A system’s approach to addressing injection and producer well challenges

Combining Stimulation, Openhole Zonal Isolation and Flow Control Devices to Optimize WAG Production / Injection Design and Performance

The results of Client focused product development using field proven innovative technology can be seen in Petrowell's latest completion system solution. Petrowell's Presto system allows the operator to deploy an open hole completion with well integrity issues addressed, without washpipe and with full circulation capability. This adaptive system can be applied to Producer as well as Injector wells and addresses various requirements including stimulation, fluids management, Staged Cleanup and zonal isolation.

The Challenges

• Long Reach Horizontal - Plus 6,000m with 1000m + horizontal
• Numerous discreet zones in the open hole required
• Sand Control Requirement for Back Flow
• Injectivity Testing required and Stimulation likely to required - Needs to be selective
• Open Hole Isolation required - Packer Axial Loads to exceed 200,000 lbs, 2,500 - 6,000 psi isolation. 150 deg C
• Drill in and fluids management required - No washpipe allowed

The Solution

Multiple Zones

Multiple discreet zones are often a feature of the well design; the Presto system provides compartmentalisation using Open Hole Packers to isolate principal zones of interest. The system allows the operator to individually and selectively stimulate the zones of choice, permits selective clean up and back flow as required, permits individual step rate testing and in its most adaptive form regulate the flow into or out of each zone - all achieved without control lines or intervention.

Long Reach Horizontal

During installation full circulation from surface to toe is achieved.

Effective Zonal Isolation - Open Hole Packer System

Petrowell's Field proven high performance packers are capable of withstanding high pressure differentials, supporting high axial forces and providing long term zonal isolation. The OH Cup Seal family of packers have been developed in conjunction with leading industry operators and subjected to the most stringent development and test criteria ever undertaken for OH Packers.

Drill in and fluids management

The Presto system provides the operator with a continuous flow path at installation, not only enhancing well control but providing a means to change out drilling fluids, spot breakers, drill in or ream in capability without the need for wash-pipe.

Presto's main Components

CZI Packer

The Petrowell CZI zonal isolation packer is a deployed cup seal system developed to meet the new challenges consistent with advanced horizontal well completion techniques. The packer is tested to ISO V3 standard and is designed for life of well performance. The packer is both mechanically stable and reactive to changing well conditions, presented by; changing differential pressure, thermal changes, well bore collapse and expansion.

 The CZI incorporates the Petrowell Rok-Ankor® to anchor the Packer in Open Hole which eliminates the requirement for an inflation element. The patented Slip system grips the formation resulting in small radial fractures which do not damage the structural integrity of the local formation.  It achieves this with a unique footprint that limits penetration of the formation generating friction and interference.

RFID Frac Sleeve

The Petrowell RFID Operated Frac Sleeve provides the most versatile fluid placement system on the market. There are no limits to the number of sleeves which may be run, there are no restrictive balls seats and there is nothing to mill out at the end of the job. Each sleeve has independent remote opening and closing capability, a wireless operation providing true selectivity of operation. Each zone can be stimulated independently and in any order, each zone can be subject to selective clean up. The Sleeve also has an override profile which allows the sleeves to be mechanically manipulated in the wells later life.

Fall Through Flapper (FTF)

Petrowell's Intervention less Packer Setting Device represents a revolutionary method for setting hydraulic completion packers. It eliminates the need for a deep set plug, thereby delivering value in terms of reduced completion time and risk. Where hydrostatic packers are commonly used in un-perforated well bores, the Fall Through Flapper affords the same benefits but in perforated applications. The FTF further enables pressure testing of the production tubing prior to the flapper being opened and permanently retained.

The FTF lends itself to any application where a production packer or downhole device is required to be set differentially.  The FTF is run in the open position, closed by dropping RFID tags, then re-opened via a frequency modulated man made pressure sequence.

The FTF can be tailored to suit the application.  For example, the duration the flapper remains closed for can be customised to suit the specific application. The tool is programmable for a variety of contingency operations.

The FTF does not compromise the completion geometry. The ID is comparable with bore through standard TRSV profiles. The internal mechanism is contained outwith the flow path.  The tool does not rely on any debris sensitive check valves or complex piston arrangements during operation. The reliability is not compromised by the need for any pre-charged or well sensitive piston chambers.

FCD

The Petrowell RFID Flow Control Device (FCD) is a Passive Well Management device actuated without the need for wash-pipe, intervention, wires or control lines. The product contains an RFID Communication system, battery power and a fuse which on command opens a sleeve to allow inflow for production or outflow for injection operations. The device is programmed specific to each application, where operations may be initiated via RFID tags, manmade frequency modulated pressure sequences, timers or indeed a combination offering unsurpassed operational flexibility.

An FCD or rather a series of FCD's are used to regulate or mange inflow or outflow across the horizontal reservoir section. Set at regular intervals each FCD will permit only a fixed "volume" of fluid to pass through a series of fixed nozzles. Flow above the fixed volume serves to create a back pressure at the tool, thus equalising flow through the next "easiest" path, by design the adjacent FCD. This pattern is repeated over the whole horizontal sections' drainage area, effectively promoting an equalisation of inflow or outflow through each FCD by volume, thus a more uniform flow pattern over the reservoir drainage area is achieved.

The correct application of FCD's can delay or minimise the onset of early water and or  gas coning therefore optimising reservoir management and ultimately improving hydrocarbon recovery. In addition to these benefits FCD's can also improve the reliability of sand control and aid well clean up.

Overview of RFID

The system uses tools that are activated using RFID as a close proximity means of transferring data with no direct line of sight required.  It works by using two or more devices - a reader and tag.  The devices are paired and able to "recognise" each other through the transmission of radio waves.

The tag, which contains an electronic circuit (transponder), is programmed with specific information.  When the tag approaches the reader, the radio frequency (RF) field generated by the reader powers up the tag causing it to continuously transmit its data by 'pulsing' the radio frequency.  The data is then captured by the reader and processed. Functionality of the tools in all situations is ensured by equipping them with pressure transducers for use when no circulation path is available.  This allows the tools to be functioned through the use of a pressure pulse sequence. 

Petrowell's Solution - Making a Difference

The Petrowell vision for the system, removes the need for washpipe eliminating weight issues and equipment handling. Benefits include improving the well control operations throughout the completion phase, isolating and closing off well losses at the point of open hole packer setting and effectively placing a barrier at the reservoir face. Tubing conduit / screen pressure integrity is maintained throughout and the ability to minimize or eliminate screen plugging is realized, Furthermore Frac operations can be carried out without intervention, a unique position in the industry and all of this, without control lines. Petrowell's solution can be tailored to suit specific well requirements to deliver numerous functional benefits with real CAPEX and OPEX savings.

Performance,Reliability,Effectiveness,Selectivity,Technology,Optimi