Anchor Project: Lessons and Challenges From Developing 20K Rated Wells Equipment

Abstract

Abstract 20,000 psi (20k psi) technology is required for development of the Anchor asset. To deliver the 20K technology, the Anchor team undertook a world class technology development program. This paper will provide an overview of the 20K drilling, completions, intervention, and source control equipment development process for the Anchor project. The paper will touch on technical and process learnings associated with equipment development and qualification as well as the associated independent third party (I3Ps) and regulatory review processes. A five-year equipment development and qualification process was initiated to define Anchor equipment requirements, award contracts, develop the 20K technology with partners, qualify to relevant American Petroleum Institute (API) standards including High Pressure, High Temperature (HPHT) Annexes, and work through the I3Ps and Bureau of Safety and Environmental Enforcement (BSEE) Review process as defined in NTL's 2019-G02 and 2019-G03. Designed as the world's first fully capable 20k psi rig complete with two 20k psi Blow Out Preventer (BOP) stacks, the Deepwater Titan, commenced operations in the Gulf of Mexico (GOM) on June 1st, 2023. The first two Anchor wells have been drilled to total depth (TD) and all 20k psi completion equipment has been qualified in preparation for completions commencing end 2023. Two means of intervention, a Hydraulic Spanner Joint Assembly (HSJA) that can be interfaced with the Tubing Hanger Running Tool (THRT) or the subsea production tree and a Completion Workover Riser (CWOR), have been qualified and completed System Integration Testing (SIT). A 20K source control strategy has been developed along with the associated capping equipment. During the equipment development process, interpretation of governing standards matured, particularly with regards to material fatigue. Similarly, regulator expectations around the I3P review process and requirements for well intervention (both planned and for a loss of containment event), also matured and required some revisions to the initial equipment development plan. As one of the industry's leading deepwater, subsea 20k psi rated projects, the development of the 20k psi rated wells equipment for Anchor has generated considerable learnings with regards to interpretation of existing industry standards, particularly in relation to pressure cycle induced fatigue, and the navigation of the technical requirements of the regulatory review process required by NTL 2019-G02 and 2019-G03. For clarity, the following terms are used throughout this paper. High Pressure High Temperature (HPHT) refers to equipment rated to pressures greater than 15,000 psi and/or temperatures equal to or greater than 350°F. Anchor is a high pressure project under the HPHT category. 20K refers to the Anchor project's technology development and qualification program.