WESTERN ENERGY PRODUCTS & SERVICES (WEPS) SWELLABLE PACKERS

Transcription

1 WESTERN ENERGY PRODUCTS & SERVICES (WEPS) SWELLABLE PACKERS

2 Table of Contents Concept Design WEPS Advantages Testing and QA

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4 WEPS Swellable Packer Oil Swell Rubber Element Water Swell Rubber Element

5 Robust End Ring Design Substantial end ring design provides protection to the rubber element during run in. Standard End Ring Rubber element is vulcanized to the base pipe using pressure, heat and chemical reaction to establish one effective annular seal. Prevents extrusion during the sealing and production operations. Enhanced AER End Ring

6 Testing and Qualification Swell Oil and Water Testing Pressure Testing Scaled Length Testing Full Scale Testing Scaled Testing Different Fluids Temperatures Full Scale Testing Diameters

7 Quality Rubber Elements Both the rubber and packers are manufactured in the same facility. Consistent quality control through the entire process. Traceability of each batch or rubber to the rubber and the date the element was manufactured.

8 Quality Rubber Elements WEPS proprietary oil swell elastomer absorbs the hydrocarbons resulting in a predictable swell that is activated by well-bore fluids and temperature. WEPS packers are effective for applications where simplicity, reliability and integrity are required. Swell packers operate with less complexity and are generally more cost effective than traditional inflatable packers.

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12 Background of current liner packer issues/ Typical Questions % of liners still do not get to TD Wells are getting more complex What is the current well design trend & where are we headed? Do swell packers work? We do not do clean out runs we run smaller 5.5 packers in a 6 hole What is better dedicated clean out run or ream while drilling?

13 Current Liner trends cont Our holes are in good shape our packers swelled prematurely that is why we did not get to TD No need for reamer run RWD / clean out at TD, we only have issues occasionally. We do not need to run centralizers, wells are easy We need to run water base packers in oil base to keep our packers from prematurely swelling Do you have enough down weight? We have seen issues where the pups have leaked. Why is there an issue? The issues with smaller OD swell packers / they require greater displacement and reduce seal effectiveness

14 Liner background We do not need to run T & D. Complex wells do require this analysis. All centralizers, reamers & packers are created equal? No they aren't. Note T & D on pad wells big change Much more difficult work. How many DLS of say 5 is in the lateral is too many 23? Does it matter which direction the well is drilled? Sometimes it does. Does it matter if it is up drill / down drill? Again, the issue is weight tension Is it a pad well with a big turn coming right out of the 7? Another Completion.

15 Note, failure of non WEPS liner run. This operator had two wells with this type of failure in three months. What is the cost of liner not getting to TD or being off depth?

16 We estimate 10-20% liners not going to TD today note end rings Non WEPS product

17 32 packer 8800 ft lat 2 DLS of over 5 DLS centralizers hole reamed

18 10,000 ft lat 23 5 DLS no centralizers Diagram is showing Helical buckling in red.

19 Same well with centralizers Diagram is showing the reduction of Helical buckling in red.

20 8,800 lat 32 packers centralizers Diagram above is showing the liner went to bottom on this well.

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22 Swelling Rubber Packer Introduced 2001 for variety of applications Low temp, heavy oil to high temp, gas Provides effective downhole zonal isolation thru swelling properties of rubber No moving parts, no service tools or surface operations required

23 Swelling Rubber Packer Design Base pipe Anti-extrusion ring OBM diffusion barrier High swelling core Low swelling outer layer

24 Swelling Rubber Packer Construction Standard oilfield grade tubular with layered rubber bonded along length Rubber swells through absorption of hydrocarbons, resulting in annular seal Swelling is time-dependent, homogeneous along length of element Seal ability depends on absolute swelling not the swelling fluid

25 Swelling Packer Concept Operation based on swelling properties of rubber in hydrocarbons Continuous thermodynamic absorption expansion expands and seals the annulus around a pipe Can be used in open or cased holes Eliminates the need for rig operations to install

26 Swelling Packer Features Operates in temperatures from 35 to over 400 F Supports differential pressures up to 10,000psi Operates in oil or water environments with varying salinity concentrations Long-term high-pressure sealing ability for oil-swelling applications Elastomers actually absorb water to provide a permanent swelling seal in water-swelling applications

27 Characteristics of Rubber Thermodynamic absorption of oil Continued rubber expansion to equilibrium Swell pressure 3-6 bars Reduced mechanical properties, not degradation Won t swell in pure water Swelling Trace oil in flowing water is sufficient Swelling pressure measurement

28 Swelling Packer Design Multi-layered Packer Design High-swelling Inner Core Low-swelling Outer Layer Diffusion Barrier (optional)

29 Swelling Packer Design Fully flexible OD/base pipe dimensions Small clearance ( OD 8.5 hole) Same bending radius as base pipe

30 Estimated/Correlated ΔP DP (bar) Simulation dead Hole ID (inch) 4.5" base pipe 5.5" base pipe 6.625" base pipe 7" base pipe

31 Use in Oil-Based Mud Swelling is delayed to RIH OBM at 106 C for 3 days 8 wells with 42 packers 8,55 8,35 8,15 7,95 7,75 7,55 7,35 Oil Based Mud Crude 106º 20 C 76 C 106 C Diffusion barrier + Low swell Low swell outer layer WBM Packer Diffusion barrier looses effect 7,

32 Testing: Autoclave Testing with temperature and crude 98% WC circulation Regains integrity after failure Erosion testing Model and full size packers Round, oval, different lengths, sand surface

33 Advantages of Swelling Packer Rugged Construction Self-Repairing, Continues to Expand Set at BHST Ease of Logistics/Setting No rig time, wash pipe, tools, pumping required No Environmental Impact Proven Track Record

34 Swelling Packer Installations 1000 Swelling Packers installed in 100 wells Through windows: 24 packers in 5 installations Eni 5 firsts on the slope Deepest well western hemisphere / 2 deep wells Coil applications

35 Swelling Packer Installation Guide

36 Swell Packer Product Line Oil Swelling (OS) Standard & Extreme H2S C ( F) Water Swelling (WS) Lo Temp (LT) 0-70 C ( F) See chart Normal Temp (NT) C ( F) Hybrid Swelling (HS) Salinity up to appx 7% Hi Temperature (HT) C ( F) Salinity up to approx 5-7% Dual Swelling (DS) Any combination of oil and water swelling WS Lo Temperature Compound Chart Temp C / F Salinity % OD Expansion (in) 0-70 / % < / % <0.5 >40 / > % <0.3

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39 Why Use WEPS Patents Detailed marketing knowledge Engineering & R/D input Global marketing experience Tender Preparation & extensive swell packer experience Operational experience with a number of very high profile jobs SPE papers / OTC committee member Product development knowledge Detailed databases Complete swellable packer marketing & operational support

40 WEPS Experience More than 1000 Swelling Packer Installations to Date Related US Patents Awarded Related Industry Publications SPE/PS-CIM/CHOA PP PS2005-XXX Innovative Completion Technology Enhances Production Assurance in Alaskan North Slope Viscous Oil Developments Michael T. Triolo, BP; Eric R. Davis and Brian R. Buck, ConocoPhillips Alaska; Rune Freyer, Easy Well Solutions; Lee Smith, Alaskan Energy Resources, Inc. Copyright 2005, SPE/PS-CIM/CHOA International Thermal Operations and Heavy Oil Symposium This paper was prepared for presentation at the 2005 SPE International Thermal Operations and Heavy Oil Symposium held in Calgary, Alberta, Canada, 1 3 November This paper was selected for presentation by an SPE/PS-CIM/CHOA Program Committee following review of information contained in a proposal submitted by the author(s). Contents of the paper, as presented, have not been reviewed by the Society of Petroleum Engineers, Petroleum Society Canadian Institute of Mining, Metallurgy & Petroleum, or the Canadian Heavy Oil Association and are subject to correction by the author(s). The material, as presented, does not necessarily reflect any position of the SPE/PS-CIM/CHOA, its officers, or members. Papers presented at SPE and PS-CIM/CHOA meetings are subject to publication review by Editorial Committees of the SPE and PS-CIM/CHOA. Electronic reproduction, distribution, or storage of any part of this paper for commercial purposes without the written consent of the SPE or PS-CIM/CHOA is prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300 words; illustrations may not be copied. The proposal must contain conspicuous acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O. Box , Richardson, TX , U.S.A., fax Abstract In the challenging North Slope operating environment, use of innovative production equipment has provided solutions to zonal isolation and packer integrity problems in viscous oil reservoirs. Operators have employed new tools and technology utilizing expandable rubber materials to manage annular fluid flow, control solids/shale production, and achieve zonal isolation in wells where high costs, shallow depths, and long step-outs create unique completion challenges. The new technology is allowing once bypassed zones to be added to existing developments, and making future developments more economically viable. The new design approach involves installing swelling rubber packer (SRP) technology as part of the completion. This technology is based on specially designed swelling properties of rubber in crude or mineral oil based mud (MOBM) to expand and seal the annulus. The paper describes one operator's use of as many as 17 devices in a tri-lateral horizontal undulating well to manage annular flow and minimize shale/solids production. The successful application of this technology has allowed shale interbedding to be effectively isolated behind blank pipe, thus allowing an additional zone to be added to the existing development. To date the technology has been applied to eleven wells, improving production assurance. Another major operator on the North Slope has used the technology to isolate potentially conductive fault crossings along the lateral and inadvertent zonal crossings while kicking off from the parent bore. Multiple packers have been run in single laterals to achieve the desired isolation without noticeable effects on liner running drag. Recent density caliper data shows significantly more washout than previously envisioned, increasing the desire to manage annular flow. Development and application of this SRP technology is detailed in the paper, including documentation of improved efficiencies as a result of its use. The paper will also discuss field operations, installation, and unique considerations associated with design and installation in viscous oil environments. Introduction On the North Slope of Alaska, there are billions of barrels of untapped viscous oil reserves. It has been estimated the North Slope contains billion barrels of OOIP. 1,2,3,4,5,6 (Figure 1) To date, development of these viscous oil reserves has been forgone for the warmer, less viscous oil that lies below. This reserve bed contains highly viscous oil due to the low reservoir temperatures caused by the extreme northern latitude, the presence of 1,800 feet of permafrost, and its relatively shallow burial depth. North Slope Heavy Oil Milne Kuparuk West Sak Orion = Heavy Oil = Light Oil Approximately Billion Barrels OOIP Figure 1: North Slope Heavy Oil Reserve Base Prudhoe

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