Technology Applications

Dennis Denney, JPT Technology Editor

Fig. 1PQ Corp. Valfor 100 molecular sieve.

Fig. 2Deploying the Sonsub lubricator module.

Fig. 3MXL long-life motor bit from Hughes Christensen.

Calcium Control in Drilling FluidsPQ Corp. has introduced its Valfor 100 as a means to control unwanted calcium in water-based drilling fluids. This molecular sieve (Fig. 1) is specifically engineered for the removal of Ca2+. The cage-like framework makes it more effective than sodium carbonate in both the amount of calcium removed and the time of reaction. It also can be used, to a lesser extent, for removing manganese and iron. The principal use has been as an additive to silicate-based drilling fluids. Before drilling calcium-based formations such as anhydrite, the system is added to the drilling fluid. Laboratory results show that 0.25 wt% of the system can reduce calcium-induced silicate depletion by as much as 20%. Field results in western Canada confirmed the slower depletion rate as well as better maintenance of drillingfluid properties such as fluid loss and rheology. The system is a crystalline aluminosilicate and is, therefore, completely inorganic, nontoxic, and noncombustible. For additional information, e-mail Mike.McDonald@silicates.com. Riserless Subsea-Well Intervention Saipem America Inc. (Sonsub) has developed its Riserless Modular Subsea Well Intervention system for workovers of subsea wells. In an emergency situation, the system disconnects the surface-deployed umbilical from the subsea equipment, leaving the lubricator and blowout preventer (BOP) safely attached to the well, eliminating the need to keep surface winches attached to the subsea equipment. The system modules include a lubricator, BOP , run-

ning tool, and an umbilical with a fail-safe disconnect. The BOP and running tool are connected together on the surface and installed with guidance from a remotely operated vehicle (ROV). The lubricator module (Fig. 2)including a tapered stress joint for control of bending loads applied to the BOP , a disconnect module, and a grease head for insertion of the workover toolis assembled on deck and installed with ROV guidance. The umbilical is then lowered to depth and connected to the BOP module by an ROV. The umbilical connector is fail-safe in that it is hydraulically powered to connect and remains connected until hydraulically powered to release. Normal operation of the connector is controlled through the umbilical; however, a secondary release system, powered by an ROV , is provided as a contingency. The multiple hose passages of the umbilical are sealed by check valves that are opened as the connector is powered to the connect condition and automatically closed as the connector is powered to release. The connection or disconnection is accomplished with a single hydraulic cylinder. The system is for use to a depth of 7,000 ft using the companys patented concentric-pipe Subsea Production Riser. For wireline service, the BOP is rated at 10,000 psi and is suitable for H2S and CO2 service. The BOP is equipped with three sets of rams, two in the production bore and one in the annulus, and it has a bypass loop for each bore to equalize the pressure across the rams after they have been closed. For additional information, e-mail tracie.ross@saipemamerica.com.

Heavy-Oil Viscosity ReducerProflux is a new production technology from OilFlow Solutions Ltd. that is designed for heavy and waxy oils. It is a cost-effective production method used to increase production by liberating stranded high-viscosity reserves. It acts on heavy oil by reducing the viscosity up to several orders of magnitude, allowing it to flow through conventional completions, in field-transport lines, process centers, and main oil pipelines. Similarly, waxy oil can flow and be transported at temperatures well below its native pour point. The product is based on a dispersion technology that creates an encapsulated oil/water continuous phase, delivering flowing viscosities of 20 to 100 cp at ambient temperatures for oils having an original viscosity of up to 70,000 cp. Unlike emulsion-based processes, the dispersion can be separated easily to re-establish the original or enhanced oil properties at the point of delivery or sale. The separated product can be recycled and reused multiple times. For additional information, e-mail mcrabtree@agtenergy.com. Metal-Sealed BitsHughes Christensen has introduced its MXL long-life motor bits: high-speed Tricone bits designed for demanding applications (Fig. 3). The design has a new cutting structure, configurable hydraulics, and a highly reliable bearing. This bit series uses a single energized metalseal bearing package. All relative rotary motion takes place between two lubricated metal-seal surfaces. A wider metal-seal surface increases sealing capacity by up to 20%. The proprietary wear-resistant surface

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Technology Applications

Fig. 4Expro Groups deepwater well-control system.

Fig. 5Comparison of two Schlumberger FlexSTONE HT cement systems with a comparative Class-G-plus-silica cement system, showing how mechanical properties of the FlexSTONE HT systems can be controlled.

retards seal wear with its lower coefficient of friction. The backup ring uses a stress-engineered shape that extends its operating life and improves its ability to keep out debris. The redesigned energizer-seal geometry improves sealing efficiency to apply the optimum face load to seal surfaces under all conditions. The redesigned bit uses optimized compact-carbide grades, re-engineered tooth shapes, and strategically placed cone savers. The cone savers protect the cone steel against abrasion by cuttings. The bits use a biased or unbiased hydraulic configuration designed for the specific application. For additional information, visit www.HCCbits.com. Deepwater Well-Control SystemOperator interest continues to rise in equipment that can control subsea wells. Well control is especially important in the fast-growing deepwater sector in which costs tend to increase in proportion to water depths. The Expro Groups high-pressure 15,000-psi landing string and its associated control system are fully adaptable to 3-, 5-, or 7-in.bore landing strings and provide hydraulic and electrical control and monitoring of subsea valves and completion equipment (Fig. 4). Compatible with all horizontal subsea wellheads, the systems are qualified for use in water depths to 10,000 ft. The systems can be deployed in applications with differential pressures of up to 15,000 psi and temperatures of up to 300F .

The control systems have a modular, flexible design to adapt to a wide range of operator applications and subsea test-tree configurations. They also achieve rapid response times that meet and exceed the industry emergency-disconnect requirements for well closure and disconnect in less than 15 seconds. The system contains three valves. The lubricator valve enables long intervention tool strings to be made up or recovered from the live well. The retainer valve closes before unlatching the subsea landing string from the wellhead, preventing any hydrocarbons in the landing string from escaping into the environment (marine riser or onto the drill floor). The subsea test tree allows safe operations on a live well during well test or completion operations. Dual ball valves provide primary well-control barriers. A latch within the assembly provides the means to disconnect and reconnect the landing string, leaving the closed-in valve section in place. For additional information, visit www.exprogroup.com. Cementing in High-Stress/High-Temperature RegionsSchlumberger has increased both the temperature and flexibility range for permanent zonal isolation of hydrocarbon reservoirs with its FlexSTONE HT cement system. The cement mechanical properties can be maintained throughout the entire working life of a well at temperatures ranging from 40 to

482F , which can be encountered while drilling for and producing deep gas reservoirs that often are highly pressured. Prejob modeling determines the set-cement mechanical properties required for the specific formation rock properties and pressure/temperature changes that likely will be encountered. This approach considers static downhole parameters and the downhole changes that can occur during pressure testing, stimulation or fracturing treatments, drawdown tests, or formation loading. An improper cement system can lead to mechanical damage of the cement sheath behind casing or the creation of microannuli, both of which can compromise a wells hydraulic isolation. This cement system uses flexible and expansive materials, and the slurries can be mixed to have a very low Youngs modulus (435,000 psi), which enables the cement sheath to conform to the tensile and compressional stresses imposed on it during thermal or mechanical expansion (Fig. 5). An optimized particle-size distribution allows increasing the solids content of the slurry and reducing the water content. Densities for the cement systems range from 10 to 21 lbm/gal. Also, with up to 2% linear expansion capability, it is possible to prestress this cement, enabling the sheath to close a microannulus of several hundred microns in size, potentially sealing fluid-leak paths. JPT For additional information, e-mail cementinfo@slb.com.

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