The Role of HSE in Field Testing the World's First Well Construction System Using Composite Pipe
Authors: Disatell Joel , Coats E. Alan , Veley Carl D. 
Published: October 2008

In the initial qualification and field testing of any new system, increased health, safety, and environmental (HSE) risks are inherently introduced because personnel are unfamiliar with the new equipment and its operation. This paper reviews the HSE challenges that were faced when an entirely new drilling system, based on advanced spooled composite technology, underwent its first field trial.

From the feasibility study forward, the Advanced Well Intervention System (AWIS) was highly focused on the development of many new enabling technologies, including Advanced Composite Coiled Tubing (ACCT), a downhole propulsion unit, and a hybrid rig design. By using a lightweight carbon-fiber pipe, the system was designed for geological steering of complex, slimhole wellpaths. The system incorporates three major subsystems: digitally controlled and automated surface equipment, a 3 1/8-in. composite drillstring with embedded wires, and an electronically controlled bottomhole assembly (BHA). This system is designed to enable the production of hydrocarbon zones that were previously bypassed and to find and exploit new reserves from existing idle land and offshore wells.

Beginning with the conceptual planning and initial feasibility study, all involved in the project, from the highest level of management downward, made a commitment to adhere to the highest HSE standards in all phases of the project. The resulting HSE program was as comprehensive as any ever undertaken and was derived from the knowledge, experience, and established procedures and processes of professionals throughout all organizations involved with the project.

This paper presents details of the HSE program that was developed and implemented as part of a qualification program for this unprecedented drilling system. The paper examines the evolution of the HSE program from project planning, through the HAZID/HAZOP/FMECA processes, and on to full implementation during the drilling phase. A detailed description of the cultural, engineering, and logistical challenges that were overcome during the implementation of the HSE program is provided. A discussion of the HSE program summary results and "lessons learned" during the project is also included.

Introduction

When an offshore operator found a suitable target well for the deployment of the new AWIS system in the GOM, the decision was made to drill an interim, or mimic, wellpath before deployment offshore. Further discussions yielded a decision to combine a hydraulic workover unit (HWO) with the AWIS. The HWO, or snubbing unit, was incorporated into an integral tower. The primary purpose for incorporating the HWO unit was to provide a means of conveying jointed tubulars (drillpipe, casing, and completion strings) into and out of the well as required. This resulting "hybrid drilling system" had never been used before and both companies recognized the risks involved in combining these systems for the first time. Fig. 1 shows the hybrid drilling system. The project management team organized HAZID, HAZOP, and FMECA sessions to address and define their concerns about applying this new system to drilling an offshore well candidate.1