Lessons Learned from HPHT Equipment Verification and Validation Process

Abstract

The industry is looking to drill in reservoirs exceeding the current limitations of associated equipment with pressures greater than 15,000 psi and/or temperatures greater than 350°F. This paper will discuss the design verification and validation efforts, integration assessment, and safety analysis for equipment with increased boundary limits to be utilized for High Pressure and High Temperature (HPHT) applications. It will also address the general areas of concern during prototype testing. The test procedures developed from the design validation process will incorporate the suggestions, recommendations, and optimizations from the design verification efforts. The created testing procedures will then assist in validating the design of the increased limits of components of drilling equipment for HPHT environments. The on-going projects that ABS is working on will be used in development of HPHT equipment design, production, and testing requirements. This paper will summarize the challenges in validation and verification that HPHT technology faces at the early stages of development and provide lessons learned for future projects and new technologies. This paper will discuss in detail the obstacles experienced during design verification, material selection, risk study, and validation programs that have been set up to perform technology qualification and satisfy newly developed regulatory requirements. Discussion about material qualification testing, prototype testing, and findings based on experienced gained on the project will be presented. The lessons learned during this project will help to establish a baseline for standardizing the certification process of HPHT drilling equipment and new technology systems for global applications. The knowledge gained also will be instrumental for the development of various codes and standards associated for HPHT technology. Class and certification can provide greater confidence to offshore operators in order to commission drilling equipment and systems capable of delivering safer, more dependably drilled wells, some of which may be considered un-drillable with the limitations of existing equipment.