OTC 24065

Rigless Intervention Case Studies, UK and Africa

Oliver Willis, Phillip Bosworth, Well Ops (UK) Ltd - Helix Energy Solutions Group

Copyright 2013, Offshore Technology Conference

This paper was prepared for presentation at the Offshore Technology Conference held in Houston, Texas, USA, 6–9 May 2013.

This paper was selected for presentation by an OTC program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
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Abstract

This paper describes and highlights, via two case studies, the benefits of conducting rigless subsea well
intervention from specialist monohull vessels. The case studies provide an overview of the operations on subsea
wells, from intervening through the production tree (XT), to XT change-out and well P&A / wellhead removal
operations.

A brief overview of rigless intervention techniques and equipment is also described.

The operations described in the case studies were completed in two very different operating regions. The United
Kingdom North Sea (UKCS) and West Africa (Equatorial Guinea).

In the first case study, the paper describes how over a 68 day period a Light Well Intervention Vessel (LWIV)
successfully and safely performed mechanical repair & well maintenance (and well integrity surveillance); data
acquisition (production logging), well suspension (for a XT recovery); scale-squeeze pumping operations
(production enhancement) and finally well plug and abandonment (decommissioning) on a variety of wells across
several subsea Fields.

The second case study summarises a 105 day campaign in which a LWIV was contracted to undertake subsea
well interventions (for both well maintenance and production enhancement needs) and a temporary well
suspension (for a XT change-out) on multiple subsea wells within a Field. The vessel optimisation, through
performance, coupled with its ease and speed of transit and set up (DP3 rated) were key to this particular
campaign as the 7 wells identified to be worked on by the Operator were a number of kilometres apart precluding
the efficient use of a moored unit.

Introduction

Rigless and Riserless Light Well Intervention (RLWI) activities have been executed for over 25 years across the
North Sea. The purpose of these case studies is to demonstrate that with effective project management (planning,
developing, execution and close-out) the use of RLWI is both a flexible and extremely cost effective method which
Operators can utilize for a single well, or across a number (a campaign) of subsea wells, irrespective of subsea
tree type or close proximity.

Case study #1 outlined below summarizes the flexibility & efficiency of multi-service LWIV in the North Sea with the
ability to perform intervention/subsea operations in a cost effective and efficient manner, allowing remedial
operations to be conducted in order to maintain well integrity, and other remedial well servicing techniques in order
to maintain and often enhance hydrocarbon production (manage life of well productivity) before eventual Cessation
of Production.
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Case study #2 highlights and provides an overview of the first subsea (RLWI) campaign utilising a LWIV in the Gulf
of Guinea, West Africa. Without taking anything away from the performance element, the key to success was the
project management demonstrating the companies’ ability to perform operations on a global basis; the planned
phase was undertaken in both Houston and Aberdeen, the Asset was operational prior to the campaign and during
the build-up to in the North Sea (being project managed out of Aberdeen) and the campaign was prepped and
executed from Malabo, Equatorial Guinea.

Communication, planning and working safely, competently and efficiently, with common goals between the
Operator, Contractor and Third party Service Companies was and is the key to success.

Overview of RLWI techniques

In order to conduct in-hole subsea well operations without the use of a traditional MODU, three pieces of critical
equipment (notwithstanding a trained and competent crew) are required;

 Dynamically Positioned (DP) vessel of sufficient size and capability to accommodate the equipment and
personnel required.
 Derrick or Tower with heave compensation to deploy and recover equipment.
 Subsea Intervention Lubricator (SIL) to facilitate well control and well access.

For the operations described below in the case studies, the vessels used were the MSV Seawell and the Well
Enhancer.

The MSV Seawell is 114m long and custom designed to DP2 class. It features a purpose built derrick over a 7m x
5m moonpool and a travelling block rated to 80te in passive heave mode. The vessel’s derrick is equipped with
guideline and podline tensioners along with a main winch for SIL deployment. The vessel also has an inbuilt
saturation diving system rated to 300m. Diving support is typically required in the UKCS on ageing subsea assets.

The Well Enhancer is 132m long and is rated to DP3 class. Featuring a 150te multi-purpose tower (rather than a
derrick), over a 7m by 7m moonpool the Well Enhancer is also capable of deploying riser and coiled tubing in
addition to the full range of wireline and pumping services. The vessel also features an inbuilt diving capability.

Subsea Intervention Lubricator (SIL)

The SIL (fig 1) provides access to the wellbore. It is interfaced with the well specific re-entry interface (usually a
tree running tool) and is run from the vessel as a standalone unit on wire, latched onto the tree, tested and then left
free standing on the well without riser back to surface. It is controlled by a single umbilical with full ESD/EQD
functionality and redundancy.

Wireline tools are run into the SIL through the water column, followed by the Open water latch system (OWLS)
which then effects a seal around the wire upon latching into the top of the SIL. Once latched the riser is flushed to
the glycol mix being used, whereupon the well is opened, toolcatcher released and the tools are RIH in the normal
manner with full compensation. All wireline techniques can be used from hand jarring of slickline through to tractor
conveyed electric line logging and perforating tools.

The SIL subsea system consists of a Lower riser assembly (LRA) housing the well control BOP’s and electro-
hydraulic control modules, this is connected via an emergency disconnect package to the Upper riser assembly
(URA) which comprises the main umbilical interface, further control manifolds, the electric line subsea grease
injection system and contingency wireline Bop’s. Integral to the URA is the lubricator (riser) section which houses
the downhole tooling prior to deployment and the Upper upper riser assembly (UURA) which contains a wireline
cutting ball valve and the hydraulic latch for the OWLS.

Should an emergency situation drive an emergency quick disconnect, the umbilical and guidewires (if run)
disconnect, all the inline and wellbore wetted valves close and the system is left free standing on the subsea tree
with well control integrity fully maintained. The SIL is typically designed (and verified on a case by case basis with
specific stress analysis) to withstand a 100 year return storm with a 10 year return current.
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Fig 1. Subsea Intervention Lubricator

A typical outline work sequence is described below.

 Mobilise vessel in port  Conduct downhole operations – electric,

 Sail to location braided, slickline, pumping as per
 Set up on DP requirements.
 Deploy Tree cap running tool (TCRT) on  Recover tooling to SIL, close well.
wire.  Flush SIL riser section clean.
 Test barriers, unlatch Tree Cap and recover  Recover tools open water.
with TCRT on wire.  Conduct well suspension tests.
 Deploy and test SIL c/w tree running tool  Recover SIL / TRT
(TRT) on wire and take control of well.  Deploy TCRT / TC and test.
 Conduct barrier tests, open tree valves and  As left survey, depart for next location.
downhole safety valve.
 Deploy wireline tools open water to SIL, latch
and test.
 Flush SIL with required medium.
 Open well and run in hole.
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Case Study #1

North Sea Campaign

Between December and February 2012 the RLWI vessel, MSV Seawell (fig 2) was mobilised by a major North
Sea operator to perform a series of Light Well Intervention operations across a number of UKCS North Sea fields
during a single campaign. The versatility of the LWI vessel was demonstrated with the varied workscope, allowing
the campaign to be performed efficiently due to the faster transit speed of a mono-hull vessel between locations,
removing the need for a supply vessel and minimising helicopter requirements.

Well intervention operations were conducted on seven wells across six fields of varying water depths with the
campaign duration of 68 days.

The workscope included:

 Well Integrity & suspension operations

- Slickline/E-line Plug & Packer Setting
 Mechanical repair/well maintenance (and well integrity surveillance)
 Data acquisition (production logging),
 Well abandonment operations
- Perforating/cement plug setting
- wellhead severance (abrasive cutting) and recovery
 Scale-squeeze/pumping operations
 Saturation diving operations

Fig 2. The MSV Seawell

The North Sea campaign was initially planned in utilising a 5 1/8” (through-bore ID) SIL for conventional XT
access. However, during the planning phase an additional well developed integrity issues which required
immediate intervention to secure well integrity. This additional well was outfitted with a horizontal XT (with a
different configuration to conventional XT’s, in that they have crown / tubing hanger plugs that need removing via
a SIL prior to undertaking LWI. These plugs are general in excess of 7” in circumference, necessitating the need
for a larger ID bore SIL).

In order to address this issue, another Contractor owned SIL, a 7 1/16” package was mobilised and utilised on the
well in question. The early identification of this issue, through good communication and planning between the
Operator and Contractor, allowed the 7 1/16” SIL (Fig 3) to be rapidly mobilised from their Asia-Pacific operations
base and flown, by charter, from Australia to the UK and in order to meet the critical operational time frame.
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Operational challenges

On discovering the integrity issues with the HXT in question it was necessary to conduct a site visit to the tree
vendor’s premises to get an overview of a tree which was similar to the one installed. Due to the workscope
requiring diver intervention, and with restricted access, a considerable amount of pre-job planning was conducted.

Comprehensive procedures and dive work packs were put in place prior to carrying out a Hazid review of the
workscope.

The fabrication of components to aid repair of the HXT was initiated and these were built in a short timeframe to
meet the operational schedule. The equipment that was required to interface the SIL and client Tree Running Tool
(TRT) was sourced via several co-operative operators and integrated / tested.

The SIL system was dispatched from South East Asia on the 15th December and arrived in UK on the 17th
December. It was transported from Prestwick Airport (South West coast of Scotland) to Aberdeen with work
commencing on it immediately to prepare for mobilisation to the MSV Seawell which was undertaking a campaign
of work for the same client with the 5” SIL.

The new SIL system was sent to the Seawell on the 4th January, the old system demobilised and the vessel sailed
three days later. The workscope was undertaken offshore and completed within two weeks with a successful well
suspension, and full well integrity being reinstated.

A total turnaround of 50 days duration saw the system fly from one side of the world to the other and carry out a
high profile integrity issue repair scope, demonstrating the benefits and flexibility of conducting LWI operations
over a short timescale.

Fig 3. The 7 1/16” Subsea Intervention Lubricator within the derrick onboard the MSV Seawell
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North Sea Campaign summary

• North Sea: UKCS

• Vessel: MSV Seawell
• Number of well locations: 6
• Number of wells: 7
• Water depth range: 90 – 141m
• Number of mobilisations through campaign: 5
- Including full demobilisation of 5 1/8” SIL in order to mobilise 7 1/16” SIL
- P&A phase included full vessel demobilisation of equipment to accommodate key equipment for
well abandonment
- A variety of XT’s, both HXT and Conventional duel-bore intervened upon during the campaign
(from three different XT manufacturers)
- Eighteen suppliers of equipment and services utilised during the campaign
• 68 days in-Field (December – February 2012) with minimal down time for Weather (<10%)

Operational Workscope

• 3 wells LWI (Well Maintenance & Production Enhancement)

• 3 wells Plug & Abandonment - Decommissioning operations
• 1 scale-squeeze/pumping inhibitors & treatment (Production Enhancement)
• The above workscopes were supported with Saturation Diving operations allowing diver inspections and
manifold maintenance to take place simultaneously.

Multi service campaign

• Total E-line Runs: 2

• Total Slickline Runs: 15
• Pumping
• Abrasive wellhead severance
• ROV & Saturation Diving

Case Study #2

Equatorial Guinea campaign

The LWI Vessel Well Enhancer (Fig 4) sailed from the UK to perform operations in Equatorial Guinea in January
2012. The planning for this operation was conducted by the operator in Houston and the LWI contractor in
Aberdeen, with the ultimate operations to be managed locally from Equatorial Guinea.

Fig 4. The Well Enhancer

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The campaign was initially planned for 8 wells (later reduced to 7 wells) with a workscope of Well integrity type
operations and a subsea tree change out. The campaign duration was performed in 66 days & was planned with
three phases such that only one port call was required during the campaign & the vessel was mobilised from the
UK with virtually all the equipment required for the first phase to be completed.

The workscope included:

 1st Phase – 4 x wells - Well maintenance & well Integrity operations

 2nd Phase – 1 x Recover and replace XT ‘Tree on Wire’ operation
 3rd Phase – 2 x wells - Gas Lift Valve change-out (Production enhancement)

First Light Well Intervention from a mono-hull vessel in Africa

For the Equatorial Guinea campaign, the Well Enhancer sailed from the UK, via Las Palmas, Spain, with the vast
majority of the key equipment onboard. From there, and upon customs clearance in Malabo, the vessel mobilised
additional equipment and well servicing personnel and sailed to the Field to commence operations.

Other than de-mob, across the campaign there was only one further port-call (in Malabo) in order to mobilize the
new/replacement XT and its TRT.

The campaign planning started circa. 6 months prior to the operation mobilization. A dedicated project engineer
was assigned to work with the client (their support staff and wells and subsea superintendents) at their corporate
office in Houston.

The project engineers also had to be the focal point in planning and coordinating between key locations (Houston,
Aberdeen & Malabo). The project engineer was pivotal in coordinating and communicating all aspects of the
operation; program (campaign) / document assembly, third party / vendor management of equipment and
personnel, in order to ensure that all the logistical challenges were dealt with professionally and efficiently within
set-out milestones. The Campaign (well-work) procedures and the overall program was written in conjunction with
the Client, who oversaw and authorised the various phased approach sequences and procedures.

Contingency measures and any other ‘possible’ requirements were also identified and put in place to support the
smooth execution of the LWI campaign.

Improved operational sequences were developed during the planning phase to streamline the logistical and
operational periods of the campaign and to identify particularly long lead items / equipment such as Tree Cap
Retrieval Tools (TCRT) and tree crossovers.

In July additional project engineers, who would later supervise from Malabo / onboard the Well Enhancer were
assigned to the client office in Houston for a 4 month period. Once the procedures were drafted, the project team
and all third parties attended a one-week planning session in Aberdeen to finalise the program, the safety
management system bridging documents and confirm the status of project equipment.

As per standard contractor procedures, a one-day Hazard identification meeting was also attended by all parties
prior to the mobilisation of the equipment to make personnel aware and to identify and possible operational risks
during the campaign.

During the planning phase the customs, medical and potential security requirements were reviewed, with
measures being implemented to ensure all personnel had the required vaccinations and visas for transiting and
working both onshore and offshore Equatorial Guinea.

Close communication with the approved shipping agents meant customs clearance for the vessel and equipment
was achieved in two days.
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Operational Challenges

The main technical challenge was based around the interfacing of subsea equipment; XT/TRT/TCRT all in
different regions. The new XT was in Houston; TRT’s (2 types) and TCRT’s were in Malabo with the SIL package
operational in the North Sea region.

The issues were resolved by placing a project engineer in the Client office in Houston working alongside subsea
equipment suppliers in order to manage and coordinate the interface of the key subsea equipment. Weekly
conference calls were held between Malabo, Aberdeen and Houston.

Project engineers were in the client office in both Houston and Aberdeen to help coordinate between the different
groups irrespective of ultimate contractual arrangement.

Once the Crossover, which interfaces between the TRT and SIL, was manufactured, the TRT’s were shipped
from Africa to Aberdeen and the Crossovers were installed and tested prior to mobilisation from Aberdeen. The
TRT’s then remained in Aberdeen until the mob, this allowed the interface of all the equipment onboard in
Aberdeen and complete testing prior to sailing to Equatorial Guinea. The final stack is shown in fig 5 below.

Fig 5. The 7 3/8” SIL stacked in the Well Enhancer tower for Equatorial Guinea operations.
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Equatorial Guinea campaign

• West Africa: Equatorial Guinea

• Number of well locations: 7
• Number of Wells: 7
• Water depth range: 120 - 471m
• Number of mobilisations through campaign: 3
- Initial Mobilisation from UK
- Customs clearance in Malabo
- Mobilise replacement tree prior to tree change operation
• 66 days in-Field operational (December – March 2012). The total transit time 39 days, to Malabo, via Las
Palmas and back to Aberdeen

Operational Workscope

• Installation of barriers in production / annulus bore x 2 wells

• Subsea Tree replacement & production re-instated x 1 well
• Gas Lift Valve change out x 4 wells (increased rate of production)

Multi service campaign

• Total Slickline runs: 52

• Gas Lift valves replaced:15
• Total E-line runs: 0 (Electric line was a contingency & was ultimately not required)
• Pumping
• ROV

Conclusion

Effective project management and close communication with the clients & Third party service providers during the
planning stage is crucial to the success of LWI operations; this is even more relevant during multi service
campaigns with a number of different Operator, Contractor and Third party personnel onboard working together at
any one time.

Considering the Equatorial Guinea campaign, where the operation was planned on one continent, mobilised from
another continent and the operation performed on a third continent with all of the operational stages coordinated
and completed successfully is testimony to the level of professional and competent project management
(attention to detail) during the planning phase and then ultimately during the execution phase.

The logistical flexibility of a Light Well Intervention Vessel (LWIV) to perform subsea well intervention operations
and complete the workscope as planned, without the need for supply and stand-by vessels, along with the need
for minimal helicopter flights, allows for operations to be performed efficiently where previously it may not have
been cost effective (utilising a drilling rig / MODU).

Based on the success of these campaigns, further overseas operations are anticipated and as such, planning is
being progressed for operations to be conducted later in 2013 and beyond.