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SUBSEA COMPLETION, WORKOVER, AND PROCESSING IN NIGERIAN DEEP WATERS

Table of Contents Pages

1.0 Introduction 3

2.0 Subsea Completion – Tool & Equipments 4-8

2.1 The Tubing Hanger (TH)

2.1.1 Hydraulic TH running tool 4

2.1.2 Orientation adapter joint 4

2.1.3 Completion Riser System 5

2.1.4 Tubing Hanger (TH) elevation check tool 5

2.2 Tubing Hanger (TH) Washout Tool 6

2.3 Lower Riser Package (LRP)/Emergency Disconnect Package (EDP) 6

2.4 Subsea Trees 6-7

2.4.1 Subsea Tree Installation Operations 7

2.4.2 Subsea Tree Cap 8

3.0 Workover Types 8

4.0 Subsea processing (SSP) systems 9 - 10

4.1 Subsea Separation 9

4.1.1 Hydrocarbon/water separation 9

4.1.2 Gas/liquid separation 9

4.1.3 Three-phase separation 10

4.2 Pressure-boosting 10

4.3 Water disposal 10

5.0 Conclusion 10 - 11

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6.0 Appendixes 11 – 20

6.1 Appendix 1: Pictures & Diagrams of some Completion Equipment 12 – 13

6.2 Sequence drawings showing the stack up & interface of the Equipments 13 - 15

7.0 References 21

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1.0 Introduction

This report is on Subsea Completion, Workover, and processing in Nigerian Deep Waters, within

the Niger Delta coastal regions.

Nigeria is one of the largest oil & Gas producers in Africa and the Niger Delta coastal region has a

greater reserve of the Oil & Gas. In Nigeria, the deepwater sector still has large opportunities to

expand and develop.

Some of the Subsea completion carried out in this region was a dual bore completion System using

a Dual bore subsea production tree and equipments. The tree offers the means by which a single

subsea well can be completed, controlled and produced.

Workover is the performance of one or more of a variety of remedial operations on a producing well

to try to increase production such as deepening, plugging back, pulling and resetting liners, and

squeeze cementing. It could also mean the action and techniques of reentering the well and

repairing the original completion to restore the well’s productivity.

Subsea processing of the produced oil and/or gas includes de-watering, or separating, the bulk of

the gas from the crude oil and sand particles using technology such as Subsea Multiphase flow

meters, Subsea Pump and compressors, Subsea separation and water reinjection etc.

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2.0 Subsea Completion – Tool & Equipments

The first step in preparing the well for completion is to installing a completion guide base.

2.1 Tubing Hanger (TH)

The TH (figure 2) will be oriented and landed in a subsea wellhead provided there is

a landing shoulder, sealing area, and provision to lock the TH to the wellhead. If no

such provision exists in the wellhead, a tubing head with these features will need to

be installed for attaching a blowout preventer stack for pressure control during

completion operations.

Some control dimensions are necessary to set the TH and complete the well.

The following Tools/equipments are needed to install the TH:

2.1.1 Hydraulic TH running tool

This tool locks the work string to the wellhead, via the TH and provides vertical

access to the annulus and production bores as well as maintains hydraulic

control of the downhole safety valves using the control system.

2.1.2 Orientation adapter joint:

This is used to connect the TH and TH running tool to the riser running string

and provide a means of orienting the TH by interfacing with an orientation pin

located directly above the wellhead in the BOP stack.

2.1.3 Completion Riser System (Figure 4):

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This system is used to lower the TH to the wellhead and provide access to the

annulus and production bores.

2.1.4 TH elevation check tool: (Figure 3)

This is used to verify that the TH is all the way down on its landing shoulder

and oriented properly.

2.1.5 TH Installation

The TH is run on its completion riser running assembly down through the

drilling riser and BOP stack which is landed and locked to the wellhead. The

TH is then tagged out on its landing shoulder with partial string weight. The TH

running assembly is then picked up a short distance so that the orientation pin

engages the helix on the orientation adapter joint and allows the TH and

running assembly to orient to the vertical slot in the adapter joint which is

preset to achieve the desired orientation of the production and annulus bore.

With the orientation pin still extended, the TH is set back down on the landing

shoulder with total string weight which will activate the TH seal assembly. The

TH is then hydraulically locked to the wellhead through the control function in

the TH running tool. An overpull test will establish that the TH is locked to the

wellhead. All downhole equipment is then tested. The TH running tool is

hydraulically unlocked from the TH and the TH running assembly is then pulled

back through the rotary.

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2.2 TH Washout Tool

This provide a means of cleaning out the upper portion of the wellhead prior to

landing the tree (see figure 11.67)

2.3 Lower Riser Package (LRP)/Emergency Disconnect Package (EDP)

LRP helps in redundant pressure control provided by hydraulically controlled valves

in the production and annulus bores above the tree. The EDP provides the second

primary function which is a means to disconnect from the tree/LRP should the rig

experience excessive wave action and the riser system need to be disconnected from

the well.

2.4 Subsea Tree

Subsea Trees (see figure 11.75) provides features including a hydraulic connector at

the bottom to lock the tree to the wellhead, seal pockets or stab sub receptacles in

the bottom to interface with the TH annulus, production and downhole tool

connections, a flow line connection system and hydraulic controls and accessories.

Generally, all of the valves in the tree are hydraulically controlled with manual

overrides which are adapted for actuation by an ROV. During the tree running

operation, the valves are hydraulically controlled from the control umbilical connected

to the EDP/LRP. Later in the operation when the tree cap is installed, the functions

will be bridged over to the control umbilical attached to the completion guide base so

that the tree can be controlled from the production platform location. It can be run

with guideline or guidelineless

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Subsea trees could basically be classified as vertical trees (VXT) and horizontal trees

(HXT). It could also be classified as production and water / gas injection trees.

The major differences between VXT and HXT are:

• In a VXT, the master valve is located directly above the TH, while in an HXT

the master valve is in the horizontal run adjacent to the wing valve

• In a VXT, the TH and downhole tubing are run prior to installing the tree, while

in an HXT the TH is typically landed in the tree, and hence the TH and

downhole tubing can be retrieved and replaced without requiring removal of

the tree. The removal of an HXT normally requires prior removal of the TH and

completion string;

• VXT systems are run on a dual-bore completion riser (or a monobore riser with

bore selector located above LRP and a means to circulate the annulus; usually

via a flex hose from surface). TH of HXT is run on casing tubular joints.

2.4.1 Subsea Tree Installation Operations

In preparation for running the tree, the EDP/LRP package will be locked to the

top of the tree at the surface in the moon pool. The hydraulic control umbilical

is connected to the top of the EDP. All hydraulics will be tested. The EDP, LRP

and tree will be picked up with the riser handling tool and hung off in the riser

spider. The tree is then lowered down to its required depth by adding riser

joints. The tree is now landed on the wellhead and locked to the wellhead by

activating the hydraulic lock function through the control umbilical to the tree

connector. An overpull is made to verify the connection and usually visual

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verification by camera or ROV is vital. Pressure test all applicable connections

and valve functional. The surface joint is now installed bringing the riser

system through the rotary. The surface tree is made up and lowered onto the

top of the surface joint. The wireline plugs can now be pulled from the TH. The

well can now be completed and flow tested. The tree is now shut in

preparation for pulling the EDP/LRP/completion riser system. The surface tree

is disconnected and laid aside. The LRP connector is hydraulically unlocked

from the tree and with the riser spider installed at the rotary; the

EDP/LRP/completion riser system can be retrieved.

2.4.2 Subsea Tree Cap

This is usually installed on the top of the tree to prevent marine growth on the

upper tree connection area and sealing bores, and may be either pressure-

containing or non-pressure-containing. Tree cap is installed using the tree cap

running tool (Figure 11.50 pg 248)

3.0 Workover Opeartions

Workover is the performance of one or more of a variety of remedial operations on a

producing well to try to increase production. Examples of workover jobs are deepening,

plugging back, pulling and resetting liners, and squeeze cementing.

It also consists of the action and techniques of reentering the well and redoing or repairing

the original completion to restore the well’s productivity.

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Certain equipments presently available for performing well entry and subsea equipment

interventions include:

• Completion/workover riser systems

• Light well intervention systems

• Seabed equipment intervention systems

• Other intervention techniques, e.g. through-flowline servicing, pigging and

reeled/coiled-tubing intervention in flowlines.

4.0 Subsea processing (SSP) systems

SSP comprises all separation and pressure-boosting operations that are performed subsea,

whether downhole or on the seabed.

4.1 Subsea Separation

This is used to increase production rates, maximize total recovery, overcome flow

assurance problems and limitations of topside facilities.

4.1.1 Hydrocarbon/water separation

This involves removing most or all of the produced water from the well fluids,

which can either be discharged subsea or re-injected into a suitable formation.

4.1.2 Gas/liquid separation

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This allows efficient single-phase pumping of the separated liquids and helps

overcome flow assurance problems, especially hydrate formation and

corrosion.

4.1.3 Three-phase separation

Three-phase subsea separation is also possible. However, there are

significant challenges to obtaining reliable performance of these systems.

4.2 Pressure-boosting

Pressure-boosting (pumping) can be applied downhole or on the seabed, to boost

production above natural flow conditions by adding energy to the system. Some

pressure-boosting (pumping) devices are:

• Submersible pumps

• Seabed multiphase pumps

• Wet gas compressors

4.3 Water disposal

Produced water is either disposed of to the environment or re-injected into a suitable

formation, consistent with local regulatory requirements.

5.0 Conclusion

Deepwater exploration in this region has been very challenging technically and difficult as a

result of the water depth involved. Also, it has been a very expensive venture.

Subsea Engineering technology (drilling, completion, workover and abandonment) have

been able to give the major producers success in exploring the Oil & Gas deposits in these

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difficult reserves in this region. New and innovative technological advancement in Subsea

Engineering technology is progressively coming into the industry like lighter weight and

increased water depth for the Subsea equipments/tools. This will help to access and explore

those difficult reserves in this region, which in the past prove difficult to reach as a result of

the water depth involved.

6.0 Appendixes

Figure 1: Running Completion Guide Base using the Running Tool

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Figure 2: Dual Bore Tubing Hanger Assembly

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Figure 3: Orientation Elevation Check Tool

Figure 4: Riser Joint

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Figure 5: TH Washout Tool

Figure 6: Subsea Tree

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Figure 7: Stress Joint

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Figure 7: Tree Cap & Running Tool

Figure 8: Debris Cover & Running Tool

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Figure 2.1

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Figure 2.2

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Figure 2.3

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Figure 2.4

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Figure 2.5

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Figure 2.6

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Figure 2.7

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Figure 2.8

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Figure 2.9

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Figure 2.10

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7.0 References

[1] ISO 13628-1 (2nd Edition, 2005); Petroleum and natural gas industries — Design and

operation of subsea production systems (Part 1: General requirements and

recommendations) [Accessed November, 2009]

[2] ISO 13628-7 (2nd Edition, 2005); Petroleum and natural gas industries — Design and

operation of subsea production systems (Part 7: Completion & Workover Risers) [Accessed

November, 2009]

[3] Dril-Quip Inc (1996). Offshore Drillings & Completions Training Manuals; Pages 253 – 295

[Accessed November, 2009]

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