11 COMP Ferrari Giuseppe Stage Master 2009-2010
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Transcript of 11 COMP Ferrari Giuseppe Stage Master 2009-2010
www.eni.it
Subsea dual completions: State of the art, benefits and risks
Author: Giuseppe Ferrari
San Donato Milanese 20-21 October 2010
Master in Petroleum Engineering 2009-2010
2
Subsea dual completions: State of the art, benefits and risks.
San Donato Milanese 20-21 October 2010
Author
Ing. Giuseppe Ferrari
Division Exploration & Production
Dept. COMP/PERF
Company Tutors
Ing. Stefano Di Vincenzo
Ing. Gianfederico Citi
University Tutor
Prof. Ing. Francesca Verga
Master in Petroleum Engineering 2009-2010
3
Project Scope 1
State of Art Subsea Completion 2
Eni applications – Camilla 2 3
Risk Analysis 4
Conclusions 5
Summary
4
Project Scope
Dual Subsea Completion State of Art – analyze existing case
history from all main subsea vendors.
The Scope of Work of this thesis is summarized by
following points:
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.
5
Project Scope 1
State of Art Subsea Completion 2
Eni applications – Camilla 2 3
Risk Analysis 4
Conclusions 5
Summary
7
RIG
Drilling Ship (dynamic position)
Semi submersible (moored)
PRODUCTION
Floating production
On-shore and land site production
facilities
LANDING STRING
Hydraulic
Electro-hydraulic
X-TREE
Vertical design
Horizontal design
State of Art Subsea Completion
8
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
State of Art Subsea Completion
9
There are three different completion options available on
the market, applicable to subsea fields:
Single string completion
Dual string completion
Intelligent well completion (IWC)
State of Art Subsea Completion
WD IV-ICV Infinitely Variable Choke size 3 1/2"
WD HF1 Retrievable Packer w/multi Feedthru
Tbg Retrievable Safety Valve size 3 1/2"
WD Flat Pack Umbilical with 3 Hydr.Lines
Size 7" x 3 1/2"
3-1/2" Tubing
7" 23-26 lb/ft Casing
1/4" Safety Valve Control Line
Crossover 3 1/2" x 2 7/8"
Locator with Moulded Seal Units
3-1/2" Tubing
Gravel Pack Screen on 4" Base Pipe
Moulded Seal Unit size 3.25"
Permanent Type Seal Bore Packer
Pup Joint
Polished Bore size 3.25"
Gravel Pack Packer with 3.25" Seal Bore
Gravel Pack Closing Sleeve
WD HV-1 Shrouded ON-OFF Type Choke
Wireline Plug
With Accu-Pulse
2-3/8" FJ Tubing
For 3.25" Seal Bore
Size 2 7/8"
Gravel Pack Screen on 4" Base Pipe
Gravel Pack Packer with 3.25" Seal Bore
Gravel Pack Closing Sleeve
Locator with Moulded Seal UnitsFor 3.25" Seal Bore
10
Factors that drive the decision to use a vertical tree:
Financial driver is “life of field OPEX”
Lower drive wells (smaller bore)
Simple reservoirs or low frequency of tubing retrieval workovers
High pressure – difficult well control issues
Pre owned installation tooling package (open water, completion riser)
Trend, gas wells, short life (little or no maintenance), well pressure
greater than 10 000 psi
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:
Financial driver is installed CAPEX
High drive wells or multilaterals (have need for large bore)
Complex reservoirs or frequent W/O requiring TBG retrieval
ESP or artificial lift technology
Bacth drilling/completion and/or requirements for drill thru systems
Little or no pre-owned installation tooling
Trend:oil wells, high maintenance or wells needing recompilation, well
pressure less then 10 000 psi
State of Art Subsea Completion
11
Horizontal Trees
Advantages Disadvantages
Suitable for large bore gas wells Requires an additional BOP trip
Can be installed on completions
wellhead
Requires a SSTT and landing
string
Reduced installation tooling
requirements
BOP may require modifications to
accommodate IWOC's umbilical
Uses rig riser system Higher bending loads on the
wellhead system
Simplified rig interfaces Potential leak paths below the BOP
Suitable for smart well technology Well must be plugged prior to
removing the tree
Allows workover without pulling
tree or disconnecting flowlines
Some concern with wireline plugs
for vertical barriers
Flow base typically not required Longer emergency disconnect time
Flexibility of design to accomodate
natural flow, gas lift, water injection
and ESP
Cannot pull tree independent of the
completion
Horizontal and Vertical X-Tree advantages and disadvantages
State of Art Subsea Completion
Vertical Trees
Advantages Disadvantages
One less BOP trip (Drill thru to
completion) tubing hanger
landed in the wellhead (or
tubing head)
May require BOP modification
for TH orientation mechanism
Allows intervention without a rig Requires leas impression tool
run to verify TH space out
Reduced wellhead loading Need more rig deck space to
accommodate additional tooling
and riser
Metal sealing gate valves for
environmental barriers, not field
installed like wire line plugs
Rig needs to handle more
tooling
Allow monitoring of all down
hole functions as standard
Additional wellhead casing
hanger required
Tubing intervention simpler as
no wire line plugs need to be
retrieved
Tubing hanger seals in the
casing that could be damaged
during drilling operations
Installed CAPEX considered to
be lower the horizontal tree
Need to remove the tree for
tubing work over
12
State of Art Subsea Completion
13
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.
State of Art Subsea Completion
INTERNAL TREE CAP
2° Environmental Barrier
Metal to metal seal with X-Tree
5” Wireline Crown Plug
14
State of Art Subsea Completion
15
Used with the horizontal xmas tree, it is installed wire
line in the internal tree cap and in the tubing hanger
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
State of Art Subsea Completion
or alternatively both in
the tubing hanger if the
supplier does not use
the internal tree cap
16
State of Art Subsea Completion
17
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
18
State of Art Subsea Completion
DUAL BORE TUBING HANGER
Production Bore
Annulus Bore
Thread for tubing
Plugs
Thread for landing string
Control lines
Orienting pin
19
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.
State of Art Subsea Completion
20
Project Scope 1
State of Art Subsea Completion 2
Eni applications – Camilla 2 3
Risk Analysis 4
Conclusions 5
Summary
21
Eni applications - Camilla 2
The well location
22
Short String
Long String
Eni applications - Camilla 2
Reservoir profile and intervals perforated
23
Eni applications - Camilla 2
PTR = 23,6 mt on water level
Water Depth = 85 mt
Csg 30” @169 mt TVD
Csg 13”3/8 @344 mt TVD
Liner head 7” @955 mt TVD
Csg 9”5/8 @1104 mt TVD
Liner 7” @1477 mt TVD
Well Schematic and casing profile
24
Dual string 2” 3/8 + Gravel Pack Assy (lev. 1 e 2+3)
lev. 1
lev. 2+3
Eni applications - Camilla 2
25
Subsea Wellhead Tubing Head Spool
Eni applications - Camilla 2
26
Subsea Wellhead Subsea X-Tree
Eni applications - Camilla 2
27
The Rig used to drill and complete the well is a
Semisubmersible moored type named Zagreb 1,
property of Crosco International LTD.
Eni applications - Camilla 2
29
OPERATION BUDGET FINAL BALANCE Δ % % of total
RIH completion 42,0 32,0 -23,8% 4,5%
Well Test/Clean up/PT data measurement 71,0 154,0 116,9% 21,4%
Scraper 6,5 4,0 -38,5% 0,6%
TCP guns 30,0 23,0 -23,3% 3,2%
Logs 6,0 5,5 -8,3% 0,8%
X-Tree installation 36,5 80,0 119,2% 11,1%
BOP Installation/testing 4,0
Killing/Static Well Control/Circulation/Brine 3,0 2,5 -16,7% 0,3%
W.L. Operations 21,5 16,0 -25,6% 2,2%
TTBP/PKR Plug installation 1,0 2,5 150,0% 0,3%
Csg Clean up/Filtering 5,0 16,5 230,0% 2,3%
BOP Installation/Disinstallation/Test 79,0 65,0 -17,7% 9,0%
Gravel Pack/Frac Pack 127,0 80,5 -36,6% 11,2%
Well securing operations 13,5 10,5 -22,2% 1,5%
Other well operations 147,0 128,0 -12,9% 17,8%
Cement mill and cleaning 20,0 9,5 -52,5% 1,3%
Divers operations 10,0 8,5 -15,0% 1,2%
ROV operations 2,0
Log correlations 12,0 3,5 -70,8% 0,5%
Not provided operations 0,0 20,0 2,8%
Maintenances 0,0 4,5 0,6%
Down times 0,0 6,5 0,9%
Negative hydraulic tests 0,0 2,0 0,3%
Breakdowns 0,0 5,0 0,7%
Waitings 0,0 39,5 5,5%
TOTAL (Hours) 637,0 719,0 12,9%
TOTAL (Days) 26,5 30,0
The completion operations time analysis
Eni applications - Camilla 2
30
Project Scope 1
State of Art Subsea Completion 2
Eni applications – Camilla 2 3
Risk Analysis 4
Conclusions 5
Summary
31
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”.
Risk Analysis
32
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
33
N
Engineering and Procurement
Dual string completion
Original Risk
Mitigations Residual Risk
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
D 4 M
plan activity where it is possible with the right completion
schematic and based also on RIG availability on the
markey
D 5 L
3) Mobilization on time: time to MOB/DEMOB and the travel C 4 M
plan the activity with right time in order to avoid any delay C 5 L
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)
C 5 L
5) Reliability (QA, HSE and maintenance)
B 4 L --- B 4 L
6) Experienced operating team
C 3 M --- C 3 M
Completion
7) Availability of the specific equipment rarely used by the oil companies:
manufacturing line set for standard equipments - B 2 M
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
B 3 M
8) Time to engineering: it takes more time because it is uncommon, personnel
not skilled and new design B 3 M
possibility to choose all standard equipments on the
market and modify the completion goals based on the
market proposal
B 5 L
9) Delivery & manufacturing: special items, like TH for dual string, are required
and they have to be manufactured ad hoc B 4 L
--- B 4 L
10) Test and qualification (no common): procedure of testing and qualification
are not defined by ISO and it could be written and agreed B 2 M
action by company to control and check procedure of test B 4 L
11) 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
B 2 M Evaluation prons and cons choose a horizontal vs vertical
X-Tree fitting with dual subsea completion B 3 M
Risk Analysis
34
N
Installation
Dual string completion
Original Risk
Mitigations Residual Risk
P I RL P I RL
Environment
Weather and sea
conditions
12) 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
C 4 M
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 C 3 M --- C 3 M
Completion
15) Staff: generally the staff does not have the skills in this area, so special
training and team building is requested C 2 H
organize few meeting between contractor and company in
order to standardize the procedure C 4 M
16) Space on deck rig number of reels: possibility to have few numers of
reels C 4 M
avoid to run control lines more than SCSSV inside of
downhole completion package C 5 L
17) Running TH with landing string: dedicated landing string and umbilical
for this operation C 1 H
define with landing string supplier and subsea vendor the
best design and optimize with market availability. Optimize
the plan in order to reduce delivery C 2 H
18) Shearability dual string completion in BOP: impossibility to shear two
strings inside of BOP C 1 H
verify with RIG contractor possibility and new design C 3 M
19) Landing dual string completion: planning procedures, new operations
C 2 H
agreed all personnel on procedures, operations meeting
before to begin, perform during the day, to have all SPV on
the rig floor
C 3 M
20) Orientation TH: it is the most difficult operation and it needs to be done
with the motion compensator working C 1 H
as point above C 2 H
21) X-Tree installation: verify the procedures with contractors
C 2 H analyze with subsea vendor best procedures and analyze
methodology C 3 M
22) Retrieving Wire Line Plugs/clean up/Well Test C 4 M
--- C 4 M
23) Cap/protective frame installation C 5 L
--- C 5 L
Risk Analysis
35
N
Engineering and Procurement
Single string completion
Original Risk
Mitigations
Residual Risk
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
D 4 M
plan activity where it is possible with the right
completion schematic and based also on RIG
availability on the markey
D 5 L
3) Mobilization on time: time to MOB/DEMOB and the travel
C 4 M plan the activity with right time in order to avoid any
delay C 5 L
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)
C 5 L
5) Reliability (QA, HSE and maintenance)
B 4 L --- B 4 L
6) Experienced operating team
B 4 L --- B 4 L
Completion
7) Availability on the market
B 4 L Take standard equipment on the market
B 5 L
8) Time to engineering B 5 L
--- B 5 L
9) Common test and qualification B 4 L
--- B 4 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
B 2 M
Evaluation prons and cons choose a horizontal vs
vertical X-Tree fitting with dual subsea
completion
B 3 M
Risk Analysis
36
N
Installation
Single string completion
Original Risk
Mitigations
Residual Risk
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
C 4 M
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 C 3 M --- C 3 M
Completion
14) Staff skilled for subsea operations
B 4 L ---
B 4 L
15) Space on deck rig number of reels: possibility to have few
numers of reels C 4 M
avoid to run control lines more than SCSSV inside of downhole
completion package C 5 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 D 5 L
17) Shearability completion string in BOP
C 4 M verify Rig BOP bullettin (shear sub)
C 5 L
18) Landing completion string: planning procedures
C 3 M agreed all personnel on procedures, operations meeting before to
begin, perform during the day, to have all SPV on the rig floor C 4 M
19) X-Tree installation: verify the procedures with contractors
D 4 M analyze with subsea vendor best procedures and analyze
methodology D 5 L
20) Retrieving Wire Line Plugs/clean up/Well Test
C 4 M ---
C 4 M
21) Cap/protective frame installation
C 5 L ---
C 5 L
Risk Analysis
37
The following matrix shows the differences between the
risk associated to the single string and the dual string
completion
Installation operations
Risk Analysis
38
The following matrix shows the risk reduction due to the
mitigating actions taken
17 – Running Tubing Hanger with landing string
20 – Tubing Hanger orientation
Risk Analysis
39
Project Scope 1
State of Art Subsea Completion 2
Eni applications – Camilla 2 3
Risk Analysis 4
Conclusions 5
Summary
40
The following conclusions could be carried out:
Conclusions
A pre-enquiry with all major subsea vendors shows a poor case
history of dual subsea completion with SSXT dual bore
Single completion is strongly preferred to dual in subsea
completion operations
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
41
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