Unlocking ultra-high-pressure reserves

When Beacon Offshore Energy's Shenandoah field achieved 100,000 barrels of oil per day (bopd) after 75 days, it didn't just exceed all regional ramp-up benchmarks and set a new performance standard for deepwater operations, it validated decades of innovation in extreme offshore environments and collaborative engineering. For Clariant Oil Services, Shenandoah represents a proving ground where meticulous testing meets reality under some of the most severe production conditions on Earth: pressures exceeding 20,000 psi (1,400 bar) and water depths approaching 6,000 feet (1,800 metres).

Shenandoah's journey from discovery to production spans decades, making its startup a remarkable achievement in deepwater development. Located off the Louisiana coast in North America, this field presents extreme operational challenges that demand rigorously engineered solutions at every stage.

The high-pressure, high-temperature (HPHT) reservoir conditions, with pressures above 22,000 psi and temperatures approaching 200 °F, push the boundaries of materials science and chemical engineering. Individual wells are delivering exceptional results, and the Shenandoah floating production system (FPS) has demonstrated high uptime and system reliability, with no known issues which would hinder its ability to meet its nameplate capacity of 120,000 bopd.

Oil produced from deepwater fields like Shenandoah depends on sophisticated chemical treatment programs, such as those developed by Clariant. The startup phase is particularly critical, requiring:

• Flow assurance solutions: Preventing hydrate formation, wax deposition, and asphaltene precipitation in subsea flowlines demands advanced chemical inhibitors specifically designed for HPHT conditions. At Shenandoah, asphaltene inhibitor performance monitoring has been critical during startup, with Clariant's ADAPT measurement system providing continuous monitoring to ensure optimal performance. This method measures the performance of asphaltene inhibitors with unaltered crude vs. the typical forced-precipitation techniques used widely in the industry.
• Corrosion management: The combination of high temperatures, pressures, and corrosive reservoir/completion fluids necessitates robust corrosion inhibition programs to protect subsea infrastructure and ensure long-term asset integrity. Chemical treatment strategies implemented by Clariant are paired with recommended field monitoring programs to ensure performance is met throughout the field’s lifecycle.
• Scale prevention: HPHT reservoirs are prone to severe scaling issues. Customized scale inhibitors must function effectively in extreme conditions while being compatible with other production chemicals and reservoir fluids. Once reservoir water production increases, it is necessary to model scaling tendencies and design chemical treatment programs if required.
• Production optimization: Emulsion breakers, primary/secondary defoamers and water clarifiers ensure efficient separation and processing, maximizing recovery while minimizing operational disruptions.

The rapid ramp-up in 75 days required extensive support. Clariant provided 24-hour coverage during this critical period, delivering chemical management, system monitoring, and troubleshooting support. Comprehensive site inspections of injection locations, sample points, and chemical injection systems ensured optimal performance from day one.

Shenandoah's successful startup exemplifies the collaborative nature of modern offshore initiatives. Chemical manufacturers like Clariant serve as technical partners, providing pre-startup planning, onsite technical support during critical phases, and continuous optimization throughout the field's lifecycle. At Shenandoah, this included platform visits to Ingleside, Texas, for comprehensive system inspections and operational feedback.

Shenandoah has now transitioned to steady-state operations under a routine coverage service plan, supported by Clariant’s in-office team overseeing chemical management, projects, supply chain, and product development. Success of this scale requires the seamless integration of multiple technologies, from drilling and completion to subsea systems and chemical treatments.

As Beacon Offshore Energy continues production at Shenandoah, with multiple wells producing at 20,000+ bopd, the field draws from reservoirs at approximately 30,000 feet (over 9,000 metres) true vertical depth, validating next-generation chemical technologies and serving as a model for future deepwater projects.

Shenandoah is not just notable; it’s exceptional for ultra-deepwater development in terms of depth, ramp-up speed, and well productivity. We’d like to congratulate our valued customer, Beacon, on achieving several exemplary milestones. It is a remarkable feat, and we are honored to contribute our expertise to a project widely celebrated as a global standard for modern innovation and operational excellence.

To learn more about Shenandoah and Beacon Offshore Energy’s work, visit beaconoffshore.com/media