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HAL22167
4-1
Features and Benefits Sealing Swelling of the elastomer is not instantaneous. It is caused by the diffusion/absorption of liquid hydrocarbon or water, or both, into the elastomer. The time taken to achieve a complete pressure seal is dependent upon oil viscosity, element thickness, and temperature and salinity. The swelling time is engineered to ensure that the system can successfully be run to depth. The addition of slow swelling rubber layers and/or diffusion barriers can delay the onset of the swelling process as per individual well requirements. This enables running with tight clearances even in situations where the packer is exposed to swelling fluids while being run into the hole. The hardness of the set element is low, ensuring effective sealing in irregular wellbore shapes such as poor hole geometry and corroded casing. Set in permeable formation, a long packer element (5 to 9 m) seals more efficiently as it reduces bypass through the formation. The self-healing element will re-heal if damaged while running in hole or due to formation changes during production. If hole conditions are rough and the packer gets a cut, packer functionality is still maintained due to the expansion capability. If the seal should lose its effect due to formation erosion around the packer element or thermal shrinkage of the element, the Swellpacker systems will restart swelling to seal off any leak path. Rig Time An alternative to cementing, perforating, and cleanout operations when running pre-perforated assemblies or sand screens. No setting or manipulation operations are necessary. Openhole Swell Technology systems can transition from cased hole to openhole operations, reducing cost and formation damage. The system enables sand control with zonal isolation plus the isolation of shales. Robustness The chemical bonding of the rubber to the basepipe is stronger than the element itself, so it cannot be torn from the basepipe under normal conditions. The packers retain the strengths of the basepipe and can be rotated and jarred to bottom.
The packer is damage-tolerant. If hole conditions are rough and the packer gets a cut, packer functionality is still maintained due to its expansion capability. Swellpacker isolation systems can be delivered with any element length depending on the basepipe length. End rings located on either end of the swelling elastomer are an important component that assist in increasing the differential pressure capability and guide and protect the packer when run into the hole. Depending on the application and metallurgy requirements, the end ring design can be anchored to the basepipe using set screws, a crimping process, or welding. Temperature ratings up to 390F (200C). Risk Profile No mechanical interaction of downhole tools. No risk of damaging element by inflation. High reliability of equipment. Helps reduce rig time. No need for specialized personnel to run on rig.
4-2
Cementing Support
For well integrity issues, the Swellpacker isolation system can also be used to complement the primary cement job. The system provides comprehensive long-term zonal isolation, increasing the productive life of the well and minimizing the potential for an expensive workover operation. This combination of proven technologies provides an effective means to address both micro-annulus concerns and incomplete cement sheath issues.
HAL32568
HAL32569
K2 End Ring
4-3
HAL32625
Perfect seal for irregular borehole geometry Alternative solution to cementing and perforating in certain applications Complements cement to resolve well integrity issues Helps reduce operational risk Isolates producing zones more effectively Helps reduce well costs and rig time Cable feature increases system reliability by eliminating cable splicing and enables openhole SmartWell completions
Installation To install the systems, simply perform standard pre-job checks, then run in hole as part of the reservoir completion string or liner system. At that point, either produce the well to begin the swelling process, allow the current well fluid to swell the packer systems prior to operations, or circulate down the designed swelling fluid. The simplicity of the operation means that specialized installation personnel are not required. For the cable design, Halliburton provides the installation tool that fits easily on the rotary cable and installs the control cable or flatpack through the packer.
4-4
Bonded-to-Pipe Tools
Operating Condition Run in Hole Fluid: Oil-Based Mud Run in Hole Fluid: Water-Based Mud Temperature Range Reservoir Fluid: Liquid Hydrocarbon Reservoir Fluid: Oil with High Water Cut Reservoir Fluid: Water Reservoir Fluid: Gas Condensate Differential Pressure Capability Time to Set Chemical Resistance Element Length Basepipe Tensile/Burst/ Collapse/Metallurgy Oil Swelling (OS) Design to suit applications All fluid systems 30 - 390F (0 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid Water Swelling (WS) All fluid systems Design to suit applications 30 - 390F (0 - 200C) Does not swell in hydrocarbons All fluid systems; swelling depends on temperature and salinity Wide range of fresh and saline water tested Requires contact with waterbased fluid for permanent seal Up to 10,000 psi (690 bar) Hybrid Swelling (HS) Design to suit applications Design to suit applications OS: 30 - 390F (0 - 200C) WS: 265 - 390F (130 - 200C) Wide range of crude oil tested. Swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid; water swelling depends on temperature and salinity Wide range of fresh and saline water tested Swells in traces of hydrocarbon fluid Up to 10,000 psi (690 bar) Comments Contact Halliburton for engineered delay system Contact Halliburton for engineered delay system Contact Halliburton for design and simulations
Contact Halliburton for design and simulations Salinity and temperature affect swell time Contact Halliburton for design and simulations Contact Halliburton for application-specific pressure ratings Contact Halliburton for application-specific simulations Contact Halliburton for application-specific questions Contact Halliburton for length requirement Can be built on any oilfield tubulars
Does not swell Swells in traces of hydrocarbon fluid Up to 15,000 psi (1032 bar)
Varies based on designs and well conditions Can be engineered for swelling delays of 1-20 days Common oilfield chemicals Application and basepipe dependent
4-5
Slip-On Convenience Traditionally, swellable packers achieved high differential pressure ratings based on the area in contact with the casing wall or borehole. Element length is a key parameter for the contact area. The resulting differential pressure, and therefore the shorter slip-on designs, traditionally had lower pressure holding capabilities. Halliburton has developed shorter slip-on tools that can handle the higher differential ratings previously only achievable through a longer bonded-to-pipe product. One of those designs, the Swellpacker HPE (high performance element) slip-on isolation system incorporates the K2 end ring to protect the rubber element while running in hole and support the rubber during and after the swelling process. In addition, the next generation of the Lite family, the Swellpacker Lite II slip-on isolation system, has been redesigned to create a step change in slip-on tool capability. Swelling Delay Systems To ensure the oil or water contained within the well fluid does not affect the packer while it is run into the hole, Halliburton has engineered several systems that delay the swelling
process. These enable control of the elastomer swelling process as the setting time can be tailored according to the customers needs, mitigating premature setting risk while optimizing the operating envelope. The systems include polymers with built-in slower swelling properties and a variety of applied diffusion barriers. Customizing a design with either of these options, or using them in combination, allows for creation of a well-specific engineered product. Applications Swellpacker slip-on isolation systems can be key components in gravel packs for isolation and stand-alone screen completions to reduce fines migration. In reservoirs prone to sand production, the slip-on tool helps enable increased productivity and reduced well construction costs since it can be installed without specialized operating personnel. In completions using inflow control devices, slip-on tools are used to create shorter compartments for improved reservoir management.
HA L3 25 78
4-6
For many reservoirs using inflow control technology, the Constrictor slip-on isolation system can be an ideal device due to its simple design and reliable performance. One of the main applications for slip-on systems is with hydraulic stimulation operations. Halliburton horizontal completions provide operators with new options for completing horizontal multi-zone wellbores and enable highly accurate fracture placement with little to no intervention. The service allows operators to selectively access, isolate, and stimulate multiple payzones in a single wellbore with the option to close off one or more zones at a future date. This makes multi-zone stimulation possible in a shorter time interval, leading to reduced overall well completion costs.
Features Suitable for cased and open holes Install on any non-upset basepipe Robust construction No moving parts Self-healing, interventionless technology Can be run in most all fluid environments Multiple polymers available to provide oil swelling, water swelling, and hybrid swelling solutions Engineered swelling delay system Benefits No specialist operator required for installation Casing integrity is maintained Simplified logistics Permits last minute adjustments to placement
HA L32 576
Perfect seal for irregular borehole geometry Protect sand screens from plugging Alternative solution to cementing and perforating Helps reduce operational risk Isolates producing zones more effectively Helps reduce well costs and rig time
Installation Slide the slip-on system onto the basepipe, securing in place with Halliburton end rings. Run in hole with assembly. The tool simplicity means installation does not require specialist attention and can be fitted by personnel at the rig site.
Slip-On Tools
Operating Condition Run in Hole Fluid: Oil-Based Mud Run in Hole Fluid: Water-Based Mud Temperature Range Reservoir Fluid: Liquid Hydrocarbon Reservoir Fluid: Oil with High Water Cut Reservoir Fluid: Water Reservoir Fluid: Gas Condensate Differential Pressure Capability Time to Set Chemical Resistance Element Length Oil Swelling (OS) Design to suit applications All fluid systems 30 - 390F (0 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid Does not swell Swells in traces of hydrocarbon fluid Up to 5,000 psi (345 bar) Water Swelling (WS) Does not swell in hydrocarbons Design to suit applications 30 - 390F (0 - 200C) Does not swell in hydrocarbons All fluid systems; swelling depends on temperature and salinity Wide range of fresh and saline water tested Requires contact with waterbased fluid for permanent seal Up to 1,000 psi (70 bar) Hybrid Swelling (HS) Design to suit applications Design to suit applications OS: 30 - 390F (0 - 200C) WS: 265 - 390F (130 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid; water swelling depends on temperature and salinity Wide range of fresh and saline water tested Swells in traces of hydrocarbon fluid Up to 5,000 psi (345 bar) Comments Contact Halliburton for engineered delay system Contact Halliburton for engineered delay system Contact Halliburton for design and simulations Contact Halliburton for design and simulations Salinity and temperature affect swell time Contact Halliburton for design and simulations Contact Halliburton for application-specific pressure ratings Contact Halliburton for application-specific simulations Contact Halliburton for application-specific questions Custom lengths available on request
Varies based on designs and well conditions Can be engineered for swelling delays of 1-20 days. Common oilfield chemicals Standard lengths are 0.3 m, 0.5 m, and 1 m
4-7
858 L30 HA
4-8
Features Suitable for all sizes of side-pocket mandrels Fits all industry standard latches Customizable for non-standard equipment No moving parts No specialist required for installation Predictable swelling in a wide variety of oil-based and synthetic-based mud environments Individual swell testing available if necessary Self-healing, intervention-free technology Benefits Eliminates the need to pull tubing in flow-eroded or fluid-corroded side-pocket mandrels Helps reduce production downtime for remedial operations Simple operation Helps isolate side-pocket mandrels more effectively
HAL31756
4-9
SwellSim Software
The Swellpacker simulator, SwellSim software program, is used for selecting the most suitable design to meet specific customer requirements. Extensive testing on the expansion properties of Swell Technology systems has led to the development of the SwellSim software which can help predict the expansion ratio, differential pressure capability, time to first seal, and time to operational seal for a given basepipe OD, rubber element OD, and rubber element length in a given hole size. SwellSim software helps enable Halliburton to provide an engineered recommendation to our customers that delivers a fit-for-purpose and reliable solution. For our customers, this helps allow the utmost confidence that the selected product will meet their expectations. Based on actual test data, SwellSim software provides the user with the ability to look at a variety of designs (bonded to pipe, slip-on, cable bypass, etc.) and polymer types (oil, water, and hybrid swelling) in the proposed well environment. Inputting the well fluid characteristics and temperature allows the user to design and optimize the delay mechanism if necessary and tailor designs for special applications. Benefits Engineered recommendations Helps predict time to first seal Helps predict time to operational differential pressure Helps predict time to maximum differential pressure Helps allow for hole size variation Helps predict delay recommendation Helps identify potential failure modes Helps reduce downhole risks Helps reduce rig time SwellSim Software Legend Expansion ratio volume increase of packer element due to absorption of hydrocarbon Time to first seal when packer OD engages hole ID Time to operational differential pressure when packer reaches customer-specified differential pressure Time to maximum differential pressure when packer reaches maximum differential pressure capability
4-10
SwellSim Software Output A differential pressure profile curve and a swell profile (time to seal and time to fully set vs. hole size) curve are automatically generated by the simulator. See the examples below for curves extracted from the simulator.
11600
(psi)
50
Time to Fully Set: 5.5 in x 8.15 in x 9 m Time to Seal: 5.5 in x 8.15 in x 9 m
10150 8700 7250 5800 4350 5.5 in x 8.15 in x 9 m 2900 1450 9.20 9.40 9.60 9.80 10.00 10.20 0 10.40
Differential Pressure
8.80
9.00
Hol e ID ( in)
SWELL PROFILE
50 45 40 35
Ti me (days)
45 40 35
Ti me (days)
30 25 20 15 10 5 0 8.15 8.24 8.32 8.41 8.49 8.58 8.66 Hole ID (in) 8.75 8.83 8.92 9.00 9.09
30 25 20 15 10 5 0 9.17
Differential Pressure
4-11
Well Construction
With the challenges presented by depleted or even overpressured reservoirs, it is becoming more difficult to achieve optimal zonal isolation using conventional methods. Complicated wellbore geometry has pushed the limits of technology in perfecting competent annular pressure confinement and isolation of multiple zones. Wells are being designed with more casing points to isolate depleted reservoirs before drilling ahead to higher pressure areas. The increased number of casing points dictate smaller annular volumes between casing and open hole or casing and casing. The smaller annular volumes make it more difficult to provide sufficient zonal isolation or sustained casing pressure prevention using current methods. More casing points can also lead to larger annular volumes in under-reamed openhole sections. With the move into deeper water and more severe environments, operators are requiring service companies to adapt to these ever changing conditions. The advent of swellable technology has presented a competent solution to many of the challenges that have been encountered. Swellpacker isolation systems, along with swellable elastomers in cement, are products that will change and adapt along with downhole conditions.
Swellpacker isolation systems on liner tiebacks Liner Hanger Swellpacker isolation systems below liner hangers
HAL33105
4-12
Swellpacker Systems Above Top of Cement Swellpacker isolation systems used above top of cement (TOC) will prevent pressure migration to surface (sustained casing pressure) from lower reservoirs without compromising the competency of the original cement job. The systems will help prevent sustained casing pressure if during the life of the well cement becomes de-bonded from the casing which could create channels for the pressure to migrate from the formation. Swellpacker TOC systems work independently from other operations regardless of conditions as long as a swell fuel is present. Swellpacker Systems at Shoe Joints Swellpacker systems used on the shoe joints will create a competent pressure seal and allow for a Formation Integrity Test (FIT) regardless of the tail cement condition. Swellpacker shoe joint systems are designed to swell in the drilling fluid. If there is insufficient mud cleanout in the shoe joint area, the contaminated fluid fuels the packer, prompting the system to swell. A formation integrity test can then be conducted to facilitate drilling ahead. If competent tail cementation is achieved, the Swellpacker shoe joint system does not activate. Swellpacker Systems Below Liner Hangers Liner hanger Swellpacker systems help provide a positive seal to isolate the openhole section from the surface. The Swellpacker systems are installed on a liner below a liner hanger inside the parent casing. The liner hanger Swellpacker system can be designed to swell either before the liner hanger is set, or after the liner hanger pack-off is energized. Using the liner hanger Swellpacker system can eliminate the need for liner top squeeze jobs, resulting in a substantial savings of time and money. The system can be employed with or without cement.
Swellpacker OBM System Liner Low-Pressure Zone
Open Hole
HAL33104
HAL33100
HAL33102
4-13
Swellpacker Systems in Production Zones with Cement Swellpacker systems when combined with primary cementing operations can provide comprehensive longterm zonal isolation, increasing the productive life of the well and minimizing the potential for an expensive workover operation. Incorporating Swellpacker systems in production zones with cement can also provide a reactive downhole means to address the micro-annulus that occurs when set cement debonds from the casing. The Swellpacker system will remain dormant while encased in the cement sheath. Once the micro-annulus opens up and liquids or gas attempt to flow through, the packer will swell to close the flow path. The swellable rubber will conform to almost any irregular geometry in the casing or cement. Swellpacker Systems on Liner Tiebacks Using Swellpacker systems on liner tiebacks provides pressure holding capability and also creates an enormous anchoring force for the liner tieback stringeliminating the need for cement to anchor the tieback string. Swellpacker systems are installed above the seal assembly and the tieback string is run in the hole to the tieback receptacle. After the seal assembly is pressure tested, it is then raised, and fuel for the swellable element is circulated to the proper place (if not in place already). The seal assembly is lowered back into the tieback receptacle, allowing the Swellpacker system to swell. Implementing Swellpacker systems frees up time and helps reduce cost because there is no cement, float equipment, or cement plugs to drill out before completing the well. Swellpacker Systems on Scab Liners Scab liners are placed in the well to simply provide a casing conduit from the lower liner to the upper tieback casing string. Cementing a scab liner in place is time consuming and can be risky. Using Swellpacker systems on scab liners helps reduce the risk of performing a competent cementing job in relative small annuli. Swellpacker systems will provide high-pressure sealing capabilities.
HAL33103
HAL33101
4-14
4-15
Swell pressure testing is performed at an early stage in elastomer compound development. The objective is to verify swelling and internal pressure building in the elastomer, which indicates the differential pressure performance on full-scale tools. The swell speed test cell determines tool swelling speed at a specific downhole temperature. The fluid used can either be a sample supplied by the customer or a standard base oil. The primary advantage of this donut testing is to help determine the correct geometry, since the shape of the sample tested has a significant impact on the test outcome. All test results are subsequently used to update the SwellSim simulation software. Differential pressure testing is conducted in large autoclaves for full-scale tools only. Maximum pressure test pressure is 15,000 psi.
Swell Speed Test Cell
HAL31901
The final test conducted on Halliburton Easywell tools before commercialization is the run-in-hole simulation or ruggedness test. In this test, full-scale tools are run through a milled window. The main objective is to test the robustness of the tools (both element and end ring) in a dry environment (no lubrication of any fluid).
HAL31905
4-16
4-17
4-18