Revolutionizing Exploration Risk Mitigation: Strategic MPD Design for HEMMER-1 Startup Project

Abstract In the 1970s, the Marcou-1 well was drilled in the continental area of the Manzano block in Punta Arenas, Chile. This well served as a key reference point for understanding the reservoir dynamics and geological characteristics of the region. The Manzano block is characterized by the presence of gas pockets in highly pressurized sandstone intercalations. The exploration of HEMMER-1 is crucial for assessing the potential of high-pressure zones, which could significantly influence future resource extraction strategies in the San Jorge basin. The HEMMER-1 well, using managed pressure drilling (MPD), represents the first such implementation in Chile. This technology proved essential for effectively managing the unpredictable pressure variances within the highly pressurized sandstone layers of the San Jorge formation. The success of the project was not solely due to the execution of advanced drilling techniques, but, as the first implantation into the region, it also hinged significantly on comprehensive training programs and meticulous planning. These preparatory steps ensured that the project team could adeptly handle the complex challenges presented, enhancing both drilling safety and operational efficiency. This study details the implementation of MPD and managed pressure cementing (MPC) as integral solutions to overcome the geological challenges and operational hazards. The employment of these techniques facilitated the control of wellbore pressures and allowed for early kick detection and influx management, both essential for maintaining well integrity. Pressure buildup tests (PBUTs) and precise pressure management ensured the accurate characterization of the formation, confirming pore pressures and enabling safer drilling practices. Moreover, the successful execution of coring operations in MPD mode marked a significant advancement. Operating under statically underbalanced conditions, this approach ensured the integrity of core samples, which is critical for evaluating the reservoir's potential. The MPC technique further stabilized the wellbore, preventing fluid contamination and optimizing cementation processes, thereby enhancing overall operational efficiency. This project not only demonstrates the feasibility and benefits of MPD in high-risk and unpredictable environments, but also sets a precedent for future exploratory and development projects in similar settings. The results underscore the effectiveness of MPD in reducing non-productive time (NPT), optimizing resource extraction, and mitigating operational risks, thus contributing substantially to the regional energy strategy and the broader goal of advancing drilling technologies in challenging environments.