SPE 123034

Design Methodologies for Upper Completion Deepwater Subsea and Dry Tree
Applications
A. Arrazola and Y. McAnally; SPE, Baker Hughes

Copyright 2009, Society of Petroleum Engineers

This paper was prepared for presentation at the 2009 SPE Latin American and Caribbean Petroleum Engineering Conference held in Cartagena, Colombia, 31 May–3 June 2009.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been reviewed
by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its officers, or
members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers 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 SPE copyright.

Abstract

Deepwater fields are one of the largest growth segments of the industry. The technologies that enable this growth economically
are those that provide improvements in operational reliability, flexibility, and cost, and which mitigated risks. With offshore rig
rates often hitting $500K US per day, special considerations must be taken into account when specifying or designing an upper
deepwater completion at depths greater than 1,000 ft (305 m). When selecting a completion scenario, an accurate assessment of
risk versus reward must be analyzed in order to design a cost-effective, yet flexible completion. In this paper, the authors outline
the proper methodologies in selecting existing technology for each completion approach in subsea and dry tree applications.

Design methodologies for deepwater completions vary when compared to conventional type completions. The basis of design in a
conventional type completion includes: 1) a production packer to isolate pressure and fluids from the producing zone and manage
production tubing movement and loads; 2) a surface-controlled subsurface safety valve (SCSSV), whose objective is to isolate the
tubing and well head from well fluids in an emergency or planned shutdown; and 3) flow control equipment, such as landing
nipples, chemical injection nipples, and sliding sleeves. Deepwater subsea or dry tree completions have similar basic requirements
as that of conventional completions. However, critical to deepwater are the completion design, planning, quality assurance and
quality control, reliability, execution/deployment, and longevity of the completion.

Drivers for completion methodologies in subsea and dry tree applications will be discussed. Issues such as tubing space-out,
packer-setting methods, SCSSV operating parameters, sub-mudline tubing and packoff hangers will be reviewed. Temporary well
suspension methods will also be discussed where applicable and different completion options will be outlined for each case.

History and Classification

The demand to replace reserves is pushing operators to drill deeper reservoirs in deeper water. Some of the challenges of
producing hydrocarbon in this type of environment are to identify viable prospects, and efficiently drill and complete these wells.
These challenges are driving the industry to develop technologies that will address this high-cost environment. So what is
considered deepwater? US Mineral and Management Service (MMS) considers water more than 1,000 ft (305 m) to be deepwater.
In the industry, some operators consider ultradeep water as more than 5,000 ft (1524 m).

Deepwater oil and gas production is increasing rapidly and output is expected to more than double by 2010. From 3 MMb/d in
2005, deepwater oil production will grow to over 6.7 MMb/d in 2010, while deepwater gas production will increase from 60 to 108
bcm (1-1.9 MMbbl equivalent) over the same period. To put this in context, deepwater oil production currently accounts for 10%
of the total offshore oil production; however over the next 10 years, its total share relative to shallow water output will rapidly
grow and account for an estimated 25% of offshore production by 2015.

The most identifiable deepwater markets are Africa, Gulf of Mexico, and Brazil, which account for 80%-90% of current deepwater
production. Latin American counties (Mexico and Colombia) and Asia (Indonesia and India) are upcoming markets that are
pursuing development in water depths in excess of 1,000 ft (305 m).
2 SPE 123034

Deepwater upper completions can be significantly different from conventional types. Higher risk, cost and longer project cycles
are usually the differentiators. Higher cost and risk can be associated to rig rates, completion time and cost of intervention.
Deepwater upper completions can be further classified by the type of tree: wet or dry. Depending on this classification, different
technologies are available to optimize the upper completion.

Deepwater Well Completion Considerations

When designing an upper completion for a wet or dry tree application, planning at all levels is critical. Contingency planning needs
to be addressed as the production declines. Selection of equipment used in the completion needs to minimize risk while
maintaining well integrity, reducing cost and maximizing production.

Also critical to deepwater projects are project management, reliability, execution/deployment, and longevity of the completion.

Project Management

When it comes to deepwater field development and specifically to the selection, design, manufacturing, and deployment of
completion equipment, it is crucial that the service company and the operator form a partnership. One key process that has been
proven to be critical to ensure a successful procurement and deployment of deepwater equipment is Quality Assurance and Quality
Control (QA/QC). The success of this process heavily depends on extensive planning and execution. The service provider, along
with the operator, needs to establish a project management structure to address the challenges associated with deepwater. This
type of structure and involvement is not typical for standard wells but it is crucial for dealing with this type of completion.
Operators need to become involved in equipment design reviews to ensure the tools meet their operational requirements before
releasing for production. The upfront involvement by the operators is essential for subsequent processes like engineering,
qualification testing, manufacturing, assembly, subassembly make-up, testing, and installation.

Flawless execution at the well site is of utmost importance for any deepwater development. Knowledge and information must be
transferred continuously from operator to service company and must continue through the drilling and completion phases. It is
critical that service center personnel and field technicians get involved when planning the deployment of the equipment. Some
operators will conduct a complete run-through of the completion procedures with the entire team of service technicians; this is
recommended.

Material Selection

Seals

Seal selection criteria are essential to a successful deepwater well. The determining factors include establishing well fluids,
downhole environment, pressure, and temperature needs. Scenarios such as high-rate stimulation and converting the well from a
producer to an injector need to be accounted for.

In some instances, elastomers can be used for seals; in other situations, alternatives may have to be identified or developed.
Sealing technologies (elastomer, non-elastomeric and metal to metal) and containment systems (backup system) need to be
compatible with the well environment.

The main difference in deepwater wells compared to conventional or even high-pressure/high-temperature (HP/HT) wells is that
since the temperature at the mudline is usually approaching 40°F (4.44°C) and below, it is critical to identify the temperature
swing between packer setting and production. This will provide operating parameters for any required qualification testing.

Static and dynamic seals are critical to the longevity of these wells. Tubing movement calculations will determine whether
floating or static seals are necessary, based on the configuration of the well.

Tubing connections are normally premium connections, keeping in mind that compressive strengths of all connections are not the
same. Some specific thread designs allow for considerably larger compressive loads.

Metallurgy

Tubulars and downhole tools have to be examined separately when analyzing strength due to temperature de-rating. For example:
a packer manufactured out of duplex stainless steel will experience a greater loss in strength at 350°F (176.7°C) than would a 13Cr
tubing string, even though both materials have equivalent room temperature properties. This differential strength loss could affect
the performance limits of the completion string.
SPE 123034 3

Strength analysis is critical to ensure the tubing, casing, and completion equipment will perform as intended. The strength
requirements of the tubing and completion equipment will be influenced by the tubing movement calculations for each scenarios
during the life of well.

Tubing Movement Calculations

Tubing movement calculations are critical in any completion. Because of high risk in completing these wells, the need for
accuracy and planning is magnified. The main objective of this section is to communicate the importance of these calculations for
a successful completion, both short and long term.

Examples of typical tubing movement cases are: (1) initial run and set of upper completion, (2) completion test, (3) production, (4)
hot shut-in, (5) cold shut-in, (6) near-surface tubing leak, (7) tubing pressure draw down, and (8) GP or fracture/stimulation with
upper completion in place.

The results of these calculations need to be documented and compared to the tubing, casing, packer, and SCSSV combined load
ratings.

Dry Tree Completions

In a dry tree application, the wellhead is located on a platform above the water. Client drivers include facility and pipeline
infrastructure, expected or planned intervention (direct vertical access to reservoir), and straightforward development plan. The
challenges include space and weight on floating structures, hydrostatic pressures, flow assurance, and environmental (wind, wave,
weather).

Dry tree completion can be either on fixed or floating structures (Figure 1).

Fixed Structures:

¾ Fixed Platforms: These consist of a jacket and a deck. The jacket is the tall, vertical section built from tubular steel
members and is locked to the seabed by driven piles. The topsides or deck placed on top has production equipment, crew
quarters, and drilling rigs.

¾ Compliant Tower: Like the fixed platform, these are made of tubular steel members and are fixed to the bottom with
piling, and support a deck. By design, compliant towers sustain more lateral deflection than the more massive and rigid
fixed platforms.

Floating Structures:

¾ Tension Leg Platforms (TLPs): These have floating hulls made of buoyant columns and pontoons. Steel pipe tendons
hold the hulls below their natural level of floatation, keeping the tendons in tension and the hulls in place. Even so, the
platforms experience some lateral motion in heavy seas. TLPs most often have dry trees on the platform, but wet tree
subsea tiebacks are also common. Like the fixed systems, TLPs can accommodate drilling operations from the deck. A
variation of the TLP design, the smaller mini-TLP, accommodates smaller deepwater reserves.

¾ Spar platforms: These get their floatation from large-diameter cylinders, weighted at the bottom to keep them upright.
Eight to sixteen wire or synthetic rope and chain combinations moor the hulls to the seabed. Because of their large
masses, spars have very little vertical heave, even in heavy seas, but there can be lateral offsets due to winds and currents.
Like TLPs, dry trees predominate, but wet trees are also used, especially in deeper waters.

Completion Design
One of the main objectives to any completion design is simplicity. However, in a deepwater completion, there has to be a
balance between simplicity and functionality. Deepwater completions are highly sensitive to the number of completion runs and
reliability. This translates into lower cost and risk to the operator during completion infancy and the life of the well.

Some of the questions that need to be addressed before designing an appropriate completion system are the following:
1) Space and weight on structure
2) Single or dual riser
4 SPE 123034

3) Flow assurance
a. Chemical injection
b. Downhole monitoring
4) Pressure and temperature
5) Downhole safety valve depth
6) Tubing movement
7) Downhole environment
8) Enhanced recovery methods
9) Compatibility with lower completion

Answers to these questions will determine the design of the completion solution.

Mudline Tubing Hanger

Two basic devices are used to alleviate the weight of the structure. Both are designed to reduce the load of the tubing below the
mudline from the structure. The slips on these products are designed to hang high load and to minimize footprint on unsupported
casing. If a single riser is used, a tubing hanger with the capability of sealing between casing ID and tubing OD can be used.
These devices have bypass capability for gas lift and operating downhole devices. Settings of these devices are generally done by a
dedicated control line; some models have a re-settable feature.

Surface-Controlled Subsurface Safety Valves

One of the key considerations when designing deepwater completions is the selection of the Surface Controlled Subsurface Safety
Valve (SCSSV) system. There are several options available that address each specific deepwater completion. One of the key
drivers for the selection of the SCSSV technology is the required pressure to maintain the valve in the open position. The other key
driver is the setting depth, which will be directly related to the mudline depth and potential hydrate formation. Since the setting
depths associated with extreme deepwater SCSSVs are considerably high, the predominant actuating system uses a rod piston and
non-elastomeric dynamic seals.

For a simple rule of thumb, a heavy sprung valve design requires about 1 psi/ft (Figure 2) of pressure plus shut-in pressure at the
valve to hold the valve in the open position. If a well has 5,000 ft (1524 m) of water and the valve will be set 3,000 ft (914.4 m)
below the mud line. The heavy sprung valve will need to be designed for a setting depth of 8,000 ft (2438 m), since we must
include the column of water just in case there is a control line break. This means the opening pressure of the valve will be around
8,000 psi (551 Bar) plus the shut-in pressure at the valve since this design is tubing pressure sensitive. Assuming a 10,000 psi (689
Bar) pressure at the valve, the opening pressure required to hold the valve open will be 18,000 psi (1241 Bar). This type of valve
is more common in dry tree application such as TLP and Spars.

Tubing Movement Devices

In every completion design, tubing movement calculations need to be evaluated. Due to the high complexity and cost in
completing these types of wells, the need for accuracy and planning is magnified. Results of the tubing movement calculations
will determine what type of tubing movement device will be needed, if any.

As mentioned earlier, when designing a deepwater completion, the objective is simplicity without hindering functionality. One
way to adhere to simplistic design is by having only static seals. This would be ideal, but often due to the loads that the equipment
will be subjected to during the life of the well, floating seals are required.

The most common types of tubing movement devices seen in these types of wells is an expansion joint (Figure 3).

Selecting the proper tubing sealing device will depend on the following:

• ID/OD compatibility with completion

• Stroke required
• Method of activation compatible with completion packer
• Straight or rotational release
• Internal flow control profile
• Seal type
• High space-out requirements
SPE 123034 5

Production Packer

Production packers are used to isolate a producing zone and manage production tubing movement and loads. To mitigate the risk
and reduce rig time, the preferred setting mechanism for a production packer is remotely set in deepwater application.

When selecting the production packer, certain factors need to be analyzed:

• Casing ID/drift
• Production tubing ID, strength, and connections
• Packer setting depth
• Packer-to-tubing interface
• Packer testing criteria (ISO 14310 V0)
• Metallurgy
• Element and slip system
• Combined ∆P and load requirements, or tubing movement calculations
• Deployment method
• Hydrostatic rating
• Temperature swing (set and production mode)

The industry-accepted norm to qualify the performance of a production packer is ISO 14310/API 11D1. Most packers used in
deepwater wells have been qualified to these norms.

Additional qualification may be required due to the low bottomhole temperature at the time of packer setting versus the packer
temperature during production. An example is setting a production packer at 40°F (4.4°C) and producing at 200°F (93.3°C). The
production packer has to maintain sealing and gripping capabilities during this temperature reversal.

Historically, permanent-set packers have been used due to reliability and performance. Due to the possibility of pre-maturely
setting the packer (mostly due to debris), the industry is moving toward a removable-type production packer in these wells.

Removable-type packers have performed well in these types of completions during the running, setting, and removal process.
These types of packers have been used in environments of 10,000 psi to 15,000 psi (689 Bar to 1035 Bar). The retrieval method
needs to be carefully considered when selecting a removable packer. The following are examples of retrieval methods:

• Shift to release
• Cut to release (mechanical or chemical)
• Straight pull
• Punch to release

Setting Methods

The following are the most common methods used in setting a packer in deepwater wells.

Hydrostatically Set

One of the main advantages of remotely setting a packer is the reduction of rig time and risk mitigation. Hydrostatic modules to
set packers have been in the marketplace for several years. They have proved to be a highly reliable setting method and provide
high value in low, medium, and high hydrostatic environments. The module is activated with applied pressure over hydrostatic.
Once this pressure exceeds the pressure rating of the burst disc, the disc ruptures, allowing wellbore fluids to enter the setting
mechanism of the tool. The well hydrostatic provides the force required to properly set the packer. Serious consideration and in-
depth analysis should be given to the working hydrostatic of the well. Too low (not enough force) or too high (system in a bind) of
a hydrostatic will prevent the module from supplying the necessary force to set the packer.

The hydraulic setting option of the packer remains unaffected by the addition of the hydrostatic module. This hydraulic packer
setting option acts as a back up to the hydrostatic module. A plug/landing nipple is used to apply hydraulic pressure to the packer

As you can see from Figure 4, over time the values required for the burst disc have increased with deeper water development.
6 SPE 123034

Hydraulic Set With Disappearing Plug

Disappearing plugs or valves are used to set hydraulically set packers. Versions of these valves include single and multiple cycle
designs. Some systems allow for self-filling of the tubing and hydraulically setting the packer. Other, more sophisticated systems
allow for self-filling of the tubing, tubing testing, and packer setting, all in separate operations.

Generally speaking, drawbacks to the design of these valves are pressure overbalance and debris intolerance. Clean downhole
environments and the pressures at the valve must be reviewed during the planning process.

Hydraulic Set With Wireline Plug

Setting a hydraulic packer using a wireline plug is another option. The plug can be deployed after the packer is run in the hole or it
can be run in place. However, running the plug in place requires consideration of heave, pressure surge, filling the tubing as it is
run in the hole, possibly resulting in packer pre-setting and formation damage risks.

Other Considerations

Most operators choose to run pre-spaced gas-lift mandrels with dummy valves for future enhanced recovery.

Flow assurance analysis will dictate if chemical injection is required and at what depths. If the required depth of injection exceeds
the packer depth, packer design must accommodate for penetrations.

Permanent monitoring is also desired in deepwater completions. As with chemical injection, if the monitoring is required below
packer depth, packer design must accommodate for penetrations.

Figure 5 shows an example of what an upper completion would look like for a dry tree application.

Wet Tree Application

With a wet tree application, the wellhead is located remotely on the seabed (in the subsea system). Subsea system options have
single or multiple wellheads on the seafloor connected directly to a host platform or to a subsea manifold. The systems include
connections by flow lines and risers to a fixed or floating system that could be miles away. Subsea systems can be used at any
depth water.

Client drivers include limited infrastructure; smaller, marginal fields; limited time to first production; and a flexible development
plan. The challenges include high intervention costs and rig availability; distance to host; hydrostatic pressure; flow assurance;
and more complex interfaces and landing procedures from floating structures.

Wet tree completion can be either on fixed or floating structures (Figure 6).

¾ Floating Production Systems (FPSs): These consist of ship-shaped, TLP-like or semi-submersible hulls with production
facilities on board. FPSs are quite free to move both laterally and vertically, so only wet trees can be accommodated.
FPSs have no drilling capability. The significant motion during heavy seas and currents calls for special equipment to
accommodate the risers that get the oil and gas from the seafloor wet trees to the production facilities on deck.

¾ Floating Platform, Storage, and Offloading (FPSOs): These have large ship shapes, made from either converted tankers
or new construction. They are moored with rope and chain. Like FPSs, FPSOs have no drilling capability. They process
production from subsea wells and store large crude oil volumes, accumulated for later transport by shuttle tankers. Water
depths present no limitation to FPSOs and FSOs.

Completion Design
As mentioned earlier, a balance between simplicity and functionally is a must.

Some of the questions that need to be addressed before designing an appropriate completion system are the following:

1) Umbical system rating

2) Distance to host
SPE 123034 7

3) Flow assurance
a. Chemical injection
b. Downhole monitoring
4) Pressure and temperature
5) Downhole safety valve opening pressure
6) Tubing movement
7) Space out
8) Downhole environment
9) Enhanced recovery methods
10) Compatibility with lower completion

Answers to these questions will determine the completion solution design.

Surface-Controlled Subsurface Safety Valves

One of the key considerations when designing deepwater completions is the selection of the SCSSV system. There are several
options available that address each specific deepwater completion. One of the key drivers for the selection of the SCSSV
technology is the required pressure to maintain the valve in the open position. The other key driver is the setting depth, which will
be directly related to the mudline depth and potential hydrate formation.

Umbilical rating is usually the limiting factor in the opening pressure required for a downhole safety valve; therefore a low
opening pressure valve is preferred in this application. This can be accomplished by using a hydrostatic-insensitive or electric-type
valve.

The balanced line valve design was one of the initial attempts to provide a low-operating-pressure deepwater SCSSV. This type of
valve requires two control lines for actuation. One is connected to the top of the rod piston seal and the other balancing line to the
bottom seal. Therefore, the power spring does not have to overcome the hydrostatic pressure in the control line, in turn lowering
the opening pressure of the SCSSV. The issue with this design is that when the valve is installed in low annulus pressure or gas-
lift applications, the valve may not be a fail-safe device. A leak from the balance line to the annulus will result in higher pressure
on top of the rod piston seal, creating a force higher than the spring force and disabling valve closure.

The dome charged design uses nitrogen to pressure balance across the SCSSV, actuating rod piston against hydrostatic in the
control line. This piston contains two sets of opposing seals that are exposed to the tubing pressure which makes this design
tubing pressure insensitive (Figure 7). The result is a much lower opening pressure. Essentially, among other things this valve
design takes away the need to overcome the tubing pressure at the SCSSV. This much lower valve opening pressure requirement
and its implications on a subsea tree drives operators to consider this valve design.

The electric- or magnetic-type safety valves are another option for these applications, but have limited run history. However, the
technology seems promising.

Space-Out Device

In deepwater wells, space-out of the upper completion above a gravel pack or liner top is a difficult issue. Different operators use
different methods, mainly long packer bore receptacles and single/multiple shear slip joints.

More common use is a tubing space-out joint that enables the liner top or the lower completion to be “tagged” with the tailpipe of
an upper completion. Before the tubing hanger is landed and above the subsea blowout preventer (BOPS), the tailpipe will take a
specific amount of compressive load, it will then collapse, leaving no compression in the tailpipe as the tubing hanger is landed.
These devices can be ordered with single/multiple shears as an indication of proper space-out, ensuring continuity of upper and
lower completions. They also come up with an option of having a fully sealable stroke. The retrieval methods for these space-out
devices vary, depending on the design.

Tubing Movement Device

As previously noted in the dry tree application section, tubing movement devices might be necessary, depending on tubing
movement calculation results.
8 SPE 123034

Production Packer

The drivers for selecting a production packer for a wet tree application are very similar to the dry tree application: to save time and
reduce risk. However, for wet tree application the two preferred setting methods are using hydrostatic module or disappearing
plug.

As discussed earlier, hydrostatic modules to set packers have been in the market for several years. The module is activated with
applied pressure over hydrostatic. The well hydrostatic provides the force required to properly set the packer. As deeper
applications are encountered, hydrostatic modules could be reaching their working limits.

Using disappearing plug to set the hydraulic production packer is another option. As mentioned before, an auto-fill device is
recommended for this application. This system will allow for tubing testing before setting the packer and, more importantly, well
suspension after setting the packer. An added benefit of some bi-directional valve designs is temporary well suspension. In subsea
wells with vertical trees, a valve can be left in the closed position, providing a second downhole barrier to the safety valve. This
barrier allows bringing the well onto production without intervention. Proper permits are required to use a bi-directional
disappearing plug as a downhole barrier.

Figure 8 shows an example of what an upper completion would look like for a wet tree application.

Assemble the Completion

Following is an outline of the running procedure for two options, (1) dry tree, dual riser, one trip with interventionless packer, and
(2) wet tree, one trip with disappearing plug. This latter completion adds a tubing space-out device to aid in the spacing-out of the
upper completion.

Dry Tree, Dual Riser, One Trip, Interventionless Set Packer (Figure 5)

The basic hookup is as follows:

• No-Go type Nipple

• Removable or Permanent Packer with Hydrostatic Module (Packer has hydraulic backup feature).
• Chemical Injection Nipple
• Gas-Lift Mandrels with Dummies
• Heavy Sprung SCSSV
• Subsea Tubing Hanger

Running Procedure Outline:

• Pick up completion and run in the hole. Keep the safety valve in the open position while running. Do not exceed the swab
limit of the packer sealing element.

• Hang the completion on the subsea tubing hanger; correlate the weight with the travel distance to set the tubing hanger. If not
correct, un-set the subsea tubing hanger, re-set and correlate. Repeat until the proper distribution of weight is reached.

• With packer at setting depth, pressure entire system (closed system). The normal pressure required to burst the disc on the
hydrostatic setting module of the packer is approximately 1,500-2,000 psi (103.4-137.9 Bar) over the well hydrostatic. Set
packer and test annulus.

• If packer is not set, review hydrostatics and applied pressure. Re-attempt to set packer with applied pressure. If packer does not
set, run plug below packer and set packer with tubing hydraulic pressure. Test annulus and remove plug from well.

• Perform SCSSV flapper seal test.

Wet Tree, One Trip with Disappearing Plug (Figure 8)

The basic hook up is as follows:

• Non-Sealing Tubing Space-Out Joint with Anchor

• No-Go type Nipple
SPE 123034 9

• Bi-directional Disappearing Plug with auto-fill sub

• Permanent or Removable Hydraulic Packer
• Chemical Injection Nipple
• Gas-Lift Mandrels with Dummies
• Dome Charged, low operating pressure SCSSV

Running Procedure Outline:

• Pick up completion and run in the hole. Keep the safety valve in the open position while running. Do not exceed the swab limit
of the packer sealing element.

• Locate in the sandface packer and shear space-out joint. This will be the indication that the subsea space-out is correct. Also,
this indication will happen when the subsea tubing hanger is still above the BOPs. If the space-out is incorrect, pull out of
hole, correct the problem, and run in hole again.

• Hang tubing/completion in subsea hanger.

• Circulate down the tubing to close the autofill sub (calibrate before running).

• Test the tubing against the disappearing plug.

• Set the packer hydraulically.

• Cycle the disappearing plug to the open position if needed. If required, the plug can be used as a temporary downhole barrier.

Conclusions

1. Project management is critical for successful deepwater developments.

2. Between a dry and a wet tree application, the main components that change are the subsea tubing hanger (sealing or non-
sealing), the surface-controlled safety valves, space-out devices, and preference of the setting mechanism of the production
packer. These all have cost and risk impacts on the completion.

3. Flow assurance is essential. The point of injection will also have an effect on the completion (i.e. packer with
penetrations).

4. Metallurgy and sealing technologies need to be compatible with wellbore environment and completion design.

5. Seating nipple of the no-go type is the preferred design for any deep well. When accessories reach their target nipple
profile, a clear indication is provided.

6. Mitigating risk vs. value of interventionless systems is critical to selecting the proper packer setting methods. Rig cost will
play a large role. Tubing testing and temporary suspension can also be key to selecting the proper system.

Acknowledgments

The authors wish to thank Baker Hughes Incorporated for permission to publish this paper, and thanks to various operators for
their investment in the future of Deepwater completions.

Nomenclature

QA/QC Quality Assurance/Quality Control

SCSSV Surface Controlled Subsurface Safety Valve
10 SPE 123034

References

1. Bernardo Maldonado, Alvaro Arrazola, Bob Morton, “Ultra Deep HP/HT Completions: Classification, Design
Methodologies and Technical Challenges,” SPE 17927, Offshore Technology Conference, Houston TX, 1-4 May, 2006.

2. Brian Wilfahrt, “Metallic Materials vs. High Temperature,” Baker Oil Tools Metallurgy Training Manual, 18 October,
1995.

3. James G. King, Alvaro J. Arrazola, “Methodology for Selecting Interventionless Packer Setting Techniques,” SPE
90678A, SPE Annual Technical Conference and Exhibition held in Houston, Texas, U.S.A., 26–29 September 2004.

4. The Deepwater Forecast 2006-2010, prospects, technologies & markets, Douglas-Westwood, 2006.

Figure 1 – Dry Tree Structures

Opening Pressure vs. Setting Depth

14,000
12,000
Opening Pressure (psi)

10,000
8,000 0 WP
6,000 5k WP
4,000
2,000
0
1,000 2,000 3,000 4,000 6,000 8,000 9,000
Setting Depth (ft)

Figure 2 – Heavy Sprung SCSSV Opening Pressure vs. Setting Depth

SPE 123034 11

Figure 3 – Expansion Joint

Rupture Disc Timeline for Hydrostatic Set Packers

20000

18000

16000

14000
Rupture Disc Values

12000

10000

8000

6000

4000

2000

0
1996 1998 2000 2002 2004 2006 2008
Years for Hydrostatic Set Packer Developement

Figure 4 – Rupture Disc Timeline for Hydrostatic Set Packers

12 SPE 123034

1,000 ft of water depth

Mudline Tubing Hanger

(Sealing or Non Sealing)

Heavy Sprung Safety Valve

Gas Lift Mandrel

Chemical Injection Sub

Tubing Movement Device

Packer with Hydrostatic

Module

Landing Nipplie

½ Mule Shoe

Figure 5 – Dry Tree One Trip System

Figure 6 – Subsea System

SPE 123034 13

Figure 7 - Dome Charged SCSSV Actuating Mechanism

Figure 8 – Wet Tree One Trip System

14 SPE 123034

Propose Equipment Dry Tree Wet Tree

Mudline Tubing Hanger

Pack Off Tubing Hanger

SCSSV - Heavy Sprung

SCSSV- Nitrogen Charge

SCSSV- Magnetic or Electric

Chemical Injection

Gas Lift

Hydraulic Packer/set with plug

Hydraulic Packer/hydrostatic module

Hydraulic Packer/disappearing plug

Tubing Space Out Devices (single,
multiple, seal and non sealing)

Tubing Movement Devices

Recommended

Not Recommended

Highly Recommended

Figure 9 – Selection Chart for Dry or Wet Tree Application