Top-Hole Technology Overcomes Challenging Sand-Based Seabed Conditions and Enables Record Drilling Performance in an Offshore Exploration Well

Abstract

Abstract Top hole construction is a critical part of any well design, especially for subsea wells. It is considered to be the foundation for the well, and it is crucial for ensuring well integrity. Uncertainties and conditions of the seabed and top layers could compromise the stability of the chosen solution. This paper describes the first implementation of the conductor anchor node (CAN®) technology in sand-based conditions and demonstrates its positive impact on the drilling performance for an offshore exploration well in the North Sea. The main challenges identified in the top-hole design for this well were the presence of boulders down to 65 m below the seabed, and hard soil that consisted mainly of very dense sand and high strength sandy-clay layers. Different solutions were evaluated using a risk-based approach, looking to optimize operational performance and decrease the environmental footprint. A technology which consists of a pre-installed short conductor within a CAN was chosen. This solution enabled the operator to establish a competent well foundation above the boulder interval and increase operational efficiency by reducing the critical rig time. However, the CAN technology had not been deployed in this type of soil previously. Thus, the feasibility of its installation became one of the main milestones of the project. This was made possible due to a set of contingencies and modifications that were the result of a strategic collaboration among the parties involved. The CAN was successfully installed by a crane vessel before the rig arrived at location, and the set of contingencies and modifications mentioned in this paper were decisive to ensure it reached the required penetration depth. Furthermore, this paper demonstrates that the CAN technology was crucial for the project to achieve top performance results and become one of the fastest exploration wells drilled in the Norwegian basin. This solution reduced uncertainties related to the conductor cementing, load and fatigue capacities, and deep surface casing cement. Improvement in the drilling performance is determined by estimating the decrease in drilling time, materials and consumables. Those results are then used to perform a cost comparison which demonstrates that the CAN technology reduced the top-hole construction cost significantly on this offshore well. In addition, the reduction in the well environmental footprint is quantified, and its contributions to the projects health and safety goals are highlighted.