Having worked in the oil and gas industry for over 20 years now, I’ve had the privilege of contributing to numerous tieback engineering projects worldwide.

Tieback engineering, particularly predrilling, suspension, and tieback, offers a proven pathway for the industry to rapidly access new hydrocarbon reserves. This approach not only accelerates the timeline to first oil and gas but also enhances overall project efficiency, reducing costs and improving return on investment – a key focus in today’s market.

So, what exactly is tieback engineering? While some may associate the term with subsea tiebacks – connecting offset subsea wells to platforms via pipelines and umbilicals – that’s not what we’re discussing here. Instead, this type of tieback involves re-establishing a structural or pressure-retaining connection to a suspended well. It allows for a range of operations, especially in the context of platform wells, enabling predrilling, suspension, and reconnection to expedite first oil.

Example timeline to first oil using sequential process versus tieback process

This form of tieback engineering presents a unique set of challenges, from managing tolerance stack-ups to ensuring collaborative project execution. Over the years, I’ve learned invaluable lessons – both from hands-on experience and from industry thought leadership. In this blog, I’ll share some of those insights, offering a practical guide to unlocking success in these specialised projects.

Align goals and establish a common thread

One of the biggest challenges I’ve encountered in tieback projects is the siloed nature of different departments, each with their own measures of success. To overcome this, it’s crucial to establish a common thread that runs through the entire project. This means aligning the goals and creating a shared sense of accountability across all stakeholders, from the drilling team to the platform installation crew.

Without this common thread, the project’s success is jeopardised. I’ve seen firsthand how the negative effects of a siloed approach can lead to suspended wells never being put into production, despite the significant investment. By fostering a collaborative mindset and a shared measure of success, we can mitigate the risks and unlock the true benefits of tieback engineering.

Meticulously manage tolerances

The tolerance stack-up between drilling, template manufacture, jacket manufacture, and installation are a make-or-break factor in tieback engineering. I’ve seen how even minor deviations in these tolerances can render a tieback impossible, underscoring the importance of careful measurement, recording, and adherence to allowable limits.

Throughout the project, it’s essential to maintain a meticulous record of the tolerances at every stage. This attention to detail can make the difference between a successful tieback and a well that never makes it into production. By managing these tolerances with the utmost care, we can ensure that the physical aspects of the project are aligned and ready for a seamless tieback.

Avoid temporary abandonment caps

During the Tech Talk event, one topic that generated significant discussion was the use of temporary abandonment (TA) caps. While these caps are often marketed as a means to protect threads and the wellbore, if installed with a pressure-retaining mandrel, they can cause significant problems during the tieback phase. Even when installed without a pressure-retaining mandrel, they can be extremely difficult to remove, sometimes even damaging the hanger they are meant to protect.

I’ve encountered numerous issues with their use, ranging from gas expansion underneath to malfunctioning pressure relief mechanisms. TA caps will never qualify as a well control barrier, and without knowing the pressure beneath them, costly and time-consuming methods, such as nippling up a full BOP system, are often required before attempting their removal.

Instead of relying on TA caps, I recommend the adoption of more reliable solutions, such as simplistic trash caps combined with inhibited fluids to prevent corrosion or marine growth. Where a TA cap is a project requirement – for example, due to a very long period between suspension and tieback – I see no valid reason to install pressure retaining mandrels. A TA cap will never be a well control barrier, and the significant risks they pose, including trapping expanding and contracting fluids or gases below and the need for a full pressure control package above, means they offer no real benefit.

Engage ‘Tieback Engineering’ experts

These types of tieback projects are highly specialised, and the lessons learned from previous experiences are going to be invaluable. Partnering with a company like Aquaterra Energy, which has completed hundreds of tieback projects globally, ensures access to the tieback engineering and tooling expertise needed to navigate the complexities of this field.

Specialists will guide you through the technical considerations including the tieback analysis, equipment requirements, and contingency planning – critical elements needed for a successful tieback project. By tapping into this wealth of knowledge and experience, you can sidestep the common pitfalls that have plagued other projects and unlock the rapid route to first oil and gas.

Plan for contingencies

The best-planned jobs start before the well is suspended, ensuring it is completed in a way that provides the very best chance of success during the later tieback phase. Sometimes this isn’t possible – such as when the well already exists – but planning and contingency is still just as critical. Tieback runs happen quickly, often within hours, so it’s essential to have a well-thought-out Plan B and C. Carefully consider the equipment and tooling required to address any potential issues that may arise and be prepared to act swiftly to maintain the project’s momentum.

Without proper contingency planning, we’ve seen offshore teams improvise solutions that, while addressing the immediate problem, can have a detrimental effect on other aspects of the tieback later on. By anticipating and planning for these contingencies, you can ensure that your project stays on track and delivers the desired outcomes.

Final thoughts

By applying these key lessons, you can unlock the rapid route to first oil and gas production through tieback engineering. The key is to approach the project holistically, with a focus on collaboration, attention to detail, and a willingness to learn from the experiences of others.

Curious to see how our team can bring these lessons to life for your next project? Please get in touch – I’m always happy to share ideas and explore how we can help.

To learn more on how drilling templates, tieback engineering and alternative project management philosophies can reduce project times and accelerate time to first oil or gas, catch up on my technical webinar.