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HP/HT Challenges
Industry focus on high-pressure/high-temperature (HP/HT) operations seems Mike Payne, SPE, is a Senior Advisor
to go in cycles as exploration successes identify new hydrocarbon resources in BP’s Exploration and Production
that can be developed commercially and as technical advances allow wells to be Technology group. He has 28 years’
drilled and completed that extend prior capabilities. When production of HP/HT experience including drilling opera-
reservoirs becomes dependent upon the development of a particular technology,
business incentives create both a substantial momentum and a sharp focus that tions, computing, technology, and
drives technology development to a successful end. consulting. Payne holds BS and PhD
degrees in mechanical engineering from
Historically, this drive has been the case with HP/HT developments. With the
Rice University, an MS degree in petro-
passage of time, some may be unfamiliar with the substantial foundation of HP/
HT technologies that were created by the hard work of our predecessors. For leum engineering from the University
example, the Association of American Wellhead Equipment Manufacturers of Houston, and an Executive Business
(AWHEM) started work on 15,000-psi wellhead equipment in 1952. That Education degree from the University
research resulted in AWHEM Standard No. 6 in 1957, which would later become of Chicago. He has extensive industry
part of the API 15K wellhead standards. The first 20,000-psi wellhead system publications and has held key lead-
was developed in 1972, which was followed quickly with the development of the
first 30,000-psi wellhead system in 1974. These developments were in response ership positions with the American
to Shell’s discovery of the Thomasville field in Mississippi, USA, in 1969. In Petroleum Institute and the International
addition to Thomasville and Piney Woods fields in Mississippi, other substantial Organization for Standardization. Payne
HP/HT developments include the Tuscaloosa fields in Louisiana, USA, and the has been an SPE Distinguished Lecturer
Central Graben fields in the North Sea. and received the SPE International
Currently, the industry is pursuing new generations of HP/HT fields including Drilling Engineering Award in 2000.
deeper wells in deep water and deep gas wells on the outer continental shelf He has chaired or cochaired several SPE
(OCS). Relative to the deepwater operations, well pressures may approach Advanced Technology Workshops and
15,000 psi at the mudline, and, hence, 20,000-psi subsea equipment is being serves on the JPT Editorial Committee.
pursued. Relative to the deep gas wells on the OCS, 20,000-psi surface wellheads
and trees, such as those used in Mississippi, Louisiana, and elsewhere, will again
be needed, and discussions are active on 25,000-psi equipment.
Just as the industry addressed the new HP/HT requirements successfully and
safely that appeared in the 1950s and onward, the industry’s current engineer-
ing rigor, innovation, and advanced technical capabilities will again converge
to address today’s HP/HT challenges. These challenges should invigorate our
engineers as they lay the foundations and groundwork for the next generation
of HP/HT capabilities. JPT
Introduction
Advances in rig design, in downhole
tools, in data communications, and in
other areas result from challenges associ-
ated with pushing and extending limits.
While in the planning stages of a deep-
water high-pressure well, risk mitigation
and contingency planning are critical in Fig. 1—Typical salt challenges.
making technology advances. It is impor-
tant to balance the drive to advance tech- high-pressure situation was evident uct development, quality management,
nology with the value created. that would require equipment that was repair, and maintenance.
unavailable at the time. Therefore, the A variety of tools was used to ascertain
Solution Potential operator approached a selected vendor existing pressure limitations and the
In many cases, wellbore construction and began a feasibility study. Open com- ability to upgrade and develop solutions
can be accomplished with standard off- munication between the companies was to increase limitations to a 30,000-psi
the-shelf products and services. When critical. After developing an understand- pressure rating. The two main compo-
the location moves into deep water, the ing of the operator’s critical success fac- nents of the analysis were the finite-
complexity, risks, and costs of those tors, the service company gained clearer element method and pressure testing of
operations require fit-for-purpose or insight into the challenges at hand and components and seals in an autoclave
application-based solutions. was able to address the effects and risks to determine limits and verify design
In this case, early in the design phase associated with “new” technology. ratings and field suitability. After all
of the well, increased potential of a engineering analysis was completed and
Development Stage designs were deemed fit-for-purpose and
This article, written by Senior Technology Typically, well-construction planning approved by the operator, the engineer-
Editor Dennis Denney, contains highlights involves a few key individuals from ing team focused on developing parts,
of paper SPE 124324, “Drilling and both companies. For this case, it was delivering specifications to manufactur-
Evaluation Technologies Extend Operating important to involve additional sup- ing, and producing maintenance proce-
Limits in Challenging High-Pressure port and expertise to ensure success. dures for the building, qualifying, and
Deepwater Environments,” by Waitus Expanded teams from the operator deployment of the downhole tools.
Denham, SPE, Shell, and Brian included the drilling, geology, and
Donadieu, SPE, Ernest Lee, SPE, Rohit petrophysical disciplines, along with Well Challenges
Mathur, SPE, and Ananth Srinivasan, asset-management and offshore-oper- The subject well is in Green Canyon
Baker Hughes, prepared for the 2009 SPE ations experts. The vendor expanded Block 434 in the Gulf of Mexico. It is
Annual Technical Conference and Exhib- its operations, applications-engineer- in deep water and has multiple riserless
ition, New Orleans, 4–7 October. The ing, and technical-support functions to sections. Fig. 1 shows typical challenges
paper has not been peer reviewed. include reliability engineering, prod- when drilling through these salt sections.
For a limited time, the full-length paper is available free to SPE members at www.spe.org/jpt.
www.atbalance.com
At Balance. A better way to drill™.
© Copyright 2010 AtBalance ™ Trademark of AtBalance
HP/HT CHALLENGES
For a limited time, the full-length paper is available free to SPE members at www.spe.org/jpt.
Source Source
Mud-pulse
Seafloor telemetry
Seafloor
Seismic reflector
High-pressure/high-temperature (HP/ and mixed hydrocarbons revealed limi- it is considered reliable for predicting
HT) gas reservoirs have pressures great- tations in terms of experimental condi- the viscosity of natural gases below
er than 10,000 psia and temperatures tions, data quantity, and in some cases HP/HT conditions.
higher than 300°F. Modeling the per- accuracy. The full-length paper details
formance of these reservoirs requires many of these limitations. A review Viswanathan Correlation. This cor-
understanding gas behavior at elevated of available gas-viscosity correlations relation is a modified LGE correlation
pressure and temperature. Gas viscos- also was performed, which showed based on NIST values of viscosity of
ity is used to model the gas mobility in that these correlations were devel- pure methane at pressures from 5,000
the reservoir and can have a significant oped from experimental data taken at to 30,000 psia and temperatures from
effect on reserves estimation during low-to-moderate pressures and tem- 100 to 400°F. However, these results
field-development planning. Accurate peratures and that their applicability at cannot be extrapolated directly to situ-
measurements of gas viscosity at HP/HT conditions could be limited. ations in which impurities exist in the
HP/HT conditions are extremely diffi- gas. The Viswanathan correlation can
cult. Public-domain databases of hydro- Available Correlations be used with confidence whenever the
carbon-gas viscosity were reviewed for National Institute of Standards NIST values are assumed to be valid.
validity of gas-viscosity correlations and and Technology (NIST). NIST devel- For HP/HT conditions, the validity of
their applicability range. oped computer software to predict both NIST values and the modified
thermodynamic and transport proper- LGE correlation must be proved against
Introduction ties of hydrocarbon fluids. The soft- actual measurements.
The growing demand for natural gas ware program uses the principle of
is driving the search for new deeper “extended corresponding states” and Gas Viscosities Measured
sources of gas, many of which encoun- was developed from pure-component at HP/HT Conditions
ter HP/HT conditions. Among gas and mixture data. The maximum pres- A project to characterize the viscosity of
properties, viscosity is seldom mea- sure and temperature that can be used gas at HP/HT conditions was initiated.
sured in the laboratory and, typically, in the program are 44,100 psia and Two types of gases were used: nitrogen
is estimated by use of correlations. At 1,340°F, respectively. The NIST gas- as a calibration fluid and pure methane.
HP/HT conditions, reservoir fluids will viscosity values closely match most The investigation was performed with
be very lean gases, typically methane of the published data, and the pre- a device that works on the basis of the
with some level of impurity, and there- dictions generally are reliable for falling-body principle.
fore the gas properties may be different HP/HT conditions in the absence of real All performed tests were compared
from those of gases at lower pressures HP/HT gas-viscosity measurements. with the reported NIST values. At high
and temperatures. pressure, all measured viscosities were
A review of large databases of pub- Lee, Gonzalez, and Eakin (LGE) lower than the NIST values, although in
lished viscosity data for pure methane Correlation. The LGE correlation is the moderate range (3,000 to 8,000 psia),
based on measured data of pure-com- values match exactly. These results were
This article, written by Senior Technology ponent gases and eight natural gases expected because the NIST values were
Editor Dennis Denney, contains highlights with specific gravities less than 0.77. calculated from existing databases with
of paper SPE 124734, “More-Accurate The correlation can be used to estimate very few points above 15,000 psia.
Gas-Viscosity Correlation for Use at HP/ gas viscosity, provided that the molecu- Fig. 1 compares measured data from
HT Conditions Ensures Better Reserves lar weight and density at the relevant this project with NIST values and other
Estimation,” by Ehsan Davani, SPE, conditions are known. existing databases for nitrogen at 134°F.
Kegang Ling, Catalin Teodoriu, SPE, The LGE correlation can be used to Test 1 was run from low to high pres-
William D. McCain Jr., SPE, and Gioia predict gas viscosities at temperatures sure, while Test 2 was run from high
Falcone, SPE, Texas A&M University, from 100 to 340°F and pressures from to low pressure. Between 3,000 and
prepared for the 2009 SPE Annual 100 to 8,000 psia. Although this cor- 8,000 psia, a good match exists between
Technical Conference and Exhibition, relation does not take into account measurement and NIST values. At high-
New Orleans, 4–7 October. The paper natural gases containing high quanti- er pressure, the measured viscosities
has not been peer reviewed. ties of nonhydrocarbon components, were less than those provided by NIST,
For a limited time, the full-length paper is available free to SPE members at www.spe.org/jpt.
0.04
Good correlation
with NIST values
Viscosity, cp
0.035
0.03
Fig. 1—At pressures between 3,000 and 8,000 psia, there is a good match between study measurements and
the NIST values. However, at higher pressure, study data fall below the NIST values.
although they show a similar trend. The On the basis of these measurements, At increased temperature, the differ-
same behavior was observed for more it can be inferred that the maximum ence between project data and the
than 100 tests conducted at the time error against the NIST values is –7.48% NIST values decreased.
this paper was written. at pressures greater than 20,000 psia.
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