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VOLUME 04 ISSUE 05-AUGUST 2011
BWAs Belclene 800 and 810 are part of a new family of biodegradable,
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Belclene 800 can prevent calcium carbonate scale in even the most severe
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Belclene 810s biodegradability, 45% more than its closest competitor,
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formulation.
For more info, please contact us at Oilfield@wateradditives.com
Too Good to be Green
ISSN 1757-2134 August 2011 Volume 04 Issue 05
Copyright
Palladian Publications Ltd 2011. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means, electronic, mechanical, photocopying, recording or otherwise, without the prior permission of the
copyright owner. All views expressed in this journal are those of the respective contributors and are not necessarily the opinions of the
publisher, neither do the publishers endorse any of the claims made in the articles or the advertisements. Printed in the UK.
On this months cover >>
Oilfield Technology is audited by the Audit Bureau
of Circulations (ABC). An audit certificate is
available on request from our sales department.
contents
| 61 | DELIVERING ON DATA SOURCES AND APPLICATIONS
Sebastiano Barbarino, OVS Group, USA, explains how asset
performance can be increased through workflow technology utilising
existing information and applications.
| 67 | THE MOBILE OPTION
Raphael Moscarello and Paul Kleinen, Bredero Shaw, Canada and
USA, and Sean Haberer, ShawCor, Canada, present a new, innovative
modular mobile plant for pipe coatings in this months cover story.
| 71 | SUBSEA HARDWARE: AIDING ACCESS TO DIFFICULT
RESERVES
Ian Jones and Thom Payne, Douglas-Westwood, UK, take a look at
the world subsea hardware market, 2011 2015.
| 74 | A VIEW FROM THE TRENCH
Pierre Boyde, CTC Marine Projects Ltd, UK, discusses the design,
build and trialling of one of the worlds biggest subsea rock
trenching machines.
| 81 | A SUBSEA SAMPLE
Eivind Gransaether, Mirmorax, Norway, discusses establishing
subsea engineering principles in subsea sampling and oil-in-water
monitoring operations.
| 85 | DECOMMISSIONING: SAFETY AND RISK
James Broadribb, RBG, UK, points out how decommissioning best
practice can deliver significant benefits.
| 89 | SINK OR SIM
Darren J Morahan, Cougar Offshore LLC, USA, highlights the
possibilities of SIM in the Gulf of Mexico.
| 95 | ALL ABOARD! LEAVING THE RIG FOR THE VESSEL
Per Lund, NCA AS, Norway, shows how exploration and
abandonment operations can be completed more cost-efficiently
through using new technology and novel approaches.
| 100 | RISK REDUCTION STRATEGIES
Steve Nairn, Helix Well Ops, UK, explains how rigless well
abandonment can address some of the funding, safety and
environmental challenges of well decommissioning.
| 104 | AD INDEX
| 03 | EDITORIAL COMMENT
| 05 | WORLD NEWS
| 10 | OFFSHORE NORWAY AND THE UK
Oliver Sanderson, Douglas-Westwood Ltd, UK, focuses on some
specific European offshore developments.
| 18 | BIG GAME HUNTING
Oilfield Technology Correspondent Gordon Cope examines the
growing importance of utilising marine seismic methods in identifying
new deposits.
| 25 | RAISING SITE SURVEY STANDARDS
Bob Van Nieuwenhuise, Manuel Perez and Mark Langer, Paradigm,
USA, discuss the task of reprocessing site survey data.
| 29 | SEDIMENTARY BASINS IN THE SIBERIAN ARCTIC
Alexander Grevtsev, Natalya Petrovskaya, Alexander Savitsky,
DMNG JSC, Russia, reveal a new approach to seismic acquisition as
a basis for new geological results.
| 35 | NEXT GENERATION SCANNING
Gordon Stove, Adrok Ltd, UK, introduces a new scanner for
determining the location of hydrocarbons prior to drilling.
| 39 | UNCONVENTIONAL TODAY, CONVENTIONAL TOMORROW
Matthew Kebodeaux and James King, Baker Hughes, USA, discuss
the technology facilitating unconventional reservoir exploitation.
| 43 | COMPLICATION-FREE CLEAN-UP
David Coull, Omega Completion Technology Ltd, UK, reveals how
an autonomous valve offers a smart solution to the issue of poor
wellbore clean-up.
| 47 | CASE STUDIES IN REMOTE CONTROL
Richard McKimmie, Red Spider, UK, reveals the importance of remote
open close technology in allowing operator freedom.
| 51 | COMPARING COMPLETIONS
Paul Higginson, Packers Plus Energy Services, UK, demonstrates the
benefits of OHMS systems.
| 55 | LEADER OF THE PACK
Michael MacDonald Arnskov, Welltec, Denmark, discusses how next
generation well packers pave the way for fast and reliable well
completion by using components that eliminate some of the issues
associated with conventional approaches when isolating and
managing oil and gas bearing layers.
| 57 | WIRELESS WELLBORE SOLUTIONS
Garth Naldrett, Tendeka, UK and Tor Inge sen, Tendeka, Norway,
explore wireless options for monitoring and control.
Brigden is ShawCors new mobile pipe-coating plant that offers the same quality and
output as the most advanced fixed plants. Fully operational in just six weeks, it can be
located near any project logistical point to reduce costs, mitigate risk and improve safety.
To learn more, please visit www.brederoshaw.com.
Nautilus
streamer,
Nautilus
frac balls.
Using controlled electrolytic materials
technology, which is an engineered
material that provides high strength
while disintegrating in a controlled
manner in the presence of brines and
acids, the need to ow back or drill out
the balls and seats after the fracture
can be eliminated. These new balls are just beginning to be
introduced to the market, but they are expected to see wider
use as production is ramped up.
While these initial 40-stage FracPoint jobs have saved
an estimated ve days per completion over a 40-stage plug
and perf job, the key to delivering real value is in minimising
fracture stage length and improving fracture efciency, thereby
maximising the productivity of wells and protability of assets.
The addition of BJ Services and RDS in the last year further
expands the Baker Hughes technology portfolio to provide a
full service, reservoir focused solution and the company aims to
improve and optimise unconventional drilling and completions,
and provide well solutions to its clients, (whether that includes
more frac stages, or more optimally placed wellbores and
fracture treatments). The bottom line is that focus and
investment is helping to change the unconventional reservoirs
of today to the conventional reservoirs of tomorrow.
O T
COMPLICATION-FREE
P
oor clean-up of high angle wells, particularly with open hole
completions, is a common issue throughout the oil industry
today. When drawdown is applied to an open hole section, uid
by nature will take the path of least resistance. In a homogeneous
well, this will obviously be at the heel of the well. Due to this
occurrence, the toe of the well will never be fully cleaned up and the
drilling uid is likely to remain across the section, leaving the ltercake
Figure 1. Sandface Valve in the open position with the ltercake highlighted in yellow.
CLEAN-UP
David Coull, Omega Completion Technology Ltd, UK,
reveals how an autonomous valve offers a smart solution
to the issue of poor wellbore clean-up.
43
OT_43-46_Aug2011.indd 43 10/08/2011 11:11
44
OILFIELD TECHNOLOGY
August 2011
undisturbed. Similarly in non-heterogeneous wells, staged
start-up has its benets, ensuring the poorer quality rock has
an opportunity to clean up before the high permeable areas.
Performance improvements gained by selective start-up has
been reviewed and matched through transient ow modelling.
This issue has been proven through actual eld experience
determined by pressure transient analysis and conrmed results
of production by BP on a major North Sea development. In
the aforementioned log, the ow was shown to be coming
predominantly from the heel of the well and in some cases
owing length was less than 20% of the overall section drilled.
Considerable value in terms of increased production and
reservoir access could be gained if the wells were designed or
modied to improve the owing interval. A well owing along
its producing intervals offers signicant benets in terms of
conformance and hence reservoir management and sweep of
hydrocarbons.
Other technologies do exist to rectify the poor clean-up
such as swabbing or surging of the well, but dealing with a live
well is a potentially dangerous operation, as well as the risk
of collapsing the reservoir wellbore. Deep nitrogen lift and coil
tubing clean-out are additional options for the operator, however
the success of such clean-outs is often limited due to the high
hole angle. These all involve intervention, which greatly increases
capital expenditure and carries signicant risk to the well and
personnel involved.
Figure 2. Illustration of a horizontal wellbore section showing swell packers providing zonal isolation and production being predominantly at the heel
of the well.
Figure 3. A unique pressure prole is sent from surface to initiate the sequential start up of the well.
Utilising Sandface Valve technology, Omega Completion
Technology Ltd addressed these issues at source, rather than
the symptoms of a poor wellbore clean-up.
Application
The use of a fully intelligent well completion to selectively bring
wells onstream and enable the clean-up of individual zones
had been successfully trialled in Brunei by Shell. Transient ow
modelling was able to match the performance improvement
gained by selective start-up.
1
An alternative mechanical
version of bringing the well
online was investigated. This
involved running a number of
SSDs in the well in the closed
position. The SSDs could then
be opened zone by zone with
wireline intervention followed by
a ow period to enable individual
zonal clean up. However, the
requirement for intervention to be
used to mechanically manipulate
the SSDs to the open position
and commence the clean-up of
each individual zone (typically
three or four per well) would
result in an extensive intervention
campaign to achieve the wellbore
clean-up. This was not achievable
without serious compromise on
a POB constrained platform with
continuous drilling operations.
Omega developed a
solution in conjunction with
BPs completions team, in the
form of a hybrid of an intelligent
well and a standard SSD.
The subsequently developed
Sandface Valve (SFV) was derived
from an earlier valve design used
by Statoil in Norway called a
Clean Out Valve (COV). Utilising
the main operating features of
the COV, which had realised an
enviable 100% eld track history,
the SFV was successfully
eld-trialled in the North Sea.
2
The valve has a one shot opening
facility without the need for
intervention but incorporates the
ability to be closed or re-opened
mechanically later on in the
wells life. The Timer Activated
Sandface Valves (TA-SFV) are
opened using an electronic timer
system, which offers 100%
redundancy and retains the full
functionality of an SSD once
the valve has been opened. The
completion runs conventionally
and the SFV is placed in the
segmented reservoir sections, in the fully closed position. Each
valve is timed to open with a staggered opening time. The well
can be brought online from the toe section and allowed a period
of clean-up. After a calculated period of time, the next SFV can
open, enabling the middle zone to clean up. After a further period,
the upper SFVs would open, enabling clean-up of the upper zone
and full production from the wellbore.
After the successful eld trials, it was quickly realised that
greater exibility in the opening of the valves would provide
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46
OILFIELD TECHNOLOGY
August 2011
BP with added control over the sequential cleaning up of the well,
mainly due to three factors:
x The unreliability of gauging well start-up times and, therefore,
the difficulty in setting the optimised opening time for the SFV
using the timer system.
x The need for a lower completion design that could eliminate
the use of a completion barrier valve.
x Reduction in rig time, by providing lower completion and
cased-hole wellbore cleanout in a single trip, saving one to
two days of rig time per well.
The next evolutionary step in the SFV design was to
incorporate the facility to open on a unique command signal from
surface, precisely at the time the operator is ready to commence
with the sequential clean-up of the reservoir section. This
requirement for greater operational exibility when most needed
provided the company with the Command Activated Sandface
Valve (CA-SFV).
Valve design
The Sandface Valve design comprises of three main sections:
x The electronic section.
x The actuator section.
x The SSD.
The electronic section comprises of two independent sets of
electronics, which in turn provide 100% backup functionality within
the CA-SFV. Each CA-SFV (and TA-SFV) is pre-programmed at
surface prior to installation, using simple computer software and
with the need for only two eld specialists. Flexibility exists to
allow the user to determine the pressure recognition setting for the
valve. This unique pressure signal sent from surface is recognised
downhole on each of the installed valves, so only one pressure
signal is required to initiate the timer sequences.
The electronics are coupled to the actuator; when activated,
they initiate the opening of an internal port in the valve, allowing
well pressure to drive the piston downwards and move the SSD
sleeve section to the fully open position. The actuator is a one shot
component, which the electronics section signals to, incorporating
two independent pressure temperature recorders. The SSD
section houses the valve ow ports and once actuated, the SSD
is decoupled from the piston section of the valve and reverts to a
standalone SSD.
To date, a total of 31 TA-SFVs and 26 CA-SFVs have been
successfully deployed, with another installation planned for this
summer. Monitoring of downhole gauges at the valves opening
time, has enabled BP to gain condence in the functionality and
design of the valve, and these recorded wellbore events or spikes
Figure 4. Sequential clean-up of the reservoir section commences with valve 1, followed by valve 2 a few
days later.
have been conrmed via PLT
surveys using electric line
tractors. On these very same
intervention operations,
shifting tools have been
deployed to both close and
re-open SFVs successfully.
In addition, a new
eld development for BP
in the North Sea will see
predominantly CA-SFVs
being installed in each
pre-installed lower
completion (approximately
six per well) with another three oil majors initiating their own
eld developments utilising the current SFV technology. The
valve family has also grown by the recent development of the
Command Activated Hydraulic Frac Valve (CA-HFV), which
has seen the pressure rating greatly increased to allow for the
safe handling of higher pressures commonly associated with
hydraulic fracking. This will also eliminate the requirement
for balls to be dropped, which results in the telescoping of
the lower well design and in extensive coil tubing clean-up
operations being required. Preliminary discussions have
shown a few oil majors to be interested in incorporating sand
screens with the SFV, which would see a fully shrouded valve.
Omegas patented demand activation technology,
which will allow the signalling and manipulation of the SSD
in a owing well, is expected to be of great interest. Part of
this challenge has already been developed and the wealth of
experience gained through eld deployments thus far, which
will have far reaching effects on other solutions and services,
especially DSTs. All these developments and technology leaps
enable Omega to move a step closer to providing the industry
with an autonomous valve that is continually self-powered once
installed within the wellbore. Providing operators with a reliable
valve which cannot only initiate the now realised benets in
sequential start-up, but can also offer additional cycles from
open to close etc., to isolate water out sections without the need
for intervention, or to carry out basic PLTs or PBUs, will obviously
greatly reduce the operators exposure to risk and reduce overall
expenditure. Such an autonomous valve offers a smart enough
solution to the common issue of poor wellbore clean-up without
the requirement for expensive intelligent systems. This will also
go a long way in eliminating the requirement for expensive
packers with multi-penetrators to allow thousands of feet of
electrical or hydraulic capillaries to be deployed to a few ICDs
in series, which in turn often only offer the operator temporary
operational exibility. Having a system that only requires minimal
manpower during set-up and deployment offshore also offers
great benets when often POB is an issue and can restrict
the operators operational planning due to these every day
challenges.
O T
References
1. Kerem, M., Proot, M. and Oudeman, P., Analyzing Underperformance of
Tortuous Horizontal Wells: Validation With Field Data: Paper 102678-MS,
presented at the SPE Annual Technical Conference and Exhibition (San
Antonio, Texas, USA, 24 27 September, 2006). DOI: 10.2118/102678-MS.
2. Russell, L-A., Elliot, G., Graham, J., Wallace, A., Coull, D. and Forsyth,
D., SPE 122181 A Novel Timer Activated Sandface Valve To Improve
Wellbore Productivity, presented at the 2009 SPE European Formation
Damage Conference (Scheveningen, The Netherlands, 27 29 May, 2009).
CASE STUDIES
IN REMOTE CONTROL
Richard McKimmie, Red Spider, UK, reveals the importance of
remote open close technology in allowing operator freedom.
R
emote open close technology is allowing operators to work differently and approach
interventions and completions in a new way by cutting rig time while improving health and
safety standards.
UK-headquartered Red Spider has invested heavily in R&D and has also worked closely with
industry bodies and major operators to develop a range of solutions initially with an eye to well
interventions but increasingly with a focus on completion work.
The companys remote open close technology product, eRED
is a downhole computer-controlled
valve that can be opened and closed via remote control. Without the need for intervention or control
lines, this saves time, money and removes risk.
The valve has allowed 13 North Sea operators on 24 elds to save up to US$ 900 000 during a
single subsea completion operation, typically reducing slickline runs from eight to one. In subsea
workover operations, savings of up to 36 hrs and US$ 800 000 have also been recorded in a single job.
eRED is a battery-powered through-tubing device that is pre-installed or deployed below a carrier
such as a wireline lock. In practice it works exactly like a wireline plug without requiring any intervention
to deploy or retrieve the plug when a barrier needs to be put in place or removed. This device can
replace any application where a wireline lock and plug is used; achieving exactly the same results
without repeated intervention jobs and removing the risk of multiple slickline runs.
Figure 1. A technician working on PowerBall.
47
48
OILFIELD TECHNOLOGY
August 2011
An eRED action, such as opening or closing, is initiated
only when a specic well condition (known as a trigger) is
detected. Upon successful completion of that action, it can
look for another trigger, which in turn initiates the next action.
Using a series of different trigger and action combinations, the
device can be used in complex well programmes, opening and
closing as many times as required without any intervention.
As an example of its exibility, the eRED, which was
originally developed for use in intervention type plugging
operations, began to be used for a variety of other
applications. These applications include shallow set for tree
testing and change out, deep set for completion deployment,
packer setting and tubing testing, annulus short string plug in
vertical subsea trees, liner deployment with external swellable
elastomers and zonal isolation during TCP gun ring. The
company continues to add to this list as the operators,
enjoying the signicant risk reduction and cost savings
made by the tool, suggest more potential applications in the
completion of wells.
New products
Further customer requests, followed by investment in
extensive research and development work, have resulted in
two new products being launched this year: the eRED-FB and
the PowerBall.
The eRED-FB is the tubing-mounted version of the eld
proven eRED. It consists of a remotely actuated full bore
ball valve that can be opened and closed multiple times,
controlling ow through the tubing without the need for any
well intervention or an umbilical control line.
The use of eRED-FB completely eliminates slickline
intervention from completion operations, resulting in savings of
up to 32 hrs and US$ 1 million in subsea scenarios. Moreover,
a mechanical downhole barrier is present at any time during
operations, which can be activated upon request and can take
control of the well.
Figure 2. The eRED-FB, one of Red Spiders latest products in the Remote Open Close
Technology eet.
In addition, the eMotion module,
which controls the eRED-FB, is
particularly exible and can be used
as a downhole pump with third party
tools. The module can be remotely
commanded to pump uid into any
hydraulic device, such as frac valves
and ow control sleeves to provide
remote control of devices without
requiring control lines up to surface.
PowerBall is a reservoir isolation
barrier precisely designed for
reliability and to be run open, then
subsequently closed during lower
completion deployment, and nally to
be permanently reopened by remote
command for production or injection
to commence. It can operate in any
type of well, including cased and
open-hole wells.
Remote opening of the barrier
happens with no pressure cycles, but
on detecting a specic trigger much
as with the eRED, thus resulting in a
more exible and quicker operation.
Savings of up to 12 hrs and US$ 250 000 can be achieved
thanks to the quick activation method of the PowerBall.
Well completion technology challenges include optimising
lower completions, which this new reservoir isolation barrier
successfully achieves by using electronic logic in its primary
opening mechanism. This offers the user increased exibility
during the opening sequence, which is another benet as the
tool set-up can be changed, if required, on the well site.
Debris is a well documented challenge during well
completion activities as the technologies utilised are often
exposed to large amounts of debris, leading to operational
failure and costly shutdown time. By moving the mechanical
parts of the ball mechanism below the closed ball area
of the tool, and as a result, protecting them from debris,
the PowerBall barrier offers maximum reliability in dirty
environments. Avoiding remedial action due to failure of a uid
loss device can result in savings in the region of US$ 2 million.
PowerBall has been tested extensively at the companys
dedicated research facility in Aberdeen to ensure reliability,
including severe debris and slurry testing to prove its
performance in dirty environments.
Both new technologies received funding through the
oil and gas Industry Technology Facilitator (ITF). Operator
members including BG Group, Chevron and Maersk Oil
invested in the development of the technology.
ITF involvement was crucial to delivering the products in a
relatively short time frame as the body secured commitment
from the operator sponsors. Through the ITF process,
Red Spider was able to pool the knowledge from the project
sponsors, drawing upon of their industry experience to
preliminarily address potential problems that may have delayed
development of the technology.
eRED and its remote open close technology family are
particularly suited for deepwater and subsea applications
where the rig time savings are most valuable. This means that
there is huge potential for these products in the North Sea,
and internationally in Brazil, the
Gulf of Mexico, West Africa and
Asia-Pacic.
Case study one
Background
The Ninian eld is operated by CNR
International, and is located in the
northern North Sea approximately
140 miles northeast of Aberdeen
in block 3/3. Produced oil from the
Ninian south platform is processed
onboard and exported to the
Sullom Voe terminal on the Shetland
Islands via the Ninian pipeline system.
This case study is on injector well S86,
side-tracked from well S43z, which
had been permanently abandoned.
The operation
In a standard platform completion deployment, wireline plugs
and prongs are used as isolation devices below the production
packer and tubing hanger. These require several interventions
together with all the associated time and risk involved with the
rig-up of surface pressure control equipment to install, test and
retrieve the each isolation device.
The conventional tubing hanger and production packer plugs
were replaced with two eREDs in well S86. The motive behind
this decision was due to several factors including the removal
of risk, improving the safety of the operation and a reduction in
operational rig time, helping reduce the overall cost of the well
operation.
Both eREDs were set to the closed position and installed into
assemblies onshore prior to shipping. The rst installation was the
deep-set device that was made up to a 4.5 in. bridge plug. This was
then set and pressure tested from above and below in the tubing
pup below the 7 in. production packer. The second eRED was
made up to a 4.7 in. lock and set in the tubing hanger nipple prole.
The lock was then pressure tested as per the deep-set device.
Upon completion of all testing each eRED was programmed to
open. The assemblies were then shipped offshore with the devices
switched onto running mode looking for their next trigger.
Offshore, with both eREDs pre-installed in the open position,
the tubing could self-ll as the completion was run to depth.
Production packer and tubing hanger were then made up as per the
completion programme, removing several interventions during the
completion installation.
The deep-set eRED had been programmed with a pressure/
time activation and was set to activate at approximately 7500 ft
(4750 psi). Once triggered, it was programmed to close after 12 hrs.
This allowed the completion to be on-depth, the tubing hanger to
be landed, the well to be circulated to inhibited seawater and the
production packer to be tested to 4900 psi.
The shallow-set eRED had been programmed to close using a
pressure activation of 2250 psi (target window of 2000 2500 psi)
applied pressure for 20 min. Since both the devices were now
closed, the well had two fully tested barriers in place without
the need for any intervention. The BOPs were removed and the
christmas tree was installed and tested against the shallow-set
barrier.
After a successful christmas tree installation, the tubing hanger
eRED was remotely opened using a positive pressure activation of
3250 psi (target window of 3000 3500 psi) applied pressure for
15 min. A positive pressure drop was observed at surface as
the tool opened. Once equalised, the eRED was recovered
using wireline. The deep-set eRED was remotely opened
with its programmed activation of 1250 psi (target window of
1000 1500 psi) for 20 min., and a pressure drop was observed as
the tool opened. Subsequent to the deep-set eRED opening, the
well pressure was monitored for a period after which the tool was
recovered using wireline.
Once the completion was run, tested and the christmas tree
installed, the 4.7 in. lock and 4.5 in. bridge plug with eREDs were
recovered and a 5.5 in. Red Spider high lift injection valve was set
on a 5.5 in. packer in the blast joint at 7450 ft prior to handing the
well back to production.
Results
Both the eREDs functioned exactly as per the designed set up.
This allowed CNR International to remotely close and open, then
Figure 3. A technician with an eRED.
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OILFIELD TECHNOLOGY
August 2011
perform various pressure tests against the eREDs without any
form of intervention. The reduction in wireline rig-ups and runs
for this operation reduced the overall cost and planned timing
of the completion. Another positive point of this operation was
the reduced exposure to potential waiting-on-weather to rig-up
slickline and all the associated risks with wireline operations. The
results can be summarised as follows:
x In total at least 18 hrs of rig time was saved utilising eREDs.
x Both eREDs were pre-installed onshore, saving one wireline
rig-up and rig-down and five wireline runs.
x Less exposure to potential waiting-on-weather time.
x Reduced associated risk involved with rigging up PCE and
running slickline.
x Various pressure tests were completed and the well was
circulated to completion fluid without the need for any
additional intervention using eREDs.
Case study two
Background
The York East well is situated within the southern North Sea
block 47/3a. York is an undeveloped gas eld located in the
southern North Sea blocks 47/2a, 47/3a, 47/3d and 47/3e
immediately north of the Rough gas storage eld and 20 km
Figure 4. Diagram showing dual eRED set-up utilised for CNR in the
Ninian eld in the northern North Sea (left) and an eRED used during
well testing as a remote downhole shut-in valve (right).
southwest from the BP operated Minerva Hub. The eld lies in
150 ft of water depth and once completed the York development
will consist of a normally unmanned installation (NUI) with a gas
export pipeline tied back to land.
Centrica planned to drill, complete, test and suspend the
well with gas across the reservoir face until recompletion at a
later date after the platform is installed over the location.
The operation
The well was drilled to a TD of 14 130 ft MD. A wellbore clean-up
and displacement was then completed prior to deploying the
sand face completion across the reservoir. After the sand face
completion was installed, the upper test string was run with coil
tubing rigged up to pump nitrogen to aid in the clean-up of the
well. The nitrogen was pumped from the toe of the well to clean
up the horizontal section, and pumping continued until the well
was sufciently unloaded and owing naturally.
After the coil tubing was recovered, two downhole memory
gauges were run and set in the lower 3.688 in. AR nipple and
the well opened up for the clean-up phase. The well was then
shut in for a build-up period prior to running the eRED in the
upper 3.688 in. AF nipple prole with dual gauges hanging off the
bottom.
Above the lower set nipple there was a perforated pup to
allow ow to surface. The eRED was used during the well test
phase as a remote downhole shut-in valve with two downhole
memory gauges attached to the bottom sub of the eRED. This
assembly includes an eRED, gauges, pinned melon equalising
assembly, crossover and a 3.688 in. AF lock.
The well was owed via the rig well test spread and the
eRED was programmed to close after 59 hrs, once the required
step rate test had been completed. It would remain closed for
36 hrs as per the well test programme to obtain the required
downhole build-up pressure data, and upon reaching the
36 hrs, the eRED opened and was recovered using slickline.
Once the tools were at surface, the data was downloaded from
the downhole gauges and the devices own integrated sensor
log. The eRED log le data was sent back to Red Spider for
conversion to pressure versus time graphs, which were then
passed on to Centrica for cross reference purposes with the
downhole gauge data.
Results
The eRED functioned (opened then closed) as per the designed
programme for the ow and pressure build-up periods on
the York East well. The reduction in wireline rig-ups and
operational footage reduced the overall complexity and cost of
the operation. Another positive point of this operation was the
reduced exposure to weather delays whilst rigging up slickline
and the general risks associated with wireline operations. The
results can be summarised as follows:
x The eRED function times could be changed on the rig to
suit the pressure build-up and flow period changes.
x Less exposure to potential waiting-on-weather time.
x Reduction in the associated risk involved with rigging up
PCE and running slickline.
x Excellent data obtained for the companys subsurface team
with downhole shut-in, build-up and step rate test data.
The downhole shut-in pressures obtained would not have
been possible with conventional gauges and as such, have
provided the reservoir engineer additional data for well test
analysis.
O T
COMPARING
COMPLETIONS
Paul Higginson, Packers Plus Energy Services, UK,
demonstrates the benefits of OHMS systems.
S
ince their introduction in 2001, many operators have
chosen to complete their wells with open hole,
multi-stage systems (OHMS), due to the time and cost
savings compared to conventional multi-stage fracturing
methods, such as cased hole or plug and perf (CHPP).
The operational efciencies provided by OHMS have been
documented in various unconventional (low permeability)
formation types around the world.
1
OHMS have also been applied to offshore completions in
South America, West Africa, the Black Sea and the North Sea
because of the even higher potential for cost savings. This
article is a brief introduction and comparison of the OHMS
and CHPP completion techniques as applied to multi-stage
fracturing of offshore wells. Two case study examples are
presented, highlighting the time and cost savings of OHMS in
offshore Scotland and offshore Romania.
51
52
OILFIELD TECHNOLOGY
August 2011
Offshore CHPP completion method
The specic CHPP method adopted in the North Sea
and Europe is slightly different to the method used in
North America, which employs pump down bridge plugs and
is performed at aggressive rates, often leading to signicant
over displacement bad practice for any fracture treatment.
2
The method used in the North Sea involves running into
a cleaned out, cased and cemented well with perforating
guns on coiled tubing (CT) to regain access to the reservoir.
After shooting the rst set of perforations, the CT is tripped
out. The stimulation treatment is then pumped with fracture
uid and proppant, which is left signicantly under-displaced
above the rst set of perforations. At this point, pressure
squeezes are applied to the tubing in order to compact the
proppant until a high pressure plug is formed.
The CT is then run in hole with a clean-up bottom hole
assembly (BHA) to dress the top of the sand plug to a
certain distance above the rst set of perforations. The CT is
then tripped out in order to change back over to perforation
guns, and the whole process is repeated for the remaining
stages. After all the stages are treated, the lower completion
is left full of proppant. The nal operation is to trip in a
clean-up BHA with CT to remove all of the excess proppant,
at which time the well is ready to be put onto production or
well test.
Offshore OHMS completion method
Although they can also be run in cased hole applications,
OHMS are typically run in open hole, taking the place of the
cemented liner described in the previous section. Cementing
and perforating are not required and CT intervention is
only required as a contingency, not as an integral part of
the planned operations. The OHMS liner consists of a liner
Figure 1. Open hole, multi-stage fracturing system.
hanger, open hole mechanical packers, fracture ports, an open
hole anchor and a toe circulation assembly (Figure 1).
Prior to running the OHMS liner, a reamer run is performed
to ensure the hole is in suitable condition. The OHMS liner is RIH
in approximately the same time as a cemented liner would be,
and can be circulated through while it is RIH and once installed
to total depth (TD). After the nal displacement is complete,
a ball is pumped to the toe circulation assembly to close off
the circulation path. This allows the tubing to be pressured
up to set the liner hanger and subsequently the open hole
mechanical packers and anchor.
At this point the running string is tripped out and the upper
completion is run. The tree is in place and the stimulation
equipment is rigged on top of it. The rst stage is opened by
pressuring up the tubing beyond the setting pressure of the
open hole mechanical packers. Once opened, a step rate test
and/or mini frac can be performed prior to pumping the rst
stimulation. The remaining stages are opened using balls of
increasing size that land on correspondingly sized fracture port
ball seats, allowing pressure to build and open the port sleeves.
CHPP versus OHMS comparison
The OHMS method is signicantly more efcient than CHPP, as
shown by the time comparison in Figure 2. OHMS are designed
so that all stimulation stages can be performed continuously
without stopping. However, stopping between stimulation jobs
is not an issue and in offshore applications this may be required
in order to reload the stimulation boat.
In many offshore locations, such as in the North Sea, other
factors come into play, such as logistics of frac boats and
proppant/uid capacity. The timeline in Figure 2 takes into
account a typical ve-stage treatment in the North Sea with
typical proppant/uid volumes and average frac boat capacity.
The decrease in operational time with OHMS not only results in
cost savings, but also lowers risks to health and safety, as less
time is spent performing high risk operations, such as the use
of perforating guns.
After OHMS stimulation is complete, the well can be turned
over to production or well test. As the well can be immediately
owed back, stimulation uids are in contact with the reservoir
for signicantly less time, thus mitigating induced damage to
the reservoir. The speed at which the stimulation treatments
can be placed, the reduction of uid loading on the reservoir
and under displacement are key benets of OHMS and
inherently follow good simulation practices that have been
developed over decades of hydraulic fracturing.
An unexpected benet that operators have experienced
using OHMS completions in unconventional reservoirs, is a
dramatic reduction of excessive fracture initiation pressure.
3
Using CHPP, it was common that some hydraulic fracture
treatments could not be initiated simply due to excessively
high breakdown pressure.
4
Since fractures are able to initiate
anywhere within the open hole stage section,
the fracture will take the path of least resistance
where the breakdown pressure is the lowest.
This in turn reduces the potential for fracture
tortuosity.
Over the last three years, several papers
have been written comparing offset wells
completed using CHPP or OHMS.
3, 5-8
These
papers show that in addition to the operational
efciencies, better production is gained
from OHMS as compared to CHPP. From a
theoretical, modelling perspective this makes
intuitive sense, as OHMS completions would
allow production from the open hole wellbore,
including natural fractures.
9
Offshore OHMS applications
North Sea: offshore Scotland
The Eastern Area Trough Project (ETAP) is a
network of nine oil and gas elds in the central
North Sea that has been in development since
the late 1990s. One of the reservoirs consists of
a naturally fractured chalk reservoir at a depth
of 1250 2800 m with low matrix permeability,
requiring stimulation for economic production.
Historically, wells were cased and cemented with
limited entry perforation clusters at each natural
fracture location and then stimulated with large
acid treatments using ball sealer diversion.
A sidetrack well presented a number of
unique challenges because the density of natural
fractures could not be determined prior to drilling.
The operator wanted to segment the lateral into
isolated sections to allow for sequential,
high-rate acid stimulations. A seven-stage
open hole StageFRAC system from
Packers Plus Energy Services Inc. was chosen
because it provided focused fracturing, allowed
production contribution from the matrix and
eliminated the cost and risk of cementing and
perforating.
The installation and subsequent stimulation treatment were
performed for the rst time from a semi-submersible rig and was
completed 11 days ahead of schedule compared to the previous
plug and perf operations. Not only were time and cost savings
realised through the completion and stimulation operation, but
the well came in signicantly higher than expected.
Black Sea: offshore Romania
The Lebada Vest Field is situated in the Black Sea approximately
95 km offshore from Constanta, Romania. The zone of interest
is limestone laminated with streaks of permeability ranging from
0.1 2 mD and porosity between 15 22%. This oil reservoir is
situated close to an undesirable gas cap.
The operator wanted to multi-stage stimulate the well
without fracturing into the gas cap. Previously, the wells had
been completed with cemented perforated liners and
polymer-based, conventional fracture uids prepared with fresh
water. The latter required that the treatment boat return to port
after each stimulation because the fracture uid had to be
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54
OILFIELD TECHNOLOGY
August 2011
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Figure 2. Timeline comparison of CHPP and OHMS
completion methods for a ve-stage offshore stimulation.
batch-mixed into the boat tanks at the dock. This process
required an average of three days for each fracture treatment.
After evaluating all completion options, the operator chose to
run a three-stage open hole StageFRAC system. Due to the lack of
a dedicated treatment boat, a supply boat was modied to hold
land-based fracture equipment. The three-stage stimulation was
executed in one day with eight hours of pump time versus an
estimated nine days for a conventional cemented liner, plug and
perf completion.
After treatment, the well became the record producer in the
Black Sea and its stabilised production rate was 2.5 times the best
offset well in Lebada Vest completed with conventional methods.
10
Conclusion
The time savings realised through OHMS completions illustrated
in Figure 2 and demonstrated by the case study examples
translate into signicant cost savings. Typical rig spread rates for
the North Sea range from US$ 150 000 to US$ 500 000+/day,
translating into US$ 6.5 million for 13 days saved on a ve-stage
job. Additionally, stimulation costs are reduced by requiring a
shorter working window for the stimulation vessel. Availability of
stimulation vessels can be an issue in certain areas, so adopting
more efcient methods can also increase the chances of
obtaining these services.
As of March this year, over 6200 StageFRAC systems
have been run worldwide in a variety of formations, both on
and offshore. Combined with signicant time savings, this
demonstrates that OHMS systems provide multiple benets
for operators looking to reduce risk, increase productivity and
improve well economics in an offshore setting.
O T
References
1. Snyder, D. and Seale, R., Optimisation of Completions in Unconventional
Reservoirs for Higher Ultimate Recovery: Paper SPE 142729, presented
at the SPE Middle East Unconventional Gas Conference and Exhibition
(Muscat, Oman, 31 January 2 February, 2011).
2. Themig, D., Advances in OH Multistage Fracturing Systems A Return to
Good Frac-Treatment Practices, Technology Update (May, 2010), p. 26.
3. Lohoefer, D., Snyder, D.J. and Seale, R., Long-Term Comparison
of Production Results from Open Hole and Cemented Multi-Stage
Completions in the Barnett Shale: Paper IADC/SPE 136196, presented at
the IADC/SPE Asia Pacific Drilling Technology Conference (Ho Chi Minh
City, Vietnam, 1 3 November, 2010).
4. Ketter, A.A., Daniels, J.L., Heinze, J.R. and Waters, G., A Field Study
Optimizing Completion Strategies for Fracture Initiation in Barnett
Shale: Paper SPE 103232, presented at the 2006 SPE Annual Technical
Conference and Exhibition (San Antonio, Texas, 24 27 September, 2006).
5. Samuelson M.L., Akinwande T., Connell R., Grossman, R.
and Strickland B., Optimizing Horizontal Completions in the
Cleveland Tight Gas Sand: Paper SPE 113487, presented at the
CIPC/SPE Gas Technology Symposium 2008 Joint Conference
(Alberta, 16 19 June, 2008).
6. Edwards, J.W.M., Braxton, D.K. and Smith, V., Tight Gas Multi-stage
Horizontal Completion Technology in the Granite Wash: Paper SPE
138445, presented at the SPE Tight Gas Completions Conference
(San Antonio, Texas, 2 3 November, 2010).
7. Houston, M., McCallister, M., Jany, J., and Audet J., Next
Generation Multi-Stage Completion Technology and Risk Sharing
Accelerates Development of the Bakken Play: Paper SPE 135584,
presented at the SPE Annual Technical Conference and Exhibition
(Florence, Italy, 19 22 September, 2010).
8. Lohoefer, D., Snyder, D.J., Seale, R. and Themig, D., Comparative
Study of Cemented Versus Uncemented Multi-Stage Fractured Wells
in the Barnett Shale: Paper SPE 135386, presented at the SPE Annual
Technical Conference (Florence, Italy, 19 22 September, 2010).
9. Augustine, J.R., Openhole versus Cemented Completions for Horizontal
Wells with Transverse Fractures: An Analytical Comparison. Paper SPE
142279, presented at the SPE Production and Operations Symposium
(Oklahoma City, 27 29 March, 2011).
10. Bukovac, T., Belhouas, R., Dragomir, A., Perez, D., Ghita, V. and Webel, C.,
Successful Multistage, Hydraulic Fracturing Treatments Using a Seawater-
Based Polymer-Free Fluid System Executed From a Supply Vessel;
Lebada Vest Field, Black Sea Offshore Romania: Paper SPE 121204,
presented at the 2009 SPE EUROPEC/EAGE Annual Conference and
Exhibition (Amsterdam, The Netherlands, 8 11 June, 2009).
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www. ener gygl obal . com/ s ect or s
LEADER OF THE PACK
W
ith todays drilling technology, horizontal and deviated
wells are routinely drilled and developed over long
distances. The technology rened just over a decade
ago has had a signicant impact on how reservoirs are drained
today, both in terms of how the wells are developed and how
they are managed. Today, wellbores can be driven in even
very thin-bedded undulating oil and gas carrying formations.
This, combined with the continuous demand for more oil and
gas, has stimulated the development of technologies able to
pursue the new challenges and not least to do so in an optimal
manner.
Optimising reservoir drainage
Optimising reservoir drainage relies on a number of factors,
not least on how the well is designed and the components that
are installed. The ability to congure and recongure a well
to match the characteristics of the reservoir is essential for
optimising the productivity, not least as smaller and more widely
spread reservoirs are exploited. In general, wells underperform
compared to what can be physically recovered due to
inadequate technology. The actual recovery rate is dictated
by costs, technology and operational considerations. Based
on these considerations, different development approaches
may be adopted; from smarter wells with built-in controllability
used to congure and adapt the production over time, to smart
intervention where technologically relatively simple wells are
maintained and congured to address the evolving conditions.
For both approaches, the choice of technology is decisive and
inuences both cost recovery and safety aspects.
Traversing the formation
The early days, where wells could be immersed and oil extracted
from large homogeneous reservoirs are long gone. Fields
developed today necessitate a much more rened approach
where oil and gas bearing layers can be separated from water
bearing layers that have a negative impact on the production.
Isolating and sealing such zones is traditionally done with
packers and cement. Extended horizontal wells pose a special
challenge in this context. In vertical or more moderately deviated
wells, gravity can be used positively during all phases of the
well. With heavily deviated and horizontal wells, gravity has the
opposite effect and becomes an obstacle. Casings, valves and
Michael MacDonald Arnskov, Welltec, Denmark, discusses how next generation
well packers pave the way for fast and reliable well completion by using
components that eliminate some of the issues associated with conventional
approaches when isolating and managing oil and gas bearing layers.
55
56
OILFIELD TECHNOLOGY
August 2011
other components required to complete the well and bring it
onstream cannot simply be lowered in to the borehole but have
to be pushed with force without getting jammed.
Safety is in this context paramount and the important
sealing of the annulus between the casing and borehole
becomes very tricky. Historically, cementing has been the
primary means to seal the borehole against the casing or
to block off sand faces and similar. For zonal isolation this
is done by inserting packers that seal the void between the
casing and the borehole, after which cement is injected and
cured. The virtues of cement cannot be fully exploited in
extended horizontal wells as it physically impossible to pump
cement over such long distances, neither from a mechanical or
operational aspect.
These difcult trajectories combined with unconventional
developments such as Steam Assisted Gravity Drive (SAGD),
gas shales and geothermal wells, has led the industry to develop
new annulus isolation solutions where prevailing solutions are
inadequate.
Todays packers
Swellable packers dominate annulus isolation solutions, where
the physical properties of elastomers are exploited to provide
a seal between casing and borehole when exposed to uids.
These packers typically come as short sections of tubes
wrapped in elastomers, which are inserted in the casing or liner
as they are lowered down into the borehole and nally placed at
the desired location. The elastomers will gradually start to swell
as they are exposed to water, oil or a mix of both depending on
the design and will gradually establish the seal once adequate
contact with the borehole or casing has been attained.
Swellable packers mold themselves and can autonomously
swell multiple times, thereby in effect adapt to changes caused
if a formation should subside or compact. One of the issues
the well designer faces is selecting the right elastomer for the
job. The well, formation and uid properties must be evaluated
carefully in order to select the most appropriate elastomer. This
also includes any possible changes during the life of the well
which have to be considered.
Swellable packers have many virtues; however, there are
also some less desirable characteristics which have motivated
further development. The type of elastomer must be compatible
with the well uid in order to swell as designed. The elastomers
start to swell as soon as they get in contact with the triggering
uid, which makes it difcult to control the process with a risk
that premature swelling occurs, in which event the casing or liner
could get stuck with serious implications. By the same token the
actual time required to achieve the desired swell can be quite
uncertain, meaning that 20 30 days may be required before the
well can come onstream.
The self-healing properties of the elastomers are particularly
attractive where there is a risk of washouts or similar changes
as the elastomers will swell further and adapt to the prevailing
conditions. In the long-term there may be some slight
uncertainty as the properties of the elastomers are degradable
over time and the quality decays as it becomes more brittle.
Tomorrows packers
The shortcomings of elastomers have stimulated the
development of packers which retain the qualities of the
swellable packers and eliminate the limitations. This is achieved
by engineering a seal that is backed by a hydraulically expanded
steel body, which when exposed to pressure, expands and sets
against the borehole creating a tight and impenetrable seal. The
expandable seal is mounted on a pipe section, which is included
in the casing or liner as an in-line component. The hydraulic
expansion of the sleeve not only conforms to the open hole, but
as the degree of expansion increases to cover badly washed out
holes, then so does the differential pressure capabilities of the
packer due to the work hardening processes of the metal sleeve
during the expansion process. The utilised technology is known
as hydro forming and was developed in the 1950s. Today it is
used extensively by a wide range of industries.
Hydro forming provides a number of benets. The actual
packers are mounted between the various casing and liner
sections and lowered into the well section by section. Once
in place the well is put under pressure and the expandable
seals begin to inate until contact is made with the borehole
preventing further expansion.
By using seals that are activated from the surface, a new
level of control and reliability is achieved. Furthermore, a much
faster completion can be achieved as the actual operation can
be carried out in less than an hour depending on the conditions.
If cement is to be used then this is completed as normal
and the cement is fed into the well. Within a few minutes of the
cement plug being bumped, additional pressure is applied to
the well to expand the packers prior to the cement setting. The
hydraulic expansion of the packer in the wet cement ensures
compliance within the open hole, eliminating the possibility of
cement channels.
Micro annulus eliminated
When the packer is deployed in a cemented liner or casing,
the risk of micro annulus between the casing and cement is
removed. The controlled centre out expansion of the packer
to the formation will extrude the cement away, leaving only the
packer to formation contact. The relative high plasticity of the
formation in comparison to the steel will ensure that steel to
formation contact remains after the release of the expansion
pressure. The removal of micro annulus will prevent migration of
uid or gas behind cemented liners or these new next generation
packers.
The well design simplicity reduces the capital expenditure,
minimises the equipment risk during deployment and maintains
the long term exibility for future work over, side track and
eventual well abandonment.
This new approach enables the oil and gas industry to
develop and bring wells on much faster than what has been
possible earlier and effectively offers the industry an annular
barrier solution, which provides a metal barrier to prevent
annular ow.
Field tests under way
The global well service provider, Welltec, has developed a
range of packers based on the hydro forming technology and
is currently conducting eld tests to complete the numerous
laboratory qualication and verication tests which have been
conducted to prove that the packers full the requirements.
The actual data shows that the capabilities of the design
exceed the requirements and that the vision of developing and
manufacturing a packer based on these principles is more than
viable. They are indeed the next generation.
O T
WIRELESS WELLBORE
GARTH NALDRETT, TENDEKA, UK AND TOR INGE SEN, TENDEKA,
NORWAY, EXPLORE WIRELESS OPTIONS FOR MONITORING AND CONTROL.
P
ermanent downhole monitoring is by no means new to the oil and gas industry. The
earliest SPE paper reference for a permanently cabled pressure and temperature
monitoring system dates back to 1963, yet despite its maturity, industry uptake of
permanent cabled monitoring systems is relatively low. The trend of increasing wellbore
complexity for extended reservoir contact, and greater reservoir heterogeneity along the
contact, are demanding improved monitoring and control solutions.
Traditionally the only option for enabling these solutions was the previously mentioned
cabled systems, limiting the application of intelligent well technology to new installations or
workovers. Cabled systems are also not always possible in new installations, especially where
the completion is discontinuous, such as with two-trip completions or multilateral wells. Slim
hole or monobore completions may also not allow cables to be deployed along the tubing
string. These complexities of cabled systems, along with the cable cost and associated
nonproductive time (NPT), means that such cabled systems have relatively low overall market
penetration.
However, new wireless technology is proving a more exible alternative and addressing all
of these issues. Tendeka has over seven years of experience in the development, testing and
deployment of wireless wellbore solutions as a feasible alternative to cabled systems. One of
the rst incarnations of a wireless system was the Tendeka Wireless Gauge, with systems being
deployed offshore in the North Sea since 2008. The wireless gauge allows real time owing
bottom hole pressure (FBHP) to be efciently transmitted to surface, an attractive option for
wells where the cabled gauge system has failed, or was not initially installed.
SOLUTIONS
57
58
OILFIELD TECHNOLOGY
August 2011
Wireless technology
The Tendeka wireless system uses pressure pulses to transmit
data from the lower completion to surface. Through a novel
tool design, the wells production is partially choked for a very
short duration to create a pressure pulse that is detectable
on the surface pressure gauge. This method has a number of
advantages, in particular having very low power consumption,
since the wells energy is being used to transmit data to surface.
The system also requires no additional surface installation
or pickup, since an existing tubing head pressure gauge
can be used to detect the pulse train. This means that for
the majority of operators, the system can be deployed by a
single intervention, allowing for highly accurate data to be sourced
almost instantaneously for a fraction of the cost of a recompletion.
Compared with a memory gauge system, it allows data to be
collected in real time and provides a continuous conrmation of
operation.
Using a wireline set packer to deploy the system, the gauge
can be set in a blank pipe, therefore giving the optimal freedom
with regards to installation depth. The alternative is to set it using
a wireline set lock, which is generally more cost-effective than the
wireline set packer option, however, this does limit the installation
location to where there are wireline nipple proles in the completion.
The gauge system can be installed as close to the producing interval
as required.
The unique nature of using pressure pulse transmission is the
ease of installation. No retrotting of topside equipment is required,
avoiding many of the technical and contractual issues when
introducing a new monitoring system. The system is also extremely
power efcient, as it is the reservoirs inherent energy (not that of
the battery pack) being used for carrying pulses from bottomhole
to surface. The power consumption does, therefore, not increase at
greater depth passing on a major benet to the customer in terms of
longer battery life and tool operation.
A common misconception,
most likely due to limitations
in MWD telemetry systems, is
that pressure pulses cannot be
utilised in the presence of free
gas. Signicant testing, modelling
and eld testing have shown that
the method is equally effective in
oil and gas producing wells, with
some of the latest systems even
being designed for operation in
water injection wells.
Wireless gauge
deployment
A major operator in the
North Sea recently deployed the
Retrot Wireless Pressure and
Temperature Gauge at a depth
of 2200 m in a low pressure
(32 bar) gas well offshore
Norway. The existing wellhead
pressure sensor was used to
capture the wireless signal
and extract the data, therefore
no extra infrastructure was
required.
During the installation planning, questions arose regarding
the effects of free gas attenuating the signal. However, once the
wireless gauge was installed at depth, the signal pulse proved
to be easily distinguishable. The application was especially
challenging as the well was a marginal producer and the wellhead
pressure had large background pressure variations due to the
limited well deliverability. Despite these conditions, pressure pulse
transmission proved effective. Therefore, the wireless technology
has been qualied to transmit pressure pulse based signals even
in low pressure gas wells, thereby demonstrating that the wireless
downhole telemetry can be applied in nearly all uid compositions
and ow regimes. The downhole tool has considerable built-in
intelligence, such that the choking mechanism is constantly
modied according to the owing conditions. Even if the well
starts to signicantly deplete while the wireless downhole gauge is
installed, the gauge itself will modify its pressure pulsing method to
ensure a detectable pulse train is transmitted to surface.
The wireless gauge is unable to transmit signals in a
non-owing or shut-in well due to an actual ow regime being
required to produce the pressure pulses. The tool can be
programmed to record pressure build-up (PBU) data during shut-in
periods, and once well production is restarted the stored data can
be transmitted to surface. During this actual installation, there were
periods of shut-in while surface maintenance was conducted. The
tool successfully recognised the shut-in events and entered its
power-saving hibernation mode. When the well resumed
production, the technology reactivated itself and the rst telegrams
transmitted following the restart, gave accurate shut-in pressure
data to surface.
This application, and two others undertaken at the time,
demonstrated that the system functions not only in oil wells, but
also in gas wells and wells with a high gas/oil ratio. During the
trials, it was demonstrated that the wireless gauge could function
in wells with slug ow and high levels of pressure/noise variations
Figure 1. Comparisons of topside decoded data to the WirelessGauge internal log and third party
memory gauge.
KH=ako`Ylqgmf]]\&
Society of Petroleum Engineers
For more information about these events or other 5PE conferences,
workshops, and forums visit www.spe.org/events.
Mh[geaf_=mjgh]Yf\JmkkaY=n]flk
1IIX[MXLSXLIVTVSJIWWMSREPWXSPIEVREFSYXERHHMWGYWWXLIPEXIWX)4XIGLRMGEP
EHZERGIQIRXWEXXLIWIYTGSQMRK74)IZIRXW
68 September 2011 SPE Offshore Europe Aberdeen, UK
1215 September 2011 Well Integrity in the Operational Phase
A Lifetime Management Approach
Noordwijk, The Netherlands
1922 September 2011 North Sea and European Area Stimulation Berlin, Germany
2530 September 2011 Unlocking the Potential of Nanotechnology
for Exploration & Production
The Algarve, Portugal
27 October 2011 Shale Gas: Beyond Current Technologies and
Going Global
The Algarve, Portugal
914 October 2011 CO
2
Geological Storage: Will We Be Ready
In Time?
The Algarve, Portugal
1820 October 2011 SPE Arctic and Extreme Environments Moscow, Russia
57 December 2011 The New FrontierBrowneld Opportunities London, UK
on surface. During shut-in periods, the tool successfully recorded
the shut-in data and transmitted it to surface when production was
resumed.
Injection rate monitoring
The downhole pressure temperature gauge is also able to operate
in water injection wells, where a back pressure is created instead of
the injection uid, and in a similar manner generating a detectable
positive pressure pulse train on the surface.
A recent development in the wireless technology products
now also allows the measurement of injection rate. By measuring
the pressure drop across a modied venturi, an accurate ow
rate can be calculated. Flow loop testing has veried the method
is extremely accurate when used in single phase uids, such as
with water injection applications. This allows the gauge to be run
between injection intervals, reporting on the pressure, temperature
and rate split between zones. All this information is then transmitted
to the surface using wireless telemetry.
Wireless activation
The susceptibility of downhole mechanical pressure counting
activation mechanisms to debris ingress has resulted in numerous
in-well failures of these systems. Due to these limitations and
the resulting lost time incidents, a major operating company
requesting an alternative electronic activation method approached
Tendeka.
Using a built-in pressure transducer, the wireless technology
is also able to detect pressure pulses from the surface. Unlike
mechanical systems, which become jammed when covered
in debris, electronic systems are still able to register pressure
changes applied from surface even through a few metres of barite
or other wellbore debris. Furthermore, electronic systems are
fully programmable to detect a pressure sequence that cannot be
accidentally created in normal operations. In the event of pressure
pulse transmission not reaching the tool, the electronics can be
programmed to activate at a preset time interval. The nal backup
is an acoustic pickup, which receives a signal from a downhole
tool hundreds of metres away.
Two systems have been developed based on the
surface-to-bottom hole wireless communication. The rst
system allows for the opening of a completion plug without
the need for intervention. The development was driven by an
operating company struggling to recover completion plugs after
high pressure stimulation from above. It is suspected the high
differential pressure across the plug causes sufcient deformation
for the completion plug to become permanently attached to
the nipple prole. In the replacement wireless system, rather
than recovering the completion plug, the wireless plug opens its
ow ports in response to the programmed signature, allowing
production or injection to take place across the device. This
not only saves the single wireline run to recover the plug, but a
potentially large shing operation for plugs that have become
permanently xed to the nipple prole.
The second wireless activation system provides a remote
ring signal for downhole barrier plugs, providing a reliable
alternative to the suppliers mechanical ratchet style activation.
Downhole barrier plugs are especially susceptible to debris since
any fallout while running the upper completion ends up on top of
the barrier plug and around its mechanical activation port. The
wireless pressure monitoring system does not suffer from these
problems for reasons mentioned above. The wireless activation
system has a substantially charged pressure chamber that is
released to activate the barrier plug on receipt of the appropriate
signalling from surface.
Wireless inflow control valve
The latest developments in wireless technology now allow these
systems to operate inow control valves. This will bring with it a
step change in the way operating companies design, test, stimulate
and operate maximum reservoir contact wells. Locations that
could not previously be controlled, such as within the laterals of a
multilateral well, or at the furthest extent of a long open hole lateral,
can now be controlled using wireless signalling. Incorporating zonal
isolation packers and inow control devices with that of the wireless
intelligent downhole devices, allows new and effective methods
of reservoir inow control to be developed. As each wireless
inow control valve is autonomous no cabling is required between
devices, allowing a large cost saving in control lines and downhole
connectors. The drilling department is also offered more exibility
in rotating the completion while running in hole without risking
damage to externally strapped control lines.
Conclusion
Wireless telemetry is equally effective for transmitting data from
bottom hole to surface, or from surface to bottom hole. Top down
communication allows for more effective wireless activation devices
to be developed for stimulation control, or for controlling downhole
barrier plugs. The realisation of wireless inow control valves will
enable completely new and novel methods for completing complex
wells at lower cost, less disruption and lower drilling risk.
O T
www. energygl obal . com
Sebastiano Barbarino,
OVS Group, USA, explains how
asset performance can be increased
through workflow technology utilising
existing information and applications.
Delivering on
P
emexs Samaria-Luna asset,
located in the southern state of
Tabasco in Mexico, produces
> 200 000 bpd, with over 200 wells
on both natural ow and gas lift. Gas
for lift operations is supplied by
skid-mounted booster compressors
at the wellhead.
The challenges
x Monitoring useable data from
multiple and often conflicting
sources of data.
x Integrating results with operational
data from modelling applications
provided by multiple vendors.
The solution
One Virtual Source (OVS) technology
combined automation of modelling
workows, real time monitoring,
surveillance-by-exception (SBE),
and virtual integration of eight
data sources, including real time,
operational, well test, eld data, and
others, into a single and user-friendly
environment.
DATA SOURCES
AND APPLICATIONS
61
62
OILFIELD TECHNOLOGY
August 2011
The results
x Standardised engineering processes across the asset, with
a heavy emphasis on automation and analytics.
x Integrated reporting and SBE methods ensure engineers
time is now focused on engineering issues, not data
gathering.
x Live links to all sources ensure that data duplication is no
longer an issue.
x Workow-based automation has brought the various
preexisting well, production network, and reservoir
modelling tools online, so they can be incorporated into
daily operational activities and decision making.
The intangible benets of standardising processes and
providing readily available access to information are seen
as key enablers of the more directly measurable economic
benets.
Background
The Samaria-Luna asset has multiple data sources eight
primary data sources that collect information including
operational data, ofcial data, real time data, laboratory uid
samples, corporate data and various data les in Excel for
nitrogen, well test, reservoir pressures, among others.
Well models are maintained to support decisions regarding
production schedule changes, well performance analysis and
optimisation efforts. This necessitates that the primary well
models are maintained by a single owner to avoid inconsistency
in updates and interpretations.
A large number of man hours were required to assemble the
necessary information before effective analyses were made of
changing well performance trends and problem predications.
This also applied to the effort required to update and maintain
the well models in an evergreen state.
The primary requirements of this project were to deliver a
software platform for engineering workows and analytics that
would:
x Virtually integrate all information from the Samaria-Luna
asset. A virtual integration was preferred in order to avoid
the high costs and disruption of migrating to a data
warehouse.
x Perform unattended SBE of critical reservoir and operational
variables using both user and model-dened operating
envelopes.
Figure 1. The key building blocks to improving asset performance.
x Deliver engineering workows to automate and
standardise key engineering processes, including nodal
analysis, gas lift optimisation, and virtual well metering.
x Assure rapid uptake of the new software platform by
providing an innovative and user-friendly interface
capable of providing a complete management solution
from acquisition through analysis to decision.
Workflow automation
The asset required three types of workow automation:
Surveillance-by-exception automation. The SBE
requirement is to provide a system for unattended monitoring
of critical operational data. Exceptions to operating envelopes
will result in alarms and email-based notications to asset
owners when critical situations are identied. Critical to the
success of such a solution, the operating envelopes would
be dened based on both user-adjustable and model-based
criteria.
Prior to implementation, it was noted that the varied
sources of data could present a potential challenge to
successfully delivering this requirement. As not all wells were
equipped with real time sensors, the SBE system had to
be intelligent enough to recognise the correct data source
on a well-by-well basis (e.g. real time sensors vs. eld data
capture). Pemexs technical team also desired that the
same workow methodology be employed across the entire
asset; all evaluation and reporting had to be standardised,
irrespective of the actual data source in use. Once identied,
this challenge could be designed for and easily addressed
during implementation.
Well modelling automation. The primary requirement for
well modelling automation was to provide the capability to
automatically run well-by-well optimisation using existing
modelling tools. In order to achieve this, a number of
individual workows were required:
x Well test validation.
x Sensitivity analysis for model ne-tuning.
x Model adjustment.
x Optimisation by well.
x Tubing head pressure validation.
It was required that all of these workows be sufciently
autonomous to automatically run when a new well test is
acquired. The workows must keep a log of the results and
store the historical evaluations so the engineers could later
analyse them in conjunction with alarms and other available
operational data.
Virtual well metering. Virtual well metering was a further
requirement for the system. Using the evergreen models, the
system had to generate estimates of individual three phase
well ow rates based on the current operation. The desired
frequency of the virtual ow rate estimates was daily.
The technology
The overarching principle of this project was to rapidly deliver
a user-friendly solution for accessing and analysing data, and
automating standard engineering workows. Pemex desired
to preserve and utilise all existing data and application
infrastructure to minimise the technical and economic costs
of the project. This approach would provide the immediate
benets of a fully integrated solution with a minimum of time
and effort.
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64
OILFIELD TECHNOLOGY
August 2011
The solution implemented was based on the use of
the commercial platform OVS that had been successfully
implemented in a number of other assets in Pemex. The platform
addressed the requirement to integrate all existing data sources
and applications into a single working environment, without
changing the existing infrastructure. Within weeks, the virtual
data integration effort was complete; the nal project, including
workow delivery, was successfully concluded within four
months an unprecedented achievement.
Implementation
Data integration phase
Once the requirements for the project had been dened,
implementation began by identifying and mapping all of the
available data sources into the software platform. The data
sources integrated were: SISRED, SICAVHI, SNIP, FINDER,
OSIsoft PI, well test, reservoir pressure and nitrogen injection.
In this early stage, it was noted that the critical well test data
was dispersed in a variety of Excel spreadsheets maintained
by different areas, all stored in different formats. Effort was
undertaken within the asset organisation to standardise the
process for well test data capture using the OVS platform, and
storing the data to a common database. This critical data was
made available at any time, and served as the starting point for
many of the new workows that were later developed. Migration
of historical data to this common data source also facilitated
standardised reporting and visibility of well test data across the
asset for all areas.
Access to real time data stored within the OSIsoft PI
historian provided much needed visibility into live data feeds
for the wells and booster compressors, which could be viewed
in real time within OVS, alongside other key data from different
sources and at different frequencies.
The implementation was developed in such a way as to
comply with a logic that represented the standard engineering
workow adopted by this organisation for production
optimisation and surveillance (Figure 2). Integrated displays
and reports provide signicant support to daily operational and
strategic decision making.
Surveillance phase
Using the integrated data access layer congured in the previous
phase, SBE criteria were congured to monitor data from
any available source in an unattended fashion. These criteria
consisted of complex, compound conditions that could be tuned
by end users, as well as model-based predictions.
Pemexs technical team specied a standardised set of
criteria for evaluating the critical operational variables on a
well-by-well basis. These same standards were applied in a
transparent fashion to end users, regardless of whether data was
captured manually or automatically by sensors.
The OVS platforms support for dynamic data sources
proved critical to meeting the requirements for standardised
SBE criteria and displays. With no additional input required by
the end user, the data integration layer transparently determines
the availability of data and the appropriate source from which
to read. All calculations and reporting have been standardised
across the asset, despite the underlying complexity.
Asset wide visualisation
With surveillance in place, standard reports and dashboards
were then delivered to increase visibility of performance metrics
across the asset. These reports combined roll ups of data and
alarms from all available sources for an integrated view of asset
performance a view previously unavailable due to the disparate
systems.
Engineering workflow automation
With the foundational data access capabilities in place,
conguration of the required engineering workows could
proceed. The intent of the workows was to not only reduce
the time spent manually gathering data, but to implement
standardised analysis procedures supported by automation. For
this project, the workows addressed nodal analysis for both gas
lifted and naturally owing oil wells.
Using a commercial nodal analysis application, the following
workows were addressed:
x Well test validation.
x Sensitivity analysis for model ne tuning.
x Model adjustment.
x Optimisation by well.
x Tubing head pressure validation.
x Virtual measurement.
While some of these processes had been previously
performed manually, the time required for data collection, model
updates, and aggregating the results in Excel was prohibitive for
frequent analysis. Supported by the OVS workow automation,
these processes are now performed automatically so engineers
can focus on value-added engineering work.
Well test validation
After every well test was taken and updated to the database,
the results were used to automatically validate whether the
accuracy of the model was within a user-dened tolerance.
This process was critical to establishing the validity of the
model to be used in further processes, such as optimisation
and virtual metering.
The workow gathers the operating variables at the time
of the well test, including THP, Qgi, GOR and water cut and
calculates the model predicted oil volume. If the model predicted
result was within a certain tolerance of the measured volume,
then the model was compliant and could be relied upon
for further analysis. The workow also extracted the model
Figure 2. Example of engineering workow for production
optimisation and surveillance.
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calculated performance curves so they were available for
comparisons and display.
The workow was scheduled to run automatically as new
well test data became available. No human action was required
for this process to be performed. The calculations were still
performed using the existing nodal analysis software and
models; OVS introduced the automation necessary to effectively
run this analysis on a wide scale.
Sensitivity analysis for model fine tuning
To better support the process of ne tuning the well models, a
workow was developed to standardise the model parameters
which may require updates. The workow iteratively sought
the proper adjustment to independent parameters necessary
to reproduce the test condition (e.g. 2% decrease in reservoir
pressure). Further reports were also available to assist the
engineer in validating this result using available data (e.g.
historical reservoir pressure measurements and forecasts).
For Samaria-Luna, the process was standardised to consider
six key model parameters, including:
x Gas/oil ratio.
x Water cut.
x Gas injection rate.
x Tubing head pressure.
x Choke.
x Reservoir pressure.
These model parameters were all selected based on level of
importance and measurement uncertainty.
Once the engineer had decided which parameter to adjust,
the adjustment was applied through the OVS Model Manager.
The OVS Model Manager recorded all changes and adjustments
made to the model so the audit trail could be consulted at any
time. Prior versions of the models were also archived for use
in future analysis and could be rolled back to undo a change if
necessary.
Optimisation by well
Using the validated well model, an optimisation process could
then be run to identify the optimal operating condition for each
well and quantify the resulting gain in oil production.
This standard process was automatically run every day for
every active well, using the wells current operating parameters
(WHP and Qinj Rate). The process is identical for wells with
real time data and those without.
To determine the optimal operating conditions, an iterative
process is run to calculate the wells maximum effective
production rate. The algorithm employed searched for the
asymptotic maximum, as opposed to the technical maximum,
in order to make the most efcient use of gas. The constraints
were congurable by the end users, and could be changed at
any time.
Tubing head pressure validation
As a further check on the validity of the model, the
model-predicted tubing head pressure was calculated using the
production line pressure measurements. If the model-predicted
THP is within a user-dened tolerance of the measured THP
(e.g. 10%), the results of the optimisation were considered valid.
If that validation failed, an alarm was generated and displayed
as an indication that the engineer could review the data and/or
model prior to applying any operational changes.
Virtual well metering
Using the evergreen well models, a virtual well metering
workow was run to predict the daily three phase ow rate for
each well. The ow rates were calculated based on the daily
operating conditions of each well.
Conclusion
The new production surveillance and optimisation tool described
has seen rapid uptake within the Samaria-Luna asset. The tool
is in daily use by engineers, and provides much needed visibility
into daily operations, enabling early response to problems and
proactive well management.
Integrated displays, unattended surveillance, and automated
engineering workows have all contributed to more effective
decision making. Processes have been standardised, data is
readily available, and uncertainty has been reduced. Productivity
of the engineers has greatly improved, and quantiable benets
are being realised.
The implementation has actively supported the continuous
growth and maintenance of production for this asset. Further
work is planned to employ this same technology to support both
reservoir engineering and well planning activities, with similar
anticipated benets.
O T
www. ener gygl obal . com/ s ect or s
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THE
MOBILE
OPTION
[COVER STORY]
Raphael Moscarello and Paul Kleinen,
Bredero Shaw, Canada and USA, and
Sean Haberer, ShawCor, Canada, present
a new, innovative modular mobile plant for
pipe coatings in this months cover story.
W
ith oil and gas exploration migrating to developing
countries, remote locations, and deep offshore
environments, there is an increased demand for
state-of-the-art, mobile facilities that reduce logistics costs,
mitigate risk and improve safety. This article describes the new
Brigden
ULTRA
.
Assessment
Assessment of existing xed offshore
platforms has to date been undertaken
in accordance with Section 17 of the
API RP2A 21
st
Edition. The Interim
Guidance for Assessment of Existing
Offshore Structures for Hurricane
Conditions API Bulletin 2INT-EX provides
updates and guidance specically
covering assessment initiators,
assessment approaches, site specic
criteria and mitigation.
Ultimate Strength Analysis is
recommended in API 2INT-EX using
linear or nonlinear techniques. Linear
analysis effectively is a design level code
check analysis with all safety factors
removed. The dead load, equipment
and environmental load are applied
and each component of the structure
is checked for capacity. This type of
analysis is therefore component-based
and does not provide an indication of the
platforms overall robustness. A nonlinear
Ultimate Strength Analysis (Pushover)
utilises the same loading and ramps up
the environmental load until collapse is
reached. As members in the structure
become over-stressed, forces are
redistributed until there is no redundancy
Figure 7. South Marsh 205 B
Platform reefed in place in 525ft
water depth. Source: Department
of Wildlife and Fisheries,
State of Louisiana.
Repairs
Assessment
Decommissioning
Inspection PIanning
Geographic Information System (GIS)
&28*$52))6+25(
SIM - Repairs - Assessment
StructuraI ConsuItants
PO Box 941536
Houston, TX 77094
T: 281-725-0942
F: 713-481-8852
www.cougaroffshore.com
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94
OILFIELD TECHNOLOGY
August 2011
left in the structure and collapse initiates. Even for older
structures that typically have small diameter and
thin-walled members, poor framing arrangements, in
service deterioration and low deck heights, a nonlinear
pushover analysis will provide a more representative
indication of robustness and certainly assist in optimising
mitigation options to reduce risk exposure. A more rigorous
pushover analysis can be carried out using irregular sea
states in the time domain as shown in Figure 5.
Mitigation of risk exposure
Mitigation is the only means to reduce risk exposure
and is a key element in the SIM system strategy. A
number of mitigation options are available including
decommissioning, well removal after permanent plug and
abandonment, strengthening, steelwork reduction in the
wave zone and/or an increased deck height. The Idle Iron
notice to lessees (NTL) effective 15 October 2010,
mandates the decommissioning of wells and platforms
no longer being used or no longer supporting other
operations. This was in direct response to the number
of platforms idle or on expired leases, the number of
platforms destroyed by hurricanes and the length of time it
has taken to decommission them.
As 2009 and 2010 were both quiet hurricane seasons
this enabled the GOM oil and gas industry to largely
recover and in a few cases even undertake pro-active
decommissioning campaigns specically to reduce risk
exposure. The NTL recognises there are approximately
650 platforms and approximately 3500 wells that are on
expired leases and/or are no longer of use or producing.
This represents a signicant risk exposure should
hurricane(s) enter the GOM.
Reefing
The number of articial reef sites in the GOM has increased
due to the number of destroyed platforms that have been
donated as special reef sites. Both the Texas Articial
Reef Programme (TARP) and the Louisiana Articial Reef
Programme (LARP) have approved special articial reef
site applications, in addition to approving numerous
applications for the donation of jackets to already
designated reef sites.
To date, in excess of 400 jackets have been reefed in
TARP and LARP. Reeng of the jacket and recycling of the
deck onshore is the norm and for larger platforms in water
Figure 8. GOM eet of platforms and pipelines as of April 2011.
Source: CougarGIS
.
depths greater than approximately 150 ft typically represents
a cost saving with less inherent risk. Once reefed, a minimum
clearance to sea surface is required for vessel clearance, so
the jacket must often be toppled or placed on its side. For
a few deeper water platforms in water depths greater than
400 500 ft, such as the SM205B computer model depiction
shown in Figure 7, the decision was made to reef it in place
by toppling the upper half of the jacket after removing the
deck for onshore recycling.
GOM uniqueness and market forces
Another signicant difference between the GOM and the
North Sea, as well as with other oil and gas regions, is the
number of xed platforms. Presently over 3500 structures
exist in the GOM representing approximately half the
structures installed since the rst facility was installed in
1937 (Figure 8). Each time a hurricane enters the GOM and
heads toward landfall, a signicant number of platforms
(Katrina/Rita > 3000 and Gustav/Ike > 2100) are either in
the direct path or close enough to experience moderate to
severe storm conditions that have the potential to cause
damage or complete collapse.
The signicance of the Idle Iron NTL and the imminent
API 2SIM is to mandate and guide the GOM oil and gas
industry to be more pro-active in mitigating environmental
risk and nancial risk for both operators and federal
agencies. In addition to the potential environmental
impact, the cost to decommission a destroyed platform
with a number of wells ranges between 10 and 20 times
the cost to decommission the same platform undamaged.
The cost liability associated with decommissioning has
meant operators in the past have deferred this in the
hope of potential re-use or for when the lease eventually
expires. This liability, combined with the recognition of
risk exposure and the requirements of the Idle Iron NTL,
initiated the divestiture of assets in 2010. The most notable
was the acquisition of approximately 310 platforms from
Mariner Energy and Devon Energy by Apache Corp. for
US$ 2.7 billion and US$ 1 billion respectively.
For better or for worse
A good SIM system can tailor consequence of failure to a
client specic business risk model and effectively manage
risk exposure (safety, environment and business). However,
specic competencies on all aspects of SIM are required with
a combination of practical and offshore structural experience.
SIM can offer signicant cost savings by targeting
inspections with reduced frequency and avoid unnecessary
costly inspections. Using nonlinear pushover analyses for
assessments, efcient repair schemes that are often not
like-for-like can be utilised for optimised mitigation. An
efcient SIM system can provide signicant risk reduction
through the adoption of mitigation and decommissioning
strategies.
Anomaly tracking should also be part of an efcient SIM
system to ensure timely repairs if required and efcient use
of resources. By developing an inspection programme and
scope of work using structural knowledge, previous inspection
ndings and assessment results, both the cost and risk
exposure can be signicantly reduced compared to purely
prescriptive inspections following existing guidance.
O T
Leaving the rig for the vessel
PER LUND, NCA AS, NORWAY, SHOWS HOW
EXPLORATION AND ABANDONMENT OPERATIONS CAN
BE COMPLETED MORE COST-EFFICIENTLY THROUGH
USING NEW TECHNOLOGY AND NOVEL APPROACHES.
N
orse Cutting and Abandonment AS (NCA) has
focused on developing rigless methods and tools
that will enable traditional rig operations to be
performed from less expensive spreads, such as hydraulic
jacks and coiled tubing units for platform wells, and subsea
construction support vessels for subsea wells. The NCA
group of companies, formed in 1999, was acquired by
Oceaneering this year. Employing alternative approaches
and new technology, NCA vessel operations, such as
subsea well abandonments, can prove more efcient than
a rig operation, especially when carried out from a vessel
spread costing less than 20% of the drilling rig spread cost.
In addition to the cost savings, the new approaches can
potentially release rig time equivalent to the time it takes to
drill ve to 10 new exploration wells in the Norwegian sector
alone.
The company has developed a rigless approach for
subsea well abandonment that has steadily introduced new
tools to enable vessel-based abandonment operations.
In parallel, subsea construction support vessels have
developed through increased size and crane capacities. To
support the subsea construction market, the subsea tooling
and ROV markets have developed technical solutions and
opportunities (which were utopian concepts only a few years
ago). Another important factor is the increased number of
ABOARD!
ALL
95
96
OILFIELD TECHNOLOGY
August 2011
vessels that are available in the marketplace, which makes
more of these vessels readily available for abandonment
operations in the spot market. The Subsea Wellhead Picker
has been successfully used in the North Sea since 2007 and is
now setting a benchmark for removal of the subsea wellhead.
Subsea wellhead removal
Subsea wellheads have traditionally been cut by the rig,
mechanically, using rotating knives run on drill pipe to cut
from the inside through the layers of casing and cement.
The mechanical cutter is run to 5 m below the seabed, as
per regulatory requirements. This technique has been used
since the early days of the offshore industry but has several
Figure 1. A subsea wellhead severed with NCAs Subsea Wellhead
Picker.
Figure 2. A severed subsea wellhead being recovered.
disadvantages. It can only be run on drill pipe and therefore
requires a rig or at least a vessel with a mast and pipe
handling capabilities. It is relatively time consuming, and
the mechanical knives face extreme loads that may result in
breakdown.
A rigless alternative using explosive charges has
sometimes been used in the past. More environmentally
friendly and safe rigless alternatives are currently available
and in North Sea operations, explosive cutting has been
phased out. This trend is expanding to other areas of the
globe.
NCA has developed a new generation Internal Multistring
Cutting Tool (IMCT) that is based on Abrasive WaterJet
Cutting (AWJC). This efcient cutting method uses high
pressure water mixed with abrasives to cut through the
combined steel and cement compound found below the
wellhead. A typical casing conguration is a 30 in. conductor,
20 in. surface casing, 13
3
/8 in. casing and sometimes a
10
3
/8 in. or a 9
5
/8 in. casing, which all results in a 3 or
4-string conductor. The patented cutting tool is capable of
cutting from inside a 7 in. casing through up to ve layers
of casing and out to a 36 in. conductor, even if the casings
are eccentric (with or without cement). Currently more than
150 cuts are carried out every year with the cutting system
for platform and subsea wells. The deepest cut to date was
performed in 375 m (1200 ft) water depths.
For subsea wellhead removal applications, the IMCT is
normally combined with a lifting connector that attaches
to the wellhead prole. The two tools used together are
called a Subsea Wellhead Picker, which can be deployed
on a heave compensated crane from a subsea construction
support vessel in a single run operation, to cut and recover
the wellhead. The wellhead removal operation consists of
a survey, removal of the net guards, drifting and cleaning
the wellbore before the equipment is deployed and stabbed
into the well, assisted by a work class ROV. When the IMCT
is at cutting depth, the lifting connector is activated and
load tested and the cutting can start. After a few hours the
cut is immediately veried by overpull in the crane and the
wellhead and casing assembly are then recovered and laid
out on the vessel deck.
The cutting process is typically completed in 2 4 hrs,
amounting to a roundtrip time for the Subsea Wellhead
Picker of only 8 12 hrs from deployment until the wellhead
is safely landed on deck.
With more than 20 subsea wellhead removal operations
performed so far, the Subsea Wellhead Picker has a 100%
success rate no wellhead has been left at the seabed.
Several wellhead picking operations have occurred during
the winter season in the North Sea, where the system has
proven robust in challenging weather. Wellheads have been
cut and retrieved in signicant wave heights (Hs) of up to
3.0 m without any major challenges. The tools capability to
work in heavy weather makes it attractive to perform these
non-value-added operations during the low season over the
winter when the subsea construction support vessels are
normally free to take on ll-in work.
Releasing rig days
The subsea wellhead removal operation is equally applicable
for old redundant production wells as for newly drilled
September 12-13, 2011
Denver, CO
Optimizing shale expansion through growing technology innovations and trends.
Mark Williams
SVP of Exploration & Development
Whiting Petroleum
Rich Smith
Executive Vice President of Exploration
& Business Development
Stone Energy
Stan Wilson
Manager, Northern Region
Resource Development
Continental Resources
Bryan Lastrapes
Business Development Manager
for North America
Shell
Dr. Peter Hill
CEO
Triangle Petroleum
John Curtis
Professor, Director of Potential Gas Agency
Colorado School of Mines
Loyd Roberson
VP Technical Sales & Marketing
Newpark Drilling Fluids
Tisha Conoly Schuller
President & CEO
Colorado Oil & Gas Association
Fred Arasteh
Senior Subsurface Advisor
for Unconventional Resources
Hess Corporation
Jennifer Leslie-Panek, Ph.D., P. Geoph.
Senior Geophysicist, Canadian Oil & Gas
Division, Shale Gas
Nexen
Carlos Calad
VP of Marketing & Sales
Archer
Chuck Kozora
Regional Business Development Manager
Aquatech
Featuring Case Studies from Leading Shale Oil & Gas Experts:
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Attending this Premier marcus evans Conference
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marcus evans invites Oil & Gas Upstream VPs, Directors,
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Who Should Attend:
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For More Information,
Please Contact: Michele Westergaard T:
312 540 3000 ext 6625
E: Michelew@marcusevansch.com
98
OILFIELD TECHNOLOGY
August 2011
Figure 3. The Island Wellserver in well intervention mode.
Figure 4. NCAs Abrasive Waterjet Cutting spread onboard a subsea
construction support vessel.
exploration wells that are not intended for future use. The
latter concept is often referred to as rig chase, where the
rig intentionally leaves the wellhead behind when it moves to
the next location. These wells are then picked up in batches
in multiwell vessel campaigns. NCA has frame agreements
with several operators for the removal of exploration wells in
the years to come. At least two multi-client campaigns per
year are anticipated. The Rig Chase
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