Recognised as the first high pressure and high temperature (HPHT) development ever embarked by PETRONAS as well as the first of its kind in Malaysia, KN-UUD Development had also marked a significant step change in well engineering design approach for Asia Pacific region.

Learning from experience of HPHT operators in the North Sea and the Gulf of Mexico, a detailed focus on lifecycle well integrity aspect had been thoroughly emphasised throughout the well design phase. Innovative design thoughts, meticulous process in selecting cost effective solutions and strong collaboration between operator and service providers proved to be the key ingredients for success.

This paper highlights the sophisticated journey of KN-UUD HPHT development well delivery, covering the initial scoping work, design phase, equipment (and material) planning and testing, execution phase as well as the lessons learnt from the campaign.

Challenges and experiences discussed include:

  • Depletion on shallow reservoirs, its impact towards pore pressure and fracture gradient profile and subsequently, overall well design.

  • First implementation of big bore well design with liner and cemented tieback philosophy in Asia Pacific.

  • HPHT lifecycle integrity aspect and considerations on worst case scenario i.e. reservoir compaction study, cement stress analysis, tubular connection and material testing.

  • Challenges in dealing with non-availability of equipment (including material) and lack of service capability within the region.

  • Complex process of identifying and procuring fit-for-purpose equipment solutions and unique contracting strategy.

  • Annulus management philosophy for HPHT development.

  • Lessons learnt from the actual well construction phase.

The well was successfully delivered to meet all of its objectives, producing from layers close to 16,000 ft. beneath the seabed. The complex process, obstacles and vital experience in overcoming the challenges has pioneered a path for future application of its kind within Malaysia and Asia Pacific region.

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