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Cutting-Edge Deepwater Completion Innovations

Explore advanced deepwater completions technology, including sand control systems, expandable liners, and intelligent completions for enhanced reservoir monitoring. Learn about challenges in deepwater environments and completion design considerations.

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Cutting-Edge Deepwater Completion Innovations

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  1. Technological Advancements in Completions for Deepwater Speaker - Amit Kubal

  2. Agenda • Innovations in Deepwater Completion Technology • Challenges in Deepwater Completion • Strategy for Tool designs

  3. 0- 300 mtrs 300- 1500 mtrs >1500 mtrs

  4. Innovations in Deepwater Completion Technology • Sand Control : Enhanced Single-Trip Multizone (ESTMZ) system, a multi-zone gravel pack system that allows multiple frac pack intervals to be completed in a single trip of the work string. This system allows us to go in and do a very aggressive frac pack with rates up to 45 barrels per minute with a proppant volume of 400,000 lb of 16/30 HSP per interval for up to five intervals, providing a total cumulative proppant volume of two million lb per well. • Treat and pack multiple zones in one trip • Isolate zones from each other • Access zones for treatment • Open zones for production

  5. Expandable Liners : For ultra-deep wells that require many large casing strings. The hangers are designed for large diameter liners (18 5/8-in. to 13 5/8-in.) to improve reliability and reduce risk in the subsea environment. The expandable liner hangers have a very smooth transition coming into them, so it makes re-entry into the liner tops much easier than with conventional liner hangers They provide an ISO 14310 V0 tested, gas-tight seal on setting is surpassed only by its ability to provide enhanced hang-weight capabilities at elevated temperatures up to 575°F (302°C) and pressures up to 15,000 psi.

  6. Intelligent Completion & Permanent Monitoring : SmartWell product offering to include a suite of tools that will allow operators to remotely monitor and selectively control multiple deep reservoir intervals in a single well without any physical intervention. The real driver for customers in deploying intelligent completions is increased ultimate recovery. Other benefits include reduced well intervention costs, accelerated production, reduced average well costs and reduced subsurface facilities.

  7. Challenges for Deepwater Completion

  8. Challenges in Deepwater environments • Amplified risk and decreased margin for error make the consequences of failure more costly • Potential safety hazards • Maximizing production with casing inner diameter limitations • Breakdown of fluids and proppants • Equipment and material availability & reliability • Long term equipment reliability • Cyclic loading of downhole materials • Technology Limitations

  9. Challenges for Completion Designs • Metallurgical Considerations • Corrosion Resistance • Temperature effect on yield strength • Elastomer Considerations • Chemical Resistance of produced and completion fluids • Long term element package sealing integrity • Completion and Work over Design Considerations • Setting methods • Retrieval methods

  10. Principles for Selecting Materials for HP / HT Completions • The first priority is to prevent environmental cracking: • Sulfide Stress Cracking - SSC (from H2S). • Stress Corrosion Cracking - SCC (from chlorides, brines, or acid). • Hydrogen embrittlement (from acidizing + galvanic coupling). • The second priority is to minimize uniform corrosion and localized corrosion: • CO2 corrosion. • Pitting from chlorides or oxygen. • H2S corrosion. • Erosion and erosion-corrosion.

  11. Materials in ANSI/NACE MR0175/ISO 15156-1:2015

  12. Strategy for Tool Design

  13. 500 Steam ServicePackers 30,000 psi 475°F 25,000 psi 450°F 400 15,000 psi 400°F 10,000 psi 325°F Temp °F 300 7500 psi 325°F 5000 psi 275°F 200 5000 10000 15000 25000 30000 Pressure Packers — How High Can We Go?

  14. ISO 14310 / API 11D1 – Design Validation Grades • Grade V6 is the minimum grade – supplier specified • Grade V5 = Liquid test • Grade V4 = Liquid test with axial loads • Grade V3 = Liquid test with axial loads and temperature cycling • Grade V2 = Gas test with axial loads • Grade V1 = Gas test with axial loads and temperature cycling • Grade V0 = V1 with special acceptance criteria (zero bubble)

  15. Sealing Systems Element technology and design Anchoring system Slip systems and design Enabling Technologies

  16. Elastomer Selection – For Long Term Purpose

  17. Sealing System • Triple Element Package – Increased sealing ability due to new ramped element design. • Back up shoes – Compliant back up system doesn’t allows element extrusion. • Teflon and wire mesh – Provides extra back up and sealing. • Qualification test in worn casing.

  18. Element Package Comparison Regular • Back up shoes • Triple Element Package • Teflon & Wire Mesh HPHT

  19. Anchoring Systems Slip Technology and Design

  20. FEA Slip casing stress analysis Slip System • Barrel slip system – Reduces packer to casing stresses and gives a complete 360⁰ coverage. • High Load capacity • Water cut used for the precise slip design

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