A game-changing single trip system for global deepwater completions

Superior’s 9645 MST (Multi-Zone Single Trip) system—a recent addition to the Complete™ MST family—is designed to enhance efficiency in well completions. By maximizing the volume of proppant pumped and integrating a barrier valve, this field-proven system streamlines operations and reduces risk and costs. It allows for the completion of multiple zones in a single trip, minimizing cycle time and ensuring consistent and reliable performance throughout the project’s lifecycle. Its versatility makes it well-suited for the demands of an ever-evolving deepwater completion landscape. 

System design. Superior designed this system to fulfill a client’s requirement for completing up to 10 zones per well, along with the capability to pump 1 million lbs (MM lbs) of proppant in each of these 10 zones in a single trip.  After successfully concluding the Front-End Engineering Design (FEED) study and iterating through various design concepts, Superior developed a unique and proprietary crossover tool port design, specifically tailored to meet this need. The prototype was rigorously tested by pumping 9 MM lbs of proppant at a rate of 50 barrels per minute (bpm), where it demonstrated sufficient capacity to go even higher. 

This innovative system was engineered to handle differential pressures as high as 12.5 Ksi, with the capacity to go as high as 15 Ksi, further enhancing its credentials in managing extreme pressure conditions. Additionally, the system incorporates various contingency options to minimize risk, while maintaining its intended functionality. To ensure seamless installation, reliability and consistency, a comprehensive System Integration Test (SIT) was conducted in a test well. The system is qualified to American Petroleum Institute (API) standards 11D1 (packers), 19V (barrier valve), and 19AC (sub-components and accessories), and it even exceeds these standards in some areas. 

System features. The 9645 MST system features a 4.5-in. inner diameter (ID) large-bore design that supports high-volume production and stimulation rates. The ID facilitates the use of a larger and more robust 4-in. internal workstring, enabling the pumping of significant volumes of proppant at higher rates, with the ability to set down more weight and maintain it throughout a long and arduous stimulation phase in every zone. This system incorporates a unique proprietary service tool design, facilitating the use of a new, positive positional indicator and a fresh set of stimulation isolation seals in every zone, drastically minimizing the uncertainty of tool position and eliminating seal leakage.  

The characteristic polished OD feature is recognized for its little-to-nonexistent resistance to movement post screen-out, permitting a seamless transition from hard screen-outs to reverse position and back down, to perform verification of a successful pack. The MST system also can be seamlessly integrated to facilitate an intelligent completion. This has recently been accomplished successfully on a campaign for one of the deepest and most challenging projects in the deepwater Gulf of Mexico (GOM). Building upon its traditional strengths, the 9645 system offers post-stimulation bi-directional zonal isolation, effortless retrievability, production selectivity, and a late-life differential rating performance. These features make it particularly suited for Lower Tertiary and Paleogene applications. 

Track record and a global first. Superior has successfully completed more than 120 wells across 450 zones since 2004, deploying MST systems in some of the most challenging and complex environments. Notably, Superior has tackled well depths of 32,000 ft in 8,500 ft of water, with deviations reaching up to 65o. In one of the most recent multi-well deepwater projects in the Gulf of Mexico, a throughput of more than 1 MM lbs of proppant into a single zone prior to moving onto other zones was achieved in consecutive wells. Treatment highlights include stimulation rates as high as 50 bpm, enabling a throughput of a record 5.4 MMlbs of proppant in a single well, with as many as seven zones achieved. 

Superior’s incorporation of a “ball”-type barrier valve into a single trip system is a global first and is considered a “game changer” by the industry, Fig. 1. The Re-closeable Hydraulic Barrier Valve (X-HBV™) was developed and qualified to overcome challenges and risks faced by the industry. This approach involved closely listening to clients’ needs, constructing a simple-yet-robust design, and rigorously qualifying the valve against the most stringent industry standards (API 19V V1 - Annex-F, gas). In fact, these qualifications exceeded API standards, ensuring the product’s reliability even under worst-case conditions.

Fig.1. Barrier valve integrated into the 9645 MST System.

Since its first installation in 2019, the X-HBV™ has been successfully deployed globally, with multiple remote actuations, thus becoming a natural fit for the MST and boosting its overall capabilities and value to the operator. With recent successes in field deployments as part of the 9645 MST in the deepwater GOM and the related remote actuations, this is now a proven and potent single trip platform ready to tackle the unique challenges in this space. 

Removing intermediate completion. The integrated X-HBV™ eliminates the need for an intermediate completion (Fig. 2) that includes an Isolation Packer assembly, a ball type barrier valve and an internal string that also reduces valuable flow area for production. This intermediate completion adds an unnecessary trip, utilizes additional equipment, increases risk, adds complexity, compromises optimum production, and increases overall costs.  

Fig. 2. Intermediate Assembly with Ball Valve in addition to Single Trip System.

The 9645 MST shortens the timeline from activating the lower completion to installing the upper completion by five to seven days, compared to previous methods. This enhancement of the MST system saves the operator millions of dollars of upfront costs with a quicker realization of production revenue.  As a result, Superior has been able to directly contribute to reducing the carbon footprint on these projects throughout the value chain. 

In summary, the new-generation MST system is designed to meet the industry’s increasing need for a reliable, field-tested platform that enhances risk mitigation, improves efficiency and reduces costs. This system represents a significant advancement in the field. Superior is dedicated to developing innovative technologies and products that positively influence client operations and business outcomes. 

About the Authors

VARUN PAI

Superior Completion Services, a Superior Energy Services company, USA

VARUN PAI is the Global Technology and Product Development manager at Superior Completion Services, based in Houston, Texas. His responsibilities include end-to-end product ownership, global support for sales and technical areas and operations for all completion products. Prior to this position, he served in a number of other roles for Superior, including product line manager, technical advisor and field engineer. He holds a master’s degree in petroleum engineering and is a member of SPE.