This paper presents the first application of metal expandable frac packers for multistage acid fracturing (MSF) completions. This technology significantly reduces deployment risk commonly associated with openhole (OH) MSF completions with the ability to rotate while running in hole without any risk of premature expansion or compromising integrity of the sealing mechanism. Additionally, it improves efficiency of fracturing operations in tight gas reservoirs with the ability to expand to larger borehole diameters than is possible with current isolation packer technologies. The overall deployment method for this technology is similar to traditional openhole multistage fracturing completions that are industry standard. The main difference is that the isolation packer used is expanded by pressure to mechanically deform the metal sleeve to provide sealing against the open hole. The technology comprises an innovative material and design that can hold high differential pressure at high reservoir temperatures while maintaining permanent isolation in a relatively compact element length. The metal expandable frac packer completed an extended qualification process, including American Petroleum Institute (API) testing, to fulfil deployment and acid fracturing completion requirements. The outcome was an overall successful deployment and stimulation operation of multistage completion with the metal expandable frac packer. The metal expandable frac packer provided the ability to deploy the lower completion in difficult wellbore conditions with ability to rotate. The metal expandable frac packer is set with pressure; therefore, there is no waiting time to have full differential pressure capabilities for the fracturing operations. This technology provided a flexibility factor for packer placement as the metal expandable packer technology can hold its rated pressure at larger borehole diameters. Since the mechanism of the metal packer is expansion by inelastic deformation, the metal expandable sleeve conforms perfectly to the geometry of the borehole, providing a highly reliable seal for high pressure fracturing operations. Through a complete diagnostic process, it was confirmed that the metal expandable packers successfully isolated each stage of the stimulation treatment. Metal expandable frac packers unique testing was conducted in the laboratory and in field to qualify the technology with special focus on the chemical composition for the fluids encountered for the deployment, stimulation, and production environments including high concentration acid fracturing applications. The metal expandable sleeve technology utilizes a unique double-sleeve system for pressure compensation to enhance the sealing integrity of MSF stimulation operations and truly provide 10,000 psi under API 19OH V1.
E&P operators are looking at innovative solutions to control water production in horizontal oil well producers, to maximize their assets’ value. The operators are putting greater emphasis on maximizing oil production from the existing assets instead of performing sidetrack or drilling new wells. Completing wells with equalizer completions; inflow control device (ICD) separated by openhole packers is one such solution. Two kinds of equalizers are used for entry of wellbore fluids; Active ICDs and Passive ICDs. For wells completed with Active ICDs, a shifting tool can be used to close the water producing ICDs. However, for wells completed with passive ICDs, plugs with cement can be used, which will isolate the section below, leaving much of the oil behind. For wells in which the heel or the middle section starts to produce water, there was no solution, but to live with it or re-sidetrack the well. Recently, a new technology of expandable steel technology has been selected, and specifically customized for ICDs isolation purposes. The patch is corrosion resistant alloy (CRA) material, which was selected to cope with the harsh corrosive environment. Pipe geometry had to be adjusted to enable "Patch thru Patch" capacity. Despite the tight restrictions of the well, the use of this technology allowed to keep enough clearance after installation to pass another Patch thru later on, if required. Prior to performing the isolation of the ICD, production logs of the horizontal section were carried out to analyze the production and locate precisely the high-water producing zones. Three (3) Patches were successfully deployed rigless using smart coiled tubing. The real time monitoring enabled accurate positioning and smooth down hole pressure control. Post patch installation, wellbore path remained clear, enabling production from the bottom zone. The well performance improved with substantial reduction in water production and consequent incremental increase in the oil production. Isolating the dominating water contributing ICDs, contributed to increase the oil contribution from the other ICDs. This was confirmed by another production log performed post patch installation. This was the first installation of Xpandable Steel Patch across ICD's worldwide. This paper will highlight the technology and its application, solution selection process and the operational deployment of the Xpandable Steel Patch including real-time monitoring capabilities of instrumented Coil tubing (CT) which can be leveraged to accurately install the patches.
Enhancing gas productivity is linked to multistage stimulation (MSS). Choosing a cemented over uncemented solution is driven by factors such as operational efficiency, drilling practices, and isolation techniques. Swellable and mechanical packers have been used widely. A new packer type, an expandable steel packer, has been qualified recently, the expandable steel packer combines the strengths of mechanical and swellable packers and will provide an option for openhole completions. The 4.5-in. expandable steel packer design was optimized to meet most demanding applications with the following characteristics: reduced running outside diameter (OD) to 5.6 in., premium assembly technique by crimping, double sleeve pressure self-compensation, and use of nickel alloys for sour environment. After the design of the packer was completed, the 4.5-in. expandable steel packer was qualified according to the API Spec 19OH (API 2018) standard protocol at 15,000 psi with thermal variation between 320°F and 68°F. The packer was tested in a casing with inside diameter (ID) of 6.5 in. The test casing had an ID of 6.5 in. whereas nominal hole size ranges from 5.875 in. to 6.125 in. It was chosen to simulate a washout and considering the calculated maximum expansion ratio for the steel to verify the 15,000-psi pressure rating capability. The test casing was built with a heat exchanger, high-pressure pump, and pressure and temperature sensors. The packer was expanded inside the dummy well with all the measuring instruments in place. Expansion pressure signatures were observed as predicted. The analysis of the packer setting pressure curves showed expansion initiation and full casing ID contact. The liquid differential pressure test from each side of the packer proved the internal pressure compensation performed as expected. No leak was observed during the pressure steps of 15.000 psi held for 15 minutes while cycling the temperature from 320°F to 68°F and back to 320°F. The expandable steel packer utilizes a unique double-sleeve system for self-pressure compensation during ball-drop stimulation operations. The packer expandable sleeve is protected during deployment by the end fittings. Expandable steel packers exhibit robustness during running in hole, enable setting on demand, have a high expansion ratio, require no de-rating vs. hole size, and have low sensitivity to thermal variations.
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