SITE CONSTRUCTION CONDITION REVIEW AND FORWARD PLAN
I. Rig Pad Design Concrete versus Matting Board 1. Major equipment load calculation. a. Drilling Rig predicted combined load: 1,683,000 lbs. b. Safety Factor: 2 (to compensate live load, wind, vibration, jarring impact) c. Total combined load for well pad design basis: 3,366,000 lbs. = 1,530 ton.
2. Unitized rigid concrete rig pad design (Halliburton main proposal as per contract) a. NIL2 well pad: 8 cellar pad. Net area: 723.5 m2. Total weight of concrete: 521 ton. Effective load imposed to soil (rig load + concrete weight): 0.25 kg/cm2 = 2.5 ton/m2 b. WJR2 well pad: 3 cellar pad. Net area: 457.3 m2. Total weight of concrete: 329.3 ton. Effective load imposed to soil (rig load + concrete weight): 0.38 kg/cm2 = 3.8 ton/m2 From above, the effective load imposed to the soil ranges from 2.5 3.8 ton/m2 depending on the size of pad related to numbers of well.
3. Matting board (alternative design for comparison) Matting board area per leg: 30m x 4m = 120m2. Total net area for both leg 240m2. Weight of matting board 43.6 kg/m2. Total weight: 10.46 ton for the 240m2 area. Effective load imposed to soil (rig load + matting board weight) = 6.4 ton/m2.
From the above it can be seen that matting board due to less area compared with the unitized rigid concrete design yields much higher effective load to the soil, i.e.: 6.4 ton/m2 compared to 2.5 3.8 ton/m2, thus potential settling is much higher than concrete.
Further concern is with limited coverage of matting board and the higher potential settlement, then the requirement to level up and re-compact the area of the following well prior to skidding may not be avoidable. There have been several cases experienced by other Operators that lost up to 5 days of down time due to requirement to cut, re-level and re-compact the following well area prior to skid after experiencing settlement during drilling the previous well.
Based on the above evaluation, our position is to use the unitized rigid concrete design (not matting board) to avoid experiencing similar problem as mentioned above.
II. Well Pad Foundation Stability Analysis There is no data of the original NIL2 and NIL1 locations prior to construction available for reference, the CPT S6 as listed in the SOL document is located outside NIL2 area and was intended for slope stability analysis. Similar to WJR2, one Hand Bor is available but the CPT S19 is located outside and intended for slope stability analysis.
Soil investigation test was then performed by Hallco after completion of NIL2 and WJR2 site to obtain data required to establish proper evaluation of soil bearing capacity.
Five CPT points were taken in the NIL2 and two were taken in WJR2 well pads. Result of soil bearing calculation based on this CPT data shows large discrepancy between the fill area of average 1.6 ton/m2 with the cut area of average 4.3 ton/m2 consistent for both NIL2 and WJR2, whereas such large discrepancy indicates that the result of compaction work on the fill area was not as per the expectation. Page 2 of 4
The value of this soil bearing capacity was established using the following approach: a. All data used are taken from our CPT result, using method (empirical formula) of Terzaghi, Meyerhoff, and Brinch-Hansen). b. Since all of the three methods are basically use empirical formulas which could lead into large discrepancy and considering its direct impact to safety of equipment during operation, our approach is to use the most conservative value among the three results. c. The Safety Factor (SF) used is 3, as this is in line with normal code of practice for shallow foundation design.
There is comment from SOL Civil Engineer on the value of our soil bearing capacity as in SOLs opinion is too low. Our Civil Consultant has then made the respond by reviewing the SOL calculation referring to the SOL CPT data with the same safety factor; the result is that we still obtained significant lower value than the SOL. For example the SOL value in WJR2, from S-19, shows 29.7 ton/m2, whereas our calculation using the same data, same depth, and same SF of 2 is ranging from 11.57 ton/m2 16.7 ton/m2 using all three methods, which value is still significantly lower than SOL.
It is therefore we question how SOL obtains this value and what method (empirical formula) they use, we are welcome to discuss this face to face with SOL Civil Engineer. Until a more reliable data is obtained, for the time being, we will stick on our number which is more conservative than SOL but provide better assurance on safety of our operation.
1. Rig Pad Design It is decided to use a unitized rig pad concrete design for all well sites with reason as explained in section-I above. This shallow concrete of type K-250 has been calculated as more than sufficient to ensure integrity providing that the soil strength underneath is adequate to withstand the load. Based on calculated effective load of 2.5 3.8 ton/m2 and considering the soil bearing value of avg. 4.3 ton/m2 and 1.6 ton/m2 on the cut and fill area respectively, then all well pad must be positioned to be on the cut area only, unless SOL agree to re-work the fill area or accept a modified design such as piled foundation.
For NIL2 we have agreed to re-position the well cellar to be all on the cut area by shifting the heading 90 deg from the original, and no issue for WJR2 since most of the area is located on the cut. However for NIL1 we do have concern on how SOL will position the well cellar of whether it will be all on the cut area.
2. Cementing Equipment Area The weight of silo has become a major concern. The effective load of a silo full of cement could reach 6.4 ton/m2, it could still be fine if it located on the cut area but since it most likely has to be positioned on the fill area then having a piled concrete foundation may become mandatorily required.
A case of fatality has been experienced not too long ago in one of the Government O&G Operator (Pertamina) where a Schlumberger silo was tumbled due to failure of the soil strength caused one person killed; we certainly do not want to have the same experience.
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3. Mud, Water, and Test Pit Area Similar concern with rig pad, the pit should be located on the cut area. In the event of a pit has to be located on the fill area than a thorough soil investigation has to be conducted to ensure adequate soil integrity and proper design is in place. In this case additional soil test will be mandatory.
III. Slope Stability Analysis Slope stability analysis should have been performed in NIL2 location considering the high slope excavation along the north side and fill on the south side. We do not know what method and what parameter that SOL referred to in order to provide assurance that land sliding will not occur in NIL2 area. It seems the BITA document is used by SOL as the only reference that in our civil consultant opinion is not adequate to be used as design basis, additional data to support a more comprehensive geotechnical analysis in order to generate reliable design is still required.
A case of land slide incident experienced not long ago by a Geothermal Operator resulted in multiple fatalities is considered as a kind of lesson learn which should never be given a chance to re-occur.
Besides NIL2, the major concern is now on NIL1 location as the area is much more confined and situated between significant cut and fill. We therefore require SOL to share the information on the method and parameters they use to generate the NIL1 stability analysis.
Not much concern on WJR2 except one point at south edge of location.
Based on the existing condition as mentioned above, from safety perspective we are not comfortable yet to accept the hand over from SOL, a thorough and comprehensive discussion between SOL Civil Engineer and our Civil Consultant will still be required to seek conclusion.
IV. Other Issue for Consideration With rejection from EBTKE on the permanent disposal pit then requirement to have a cutting house (cutting bunker) in every well site has become mandatory.
Attempt to put the cutting house at location outside well site will not be an appropriate approach since additional measures will be required such as to build supporting pit to collect liquid from wet cutting, besides the continuous movement of cutting transportation from well site to cutting house will still be required which may result complication during operation.
Our proposal remains to have the cutting house having concrete base and permanent roof to be located next to the mud pit be available for each well site. Due to its limited capacity, SOL needs to be aware that they will require Utilization Permit to enable a regular moving of the cutting out of location for use in somewhere else.
V. Forward Plan 1. Requirement for Additional Data and Geotechnical Investigation. Due to concern on slope stability and foundation integrity, a more comprehensive geotechnical investigation is become mandatory with the objective to: Assess subsurface condition Obtain accurate stratification, physical, and mechanical characteristic of soil. Page 4 of 4
Provide comprehensive information to support proper geotechnical design.
The complete geotechnical investigation is programmed to be as follow: a. Technical drilling (BH) is planned for approx. 6 points in NIL2 and 3 points in WJR2. The technical drilling shall cover all area of concern such as slope, fill, mud pit, cement unit, and others as required. Standard penetration test (SPT) Undisturbed samples (UDS) Laboratory test for soil samples to obtain physical and mechanical properties of soil. Note: Result of soil strength calculation derived from the technical drilling is considered as better representative compared to CPT which is based on empirical method.
b. Additional CPT as required to support the existing data.
2. Civil Works Acceptance The criteria used for acceptance as per the Annex B.2 comprises the following part: i. Total well pad area shall be compacted to 95% to a 1 meter depth. Since there is a large portion of the well site area consists of fill and the soil tests have indicated that the result of compaction is below expectation, therefore a 1 meter depth of investigation is no longer adequate to assess stability. Additional information from CPT and / or technical drilling has become a requirement thus to be part of the acceptance criteria.
ii. Slopes shall be well stabilized in order to avoid future landslides problem. To do this we will need to review the method and parameter used by SOL to ensure stability. Currently with our own initiative we are doing technical drilling focused on assessing soil stability.
Without comprehensive geotechnical investigation as mentioned above, we as operation and site construction cannot determine the integrity and safety of the location and therefore for the time being we are not able to accept the hand over from SOL.
However to support the continuity of activities and avoiding further delay, the technical drilling is conducted parallel with conductor setting which already started in NIL2, whereas location acceptance will have to wait on the result of the above.