The overall cement process was com-
municated, and several key observations were made that helped to
streamline cement delivery.
A cement-cutting machine dedicated to Murphy was installed.
Extra silos were installed at the jetty for cement storage and trans-
fer. Additional 550-gal chemical tote tanks were secured for the
transfer of chemicals from shore base to the rig.
Mud. Similar to cement, a drill-the-well-on-paper exercise was
held, specific to mud. A much greater awareness of the scope of
the project was realized here: The overall mud process was com-
municated, bottlenecks were identified, and several key observa-
tions were made that helped to streamline mud delivery.
Additional mixing pits were fabricated and piped in. This in-
creased the build rate of DKD mud from 2,000 B/D to 4,000 B/D.
Extra storage space for barite was secured. The total mud storage
onshore was 9,000 bbl.
Rig. All four cement silos on the rig were for surface cement. The
two bulk silos were to be emptied of bentonite and used for ce-
ment. Additional piping was installed to allow transfer from these
two bulk silos to the cement system.
A minimum of three complete strings of both 36-in. and surface
casing were planned to be stored on the rig. This was to provide
some cushion in case of weather, boat delays, etc. All of the riser
was to be offloaded from the rig and stored onshore.
Additional crane operators and roustabouts were identified. A
third company supervisor was planned to assist with logistical
planning, material movement, and meetings.
Hydrates. Some areas of the field have been prone to hydrate
formation on the bottom of the blowout preventers (BOPs). To
September 2008 SPE Drilling & Completion

Fig. 3—Typical well schematic.
prevent this, an 8-ft-diameter hydrate deflector was installed and
sealed to the outside of the 36-in. wellhead housing.
Gumbo. Occasional wells in deepwater Malaysia have shown
gumbo in the surface hole section. No gumbo was noted while
drilling Slot 1. A ball-activated wash tool was planned in the BHA
as a contingency for jetting the wellhead.
Remote Operated Vehicle (ROV). Extra spare ROVs were mo-
bilized to the area in addition to the normal complement of critical
spares. A second ROV was installed on one of the vessels. In
addition to providing backup for the batch set, the second ROV has
other facilities-related tasks.
A wireless video link was purchased to allow each ROV to see
what the other was doing. This provided redundancy in case the rig
ROV failed, and it also increased the effectiveness of both ROVs
remotely working together. Either ROV video could be displayed
on the drill-floor monitors, which is required when stabbing the
36-in. conductor inside the 48-in. target.
Wellhead Positioning. All wells were marked with buoys attached
to cement blocks. An array of eight Compatt transponders was
Fig. 5—Transponders installed on hydrate deflector.
September 2008 SPE Drilling & Completion
Fig. 4—ROV bracket and clump weight.
installed on the seafloor to provide the required positioning accu-
racy (±6 in.). The tight tolerance was based on modeling of riser
clash for the spar.
A tuning-fork-shaped bracket was fabricated for the ROV and
allowed consistent positioning of the cement blocks relative to the
ROV manipulator arms. A transponder was mounted on the ROV
and calibrated for the position of the bracket. Extra marker buoys
and cement blocks were procured. The ROV onboard the vessel
was also fitted with this equipment for backup (Fig. 4).
The ROVs were ballasted lightly so they could come off the
bottom without using thrusters. Downward thrust caused seafloor
disturbance and an immediate reduction in visibility. Because of the
low seafloor currents, visibility could sometimes take hours to return.
Wellhead Height. Slot 1 was drilled before the batch set. All
wellheads were planned to be within 1 ft of one another in height.
This would reduce the amount of riser pup joints required for the spar.
Transponders were used to accurately determine wellhead
height relative to Slot 1. A minimum of two transponders is re-
quired. Both are placed on the seafloor and calibrated to each
other. One is then installed in the control slot (Slot 1), and the other
is placed in the string being jetted. Jetting then commences until
the transponders identify that they are at the same height. Note that
these transponders provide real-time depth monitoring and can
also provide real-time inclination.
ROV-friendly buckets were welded to the hydrate deflectors. A
primary and a backup transponder were planned for both the con-
trol slot and the slot being jetted (Fig. 5).
Anticollision. All surface hole sections were directional, with the
maximum inclination planned at 35°. A gyro measurement-while-
drilling (MWD) tool was used to eliminate magnetic interference
in the surveys.
Hole Sizes. The 36-in. conductor was to be jetted with 24- or
26-in. bits as available. A 16-in. surface casing was planned to be
set inside a 20-in. hole, and a 133⁄8-in. surface casing was to be set
inside a 17½-in. hole.
Slot 1 was jetted in place with 24-in. hole, and the soils were
found to be firm. The performance of jetting 36-in. wells with a
17½-in. bit in these firm soils was a concern.
Drilling Sequence. The initial plan was:
• Jet 36-in. wells and drill the 11 wells with 16-in. surface
casing.
• Jet 36-in. wells and drill the six wells with 133⁄8-in. casing.
• Jet the six wells with only 36-in. conductors.
The actual drilling sequence was intentionally flexible to allow
room to react to events, such as
• Poor visibility. If required, move to another area of the pat-
tern where visibility is good.
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278 September 2008 SPE Drilling & Completion
 Fig. 6—Conductor and surface casing performance.

• Availability of mud or cement. If problems arise getting cement
or mud to the rig, jet wells while waiting on the required materials.
• Marker buoys. If problems arise with buoys sinking or be-
ing knocked over, move to another area of the pattern while re-
setting buoys.
To give soils additional time to develop strength, a decision
was made to avoid jetting two wells side by side.
Several sequence options were discussed, including
• Jet and drill each well. This is the baseline case and the most
conservative option.
• Jet all 36-in. wells first. This would require all surface cas-
ings to be constructed back to back. One concern was the ability to
supply the required volumes of cement and DKD mud. This option
would reduce the costs incurred by wellhead-positioning personnel

Fig. 7—Times to install 36-in. casing.

September 2008 SPE Drilling & Completion 279

 Fig. 8—Stabbing 36-in. conductor between buoys.
and allow jetting with a bigger bit (26 in.) and thus potentially
faster jetting times.
• Drill multiple surface holes and run multiple strings of sur-
face casing. This option would cause uncertainty regarding hole
stability and would be limited by the battery life of the gyro tool.
This option would save tripping time.
• Drill a single surface hole, hang off BHA on trip saver, run
the casing, retrieve BHA, and drill the next slot. This option would
save tripping time but would be limited by the battery life of the
gyro tool.
• Configure the drilling order to reduce or minimize the num-
ber of wells that require the use of the gyro tool. This option would
save gyro survey time, personnel, and cost, and it would reduce the
dependence on the gyro tool.
Success. The importance of starting the program with success was
emphasized to the rig team to generate positive momentum. Thus,
the first two wells were to be drilled conservatively, building up
some momentum before attempting some of the more aggressive
time-saving options.
Experience has revealed that some offshore personnel become
intimidated in larger onshore meeting venues and infrequently par-
ticipate in discussions. As a result, several planning sessions were
held offshore to gain input from all levels of offshore personnel.
The meetings offshore had great results.
Tracking the learning curve was the task of the performance
coach offshore and the onshore drilling engineer. Performance
coaches have been active in Murphy’s drilling program in Malay-
sia and are integrated with the drilling team and its culture. A
detailed list of operational steps was provided to the coach, and
start and stop points were identified for each step to allow consis-
tent benchmarking.
An incentive plan was generated that included all offshore per-
sonnel. Efforts were made to ensure that communication between
all parties was open and consistent.
Results and Lessons Learned
The average time to construct 17 conductor and surface casing
wells was 3.36 days. The average time to construct the 6 conduc-
tor-only wells was 0.93 days. Note that construction time is con-
sidered to be all time charged against the well (Table 1).
Overall. Fig. 6 shows the construction times for the 17 conductor
and surface casing wells, including the learning curve and trouble
time. Although Slot 1 was not part of the batch-set program, it is
included because it established the first benchmark. A 43% reduc-
tion in “no trouble” time was noted from the first well to the
average of the entire batch set.
Conductor. Fig. 7 depicts total installation time for the 36-in.
conductor. This sequence saw a learning curve of 40%. The big-
280
Fig. 9—Photo showing 10-ft markers after seafloor movement.
gest improvement in jetting times was brought about by increasing
the flow rate of the BHA from 1,200 to 1,400 gal/min by replacing
the plug in the motor with a nozzle.
A large variation in the soils was noticed and could not be
predicted. No difference in jetting times was noted between jetting
with a 24- or 26-in. bit. A difference in jetting times was expected
between a 20- and 24-in. bit, but it could not be substantiated
because of the soil differences. In several cases, the 20-in. bit jetted as
fast as the 24-in. bit. No attempt was made to jet with a 17½-in. bit.
Pickup, makeup, and land-out of the 280 ft of 36-in. conductor
was 7 hours on Slot 1. After two wells, this time had dropped to 2.5
hours, and it further decreased to 1.5 hours by the end of the
program. Note that joint length was 40 ft on Slot 1. The joint
length was increased to 80 ft for the batch-set program.
Weight on bit was aggressively applied while jetting, to the point
that the lugs on CADA tools began to show signs of deformation.
No problems were noted while stabbing the 36-in. conductor
inside the 48-in. square bounded by marker buoys. A maximum of
1 hour was required to position the rig (Fig. 8).
Wellhead height targets of ±1 ft were achieved, with the maxi-
mum difference being 9.80 in. between all wellheads. Although the
use of transponders went well, the vibration from jetting resulted
in damage to some. Procedures were changed to install transpon-
ders while making the last drillpipe connection in the slot being
jetted (Fig. 5).
During jetting of one slot, the CADA tool released and the
string dropped suddenly. Both transponders were ejected from
their buckets, falling to the seafloor, and were submerged from
sight. Even though both continued to send signals, only one could
be located and recovered. Therefore, 10-ft tethers with small flo-
tation buoys were attached to subsequent transponders. The backup
ROV on the vessel was used to search for the transponders while the
ROV on the rig continued to support the batch-set program.
The difference in seafloor elevation is 9 ft across the 150-ft
pattern. All indications were that the seafloor was stable. The first
three wells were all jetted, drilled ahead, cased, and cemented.
While preparing for the fourth well, the ROV operator noticed that
movement of the seafloor had occurred and wiped out most of the
marker buoys in the lower quadrant of the pattern (Fig. 9). Visual
ROV inspection revealed that a large buildup of cuttings, DKD
mud, and excess cement caused this movement. The sequence was
then changed to allow for the reset of the marker buoys. The
backup ROV on the vessel was used to reset marker buoys while
the ROV on the rig continued to support the batch-set program.
The sequence focus then changed to drilling downslope wells be-
fore drilling the upslope ones.
Drill Surface Hole. Fig. 10 presents times to drill the surface
interval for each of the wells. A 29% reduction in time for this
interval was achieved over the batch-set program.
September 2008 SPE Drilling & Completion
 Fig. 10—Times to drill surface interval.
All wells were directional, and kickoff was as close as possible
to the 36-in. conductor shoe. No problems were noted with the
building angle. The average angle at total depth (TD) was 21°; the
maximum was 35°. No wellbore collisions occurred.
The most efficient sequence was to drill, pull out to the well-
head, hang off the BHA on the trip saver, run casing, and then pick
up the BHA off the trip saver, move over, and drill the next hole.
Unfortunately, this was limited to a maximum of two wells be-
cause of the gyro tool battery life. This method alleviated concerns
of wellbore stability, yet still reduced tripping time.
Problems were encountered in obtaining good-quality gyro sur-
veys. Contingency plans were created to allow for the rotation of
an additional stand or more until the gyro quality improved. Usu-
ally, the gyro survey quality got better with depth, but not always.
In two separate instances, difficulties were experienced getting
gyro surveys. A decision was made to pull out to the well and stab
Fig. 11—Looking down at gumbo on 36-in. wellhead.
September 2008 SPE Drilling & Completion
into another well with the same bit, BHA, etc. No gyro problems
were encountered on the second well in either case.
The root cause was identified as too much noise, but the source
of this noise was never found, even after efforts by the gyro com-
pany and the rig team. The problems were present in both seawater
and DKD mud. Coincidentally, no further gyro problems were
experienced after the nozzle in the mud motor was replaced with
a plug later on in the program.
SWF was identified on only 12 of the 17 surface intervals. The
depth of the SWF was relatively consistent, with a couple of the
wells being 100 ft higher or lower than the norm. The location of
the SWF varied, with one well having flow, the one beside it not,
and so on. The five non-SWF wells were scattered throughout the
drilling order (not the last five wells drilled).
Fig. 12—Slot 11 initially set 13 ft above mudline.
281

Fig. 13—Slot 10 initially set 4 ft above mudline.
The SWF diminished in intensity as the program progressed.
Visual confirmation with the ROV was made to confirm a positive
flow. At least two instances were noted whereby the ROV sonar
identified a plume above the wellhead, but the well was visually
observed to be static. It is suspected that the plume was from a
previous sweep not being dispersed from the wellhead area be-
cause of the lack of seafloor current.
Gumbo was not noticed during the drilling of Slot 1 but ap-
peared as the program progressed. Large amounts of gumbo were
observed while drilling with seawater, with little or no change after
changing to DKD mud (Fig. 11).
Early in the program, some wells had gumbo on the BHA, but
none was visible while drilling. The shear pins in the CADA tool
Fig. 14—Times to run and cement surface casing.
282
were then removed to allow the tool to float and possibly give any
gumbo a larger area for exiting. A significant increase in gumbo
exiting the wellhead was noted, as was a corresponding decrease in
the amount of time to run casing.
All surface intervals were drilled 20 in., including the holes for
133⁄8-in. casing. Although originally planned for 17½ in., those
holes were changed to 20 in. to eliminate the need to jet with 17½
in. and because of concerns running 133⁄8-in. casing in a 17½-in.
hole with possible large amounts of gumbo present.
Cuttings, gumbo, and cement buildup around the wells became
a concern. In some cases, the gumbo piled up higher than the
wellhead; the ROV was unable to move, clear, or pump away the
gumbo. The difference in elevation across the 150-ft pattern was 9
ft. By the end of the program, the entire pattern was almost filled
in because of the large quantity of cuttings and gumbo from the 17
surface intervals (Figs. 12 and 13).
Run and Cement Surface Casing. Fig. 14 displays times to run
and cement surface casing for the 17 wells. A learning curve of
23% improvement was achieved.
The 16-in. casing was thread and coupled and bucked up into
80-ft doubles in town. The 133⁄8-in. casing was semiflush and
shipped in singles. Previous trials on the rig have demonstrated
that the semiflush is slower to run in doubles because of the lift
nubbins and stabbing the slip-type elevators over the end of the
double. In addition, an extra man is required in a basket to help
guide the slip-type elevators over the end of the double.
Casing makeup and running inner string dropped quickly from
13 hours at the start to 9 hours after a couple of wells, and con-
tinued to improve to 7 hours by the end of the program.
Some of the wells pushed gumbo out of the wellhead when
casing was run. Multiple attempts were required to latch some
wellheads. All wellheads were eventually latched and preloaded.
Full returns were noted on all cement jobs and were planned to
have cement to surface. The ROV operator was able to distinguish
mud from cement on only two wells.
September 2008 SPE Drilling & Completion
Conclusions
All goals and objectives for the batch set were met or exceeded.
Numerous lessons learned have been identified for each sequence
of the batch-set operation.
The success of the Kikeh batch-set operation required a strong
team effort, solid planning, and clear communication. Bulk
materials, boats, logistics, and the rig itself are key components of
equal importance.
Flexibility in the execution sequence allowed several potential
“trouble time” events to be avoided or reduced. Planning, com-
munication, and positive attitudes allowed continuous change and
adaptation to challenges as they were encountered and overcome.
Improved efficiency was noted in all areas of the rig perfor-
mance. A 43% reduction in “no trouble” time was noted from the
first well to the average of the entire batch set. This is attributed to
the drilling and logistics team culture, a willingness of personnel to
challenge and share ideas, and a willingness of personnel to listen.
Acknowledgments
The authors thank Murphy Oil and Petronas for permission to
publish this paper. Murphy Oil would like to thank the hundreds
of personnel who were involved with this program for their safe
work practices and consistent effort that made the Kikeh batch set
a success.
September 2008 SPE Drilling & Completion
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dam, 23–25 February. DOI: 10.2118/92289-MS.
Reinhardt, W.R., Williamson, R.H., Eaton, L.F., and Actis, S.C. 2006.
Magnolia Deepwater Development: Striving for Best-in-Class Drilling
Performance. SPEDC 21 (4): 268–278. SPE-92439-PA. DOI: 10.2118/
92439-PA.
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Chris Flannery is the Deepwater Drilling Team lead for Murphy
Oil in Malaysia. Before joining Murphy Oil, he worked in
Canada as a drilling engineer (land and offshore) and pro-
duction engineer. He graduated from the University of Mani-
toba in 1994 with a degree in mechanical engineering. Ben-
jamin Choo is the staff drilling engineer for Murphy Oil in Ma-
laysia. Before joining Murphy Oil, he worked for Schlumberger
as a drilling engineer. Ben graduated from the Monash Univer-
sity of Melbourne, Australia, in 1995 with a degree in chemical
engineering.
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