OTC 15178 Multi-Service Vessel Well Intervention With New SILS

Clyde Hewlett/Oceaneering International, Inc.; Bill Clegg/Oceaneering International, Inc.; Don Thorne/Oceaneering International, Inc.; Peg Newman/Oceaneering International, Inc.
Copyright 2003, Offshore Technology Conference This paper was prepared for presentation at the 2003 Offshore Technology Conference held in Houston, Texas, U.S.A., 58 May 2003. This paper was selected for presentation by an OTC Program Committee following review of information contained in an abstract submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Offshore Technology Conference and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the Offshore Technology Conference or its officers. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the Offshore Technology Conference is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of where and by whom the paper was presented.

effective intervention method will be required. SILS/MSV/ROV equipment combination offers a

The

diverless/rigless first step solution toward lowering the life cycle costs for subsea wells at any depth. Definitions BOP Blow Out Preventor DP Dynamic Positioning MUX E/H Multi-phased Electro-hydraulic HAZID Hazard Identification HAZOP Hazardous Operation HPU Hydraulic Power Unit MSV Multi-Service Vessel OEM Original Equipment Manufacturer P&A Plug and Abandonment ROV Remotely Operated Vehicle (work class) SILS Subsea Intervention Lubricator System SSSCV - Surface Controlled Subsurface Control Valve Design Approach The new SILS design began with the simple objective to reduce the cost of wireline intervention on subsea completions. As many of the other technical barriers to subsea production have been overcome, downhole intervention costs remain the largest disadvantage to the complete subsea solution. Without the ability to cost-effectively re-enter the well bore, valuable reserves are often left in the ground for want of a simple downhole manipulation. The concept of subsea wirelining is by no means new. It has been employed for years in the North Sea, in relatively shallow waters, from dedicated vessels, relying heavily on diver assist. To be most cost-effective in arenas such as the Gulf of Mexico, the new SILS design would have to be fully diverless in operation and be capable of being extended into water depths up to 10,000fsw. Investigating a possible SILS solution began with a Gulf of Mexico market review of existing subsea installations where dynamically positioned MSVs already perform a multitude of other well services. Adding wireline capabilities to any reasonably sized (250) DP-2, MSV of opportunity seemed a logical extension of other vessel capabilities and when combined with maximum utility of the vessels ROV system were key considerations in keeping the SILS cost-

Abstract This paper introduces a new Subsea Intervention Lubricator System (SILS) that utilizes remotely operated vehicle (ROV) technology and a MSV to safely perform wireline well intervention on subsea completions, in water depths ranging from 300fsw to ultimately 10,000fsw. Operators employing this simplified system can consequently lower their associated costs. Introduction Demand for hydrocarbons continues to expand and subsea developments in deepwater arenas such as the Gulf of Mexico, West Africa and Brazil are projected to grow considerably. (Figure 1) To improve production, wireline intervention services for simple mechanical manipulations, component changes, downhole surveys, etc. will be required. The concept of utilizing a wireline intervention system is not new. Best known for use in surface deployed applications, the wireline lubricator, when used in the subsea environment allows access to the well bore without the need for a drilling rig and a workover riser. Historically, operators have utilized a drilling rig or a dedicated vessel and divers to perform most wireline operations on subsea wells. Now, increasing numbers of subsea developments installed in deepwater beyond the range of divers are causing operators to seek containment of project costs by searching for innovative techniques that will challenge the traditional drilling rig/diver-based intervention model. Independent of water depth, the SILS/MSV/ROV combination can lower the cost of well interventions for tasks including wireline and P&A operations. (Figure 2) As subsea wells become a more commonly employed field development solution, a safe, rapidly deployed and cost-

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effective. The new SILS should be available for rapid mobilization to the DP MSV of opportunity and would not be consigned to a dedicated vessel. Next, specifications for existing and planned trees including sizes, types, water depths and horizontal or conventional configurations were examined. The resulting decision was to produce a 5 inside diameter system with an internal working pressure rating of 10,000 psi that could be used on both horizontal and conventional trees. While this did not cover the complete range of pressure ratings or plug sizes found in the internal tree caps of some horizontal trees, these specifications were sufficient to satisfy the 80/20 rule. Higher pressures and larger bores have a compounding effect on overall size and costs that would have jeopardized the primary objectives of rapid and cost-effective intervention. With the systems primary specifications decided, the detailed system design was driven by functionality, efficiency and safety. The safety aspect of the SILS design was considered overriding. The SILS design employed a comprehensive HAZID and HAZOP approach to system development. Each different aspect of SILS operation was story boarded and subjected to a formal hazards review. Adverse potential impacts to personnel safety, the environment, the well and other assets were evaluated and fed back into the design for mitigation. The methodology used is described in greater detail later in this paper. Recognizing that SILS will never have the broad capability of a drilling rig, the system must always be able to safely contain any adverse condition and leave the well such that it can be safely re-entered using a rig. Some of the other salient design parameters for the SILS include: All well fluid wetted materials per NACE MR-01-075. All material specifications per API 6A, PSL 3. Two barrier isolation of the wellbore to the environment. Fail safe closure in the event of MSV drive-off.

Typical tasks that can be accomplished using SILS are: Wireline Intervention: Sleeve Shifting for Zone Isolation/Opening Plug Setting SCSSV Replacement (insert type) Wellbore Surveys Gas Lift Valve Replacement Downhole Choke Setting Tubing and Casing Cutting/Perforating In the case of rig-less subsea well plug and abandonment, the SILS is used to enter the well bore and facilitate installation of the typical three cement plugs required to safely isolate the wellbore. The MSV can then be used to recover the tree, cut the casing below mudline and recover the wellhead housing/casing stub. For ecological reasons, it is becoming increasingly difficult to obtain permits for the quantities of explosives required to sever the casing below mudline. Therefore, the SILS project also includes the development of a subsea mechanical casing cutter which uses ROV power to operate conventional blade style cutters. SILS System Description In order to accomplish its goals, the SILS is a system that is designed to take maximum advantage of the existing capabilities of the MSV, ROV and tree OEM tools. The SILS system is comprised of several components and sub-systems. These include the subsea wireline package, the surface/delivery systems, and the mechanical casing cutter system. The subsea package with it's various sub-assemblies and components together makeup the heart of the overall system. The surface components support the subsea package installation and/or operation. To improve the utilization of the system in the market by expanding it's work scope to include plug and abandonments, a mechanical casing cutter system was also developed and tested. The system's basic design provides for utilization on projects where high-pressure, 10,000 psi, and deepwater are encountered. The nominal bore size of the subsea package components allows for work on trees with nominal 5" bores. Operations on the subsea package and casing cutter system are tailored to the use of ROVs and associated tools. Subsea Package. The subsea package, as shown in Figure 3, is comprised of the tree interface, BOP assembly, lubricator sections, stuffing box/latch assembly and various controls components such as accumulators, valves, plumbing, junction plates and hot stab manifolds. The tree interface constitutes the means of adapting the subsea wireline system to various tree designs. For conventional trees, this interface is made-up of the OEM tree running tool package with appropriate adapters for mounting the BOP assembly. The adapters provide a means of mechanically joining the components, sealing between them

SILS Applications/Use While considered a very mature technology in surface applications, the SILS technology is newer, when used in the subsea environment allowing access to the well bore without the need for an expensive, rig deployed workover riser. The smaller profile and lighter SILS can be deployed from a dynamically positioned MSV of opportunity and is designed to provide typical live-well slickline services for conventional and horizontal subsea trees. The SILS configuration also facilitates subsea well plug & abandonment, a growing segment of the subsea market requiring a more cost effective-approach.

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and aligning the bore of the wireline system to that of the particular tree for wireless access. For horizontal trees, an 183/4 connector is provided with the system. The conventional tree design utilizes the installation alignment capabilities of the OEM tree running tool. On horizontal trees, the ROV and vessel position the package directly over the tree mandrel and therefore do not require additional alignment mechanisms. The BOP assembly is comprised of a 4-ram style BOP utilizing 5.5 inch 10,000 psi rated BOP elements. The arrangement, while re-configurable to some degree, is generally arranged from bottom to top with a shear seal ram, capable of shearing 2-1/8" sinker bar, a stripper ram, a gripper ram and finally a shear seal ram. The BOP utilizes autolocking actuators that require 3500-psi maximum operating pressure. The BOP body is configured with API 6A 11 inch 10,000 psi flanges on each end. The bottom flange is made-up to the tree interface adapter while the upper flange is mated to a connector mandrel. Porting in the BOP body allows for the connection of plumbing to a port that enters below the lower ram and above the upper ram cavity. The ports allow for cementing, circulation and flushing operations. The lubricator section of the subsea package is comprised of a hydraulic connector, tool trap, lubricator riser sections and upper adapter with stuffing box latch assembly. The hydraulic connector is a dog style design and is located on the lower end of the sub-assembly, where it allows for remote connection to the BOP assembly upper mandrel. The tool trap, situated just above the connector in the lower lubricator joint, provides a hydraulic function mechanism for capturing wireline tools in the event of failure of the supporting wire. Tool strings can be pulled up through the trap that acts similarly to a check valve. A flapper falls back into the bore after any tools are pulled through. Hydraulic pressure causes the tool trap flapper to retract from the bore so the workstring can pass. Lubricator riser sections are designed with special bolted flanges and are approximately 10 feet long. The system is configured with 3 riser sections but more can be added should longer wireline tool packages be needed. The stuffing box latch assembly is mounted to the upper riser section and provides a hydraulically actuated connector for locking and sealing the stuffing box. A coupling junction plate mounted on the latch assembly allows for the remote connection of the mating coupler halves located on the stuffing box assembly. During wireline running and pulling operations, these couplings convey the necessary functions of hydraulic packer pressure and lubricating fluid supply between the main assembly and the stuffing box. Located on top of the subsea package is the remotely removable stuffing box assembly. This assembly contains two pressure activated packing elements, two injection ports, tool catcher and mating coupler junction plate to mate to the junction plate couplers mentioned above. The tool catcher is a hydraulic-actuated release mechanism that is designed to catch the top of a wireline tool string. The catcher is intended to prevent the accidental dropping of the wireline tool string in

the event the wire is broken at the rope socket. The tool trap mentioned above is a backup to the catcher. A metering pump assembly is used to control and supply high-pressure lubricant for wire stripping operations. The pump is attached to the lubricator portion of the system. Controls. The subsea package is controlled via a direct hydraulic system design that includes a surface HPU, reel and umbilical. As a means of minimizing initial development costs, the controls were limited to less expensive rental equipment readily available for call out. A special control panel mounted to the umbilical reel provides necessary safety operating mode functionality. These modes include a latch/upper BOP close interlock, emergency shutdown yellow, emergency shutdown red and emergency disconnect. The interlock mode prevents the accidental unlocking of the stuffing box latch while the well bore is in an uncontrolled condition. The emergency shutdown yellow mode provides for a single valve actuation that closes all subsea cementing/flushing valves, the gripper BOP ram and the stripper BOP ram. The red mode adds to this the closing of the upper shear ram. An emergency disconnect mode is also provided. This mode essentially disengages the circulation line large bore hot stabs and severs the control umbilical that then by design leads to the fail-safe closure of all BOP rams. The BOP assembly is fitted with hydraulic accumulators for this purpose. Future incorporation of MUX E/H controls will allow the system to extend its operating depths by reducing the reaction times to actuate subsea hydraulic functions. Some functions on the subsea package are ROV controlled. The BOP section contains two ROV panels arranged to group functions logically by operation. The control of the tree interface connector and the BOP to the lubricator connector are via ROV supply. This improves installation operations by eliminating the need for an umbilical at the time the BOP system section is landed on the tree. It also reduces the number of umbilical control required for the system. Circulation System. The system requires the ability to circulate well bore fluids out of the subsea package as well as allow for pumping fluids into the well bore for kill and cementing operations. This is accomplished by use of a dual circulating riser system. The system is made up of dual 1-3/4 inch outside diameter coiled tubing strings stored on dual units, each with independently operated drums. Flexible high pressure hose jumpers on the subsea end of the coiled tubing strings allows for connection to large bore hot stabs. The hot stabs in turn engage mating manifolds on the subsea package. The subsea package is configured with hydraulic/mechanical means of ejecting the hot stabs out of the manifolds for emergency disconnection mode requirements. Deployment Equipment. The subsea package is deployable off the deck of a DP MSV equipped with a moonpool. A special handling A-frame/spider assembly provides the means to handle the large equipment loads and heights. It also provides a means of simulating a rig drill floor by providing a

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false rotary table in a structure that covers the moonpool (16 x 16 feet) opening. The simulated drill floor is retractable to allow full access to the moonpool opening. The A-frame is designed for a 60-ton load and can slew while moving loads from the work deck to the moonpool. Mechanical Casing Cutter System. The movement in the GOM towards more environmental friendly operations has lead to the restrictive use of explosive charges for well P&A operations. As a consequence, a mechanical casing cutter system was developed for the SILS project. (Figure 4) The design includes a gripper assembly that is landed on the wellhead housing and which is mechanically gripped via hydraulically generated forces to react cutter tool torque. A hydraulic motor package is designed to land on the gripper assembly. Attached to the motor package is a work string that includes spacer subs as required and a mechanical rotor cutter tool package. The motor is powered by taking hydraulic power from the ROV system itself. Cutting/operating water is delivered to the system via the circulation riser system. This water flows down the work string to the cutter assembly where it both energizes the cutter blades and washes out cuttings. Change out of cutter blades dictates that the motor assembly is relatively easy to recover and so all interfaces to it are ROV operable. SILS HAZID & HAZOP Results Once the basic configuration of SILS was known, the design team developed schematics and storyboards to represent all the operational aspects of the system. A multi-disciplinary team was then assembled, with representatives from the design team, wireline operations, vessel operations and ROV operations. Each operational scenario was played out in sequence and subjected to a series of what if failure situations. These failure conditions ranged from simple component failures, dropped objects, to vessel drive offs and tools stuck in the well. Any mitigating features of the design to safeguard personnel, the environment and the assets were noted. The possible consequences of each failure were also noted and a numerical factor assigned relative to severity. Similarly, the relative probability or frequency of each failure was given a factor and a risk matrix was created by the product of these factors. Ultimately, the numerical values of these factors were used to determine if, and what additional safeguards would have to be designed into SILS. High product factors infer unacceptable risks returning to the beginning of the process for additional safeguards. Figure5 is a graphic representation of the process.

SILS Relative Cost Advantage The SILS cost advantage relative to the drilling rig is derived primarily from the following: System is compact and does not require a dedicated vessel System is easily mobilized onto an MSV and can transit quickly to site without tug assistance. The MSV DP system can take up station quickly without the time and cost of running anchors. Once the SILS is run there is no ancillary equipment such as risers to run and retrieve. Rapid demobilization. While the absolute cost of a specific job will depend on many factors including regional market conditions, the operational time line for SILS versus moored rig intervention for a simple subsea wireline intervention is less than half. (Figure 6) Taking into account typical spread rates for in an area such as the Gulf of Mexico, this translates into a total job cost differential of US $2-3 million in favor of SILS. For example; it should be possible to accomplish a sliding sleeve, zone change in a deepwater subsea well (3000fsw) for less than US$1million verses US$4-5 million from a moored semisubmersible-drilling rig. As the duration of the job on station increases, the relative advantage of SILS is diminished. Conclusions This paper describes a new subsea wirelining system, SILS, which is currently under construction for application in deepwater areas such as the Gulf of Mexico. Through maximum utility of existing technologies, primarily in MSVs and ROVs, SILS will make subsea well intervention more cost effective than conventional rig based methods. Rigorous application of hazard and qualitative risk assessment through the design cycle helped shape the system to be safe, efficient and cost effective. Once in application and commercially successful, the methods proved will be used to expand into a full suite of electric line services as well as subsea coiled tubing equipment.

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Worldwide Subsea Completions

Expected to Nearly Triple
Number of Subsea Completions

Completed 4000 3000 2000 1000 0 68 60s 87 70s 80s

Estimated

2748

Total = 3556

1092 426 808 90s 00s

Figure 1 Source: Quest Subsea Database January 2003

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SILS/MSV/ROV Subsea Wireline Intervention Source: Oceaneering

Figure 2

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SILS Assembly
Stuffing Box

Latch

Lubricator Sections

Stuffing Box Flying Lead

BOP Assembly

Subsea Tree Interface

Source: Oceaneering

Figure 3

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ROV Operated Mechanical Casing Cutter

Figure 4

Source: Oceaneering

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HAZID / HAZOP Process

Assemble Team: Experts on System Design / Process Define Risk Matrix (Ranking for Probability and Impact)

Document HAZID / HAZOP Analysis

Create Operations Storyboards Nominal Contingency

Review Ops Storyboards; Brainstorm Potential Hazards for each Step Review Safeguards for Hazard Prevention Recommend Action for Additional Safeguards

Implement Safeguards in Design and Ops Procedures

Assign Probability (P) Assign Impact (I) Calculate Risk (R) { R=PxI }

NO

Risk Acceptable ?

Verify Implementation of all Safeguards prior to Equipment Delivery or Job Initiation

YES

Source: Oceaneering

Figure 5

10

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Subsea Well Wireline Job Time Comparison

250 200 Hours 150 100 50 0

Operation Preparation Anchors Transit

Anchored Semi DP Semi MSV

Vessel Type

Figure 6 Source: Oceaneering Estimates