Drilling Optimization to Overcome High Torque Problem: Lesson Learned on Kujung First Offshore-Near HPHT-Horizontal-Critical Sour-Slim Hole Development

BD Field is the first development project of Husky-CNOOC Madura Limited (HCML) in Madura Strait, Indonesia which has a pressure of 8,100 psi and a temperature of 300°F. This Kujung gas reservoir contains of 5.5% CO₂ and 5,000 ppm H₂S, indicating that the reservoir is near High Pressure High Temperature (HPHT) and critical sour environment. This paper describes the best practices, lessons learned and strategy to control drilling issues such as slim hole, horizontal, near High Pressure-High Temperature, high density, and sour/acid gas environment to achieve the well TD with torque and ECD limitation, without compromising production target.

Kujung reservoir section was drilled with an overbalance mud system as per CNOOC HPHT and sour well requirement. Drill-In fluid (DIF) system treated with potassium formate and manganese tetraoxide as weighting agents was chosen for drilling the 5-7/8-in. reservoir section.

Throughout the drilling operation, higher torque and ECD value was identified compared with Torque and Drag (T&D) Calculation and Hydraulics simulation. This can lead to shallower TD decision, which has consequence of possibility not achieving initial target depth/production. Calibrating T&D model using the pickup/rotate/slack-off value from actual measurements on both cased and open holes was done in order to match the model with actual condition. Several analysis and review of all possible causes was performed, including performance of solids control equipment, inadequate hole cleaning, dog leg severity, wellbore direction and/or formation lithology changes. T&D and hydraulics simulation was also performed to foresee the possible operation limitation with several lateral lengths to ensure having successful drilling operation without compromising both operational safety and future well production.

Based on the original model, with friction factor values of 0.25 (cased hole) and 0.35 (open hole), 1000-1500 ft lateral length of 5-7/8-in. slim hole section can be achieved. However, with calibrated T&D model, friction factor values were almost double the original model. Comprehensive planning was done to accomplish the drilling objectives, such as re-plan well trajectory to reduce dog leg severity, selection of drill fluid lubricant additives to ensure its stability at pH > 11 environment as planned to control sour gas and compatibility with other products, maximize centrifuge usage to minimize excessive LGS build-up caused by successive and repetitive mud system re-use for batch drilling operations, and diluted system using rehabilitation mud.

Reduced friction factors and decreased torque values were the key parameters to successful drilling through the updated planned horizontal length. In terms of gas well production, the objective of well productivity was achieved during unloading operation when gas production result from the wells yielded higher Absolute Open Flow (AOF) as compared to the planned target. Hence a successful BD wells had been delivered to production.