The Hammerhead ultradeepwater system is the latest development in Baker Hughes’ strategy to improve well efficiency, optimize production and increase ultimate recovery.
Hammerhead system is the industry’s first fully integrated wellhead-to-reservoir ultradeepwater completion and production system. Developed to withstand extreme environments, such as the Gulf of Mexico’s Lower Tertiary trend, the Hammerhead system is designed to enable reliable long-term, high-rate production. The system will close an important technology gap to help operators realize full-field economic payback from their ultradeepwater assets.
“We expect the Hammerhead system to improve recovery factors by 2% in the Lower Tertiary through enhanced reservoir stimulation, higher drawdown capability and long-term optimized production,” said Richard Ward, President, Global Products and Services at Baker Hughes. “Using a standard well in a lower tertiary field as an example, a 2% improvement could translate to more than USD4 billion at prices of USD50 per barrel over the life of the well.”
About the Hammerhead? system
The Hammerhead? system is a built-for-purpose, integrated completion and production solution that allows operators to reliably access and economically produce high-pressure/high-temperature (HP/HT) ultradeepwater reservoirs. The system is designed for wells as deep as 33,000 ft (10 060 m) total vertical depth, located in water depths up to 10,000 ft (3050 m), and offers reliable performance in pressures and temperatures up to 25,000 psi (1724 bar) and 300?F (150?C). This first-to-market wellhead-to-reservoir solution addresses all aspects of the product life cycle, including safety, reliability, quality, manufacturability, and operations.
Fully assembled, the system includes an upper completion, an isolation assembly, a lower completion, and intelligent production capabilities. The lower completion features a 5?-in. minimum production inside diameter—the industry’s largest for a high pressure 8?-in. drift completion. The system is capable of handling sustained flow rates up to 30,000 bpd with high differential pressures up to 15,000 psi (1034 bar), and is fully compatible with subsea boosting technology, supporting reduced abandonment pressures and maximum reservoir drainage.
The lower completion, including screens, sleeves, and packers, is run in hole in a single trip, and features a high-performance frac-pack system designed and tested for extreme rates, pressures, and temperatures. The frac-pack system is engineered to increase reliability and simplify operations through positive tool indications that enable greater set-down weight and higher up strain. When supported by advanced stimulation vessels, the frac-pack system can deliver as much as 5,000,000 lb (226 7960 kg) of proppant at up to 50 bbl/min, into as many as five zones, ensuring optimal reservoir connectivity and conductivity for increased hydrocarbon flow.
Selective shifting profiles allow the lower portion of the isolation assembly to be run into the lower completion before any sleeves are opened, minimizing fluid loss into the formation. A mechanical barrier is included to maintain reliable well control during upper completion installation. Downhole wet-mate technology allows distributed temperature sensing fiber-optic cables to be placed inside the lower completion and then brought online during production. Once the well is turned on, surveillance and control capabilities permit remote monitoring and facilitate selective zonal control with dual choking, hydraulic intelligent well system valves for proactive reservoir management. The system enables operators to selectively control zones to optimize production, and deliver flow assurance technology as needed via chemical injection valves, helping to avoid costly production interruptions and ensuring sustained hydrocarbon flow.
With the integrated system, operators can reliably access Lower Tertiary reservoirs and maintain long term production, safely and reliably, for full-field economic payback.
Features and benefits
Integrated system-based design and testing;
Eliminates multi-vendor tool integration issues;
Single-trip, multizone lower completion;
Enables high stimulation rates of up to five zones with large proppant volumes;
Achieves maximum reservoir connectivity, even in low-permeability formations;
Supports set-down weight for added reliability;
Reduces operational time;
Industry’s largest production ID;
Enables production rates up to 30,000 bpd;
15,000 psi differential pressure;
Supports HP/HT environments;
Enables maximum reservoir drainage;
Chemical injection valves;
Enable delivery of chemical flow-assurance solutions;
Surveillance and control capabilities;
Enable proactive reservoir management;
Fluid loss control system;
Provides reliable well control while the upper completion is installed.
Maximize production
The extreme pump rates and volumes required for effective stimulation of Lower Tertiary reservoirs typically extend beyond the reliable operating range of almost all available tools, fluids, and vessels. But the Hammerhead system’s frac-pack tool—designed and tested for extreme rates, pressures, and temperatures—can deliver as much as 5,000,000 lb (2,268,000 kg) of proppant at up to 50 bbl/min, into as many as five zones. These aggressive treatment capabilities help to ensure optimal reservoir connectivity and conductivity for increased hydrocarbon flow. Completion design, placement, and fracture design are optimized through comprehensive modeling from our reservoir development service team. Industry-leading differential pressures up to 15,000 psi (1030 bar), combined with subsea boosting technology, help to reduce abandonment pressures for maximum reservoir drainage. The system’s lower completion features a 5?-in. minimum production inside diameter (the industry’s largest for a high-pressure 8?-in. drift completion), thus allowing it to handle flow rates up to 30,000 BOPD over the life of the well for improved recovery rates.
Improve safety and reliability
The Hammerhead system encompasses a new portfolio of technology specifically designed for reliable long-term operation in conditions up to 25,000 psi and 300°F. Developed using a holistic, wellhead-to-reservoir engineering approach, it offers total integration and full compatibility of all parts. This system based approach reduces operational risk, and also eliminates the burden of multi-vendor integration.
The system’s frac-pack tool increases reliability and simplifies operations through positive indications that enable greater set-down weight and higher up-strain. HSE risk is significantly reduced through an ultra-durable mechanical barrier that maintains reliable well control during the upper completion installation, and throughout a production life of 20+ years. Additionally, remote surveillance and control capabilities allow operators to identify and mitigate potential issues before they occur.
Applications
Cased-hole producers；
HP/HT environments；
Ultradeepwater applications；
Subsea installations.
Technical Data
Casing size: 8.5 in. (216 mm) drift；
Sand control system bore size: 5.250 in；
Temperature rating: 65 to 300°F (18 to 149°C)；
Reservoir pressure: 25,000 psi (1724 bar)；
Differential pressure: 15,000 psi (1034.2 bar);
Production rate: 30,000 bpd (2068 bar)；
Well stimulation – frac port rating: 5,000,000 lb (344 738 bar)；
Well stimulation – flow rate: 50+ bpm.
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