08 woodside
TRANSCRIPT
BOP Shear and Pressure Testing ofIntelligent Completion Tubing
–Results and Lessons LearnedResults and Lessons Learned
A Short History
In March 2012 it was made known to WEL that Hydril had attempted to shear anEXPRO shear sub, dressed with 15 x ⅜-inch stainless steel control lines, utilizing their standard blind shear rams.There was no problem shearing the sub itself but a seal could not be obtained dueto pieces of control lines being drawn in between the upper and lower shear bladesthen compromising the lateral seal.
It was incidents such as this that prompted the development of improved shear ramassemblies such as the Hydril WSR (wireline shear rams), Cameron’s CDVS (cable
Slide 2Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana
assemblies such as the Hydril WSR (wireline shear rams), Cameron’s CDVS (cabledual V-shear rams) and Shaffer’s CVX-W (wireline shear rams).
Both of these shear rams are able to successfully shear and seal when cuttingproduction tubing and SLS shear subs when fitted with a variety of control tubingsizes and electrical cables.
The interlocking features of these rams enable them to cut slack tubing and cableswithout compromising the sealing qualities of the rams.
A Short History cont’d
Cameron CDVS Shear Rams
Slide 3Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
A Short History cont’d
Hydril WSR (wireline shear rams)
Slide 4Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
The Atwood Eagle & GWF
The Atwood Eagle is fitted with a Cameron Type U BOP.This BOP type can only be fitted with the SBR (shear blind ram).The SBR shear ram Upper blade has a shallow ‘V’ profile andthe Lower blade has a straight edge profile.
Slide 5Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
The Atwood Eagle & GWF
Standard blind shear rams exhibit varying degrees of verticalseparation between the upper and lower blades during theshearing action.
The result of this separation can be seen in the following videoclip, observe the size of the “toe nails” that break away at pipe
Slide 6Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
clip, observe the size of the “toe nails” that break away at pipeseparation.
What wasn’t known was just how much separation would theCameron SBR rams exhibit and what effect would that have onshearing/sealing tubing, the SLS shear joint and control lines.
The Atwood Eagle & GWF
Slide 7Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
GWF Smart Completions & the SLS Shear Joint
SLS Shear Joint8.16” OD, 0.5” WT, P110 grade
Slide 8Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Sample Smart Completion Joint7-inch, 29 ppf, 13Cr, L-80
Cameron Services, Patterson Louisiana
Atwood Oceanics and WEL cooperated on an arrangement to conduct sheartesting at the Cameron Services facility in Louisiana.Samples of the smart completion system and the SLS shear joint wereshipped to the facility along with SBR ram blocks from the Atwood Eagle andvideo recording equipment.The facility was equipped with shielded high-pressure testing bays and aType U single ram body, fitted with tandem booster operators, had beeninstalled on a blind hub test assembly.
Slide 9Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
installed on a blind hub test assembly.
Tandem boostersand shear ramsidentical to EagleBOP
Smart Completion First Cut
Control tubing package parallelto ram lower (straight) blade
7-inch tubing sheared at 2400 psi
Slide 10Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Smart Completion First Cut
Slide 11Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Upper section cut
Lower section cut & fold
Smart Completion First Cut – Pressure Test
Low Pressure – 270 psi High Pressure – 5000 psi
Slide 12Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Smart Completion Second Cut
Control tubing package @ 90º toram blade travel
7-inch tubing sheared at 2300 psi
Slide 13Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Smart Completion Second Cut
Slide 14Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Smart Completion Second Cut
With the control packages @ 90º to the blade travel the second cut of theencapsulated lines was considerably cleaner than when facing the blades.
Slide 15Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Upper section of second 7-inch tubing cut
Smart Completion Second Cut – Pressure Test
High Pressure – 5000 psiLow Pressure – 290 psi
Slide 16Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Smart Completion Summary
•The shear and seal exercise on both configurations of the SmartCompletion Packages was successful.
•The attitude of the encapsulated packages with respect to blade travel hadno effect on the sealing capability of the rams – although the shear of thecontrol line package was much cleaner when placed adjacent to the blade
Slide 17Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
control line package was much cleaner when placed adjacent to the bladetravel.
•The current plan for the clamping of the control line packages on theproduction tubing appears to be adequate.
SLS Shear Joint
The original SLS shear joint
OD = 8.625”ID = 7.165”
WT = 0.73”
Original SLS joint was geometricallyunshearable in Atwood Eagle BOP
Slide 18Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXx
Cameron SBR Limitsin Type-U BOP
OD = 8.84”ID = 7.74”
WT = 0.55”
GWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS Shear Joint (modified)
Agreement was reached with FMC Technologies to re-size the SLS shearjoint to accommodate the capability of the Atwood Eagle BOP
The shearable section of thejoint was machined down toan OD of 8.17”. This resulted
Slide 19Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
an OD of 8.17”. This resultedin a wall thickness of 0.5”.
The SLS shear joint wasnow within the geometriclimits of the Type-U BOPand SBR shear rams
SLS @ Cameron Services, Patterson Louisiana
The two samples of SLS shear jointmaterial were only 1.0 M long.
As the actual shear joint is almost 3.8 Mlong it was decided to loosely mount thecontrol tubing arrangement to simulatethe unrestrained length of the control
Slide 20Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
the unrestrained length of the controllines.
This arrangement would allow for a fairindication of how far the control linesmay be displaced before being sheared.
SLS @ Cameron Services – First Cut
SLS joint sample shearedat 2400 psi
Slide 21Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS @ Cameron Services – First Cut
Slide 22Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS @ Cameron Services – First Cut
Five of the six control lines werepushed to the outer edges of theram blocks
Slide 23Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Two of the five displaced lines didnot shear resulting in a failedpressure test
SLS @ Cameron Services – First Cut
SLS first cut Upper & Lowersections
Slide 24Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Upper
Lower cut & fold
SLS @ Cameron Services – First Cut
Control line that did not shear became trapped between the faces of theside packers
Slide 25Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Tubing trapped here
SLS First Cut – Pressure Test
Low pressure test failed
Rams were opened and inspected
Slide 26Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Rams were opened and inspected
Rams closed (no tubulars)
LP / HP tests conducted successfully
SLS @ Cameron Services – Second Cut
Second SLS sample control lines were securelyclamped and the tubing ends bent to assist inpreventing excessive displacement
Slide 27Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
It was necessary to make use of the encapsulatedtubing as the SLS samples were delivered withoutthe requested stock of ¼” stainless steel lines
SLS @ Cameron Services – Second Cut
SLS sample #2 sheared at 2270 psi
All six control lines sheared and broke awaycleanly when upper section was lifted
Slide 28Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS @ Cameron Services – Second Cut
Control tubing was stilldisplaced towards the edgesof the ram blocks
However all control tubinghad been sheared beforereaching the packer areas
Slide 29Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
The SLS control tubingclamping arrangement willhave to be reviewed
SLS @ Cameron Services – Second Cut
SLS 2nd cut Upper & Lowersections
Lower cut & fold
Slide 30Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
Upper
Lower cut & fold
SLS Second Cut – Pressure Test
Low Pressure – 280 psi High Pressure – 5000 psi
Slide 31Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS @ Cameron Services – Second Cut
Lower section Cut & Fold – All control lines cleanly severed
Slide 32Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS Shear Exercise Summary
• The SLS tubular sheared at well below the BOP max system pressure
• Control lines will need to be clamped above and below the shear rams
• Suggest the use of encapsulated control line packages to eliminate linedisplacement during shear action
Slide 33Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221
SLS Shear Exercise Summary
Slide 34Implementation of New Technology. Flow meter selection. Vincent Phase III. DRIMS #xxxxXxGWF Shear & Seal Testing at Cameron Services, Patterson, Louisiana DRIMS #8936221