Copyright 2000, Offshore Technology Conference

This paper was prepared for presentation at the 2000 Offshore Technology Conference held in
Houston, Texas, 14 May 2000.
This paper was selected for presentation by the OTC Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Offshore Technology Conference and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Offshore Technology Conference or its officers. Electronic reproduction,
distribution, or storage of any part of this paper for commercial purposes without the written
consent of the Offshore Technology Conference 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 where and by whom the paper was
presented.
Abstract
To maintain profitability in the development of marginal
fields, many new technologies and concepts have been
exploited. One of the most promising technologies has been
the Intelligent Well Concept, which allows the operator to
produce, monitor and control the production of hydrocarbons
through remotely operated completion systems. These
systems are developed with techniques that allow the well
architecture to be reconfigured at will and real-time data to be
acquired without any well intervention. This paper concerns a
case history in the Gulf of Mexico in which an operator was
able to justify completion of marginal wells based upon the
cost savings generated from innovative technologies.
The completion methods chosen for this development were
successful because of careful preplanning for all phases of the
completion scenario and proved that close interaction among
all suppliers and parties involved in the actual equipment
purchasing, interface issues, and all operational strategies is
critical for project success. These topics will be discussed in
depth. Detailed test programs were implemented during the
design and manufacturing processes to eliminate field failures.
In this case, testing revealed system issues that ultimately led
to the use of an alternative design.
Also shown is the importance of allowing the proper
amount of time to adequately plan and test these systems for
their specific applications in order to assure delivery of a
design that can meet the functional requirements for that
application. In this case, although the system design was
changed, the original functional goals were met. Two wells in
this field were completed in April and July 1999. An
additional well may be completed in early 2000.
Introduction
This case history is the first in the Gulf of Mexico in which
intelligent completion technology was used. The field is
located offshore in approximately 3300 ft of water. Fig. 1
indicates field location. The field is comprised of sand units
that are vertically and laterally discontinuous across the
breadth of the field. With the need for multiple take points in
the layered reservoir system, the operator had developed a
depletion plan, which described the order in which the
different zones would be accessed to maximize both reserves
and upfront production.
It had been recognized early on that there was a need for
lower overall cost solutions to develop this field because of its
marginal reserves. Many innovative techniques from the
incorporation of a mini-TLP platform to unique pipeline
systems were planned, and it was felt that the use of intelligent
completion systems could maximize field development. Fig. 2
shows an intelligent well configuration used in this field.
The wells were to be completed with stacked gravel packs
to produce two independent zones. The intelligent completion
would allow the operator to monitor pressure and temperature
from either zone and to produce from the lower zone, the
upper zone, both zones, or neither. The wells were also to be
completed in different sands to optimize current well location
and to maximize producing and sustainable production rates.
The zones were completed simultaneously with the
intelligent completion system run as part of the production
tubing string. This was done to minimize and/or eliminate the
need for future well interventions to initiate changes in
production from either of the producing intervals.
Pre-Planning
As stated earlier, the use of intelligent completion technology
requires a different and more involved type of pre-planning
than conventional completion work.
1
The intelligent
completion directly affects the subsea interface, tubing hanger,
the umbilical to the production vessel or platform, topsides,
and the permanent completion itself. Thus, it is important to
start in-depth planning early in the life of the project to
effectively interface multiple systems.
In this case history, project planning for the intelligent
completion system began a year and a half prior to installation.
The intelligent completion used was an electro/hyraulic
system. Although there are other types of intelligent
completion systems, the electro/hyraulic systems often require
more interface consideration than pure hydraulic or electrical
OTC 11928
Case Study: First Intelligent Completion System Installed in the Gulf of Mexico
V. B. Jackson, SPE, Halliburton Energy Services, Inc. and T. R. Tips, SPE, Petroleum Engineering Services, Inc.
2 V. B. JACKSON AND T. R. TIPS OTC 11928
systems. Following is a description of the equipment chosen
for the completion, and why it was chosen over other
alternatives.
Subsea Interface and Direct Umbilical
A seamless interface for control of subsea systems can be
created with the use of a direct umbilical with dedicated
electric and hydraulic lines from the production platform. A
direct hydraulic system was used, as the wells are a short
distance from the field surface facility. A direct umbilical
from the platform was connected to each template, and the
individual wells were then connected to the templates. The
direct umbilical requires less interface work than does a
subsea pod and is used in applications in which the wells are
clustered around one or several points, or all the wells are near
the production vessel or platform.
To control subsea systems using direct hydraulic
umbilicals, it is important to note the type of umbilical being
specified. The density of the hydraulic fluid for the intelligent
completion system will affect the burst and collapse rating
required. The oil-based fluids, having a lower specific gravity
than the water-based fluids, require higher collapse resistant
umbilical passages. The other factor directly affecting the
intelligent completion system is the type of umbilical
flexible thermoplastic hose or stainless steel/incoloy type line.
The flexible umbilicals have non-linear expansion
characteristics and can make valve characterization and
precise movement more difficult, though adequate techniques
have been developed for the short umbilical lengths used in
the case described.
The use of a direct umbilical over long distances can be
both costly and inefficient as the line loss on the electric lines
becomes inhibiting, and the response time on the hydraulic
lines becomes unacceptable. In these instances or when the
wells are scattered over a large area, the use of an
electro/hydraulic subsea control system may be more cost
efficient and design effective.
Subsea Pod/Control Module
An alternative method for controlling an intelligent
completion is through the use of a subsea pod.
2
An
electro/hydraulic umbilical is run from the master control
station (MCS) to a pod system subsea. Power (both electric
and hydraulic) and communication are transmitted subsea via
an electro/hydraulic umbilical before being split off to the
individual wellheads or production manifold.
Subsea control modules are used when the wells are
located far from one another or when the wellheads are far
from the production vessel or platform. The use of a subsea
pod requires detailed interfacing with the subsea control
system. If the intelligent completion system is to be controlled
from the surface through the master control system on the
platform or production vessel, an interface at the pod will be
required to communicate with the downhole tools.
The added complication of communication protocol from
the MCS to the wellhead to the downhole intelligent well
completion system requires additional time for pre-planning
and interface development. If possible, the intelligent well
completion system supplier should be involved prior to the
contract award of the subsea pod system. Detailed
engineering work may be required to develop a control
interface to supply hydraulic and/or electric power and signal
to the downhole intelligent well system components.
If a subsea electro/hydraulic production control system had
been used instead of the direct umbilical, the modifications
made late in project life might not have been possible. The
control system integration, once complete, is fixed, and the
method of supply of hydraulic fluid to the intelligent
completion system cannot be altered.
There are additional problems during installation of the
system when its function is to be tested from the rig. The
direct hydraulic/hardwired system allowed for the intelligent
completion system to be completely function tested from the
rig prior to leaving the well.
Tubing Hanger
The field has been completed with horizontal subsea trees that
accommodate eight tubing-hanger penetrations. The
intelligent completion system used is comprised of dual
hydraulic/electric encapsulated flatpacks between the tubing
hanger and the downhole equipment for redundant electric
control. The hydraulic system is not redundant due to design
modifications, which will be discussed later. Low reservoir
temperatures and the specific oil characteristics encountered
required the use of two chemical injection subs and a deep-set
tubing-retrievable subsurface safety valve (TRSSV). The
TRSSV is a hydraulically redundant system, using two
independent control lines. Thus, the tubing hanger required
eight penetrations six hydraulic and two electric.
The number of possible penetrations differs according to
tree manufacturers; therefore, this issue must be addressed
early in the process planning. This will allow the tree
manufacturer sufficient time to design the tubing hanger with
the necessary penetrations. Ideally, since the tubing-hanger
interfaces with the intelligent well completion equipment, the
interface requirements should be identified prior to obtaining
the bid for the tubing subsea trees as was done in this project
case.
Topsides/Electrical
In the case of the hydro/electric intelligent completion system
used, the topsides interface involves electrical communication
via a surface control unit and a stand-alone computer in a 19-
in. rack mount system. The platform computer is linked via a
Modbus interface to the MCS on the platform such that well
temperature, pressure, and sleeve position can be monitored
from the MCS. A PC Anywhere computer software system
was also installed so that an engineer in an onshore office
could look at the platform computer and identify faults or
install minor system upgrades.
The electrical interface can be designed as per the specific
project. These modifications need to be addressed and
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 3
specific requirements identified by the end user (i.e.
production manager, production engineer, or reservoir
engineer) early in project development as the process of
software and integration testing can be complex and time
consuming.
Sufficient time must be allowed for internal system testing
along with the MCS, subsea tree, or other systems in which
interfacing is required. Software testing and communication
protocol is an ongoing process. After well completion and
platform commissioning, software upgrades and modifications
must be capable of being handled from the surface. Therefore,
all components of the intelligent well completion system
gauges, position sensors, solenoid valve controls, subsea pod
interface, MCS, etc. must be verified and checked. The
topsides interface must be compatible with all the equipment
in the system and be able to identify that each system is
functional.
Hydraulics
Hydraulic Fluid Selection. In addition to the effect on the
subsea umbilicals, hydraulic fluid has a direct impact on the
topsides configuration of the platform. If the intelligent
completion system uses the same hydraulic fluid as other
systems in the wellbore (i.e. TRSSV), the same fluid reservoir
can be used. However, if the hydraulic fluid to be used by the
intelligent completion system differs due to completion fluid
compatibility, reservoir fluid compatibility, specific gravity
requirements, environmental concerns of venting to the sea
floor, etc., separate fluid reservoirs, hydraulic power units
(HPU), and separate filtering systems will be required.
Hydraulic Power Unit (HPU). The hydraulic interface can
be integral and operated by the MCS, a separate HPU, or
manually operated valves in conjunction with the MCS. The
HPU provides hydraulic power from the platform to the
subsea tree, and eventually, to the intelligent completion
system.
The hydraulic system can be tied in directly to the MCS
such that the MCS controls the HPU for all systems on the
platform, including the intelligent completion system. With
integral MCS functioning, the system can be automated from
the platform. A subsea pod system will require integral HPU
functionality, and it can be implemented in a direct umbilical
installation as well.
The simplest method is an HPU solely dedicated to the
intelligent completion system. This requires manual
intervention to turn the HPU on prior to functioning the
equipment. This method can be implemented only with direct
umbilical or platform applications and eliminates the need for
interfacing the topside systems, though umbilical interfacing
may be required.
Downhole Completion
Completion hardware size, weight, and grade of smallest
inner diameter of casing, liners, or gravel pack base pipe
dictates what types of intelligent completion equipment can be
used. As an example, the intelligent completion equipment
installed in these GOM wells was set above the 7-in. liner.
This was done to maximize flow area from both the upper and
lower zones and to allow clearance for the hydro/electrical
flatpacks connected at the top of the production packer.
The intelligent completion system is run on the production
tubing. The hydraulic and electric lines are clamped to the
tubing using over-the-coupling clamps. Clearance around the
clamps is critical as it should not be too small, which might
crimp the lines or hinder production, or too large, which
would result in decentralized equipment.
The downhole completion usually requires interfacing
between numerous service companies and equipment
providers. In the Gulf of Mexico completions, the project
involved no less than 10 companies, each of which handled
significant portions of work. Different vendors were
employed for spooling, TRSSV equipment, gravel packing,
intelligent well completion technology, tubing testing, the rig,
perforating, subsea tree company, well testing, etc. A pre-
spud meeting, which proved helpful in communicating
possible concerns regarding the equipment involved, was held
in October 1998.
Zonal Isolation
Mechanical. The operator used two types of zonal isolation
techniques to mechanically isolate the formations from the
kill-weight fluid in the wellbore. The lower-zone gravel pack
had isolation sleeve ports, which were to be opened by
slickline after the tubing was landed and the well-testing
commenced. To isolate the lower-zone production from the
upper zone, a flow tube was run through the upper gravel-pack
assembly and stung into the PBR of the lower-zone gravel-
pack packer. Flow from the lower zone produces up the flow
tube, around the slickline nipple in the intelligent completion
system, and into the flow ports of the dual-zone interval
control valve (DZICV) inside the shroud (Fig. 3).
The upper-zone gravel pack contains integral pressure-
actuated valves
3
to isolate the upper zone while running
tubing, landing the hanger, circulating packer fluid, and setting
the production packer. This was necessary because the flow
tube described above isolates the upper zone from any
slickline manipulation of sliding sleeves, etc. The upper zone
is produced around the flow tube, between the OD of the
shroud and the ID of the production casing, and into the flow
ports of the DZICV. (Fig. 4)
Hydraulic. The other viable means of zonal control and
isolation is maintaining kill weight fluid without independent
isolation between the two zones. If the zones are of similar
pressure regimes, a kill weight fluid can be optimized to
decrease the damage created by the fluid. However, if the
zones are at significantly different pressures, the zone of lesser
pressure may experience significant damage and costly fluid
loss may result.
4 V. B. JACKSON AND T. R. TIPS OTC 11928
The Intelligent Well Completion System
System Overview
The original system design contained a single DZICV to
isolate production from either zone or to produce from both
simultaneously or neither. The valve was to be actuated
through a redundant system utilizing actuator electronic
modules (AEMs). As the downhole control system, the AEM
responds to information and command requests from the
surface control unit and reacts accordingly. The AEM also
communicates to the solenoid valves, which are used to
control valve movement and to set the packer.
Hydraulic Set Retrievable Packer
The production packer is a hydraulic set (minimal lateral
motion while setting) retrievable packer. The packer
incorporates five feed-through ports to pass -in-OD
hydraulic or electrical lines through the packer. It is not
necessary to terminate the lines at the packer as they are fed
through the top of the packer, between the slips and elements,
and the packer body. The pass-through sections then seal the
annulus above the packer from the annulus below the packer
with proprietary connections.
The original design of the system had incorporated a
solenoid valve to allow hydraulic pressure to reach the packer
setting chamber to set the packer. This function is fully
automated and the only method by which the packer can be set
is with direct hydraulic communication into the packer setting
chamber. The packer sets through realization of differential
pressure between the packer setting chamber and the annulus.
The packers require 4,500 psi differential to set.
Dual Zone Interval Control Valve (Fig. 5)
A four-position thermoplastic sliding sleeve, the DZICV,
allows the following production options with production from
the bottom-most position to the top-most position 1) lower
zone only, 2) both zones closed, 3) upper zone only, and 4)
both zones open. The 2
nd
position both zones closed was
designed to allow an intermediate position between zones such
that the operator could be assured that crossflow could not
occur. This position may also be important if the reservoir
liquids prove to be incompatible with one another. The
implications of these four positions and the order in which
they exist in the valve became significant when problems
arose with the hydro/electronics package.
The intermediate position of both zones closed is also
critcal if there is a large pressure difference between the two
zones. This position allows the pressure in the tubing to be
altered from the platform to within the acceptable operating
limits for DZICV function of 1500 psi differential.
Solenoid Valves
In the system as originally designed, in order to operate the
valves and set the packer, solenoid valves are used to direct
hydraulic fluid to the open or closed side of the actuated
piston. Power and command functions are sent via the
instrumentation wire in the flatpack. The system contains five
solenoid valves two normally open (to provide hydraulic
communication to additional tools), two normally closed (to
actuate the valve), and a fifth normally closed (to provide
hydraulic power to an auxiliary mechanism such as a packer).
Unlike the systems installed in other areas, the two normally
open solenoid valves were not necessary as there was only one
DZICV in the system.
4
A system containing solenoid valves, though not
inherently less reliable, is more complex than one without
solenoid valves. It was suggested in July 1998 that an option
be developed to actuate the DZICV by directly connecting to
the open and closed sides of the actuated piston housing. (See
Figs.6 and 7) Due to time constraints and delivery schedules,
this option was not fully pursued at that time. However, the
idea would eventually be adopted for these completions. The
advantages and disadvantages to the direct hydraulic option
are:
Advantages:
With the solenoid system, several single point electrical
failures render the valves inoperable without slickline
intervention.
The direct hydraulic system is not dependent on electrical
components for actuation. The direct hydraulic system
requires at least two electrical failures to prevent
actuation.
The direct hydraulic system is less complex, and thus, can
be more cost effective.
Disadvantages:
Production from more than two indepenedent zones will
require additional hydraulic lines, as the system is no
longer multiplexed.
The hydraulic supply to the intelligent completion system
is no longer redundant.
If a subsea pod is used, a direct hydraulic system becomes
much more complex than the standard electro/hydraulics
module as hydraulic steering would have to be designed
to take place in the pod system. While the intelligent
completion equipment would be simpler, the intelligent
system would be more complex.
System integration during which the valve section
(DZICV) is attached to the position sensor and the electronics
module containing the solenoid valves, gauges, and position
sensor feedback began in January 1999. The hydro/electronics
modules had been fully tested in late 1998 to 16,000 psi
absolute pressure and 235F. System integration involves
connection of the appropriate hydraulic outlets to the piston
housing and the appropriate electrical outlets to the position
sensor. The system is then function tested at 120% of
reservoir pressure and temperature.
The first integrated DZICV left Houston on January 12,
1999. The tools were shipped to Houma, Louisiana for final
stack-up and function testing. Stack-up involves incorporating
the DZICV, the packer, necessary slickline nipples, pup joints,
and other miscellaneous equipment for installation offshore.
During stack-up testing, an anomaly was noted with the
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 5
solenoid valves. It was confirmed that power and
communication were reaching the hydro/electric module, but
it was not possible to move the sleeve into the closed position.
It became apparent after additional testing that one of the
normally closed solenoid valves was not functioning correctly.
The tools were shipped back to Houston to identify
whether the problem involved a single-point failure, or
whether the solenoid valve problem was inherent in all of the
solenoid valves being used for the equipment. Design
modification had been done on these solenoid valves to
increase pressure rating and improve corrosion resistance
through the use of CRA material. While investigative testing
was being conducted on the first of the three sets of
equipment, the second set of equipment began experiencing a
similar problem.
While integrating the second set of equipment, a similar
but not identical problem arose with one of the normally
closed solenoid valves. While the first experienced a problem
in which the solenoid ball would not come fully off-seat, the
second set experienced a problem in which the ball acted as if
it was not fully off-seat or fully on-seat. The ball was floating
in the chamber such that the solenoid valve could not supply
pressure to the actuated piston housing, or would not fully
close. When the valve was instructed to close, fluid would
continue to bleed back through the inlet port.
Design modifications were considered as well as whether
sufficient time remained prior to the delivery date to design,
qualify, and build new solenoid valves. Given the time
constraints on delivery, it was decided that alternative
solutions would need to be devised. The option of connecting
directly to the piston housing with the hydraulic lines in the
flatpacks was revisited. It was recognized at the time that the
direct hydraulic option was feasible in this application because
1) direct hydraulic umbilicals would be used, and 2) a single
DZICV could still be controlled with the two available
hydraulic lines.
A test was conducted to attempt to control the valve with
hydraulic pressure and the information obtained from the
position sensors. It was not known whether the valve could be
stopped at a discrete position with direct hydraulic control.
The test was conducted through approximately 5500 ft of
flexible umbilical and 10,300 of -in. 0.049-in. wall thickness
hydraulic line per side of the actuated piston housing.
Testing concluded that the valve could be stopped at an
intermediate position with the use of position sensors.
Attempts were made to quantify the accuracy of volumetric
displacement. A specific volume of fluid was bled from the
open or closed side of the piston, and valve motion was
measured. The exact distance of valve travel was found to be
inconsistent with the volume of hydraulic fluid removed. (i.e.
50 ml may equate to 2-in. of valve motion or it can equate to
2.25-in. of valve motion) The 4-position position sensors such
as are used in these tools have a finite distance of travel to be
on position. The volumetric displacement was neither exact
nor repeatable. This is due to the flexible subsea umbilical
and the static friction pressure of the actuated piston.
Testing concluded that the only means to verify position in
this application is with the use of position sensors. A position
of full up or full down can be obtained by monitoring
pressure response or the cessation of bleed fluid on the drain
side of the piston. The intermediate positions both zones
closed or the upper zone open require position sensors to
indicate to the operator of the valve when to equalize the
pressure and stop the motion.
At the conclusion of the test, the decision was made to use
the direct hydraulic solution. This option required the
development of other devices, such as the packer setting sub.
These devices were subsequently developed and tested.
It is important to note that although the aforementioned
solenoid valve-control issues were subsequently solved, the
operator elected to continue using the direct hydraulic solution
for subsequent well completions. This choice was primarily
made to maintain compatibility throughout the field and for
the technical advantages stated earlier.
Packer Setting Mechanisms
The intelligent completion system uses a hydraulic-set,
minimal-vertical-motion-during-setting, retrievable packer.
As mentioned previously, the original design involved use of a
solenoid valve to provide hydraulic force to the packer setting
chamber. Due to the system modifications discussed above,
an alternative solution was required.
A slickline setting sleeve was developed to allow the
operator to set the packer through application of tubing
pressure. The setting sleeve is pressure balanced while
running in the hole to avoid premature packer setting and is
isolated from the packer setting chamber to allow the tubing to
be tested during the completion.
Preparation
A focused effort on project engineering for the intelligent
completion portion of this project began in November 1997.
Detailed scheduling and requirement documentation was
started at this time to reconcile any differences and develop a
design basis for the equipment. The DZICV, packer, the filter
mandrel (which eventually would not be used), the particular
version of the electro/hydraulic module, and the contingency
size packer, were all first-time builds that required prototype
design and testing. Three sets of intelligent completion
equipment were ordered one for each well and one backup
system.
The long lead-time (greater than a year in this instance)
required the operating company, the service companies, and
all other equipment suppliers to become involved early in the
process. A representative of the intelligent well system was
made a member of the operators drilling and completions
team and served to coordinate efforts and resolve interface
issues for more than a year, through the time of installation.
With current installations still essentially one of a kind per
every field design, intelligent completion projects can not be
completed in a couple of months. The many issues and
interface questions should also be considered as an ongoing
effort with all concerned throughout the project planning.
6 V. B. JACKSON AND T. R. TIPS OTC 11928
Design
Detailed design work began in March 1998 on the DZICV, the
packers, and the modifications to the then current model of the
electro/hydraulic module. Various sizes of this packer style
had been developed, tested, and successfully installed, though
the two sizes discussed above were new developments.
Testing
Integration. As mentioned previously, the equipment must be
tested several times. The first system test is conducted after
make-up of the electro/hydraulic module to the DZICV. The
system is function tested at ambient conditions, pressure tested
to 7500 psi (internal-external differential), and then, the
system is put into a test element and heated for 12 hours at
120% reservoir temperature. 120% of reservoir pressure is
applied, and a full hydraulic and electrical function test is
conducted. At the conclusion of this environmental test, the
equipment is pressure tested to 7500 psi to verify seal
integrity.
Stack-Up. The DZICV assembly is shipped for final make-up
in the district office. The packer, DZICV w/shroud, and pup
joint with slickline nipple to divert flow are made up and
tested to 7500 psi differential. A full function test is
conducted, and the make-up of the full assembly begins. (Fig.
8).
After pulling the lines through the packer, the hydraulic
lines are made up to the piston housing and the electric lines
are made up to the inlet ports of the electro/hydraulic module.
The connections are externally tested for 15 minutes at 10,000
psi. The hydraulic lines are then tested to 7500 psi working
pressure, thus testing the piston seals. An electro/hydraulic
splice sub was used so that the lines could be fed through the
packer in the workshop, decreasing rig make-up time. A body
test was again performed to verify seal integrity and to test the
slickline nipple and plug.
The stack-up testing is critical to ensuring field success.
The extensive function testing is beneficial not only in
verifying equipment integrity, but also as a means to
familiarize the operations personnel with the particular
installation. The personnel who will be performing the job are
also responsible for making sure the equipment is fully
checked and tested prior to shipping.
Installation. As with other phases of the project, extensive
pre-planning was required prior to installation. Multiple pre-
spud meetings and rig visits allowed all service companies and
suppliers the necessary interfacing to coordinate efforts. Best
practice documentation for the intelligent completion system
was coordinated with other installation teams in the North Sea
to ensure the best installation possible.
The first intelligent completion system in the Gulf of
Mexico was installed in April 1999 with a six-man crew
splitting the work into roughly two shifts. The equipment was
shipped offshore as a full assembly as described above. A
complete function test was again completed on the deck, and
the body test was repeated. The slickline lock and plug were
removed, and the assembly was visually inspected prior to
picking up in the rotary table.
After picking up into the rotary table, the hydro/electric
splice sub was connected to the flatpacks. The two electric
and two hydraulic terminations were made up and tested,
followed by the make-up of the packer setting sub located
approximately 40 ft above the packer. Cross-coupling
protectors were used to protect the control lines and to hold
tension on the flatpacks at each tubing joint. Special
provisions were made by the chemical injection manufacturer
and the TRSSV manufacturer to protect the flatpacks around
the equipment. Function testing of the intelligent completion
system was ongoing while running the completion.
After picking up the tubing hanger, the intelligent
completion system was functioned prior to terminating the
lines. The tubing hanger was made up and run to the mudline.
There was no electric communication until after the tubing
hanger was hard landed. This is a critical test of the
equipment to verify that the DZICV would not move from
position and that electric communication would be restored.
The first verification that the sleeve had remained in the
closed position was a positive test of the seal assembly in the
lower gravel-pack packer. Electric communication was
reestablished with all equipment.
The valves were moved to the upper-zone open position to
allow for packer fluid circulation. The DZICV was closed,
and a slickline plug was set in a back-up slickline-accessible
sliding sleeve, which had been run below the DZICV. A
slickline trip opened the packer setting sub. The tubing was
pressurized, and the packer set. The final process for the
completion was to flow test each zone independently.
Functionality. The original design of the intelligent
completion system used an electro/hydraulic module with
integral solenoid valves, pressure and temperature gauges, and
position sensors. While system testing was being conducted,
the solenoid valves began experiencing erratic behavior.
System modification began in January 1999 to modify the
design and take the solenoid valves out of the system.
For this particular application a direct subsea umbilical
(similar to platform completion for this discussion) with a
single valve controlling two zones the change to a direct
hydraulic solution was both functional and appropriate. If a
subsea pod had been used or if the design had not allowed two
hydraulic lines to control all valve positioning, an alternative
solution would have been required.
Conclusions
1. Several intelligent completion systems have successfully
been installed in the Gulf of Mexico, expanding on the
installation experience in the North Sea and Adriatic. The
elimination of planned well intervention has allowed the
operator to additionally enhance field economics.
2. The fully integrated intelligent completion system places
the responsibility and control of each portion of the project
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 7
under the onus of the responsible individual or company and is
an ongoing committment. This allows for system
modification and design review when necessary.
3. The coordination of all parties involved with the
completion is critical to project success. Without early and
constant involvement, critical interface issues may be missed.
The operator, all service companies, and other suppliers must
work as a team to insure that project goals are met.
4. In these completions, the flexibility of the team allowed
the intelligent completion system to be modified late in the life
of the project. Without this flexibility, project delays would
have occurred, as the equipment would not have been
delivered on time.
Acknowledgements
The authors would like to thank Halliburton Energy Services,
and PES, Inc. for support and permission to publish this paper.
The authors would also like to thank all the people involved in
this project for their support in bringing the project to a
successful conclusion.
References
1. Robison, C.E. Overcoming the Challenges Associated with the Life
Cycle Management of Multilateral Wells: Assessing Moves
Towards the Intelligent Well, paper OTC 8536, presented at the
1997 Offshore Technology Conference held in Houston, Texas, 5-
8 May 1997.
2. Botto, G., Giuliani, C., Maggioni, B., Rubbo, R. Innovative
Remote Controlled Completion for Aquila Deepwater Challenge,
paper SPE 36948, presented at the 1996 SPE European Petroleum
Conference held in Milan, Italy, 22-24 October 1996.
3. Worlow, D.W., Grego, L.V., Walker, D.J., Green, G.R., Smith,
B.E., Harris, M.E. Pressure-Actuated Isolation Valves for Fluid
Loss Control in Gravel/Frac-Pack Completions, paper SPE
58778, presented at the 2000 SPE International Symposium on
Formation Damage held in Lafayette, Louisiana, 23-24 February
2000.
4. Lie, O.H., Wallace, W. Intelligent Recompletion Eliminates the
Need for Additional Well, IADC/SPE Paper No. 59210 presented
at the 2000 IADC/SPE Drilling Conference held in New Orleans,
Louisiana, 2325 February 2000.
SI Metric Conversion Factors
in x 2.54* E + 01 = mm
psi x 6.894 757 E + 00 = kPa
ft x 3.048* E - 01 = m
F (F 32)1.8 = C
Conversion factor is exact
Modbus is a registered trademark of Modicon, Inc.
PC Anywhere is a registered trademark of Symantec, Inc.
Fig. 1 Field Location
Intelligent Completion System Installation
Gulf of Mexico
Louisiana
8 V. B. JACKSON AND T. R. TIPS OTC 11928
Fig. 2 Intelligent Well Completion
7" 38.00#
RKB - MSL -- 99.0'
PBTD - Cmt Retainer
9-5/8" 53.50#
Water Depth -- 3,226'
CI
CI
SCSSV
7" 26-38# Sump Pkr
4" 13Cr, 0.008 ga prepack screen
2-3/8" 4.70# isolation assembly
w/1.875" ID sliding sleeves
7" 32-38# GP Pkr
4" 13Cr, 0.008 ga screen w/3 PAVs per jt
2 - 2.813" ID sliding sleeves
7" 32-38# GP Pkr
DZICV w/integral DHPT
9-5/8" HF-1 Pkr
Chem Inj Mandrel
Chem Inj Mandrel
DZICV Operation
Position Lower Zone Upper Zone
1 open isolated
2 isolated isolated
3 isolated open
4 open open
9-5/8" 53.50#, Tie-back
Production Tubing
3-1/2" 10.20#, 13Cr85, VAM Ace
10K SpoolTree @ 3,311'
SCSSV
2-3/8" 4.70# Isolation Tubing
w/ATR seals
PSS
Packer Set Sub
11-3/4"
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 9
Fig. 3 Lower-Zone Production
SCSSV Control Line
Chemical Injecti on Line
PES Flatpack
Control Umbilical
SCSSV
Dual Splice Sub
Cross-Coupling Protector
Hydrauli c Set Packer
Electro/Hydrauli c Module
Sliding Sleeve (DZICV)
Plug
Upper Zone Gravel Pack
Lower Zone Gravel Pack
PBR Isolates
Upper and Lower Zones
Methanol Injection Valve
Chemical Injecti on Valve
Shroud
Position Lower Zone Upper Zone
1 open closed
2
3
4
SleeveOperation
Packer Setting Sub
closed closed
closed open
open open
10 V. B. JACKSON AND T. R. TIPS OTC 11928
Fig. 4 Upper-Zone Production
SCSSV Control Line
Chemical Injecti on Line
PES Flatpack
Control Umbilical
SCSSV
Dual Splice Sub
Cross-Coupling Protector
Hydrauli c Set Packer
Electro/Hydrauli c Module
Sliding Sleeve (DZICV)
Plug
Upper Zone Gravel Pack
Lower Zone Gravel Pack
PBR Isolates
Upper and Lower Zones
Methanol Injecti on Valve
Chemical Injecti on Valve
Shroud
Position Lower Zone Upper Zone
1 open
2
3
4
SleeveOperation
Packer Setting Sub
closed
closed
open
closed
closed
open
open
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 11
Fig. 5 Dual-Zone Interval Control Valve (DZICV)
Upper Actuator Seal
(UA)
Lower Actuator Seal
(UA)
Upper Isolation Seal
(UI)
Middle Isolation
Seal (MI)
Lower Isolation Seal
(LI)
mingle Position
Upper Zone Only Position
Closed Position
Lower Zone Only Position
Com
12 V. B. JACKSON AND T. R. TIPS OTC 11928
Fig. 6 Electro/Hydraulic Module and ICV w/Solenoid Valves
Fig. 7 Hydraulically Actuated ICV
Hydraulically Actuated ICV
TUBING
HANGER
HF-1
PACKER
SSSV
TUBING
INTERVAL CONTROL
VALVE
SUBSURFACE
SAFETY VALVE
PACKER
SETTING
PISTON
PACKER SETTING SUB
Hydraulic Piston Up
Hydraulic Piston Down
Electro/Hydraulic Module and ICV w/Solenoid Valves
TUBING
HANGER
HF-1
PACKER
Hydraulic Line #1
ANNULUS
SSSV
TUBING
SOLENOID VALVE
SOLENOID VALVE
INTERVAL CONTROL
VALVE
SUBSURFACE
SAFETY VALVE
PACKER
SETTING
PISTON
Hydraulic Line #2
OTC 11928 CASE STUDY: FIRST INTELLIGENT COMPLETION SYSTEM INSTALLED IN THE GULF OF MEXICO 13
Fig. 8 Direct Hydraulic Stack-Up
Through Tubing Hydraulic
Set Retrievable Packer
Direct Hydraulic Sleeve for
Dual Zone Control
Shroud for Dual Zone Control
Slickline Plug
Dual Flatpack Splice Sub w/
two pass through slots for
packer-set-sub lines.
Clamps on filter mandrel at top
of packer.
Electro/Hydraulic Module
Permits Control and
transfer of Downhole data
telem try, Gauges, Position
sensor and Solenoid Valve
Activation.
Position Sensor
Indicates Sleeve position
via communications with
the electro/hydraulic
module.
e