The HP/HT Completion Landscape
T he methods used for high-
pressure/high-temperature
(HP/HT) tool development are
evolving, and development cycles
are lengthening, particularly for
ultra-HP/HT applications (those
involving pressures greater than
15,000 psi or temperatures greater
than 350°F) in which materials
screening and stability assessments
are required. What can the industry
anticipate for future HP/HT wells
in terms of architecture, product
development, and regulatory
challenges? This paper identifies
current development paradigms and
discusses the future challenges in
well planning, product development,
and regulation.
HP/HT Completion
Technology Challenges
The technological challenges associat-
ed with the completion of wells at and
above HP/HT conditions are diverse and
continue to increase. Previous inves-
tigations into HP/HT projects identi-
fied technology gaps related to packers,
bridge plugs, liner hangers, subsurface
safety valves (SSSVs), tubing-to-packer
seals, and related products. (Please see
the complete paper for a comprehen-
sive list of challenges faced in HP/HT
environments, as well as a discussion
of the historical perspective in HP/HT
well development.)
In addition to the general challenge
of  materials design and testing for
HP/HT environments, several spe-
cific component-based challenges
also exist.
This article, written by JPT Technology Editor Chris Carpenter, contains highlights
of paper SPE 170919, “The HP/HT Completion Landscape—Yesterday, Today, and
Tomorrow,” by Douglas J. Lehr and Scott D. Collins, Baker Hughes, prepared for the
2014 SPE Annual Technical Conference and Exhibition, Amsterdam, 27–29 October.
The paper has not been peer reviewed.
For a limited time, the complete paper is free to SPE members at www.spe.org/jpt.
JPT • APRIL 2016
Packers. Packers and bridge plugs
have  been developed for service con-
ditions as challenging as 500°F and
25,000 psi, but the primary difficul-
ty in the development process today is
the availability of materials, both me-
tallic and nonmetallic, which are suit-
able for very high levels of stress and
strain and which possess the desired
corrosion resistance to achieve longev-
ity requirements.
SSSVs. SSSVs contain many dynamic
seals which must maintain their integri-
ty and operating characteristics over the
life of the completion. Also, the opera-
tor must have the capability to extend
the life of a malfunctioning safety valve
through the use of “insert valves.” These
are smaller-diameter wireline-conveyed
valves that can be run and inserted into
the bore of the tubing-mounted safety
valve so that production can continue
under fail-safe conditions.
Liner Hangers. Liner hangers with in-
tegral packoff capabilities (packer-type
expandable seals) have been developed
for HP/HT applications. Typically, these
tools are required to perform their seal-
ing role to a gas-tight requirement.
However, an industry specification tai-
lored for the operational role of liner
hangers does not yet exist.
Electronics. Conventional industri-
al and military electronic components
are typically rated only to 125°C, far
below the rating required for HT down-
hole electronics applications such
as measurement-while-drilling and
rotary-steerable systems in which they
are used. Despite this, the oldest and
largest consumer of electronics for HT
applications is the downhole oil and
gas industry.
Intelligent Monitoring and Produc-
tion Systems. For downhole monitor-
ing, electronic systems and fiber-optic
(FO) systems are available. Electronic
monitoring systems are marketed for
use at 150°C and 30,000 psi, at which
life expectancy is 10 years. Higher-
temperature versions are currently
marketed for use at downhole condi-
tions as high as 175°C and 30,000  psi.
At these conditions, life expectancy is
only 5 years. FO monitoring systems are
currently marketed for temperatures as
high as 536°F at 20,000  psi. An im-
portant feature of FO systems is that
they contain no electronic components;
hence, they can operate reliably at much
higher temperatures than electronic
systems, and for much longer periods
of time.
Intelligent production systems, some-
times referred to as intelligent-well sys-
tems, consist of flow-control valves,
gauges, chemical-injection valves,
and other components, and are used
to control zonal production and act as
platforms for monitoring systems. In
general, these systems have been up-
graded to “near-HP/HT” status. Com-
mercially available electric systems on
the market are rated for pressures up
to 15,000 psi, but for sub-HP/HT tem-
peratures, with life expectancy as high
as 20 years.
HP/HT Challenges Specific
to Well Intervention
Historically, discussions regarding
technology gaps and challenges tend to
focus on completion tools and systems.
However, there are also significant chal-
lenges in well intervention.
75
 Redundancy in Shoe-Track Isolation.
Several Gulf of Mexico (GOM) operators
have recently used advanced permanent
bridge plugs for standalone barrier ap-
plications in ultra-HP/HT conditions to
achieve redundancy in shoe-track integ-
rity. These advanced permanent bridge
plugs (sometimes referred to as iso-
lation plugs) combine bridge-plug and
production-packer technology to satis-
fy the need for ultra-HP/HT shoe-track
isolation and life-of-the-well longevity.
Tubing Cutters. A variety of tubing cut-
ters are available commercially. Some
are effective into the ultra-HP/HT re-
gion, but few are known to be consis-
tently effective in these applications. Jet
cutters use a shaped-charge explosive to
make the cut. A variety of charges can be
used, and these models will be subject to
(approximately) the same temperature
limitations as perforating guns.
Chemical cutters operate by spraying
a chemical through small ports in a tool
body. In HP environments, their effec-
tiveness is reduced by the backpressure
effect (high hydrostatic pressure) on the
chemical cutting fluid. At HP/HT condi-
tions, chemical-cutter efficiency is well
below 50%.
Radial torch cutters use energized
plasma to make a cut. They are current-
ly rated up to 500°F and 20,000 psi.
Mechanical cutters are limited by
temperature because of the electronics
and pressure owing to the housings that
carry the electronics. Current technolo-
gy can operate at 392°F and 20,000 psi.
Mechanical cutters provide a controlled
cut and generate only fine debris. The
cut is controlled at surface, with the
ability to modify the cut in real time.
Logging Tools and Electronics. Ser-
vice life for printer-circuit-board (PCB)
-based electronics packages at HP/HT
conditions is very limited; at temper-
atures greater than 150°C, PCB life is
measured in hours. A few new logging
tools use hybrid or multichip modules
and are rated at 175°C; their longevity
is measured in days. At temperatures
greater than 175°C, electronics usage is
76
currently limited to a few passive log-
ging tools, and longevity is measured in
hours. These tools are passively cooled,
which explains their short life span.
Miscellaneous Challenges. Several fur-
ther significant intervention challenges
exist in conveyance and fishing in HP/HT
conditions, including work-string limi-
tations, packer removal, temperature
limitations of positive-displacement
motors, and pressure and temperature
limitations of ballistic setting tools.
Well Planning
Systems-Integration Testing. Systems-
integration testing for many applica-
tions can prove challenging, but is criti-
cal to the success of the completion or
intervention. For example, an HP/HT
bridge plug, HP/HT nonballistic hydro-
static setting tool, and an HP/HT casing-
collar locator can each be validated sep-
arately, but integrating them and testing
them as a system at downhole condi-
tions is the so-called “acid test.”
Conveyance Methods. There are sev-
eral methods to convey tools into a well.
These methods include pipe, coiled tub-
ing, and wireline (slickline and electric
line). The decision to use one method
over another will depend on many fac-
tors and will determine how the rig
must be configured for the operation.
At greater depths, it is preferred, when
possible, to use wireline because this
can reduce rig time significantly.
Hazard and Operability (HAZOP)
Analysis. A HAZOP analysis is used to
identify hazards and operational prob-
lems that may occur during well op-
erations. Identifying potential hazards
and operational problems correctly
and having a plan in place and know-
ing the advantages and disadvantages
of various options can ultimately help
prevent loss of well control and can
save lives. In an HP/HT application, a
HAZOP analysis may prove useful in
identifying contingency tools that need
to be developed or tested before use
in a well.
The Regulatory Landscape
Regulatory requirements vary globally
and are beyond the scope of this paper.
Instead, this section describes some of
the Bureau of Safety and Environmental
Enforcement (BSEE) requirements for
US GOM waters.
Deepwater-Operations Plan (DWOP).
All HP/HT completions require a new-
technology (NT) DWOP (NTDWOP),
regardless of water depth. BSEE regu-
lators require that any NT that is tech-
nically complex, and that requires a
high degree of specialized knowledge,
be reviewed by an independent third
party. If the NT exceeds the limit of ex-
isting standards, industry experts and
the BSEE must discuss the matter and
achieve a high degree of convergence. If
the NT conflicts with existing engineer-
ing standards, the BSEE will not approve
its use.
NTDWOP Process for HP/HT Applica-
tions. The BSEE recommends that the
well operator contact the Technical As-
sessment Section of the BSEE as early
as possible concerning an HP/HT proj-
ect to receive up-to-date guidance. For
any NT, an NT Conceptual DWOP must
be submitted with a complete list of all
equipment and materials that will be
used in the HP/HT well along with the
proposed engineering standards that
will be used to evaluate materials se-
lection and design-verification analysis,
and perform validation testing. After
the development of the NT is complete,
the NT DWOP submittal must contain
all the analysis and test reports pro-
posed in the NT Conceptual DWOP (see
the complete paper for a description of
these elements).
Design Verification and Analysis.
The BSEE currently defaults to Ameri-
can Petroleum Institute (API) PER 15K
and API 17 TR8 for guidance on HP/HT
material selection, design-verification
analysis, and validation testing. How-
ever, the BSEE does not consider
these documents to be all-inclusive
or complete. JPT
JPT • APRIL 2016