denver, colorado february 28 - march 2, 2005 … · – request to halliburton ... 200 bar surface,...

Shell Exploration & Production

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Development / installation of

permanent downhole capillary

injection facilities in gas wells with

sub-surface safety valves

Gas Well De-Liquification Workshop

Denver, Colorado February 28 - March 2, 2005

Eelco Bakker, Dick Klompsma, Hans van Dijk, Gerben Wieldraaijer

Nederlandse Aardolie Maatschappij

(Shell Exploration and Production in The Netherlands)


Field exampleHourly 19/12/00 00:00:00

3-12-00 4-12-00 5-12-00 6-12-00 7-12-00 8-12-00 9-12-00 10-12-0011-12-0012-12-0013-12-0014-12-0015-12-0016-12-0017-12-0018-12-00

0.05

0.1

0.15

0.2

0.25

0.3

0.35

0

0.4

18.75

37.5

56.25

75

93.75

112.5

131.25

0

150

pressure

flowrateSudden drop in flow, result of liquids building up and well no longer capable of flowing or flowing intermittently


Field example?

Hourly 20-09-02 08:13:56

16-9-02 17-9-02 18-9-02 19-9-02 20-9-02

L15FA1-CCFI01.PV

MILJ.NM3/D L15FA1-CCPC1.PV

BARG L15FA1-CCTI01.PV

DEG.CELC.

0.1

0.2

0.3

0.4

0.5

0

0.6

25

50

75

100

125

0

150

15

30

45

60

75

0

900.00

95.00

35.40

L15FA1-CCFI01.PV

MILJ.NM3/D L15FA1-CCPC1.PV

BARG L15FA1-CCTI01.PV

DEG.CELC.

0.0988.0047.30

17-09-02 09:41:39

Drop in flowrate

Drop in temperature while not flowing


Solutions• background

– European legislation requirement for surface- and subsurface safety valves (SSV + SC-SSSV)

– No equipment (SC-SSSV+capillary) readily available within industry

• Conceptual ideas only

– In-house idea Shell patent (TS 9521 EPC)

• Principle: use existing C/L to pump down foam solution + modify SSSV to hang off capillary

• 2-tier follow-up

– In-house development use of existing equipment / components “Foam Insert Sleeve” (FIS concept)

– Request to Halliburton (main supplier completion eqpt.) to modify existing valve (Chemical Injection Safety Valve - CISV)

– Design criteria

» Low cost / standard components / minimal mods existing equipment / cover all tubing sizes 3 ½” 9 5/8” with main focus on 3 ½” and 5 1/2”.

» For both W/L as TR safety valves


Foam Insert Sleeve (FIS) concept

Auxiliary equipment

1.Wire-line BOP for sleeve (similar as for SC-SSSV)

2.CT Quad BOP for control valve / hanger 2” ID BOP with slip-type rams for ¼”

Existing SV landing nipple (part of existing completion)

Sleeve with new SV landing nipple profile and by-pass for foam from C/L inlet to control valve/hanger capillary

Control valve (hanger) installed at bottom of sleeve

Capillary string


FIS - equipment Standard RQ running / GS pulling tools

Guide sleeve

Insert sleeve

Standard Insert safety valve

SV Control valve + hanger


FIS installation sequence

Install insert nipple

Install guide sleeve

RIH 1/4” capillary + space-out

Cut string & connect to Hanger

Install Hanger in Insert Nipple

Start Foam Injection

Pull Guide sleeve

Pull SC-SSSV

WL operation,wire 0.125”

CT operation

Install and test SC-SSSV

Hang-off string in BOP

Shell Exploration & ProductionBegin situation:

1

4

5

6

2

3

7

Install insertnipple

RIH 1/4” capill.+ space-out

Cut string &connect

to hanger

Install hanger in insert nipple

Pull SC-SSSV

Install and testSC-SSSV

Hang-off stringin BOP

1

4

5

6

7

2

3


Begin situation: End situation

SC-SSSV installed in sleeve, foam injection + SV operations via ¼”controlline

SC-SSSV installed in tubing SV-LN, operated via ¼”controlline


time

Time

(P tbg @ SV depth + P SV full opening – P hydraulic C/L + safety margin)


Chemical Injection Safety Valve concept (Halliburton - CISV)

Existing SV

Connection capillary to SV

Auxiliary equipment

1.Full size Modified BOP for modified SV including rams to hold capillary during make-up

• existing for 3 ½”size

Clamp to hold down capillary

Capillary string connected to SV


CISV installation sequence

Perform Dummy run

RIH 1/4” Capillary string

Hang-off string in BOP

Cut string & connect SC-SSSV

Install SC-SSSV+coil in LN

Start Foam Injection

Test SC-SSSV

Pull SC-SSSV

WL operation

CT operation


CISV – equipment (Halliburton)Connection capillary to safety valve

Capillary clamp construction

Conventional

Flapper valve

By-pass allowing foamer to capillary

Foam Inlet ports

Courtesy Halliburton


FIS versus CISV• Key differences

– Halliburton CISV

• SV integrated with chemical injection

• Full size capillary deployment BOP’s required for different valve sizes

• System acts as 1 pressure vessel, SV operating pressure driven by depth / wellhead pressure drives setting of downhole injection valve high operating pressure entire system.

– Pressure range, 200 bar surface, up to 600 bar downhole

– FIS

• Possible to install / pull SC-SSSV independent from capillary injection system

• flexibility in sizes ( 5” - 9 5/8” ) only 1 size capillary deployment BOP required

• 2 operating vessels, operating pressure setting control valve/hanger independent of SV operating pressure lower operating pressures

– Pressure range, 200 bar surface, up to 300 bar downhole


QA / QCitem criterion Ensured by

All safety critical equipment installed in the well to meet standard requirements (RQ / XO lockmandrels / 2.75” Halliburton FXE wireline retrievable SV)

In line with API - 14A 1&2

• Materials send to location certified (workshop testing acc procedures)

• function & inflow testing once installed before well taken into production

Critical seals Viton / Chemraz Sh. 90 spec

• tested in NAM lab (autoclave)

Foam selection Stability / compatibility

• tested in NAM lab (autoclave)

No outstanding issues from reviews

• Multidisciplinary HAZID / HAZOP review (WS/ PT/ Ops/ PC / Eng)

Installation /running procedures of capillary & modified safety valve or modified sleeve+ safety valve No outstanding

issues after “dry run”

• All issues closed-out after Zuidbroek testing

Safety Impact of foam systems No significant increase in overall risk levels

• QRA / RAM approach


Risks mitigation• Impact foam injection on well related safety

– 3 different steps

• HAZID running & operation of systems

• Qualitative analysis (RAM approach)

• Semi-quantitative analysis

– HAZID running & operation of systems

• Key challenges identified:

– Compatibility foam – seals

– Foam stability

– Compatibility foam solution – hydraulic oil

– Interaction existing ESD-systems

– Impact on (production) surface facilities

– Familiarisation with “new”equipment / services.


Risk Assessment Matrix (RAM)

Increasing risk

• Combines scenario consequence with its probability

• Experience is used to determine both classifications

• Focuses on the high impact scenario

• Not a lot of “granularity” for comparison

The level of control should depend on the level or risk !

worst case Likelihood case


Quantitative Assessment

• Objective

– Estimate the annual blowout and/or release rates for each of the designs and compare with current background rate

• Industry accepted blowout frequencies (SINTEF, EUB) and failure rate for installed equipment (Wellmaster / Oreda)

• Intervention frequencies based on actual (historical) data

• Results

– No significant differences between without foam / with foam injection

– No impact on location related risk level (effect of exposure included !!)


Field installations

COV-55 WAV-18 MKZ-3Tubing 5 1/2" 18#, L-80 Cr-13 3 1/2", 10,2#, CS 7" , 32#, Cr-13Injection valve depth 2850 meter 1760 meter 3880 meterPerforations 2762 - 3161 meter 1756 -1820 meter 3838 - 3934 meterDeviation @ reservoir 20 ° 42 ° 45 °SC-SSSV depth 301 meter 85 meter 103 meterConcept 4.562" FIS 2.75" CISV 5.875" FISCap. Type 1/4" 0.035 " Inc. 625 1/4" 0.035 " Inc. 625 1/4" 0.035 " Inc. 625


Learnings– Extensive equipment testing incl. dry runs in test well with capillary paid of

• Equipment behaviour / pressure setting control- and injection valves

• Operational procedures

– Accidentally capillary cutting fishing successful

– Material selection equipment incl. seals critical

• Foamer composition

• Well conditions

– Functioning downhole injection valve critical

• Accurate dosing of chemicals to optimise well lift

• Impact on safety valve operations / behaviour

– Campaign approach

• All systems tested and installed (1*3 ½”, 1 * 5 1/2”, 1* 7”)

– Further investigations for simplifications future installations


Contributors & acknowledgements

•

• Shell

– Chris Kuyken

– Hendrik Hindriks

– Dick Klompsma

– Hans van Dijk

– Gerben Wieldraaijer

– Rob Eylander

denver, colorado february 28 - march 2, 2005 … · – request to halliburton ... 200 bar surface,...

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