Case Study: Deepwater Design, Verification, and Validation Testing for Production Packers in HPHT Environments

摘要

With increasing technological demands of HPHT (high pressure high temperature) equipment and regulatory oversight, with respect to verification and validation, additional qualification testing on Production Packers is needed to ensure the equipment is fit-for-service in the applicable HPHT environment. Understanding the requirements needed to produce "fit-for-service" equipment is complex and challenging. The added challenges introduced by HPHT environments required the collaboration of the Operator and Supplier to develop specific design verification and validation testing programs for Production Packers. This paper specifies a method for developing a "fit-for-service" design verification and validation testing program that was jointly developed and applied by an Operator and Supplier. The paper includes details on metallic component analysis using finite element analysis (FEA) methods specified in ASME BPVC Section VIII Division 3. The global collapse, local failure, and buckling verification, as well as ratcheting were analyzed to determine if the design is acceptable, or if additional re-design and/or analysis is required. Additionally, the validation testing plan is based on the requirements of VO-H Validation Grade, with the addition of an internal tubing pressure test, along with required Annexes B, C, and D testing found in API 11D1, 3rd Edition. Production packers serve as a critical barrier in the overall HPHT well design. Providing "fit-for-service" verification and validation testing for equipment in these increasingly challenging environments requires in-depth knowledge of the applicable industry standards as well as equipment design, function, and failure modes. In this paper, the Supplier and Operator share their experience and lessons learned, with the intent of enabling practicing engineers to better navigate design and validation testing requirements for HPHT production packers.