Master in Petroleum Engineering 2009-2010

Subsea dual completions: State of the art, benefits and risks

Author: Giuseppe Ferrari
www.eni.it

San Donato Milanese 20-21 October 2010

Master in Petroleum Engineering 2009-2010

Subsea dual completions: State of the art, benefits and risks.
Author Ing. Giuseppe Ferrari Company Tutors Ing. Stefano Di Vincenzo Ing. Gianfederico Citi University Tutor
Division Dept.

Exploration & Production

COMP/PERF

Prof. Ing. Francesca Verga

San Donato Milanese 20-21 October 2010

Summary
1

Project Scope

State of Art Subsea Completion

Eni applications Camilla 2

Risk Analysis

Conclusions

Project Scope
The Scope of Work of this thesis is summarized by following points:
Dual Subsea Completion State of Art analyze existing case history from all main subsea vendors. Prons and Cons of Dual subsea completion, compared with standard single subsea completion. Camilla 2 Eni case history and close out post job report analysis.
Risk analysis and Risk evaluation of Camilla 2 activity.

Summary
1

Project Scope

State of Art Subsea Completion

Eni applications Camilla 2

Risk Analysis

Conclusions

State of Art Subsea Completion

RIG Drilling Ship (dynamic position) Semi submersible (moored)
PRODUCTION Floating production On-shore and land site production facilities

X-TREE Vertical design Horizontal design LANDING STRING Hydraulic Electro-hydraulic

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State of Art Subsea Completion

Subsea wells
All wells completed with subsea facilities

Deep Water Completion

(500 m < water depth < 1,500 m)

Ultra Deep Water Completion

(1,500 m < water depth)

Multilayers Reservoir
(more than two zones completed)
Simultaneus production from all completed zones
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State of Art Subsea Completion

There are three different completion options available on the market, applicable to subsea fields:
1/4" Safety Valve Control Line WD Flat Pack Umbilical with 3 Hydr.Lines Tbg Retrievable Safety Valve size 3 1/2" 3-1/2" Tubing 7" 23-26 lb/ft Casing WD HF1 Retrievable Packer w/multi Feedthru Size 7" x 3 1/2" 3-1/2" Tubing WD IV-ICV Infinitely Variable Choke size 3 1/2" With Accu-Pulse

Single string completion

Crossover 3 1/2" x 2 7/8" WD HV-1 Shrouded ON-OFF Type Choke Size 2 7/8" Wireline Plug 2-3/8" FJ Tubing Gravel Pack Packer with 3.25" Seal Bore Gravel Pack Closing Sleeve

Dual string completion

Gravel Pack Screen on 4" Base Pipe

Moulded Seal Unit size 3.25" Polished Bore size 3.25" Pup Joint Locator with Moulded Seal Units For 3.25" Seal Bore

Intelligent well completion (IWC)

Gravel Pack Packer with 3.25" Seal Bore Gravel Pack Closing Sleeve Gravel Pack Screen on 4" Base Pipe

Locator with Moulded Seal Units For 3.25" Seal Bore Permanent Type Seal Bore Packer

State of Art Subsea Completion

A number of factors must be considered when deciding whether to use a horizontal or vertical Xmas tree and these are described below. However the otpimum subsea Xmas tree configuration will be driven by reservoir requirements:
Factors that drive the decision to use a horizontal tree: vertical tree:
Financial driver is installed CAPEX life of field OPEX
High drive wells or(smaller bore)(have need for large bore) Lower drive wells multilaterals Complex reservoirs or frequent W/O requiring TBG retrieval Simple reservoirs or low frequency of tubing retrieval workovers ESP or artificial lift technology High pressure difficult well control issues Bacth drilling/completion and/or requirements water, completion riser) Pre owned installation tooling package (open for drill thru systems Little orgas pre-owned installation tooling Trend, no wells, short life (little or no maintenance), well pressure greater than 10 000 psi Trend:oil wells, high maintenance or wells needing recompilation, well pressure less then 10 000 psi

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State of Art Subsea Completion

Horizontal and Vertical X-Tree advantages and disadvantages
Vertical Trees
Advantages One less BOP trip (Drill thru to completion) tubing hanger landed in the wellhead (or tubing head) Allows intervention without a rig Reduced wellhead loading Disadvantages May require BOP modification for TH orientation mechanism Advantages Suitable for large bore gas wells Can be installed on completions wellhead Requires leas impression tool run to verify TH space out Need more rig deck space to accommodate additional tooling and riser Rig needs to handle more tooling Additional wellhead casing hanger required Reduced installation tooling requirements Uses rig riser system

Horizontal Trees
Disadvantages Requires an additional BOP trip Requires a SSTT and landing string BOP may require modifications to accommodate IWOC's umbilical Higher bending loads on the wellhead system Potential leak paths below the BOP Well must be plugged prior to removing the tree Some concern with wireline plugs for vertical barriers Longer emergency disconnect time Cannot pull tree independent of the completion

Metal sealing gate valves for environmental barriers, not field installed like wire line plugs Allow monitoring of all down hole functions as standard

Simplified rig interfaces Suitable for smart well technology

Allows workover without pulling tree or disconnecting flowlines Flow base typically not required Flexibility of design to accomodate natural flow, gas lift, water injection and ESP

Tubing intervention simpler as no wire line plugs need to be retrieved Installed CAPEX considered to be lower the horizontal tree

Tubing hanger seals in the casing that could be damaged during drilling operations Need to remove the tree for tubing work over

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State of Art Subsea Completion

12

State of Art Subsea Completion

INTERNAL TREE CAP
2 Environmental Barrier

Metal to metal seal with X-Tree

5 Wireline Crown Plug

It is used with the horizontal xmas tree, it accomodates the crown plug. Some suppliers may replace the internal tree cap with a longer tubing hanger.

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State of Art Subsea Completion

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State of Art Subsea Completion

CROWN PLUG
Bore closures for both Tubing Hanger & ITC
10 000 psi working pressure Primary Seal Metal - to - Metal SSD Seal

Secondary Seal Non - Elastomeric packing set

Pressure Set Used with the horizontal xmas tree, it is installed wire line in the internal tree cap and in the tubing hanger or alternatively both in the tubing hanger if the supplier does not use the internal tree cap

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State of Art Subsea Completion

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State of Art Subsea Completion

TUBING HANGER
HT - SG Seal

- Rated to 15 000 psi

- Above & below production/injection Bore 5 Wireline Crown Plug downhole control lines downhole control line for SCSSV downhole control line for downhole smart completion spare hydraulic line electrical lines Wet-mate electrical connector Hanger premium thread

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State of Art Subsea Completion

DUAL BORE TUBING HANGER
Thread for landing string Production Bore

Orienting pin Control lines Plugs

Annulus Bore Thread for tubing

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State of Art Subsea Completion

Dual Subsea completion WW case history FMC: one application for Chevron in UK North Sea in 1990.
Cameron: two applications for ENI in the Adriatic Sea, Elena 1 in 1989 and Camilla 2 in 2000. Vetco: one application for Shell UK in Cormorant Field (UK North Sea) in 1982.

Aker: NO applications.
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Summary
1

Project Scope

State of Art Subsea Completion

Eni applications Camilla 2

Risk Analysis

Conclusions

20

Eni applications - Camilla 2

The well location

21

Eni applications - Camilla 2

Reservoir profile and intervals perforated

Short String

Long String

22

Eni applications - Camilla 2

Well Schematic and casing profile

PTR = 23,6 mt on water level Water Depth = 85 mt Csg 30 @169 mt TVD Csg 133/8 @344 mt TVD Liner head 7 @955 mt TVD Csg 95/8 @1104 mt TVD Liner 7 @1477 mt TVD

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Eni applications - Camilla 2

Dual string 2 3/8 + Gravel Pack Assy (lev. 1 e 2+3)

lev. 1

lev. 2+3
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Eni applications - Camilla 2

Subsea Wellhead Tubing Head Spool

25

Eni applications - Camilla 2

Subsea Wellhead Subsea X-Tree

26

Eni applications - Camilla 2

The Rig used to drill and complete the well is a Semisubmersible moored type named Zagreb 1, property of Crosco International LTD.

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Eni applications - Camilla 2

The completion operations time analysis
OPERATION
RIH completion Well Test/Clean up/PT data measurement Scraper TCP guns Logs X-Tree installation BOP Installation/testing Killing/Static Well Control/Circulation/Brine W.L. Operations TTBP/PKR Plug installation Csg Clean up/Filtering BOP Installation/Disinstallation/Test Gravel Pack/Frac Pack Well securing operations Other well operations Cement mill and cleaning Divers operations ROV operations Log correlations Not provided operations Maintenances Down times Negative hydraulic tests Breakdowns Waitings

BUDGET
42,0 71,0 6,5 30,0 6,0 36,5 4,0 3,0 21,5 1,0 5,0 79,0 127,0 13,5 147,0 20,0 10,0 2,0 12,0 0,0 0,0 0,0 0,0 0,0 0,0

FINAL BALANCE
32,0 154,0 4,0 23,0 5,5 80,0 2,5 16,0 2,5 16,5 65,0 80,5 10,5 128,0 9,5 8,5 3,5 20,0 4,5 6,5 2,0 5,0 39,5

%
-23,8% 116,9% -38,5% -23,3% -8,3% 119,2% -16,7% -25,6% 150,0% 230,0% -17,7% -36,6% -22,2% -12,9% -52,5% -15,0% -70,8%

% of total
4,5% 21,4% 0,6% 3,2% 0,8% 11,1% 0,3% 2,2% 0,3% 2,3% 9,0% 11,2% 1,5% 17,8% 1,3% 1,2% 0,5% 2,8% 0,6% 0,9% 0,3% 0,7% 5,5%

TOTAL (Hours)

637,0

719,0

12,9%

TOTAL (Days)

26,5

30,0

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Summary
1

Project Scope

State of Art Subsea Completion

Eni applications Camilla 2

Risk Analysis

Conclusions

30

Risk Analysis
The Risk Analysis was developed with these hipotesys:
The completion operations were deducted from the Camilla 2 completion because it is the most recent well completed with dual string by Eni. There are very few subsea wells with dual string completion, and a lot of them are old, so it is difficult to find the informations about the operations and the related problems. Therefore the values of Probability and Impact for the operations were found out with the help of expertises.

The analysis is qualitative and based on STAP-P-1-N-20913: Project Risk Management for Drilling, Completion and production Optimization Activities.
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Risk Analysis
Completion execution phases:

Engineering & Procurement

Installation

Operations & Maintenance

Decommissioning

The Risk analysis was developed for Engineering & Procurement and Installation for the Single String and the Dual String with the mitigating actions for a risk reduction
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Risk Analysis
N

Engineering and Procurement Dual string completion

Global Riser Analysis ---> simulation of RIH and installation of Landing String and Tbg string: poor data and uncertainties on the RIG, for the availability and for the RIG choice

Original Risk P I RL

Residual Risk

Mitigations

RL

Environment
Weather and sea conditions 1) B 2 M this could affect the real functioning system for the landing string and for drilling riser, so simulation could be aborted and not considered during the operations B 3 M

Rig
Availability 2) Market conditions: availability of the rig and costs: depend by the area of working, in case of mediterranean sea floating RIG are very poor, other areas permits to have RIG availability with different daily rate Mobilization on time: time to MOB/DEMOB and the travel Availability of specific equipment: Rig set for drilling activities C 5) Reliability (QA, HSE and maintenance) 4 M D C 4 4 M M plan activity where it is possible with the right completion schematic and based also on RIG availability on the markey plan the activity with right time in order to avoid any delay doublecheck before to commence the moving or before to sign the contract the availability of the completion tools on board, finalize right contract for completion activity (services) --D C 5 5 L L

3) Performance 4)

6)

Experienced operating team

---

Completion
7) Availability of the specific equipment rarely used by the oil companies: manufacturing line set for standard equipments Time to engineering: it takes more time because it is uncommon, personnel not skilled and new design Delivery & manufacturing: special items, like TH for dual string, are required and they have to be manufactured ad hoc Test and qualification (no common): procedure of testing and qualification are not defined by ISO and it could be written and agreed Orizontal vs vertical X-Tree ---> it is suggested to use horizontal XT where it is necessary to re-entry instead in shallow water it is possible to go with vertical XT. where few hydraulic lines and electrical lines are requested it is suggested to avoid vertical XT

plan the activity with right time in order to avoid any delay or consider the activity without Rig window availability but always on the market possibility to choose all standard equipments on the market and modify the completion goals based on the market proposal --action by company to control and check procedure of test

8)

B B B

3 4 2

M L M

B B B

5 4 4

L L L

9) 10) 11)

Evaluation prons and cons choose a horizontal vs vertical X-Tree fitting with dual subsea completion

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Risk Analysis
N

Installation Dual string completion

Original Risk

Residual Risk

RL

Mitigations

RL

Environment
Weather and sea conditions 12) Strong heave ---> need of motion compensator to counter the movement

squall not considered, wave abnormal, strong wind more than 45 kn; possibility of investigation on environment conditions historycally

Rig
Availability 13) Truster functioning (DP) ---> it keeps the rig in the right position B 2 M --B 2 M

Performance

14) Motion compensator ---> if it does not work, it can append that the rig must stop the operations

---

Completion
15) Staff: generally the staff does not have the skills in this area, so special training and team building is requested 16) Space on deck rig number of reels: possibility to have few numers of reels 17) Running TH with landing string: dedicated landing string and umbilical for this operation 18) Shearability dual string completion in BOP: impossibility to shear two strings inside of BOP C C 2 4 H M organize few meeting between contractor and company in order to standardize the procedure avoid to run control lines more than SCSSV inside of downhole completion package define with landing string supplier and subsea vendor the best design and optimize with market availability. Optimize the plan in order to reduce delivery verify with RIG contractor possibility and new design C C 4 5 M L

C C

1 2 1 2 4 5

H H H H M L

C C C C C C

3 3 2 3 4 5

M M H M M L

19) Landing dual string completion: planning procedures, new operations

agreed all personnel on procedures, operations meeting before to begin, perform during the day, to have all SPV on the rig floor
as point above analyze with subsea vendor best procedures and analyze methodology -----

20) Orientation TH: it is the most difficult operation and it needs to be done with the motion compensator working 21) X-Tree installation: verify the procedures with contractors 22) Retrieving Wire Line Plugs/clean up/Well Test 23) Cap/protective frame installation

C C C C

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Risk Analysis
N

Engineering and Procurement Single string completion

Original Risk

Residual Risk

Mitigations
P I RL P I RL

Environment
Weather and sea conditions 1) Global Riser Analysis ---> simulation of RIH and installation of Landing String and Tbg string: poor data and uncertainties on the RIG, for the availability and for the RIG choice B 2 M this could affect the real functioning system for the landing string and for drilling riser, so simulation could be aborted and not considered during the operations B 3 M

Rig
Availability 2) Market conditions: availability of the rig and costs: depend by the area of working, in case of mediterranean sea floating RIG are very poor, other areas permits to have RIG availability with different daily rate Mobilization on time: time to MOB/DEMOB and the travel D 4 M plan activity where it is possible with the right completion schematic and based also on RIG availability on the markey plan the activity with right time in order to avoid any delay D 5 L

3)

Performance

4)

Availability of specific equipment: Rig set for drilling activities

C 4 M

doublecheck before to commence the moving or before to sign the contract the availability of the completion tools on board, finalize right contract for completion activity (services)
-----

5) 6)

Reliability (QA, HSE and maintenance) Experienced operating team

B B

4 4

L L

B B

4 4

L L

Completion
7) 8) 9) Availability on the market B Time to engineering Common test and qualification B B 4 5 4 L L L ----Evaluation prons and cons choose a horizontal vs vertical X-Tree fitting with dual subsea completion Take standard equipment on the market B B B 5 5 4 L L L

10) Horizontal vs vertical X-Tree ---> it is suggested to use horizontal XT where it is necessary to re-entry instead in shallow water it is possible to go with vertical XT. where few hydraulic lines and electrical lines are requested it is suggested to avoid vertical XT

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Risk Analysis
N

Installation Single string completion

Original Risk

Residual Risk

Mitigations
P I RL P I RL

Environment
Weather and sea conditions 11) Strong heave ---> need of motion compensator to counter the movement
C 3 M

squall not considered, wave abnormal, strong wind more than 45 kn; possibility of investigation on environment conditions historycally

Rig
Availability 12) Truster functioning (DP) ---> it keeps the rig in the right position B 2 M --B 2 M

Performance

13)

Motion compensator ---> if it does not work, it can append that the rig must stop the operations

---

Completion
14)
15)

Staff skilled for subsea operations

Space on deck rig number of reels: possibility to have few numers of reels

B C

4 4

L M

--avoid to run control lines more than SCSSV inside of downhole completion package

B C

4 5

L L

16)

Running TH with landing string

D 4 M

define with landing string supplier and subsea vendor the best design and optimize with market availability. Optimize the plan in order to reduce delivery verify Rig BOP bullettin (shear sub)
agreed all personnel on procedures, operations meeting before to begin, perform during the day, to have all SPV on the rig floor analyze with subsea vendor best procedures and analyze methodology -----

17)
18) 19) 20) 21)

Shearability completion string in BOP

Landing completion string: planning procedures X-Tree installation: verify the procedures with contractors Retrieving Wire Line Plugs/clean up/Well Test Cap/protective frame installation

C C D C C

4 3 4 4 5

M M M M L

C C D C C

5 4 5 4 5

L M L M L

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Risk Analysis
The following matrix shows the differences between the risk associated to the single string and the dual string completion

Installation operations
37

Risk Analysis
The following matrix shows the risk reduction due to the mitigating actions taken

17 Running Tubing Hanger with landing string 20 Tubing Hanger orientation

38

Summary
1

Project Scope

State of Art Subsea Completion

Eni applications Camilla 2

Risk Analysis

Conclusions

39

Conclusions
The following conclusions could be carried out:
A pre-enquiry with all major subsea vendors shows a poor case history of dual subsea completion with SSXT dual bore Actual market does not propose standard equipments for dual subsea completion and SSXT with dual bore. This condition affects the choice of subsea dual completion development

Risk analysis conducted on previous experience of ENI, shows major criticalities during operations compared with a single completion
Vertical XT is preferred to horizontal type to couple to dual subsea completion, but with all constrains of subsea applications

Single completion is strongly preferred to dual in subsea completion operations

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Acknowledgements

I would thank Eni E&P Division Management for permission to present this work and related results
and COMP colleagues for the technical support and needed assistance.

San Donato Milanese

20-21 October 2010

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