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BOP Shear and Pressure Testing of Intelligent Completion Tubing Results and Lessons Learned Results and Lessons Learned

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Page 1: 08 Woodside

BOP Shear and Pressure Testing ofIntelligent Completion Tubing

–Results and Lessons LearnedResults and Lessons Learned

Page 2: 08 Woodside

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.

Page 3: 08 Woodside

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

Page 4: 08 Woodside

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

Page 5: 08 Woodside

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

Page 6: 08 Woodside

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.

Page 7: 08 Woodside

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

Page 8: 08 Woodside

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

Page 9: 08 Woodside

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

Page 10: 08 Woodside

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

Page 11: 08 Woodside

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

Page 12: 08 Woodside

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

Page 13: 08 Woodside

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

Page 14: 08 Woodside

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

Page 15: 08 Woodside

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

Page 16: 08 Woodside

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

Page 17: 08 Woodside

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.

Page 18: 08 Woodside

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

Page 19: 08 Woodside

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

Page 20: 08 Woodside

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.

Page 21: 08 Woodside

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

Page 22: 08 Woodside

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

Page 23: 08 Woodside

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

Page 24: 08 Woodside

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

Page 25: 08 Woodside

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

Page 26: 08 Woodside

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

Page 27: 08 Woodside

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

Page 28: 08 Woodside

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

Page 29: 08 Woodside

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

Page 30: 08 Woodside

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

Page 31: 08 Woodside

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

Page 32: 08 Woodside

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

Page 33: 08 Woodside

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

Page 34: 08 Woodside

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