Swell Packer case histories

FORCE Stavanger, April 2004

Rune Freyer
Contents
• Rubber swelling
• Swell Packer
• Constrictor
• Installations
• Applications
Rubber swelling
• Thermodynamic absorption rubber/oil
• Continued expansion until equilibrium
• Swelling pressure 3-6bar
• Reduced mechanical properties, not degradation
• No swelling in pure water
• Traces of oil in flowing water enough

Swelling pressure measurement

Dimensions and design
• Fully flexible OD/base pipe dimensions
• Small clearance (7.9-8.15” OD–8.5” hole)
 Estimated/correlated ∆P
8.15”
200
180 4.5" base pipe
5.5”
160 5.5" base pipe
140 6.625" base pipe
DP (bar)

120 7" base pipe

100 6.625”
80
60
40 7”
20
8.5 9.5 10.5 11.5
Hole ID (inch)
Simulation live Simulation dead
 Swell Packer for oil based mud
• Delays swelling to run in hole
• OBM at 106°C for 3days
• 3 layer construction
• 8 wells with 42 packers
• So far 50-124 °C

8,55

8,35 O il B a s e d M ud C rud e 1 0 6 º

8,15 2 0 °C 7 6 °C 1 0 6 °C Diffusion barrier + Low swell

7,95 Low swell outer layer
WBM Packer
7,75

7,55
D iffus io n b a rrie r lo o s e s e ffe c t
7,35

7,15
0 1 2 3 4 5 7 10 12 14 18 26 38
 TM
Constrictor alternative to gravel pack
• Limit annular solids transport
• Avoid logistics, rig cost, fluids and risk
• Short (300mm) elements
• Slide onto base pipe
• Not a testable seal
• +/-6” and 8.5” OH
• Flexible OD

Constrictor application
Splice less cable feed through
Splice less application

PS! Better
installation tool
designed shortly
Advantages
• Self repairing, continues to expand
• Rugged construction
• Set at BHST
• Logistics/setting
– No rig time, wash pipe, tools, pumping
• No environmental impact
• Track record
Applications
OH Smart
Multilateral Well
Carbonate
junction
Stimulation/
water control OH
Gravel pack Frac
Replacement Mechanical HPHT
inflow Steam DTS
control control
OH screen
isolation
CH
straddle Expandable
Replace cement
OH in reservoir / perf
straddle
Gas wells
Installations
• 197packers installed in 43 wells
• 24 packers in 5 installations through windows
• 9 wells with 64 packers verified, no failure
• 41 packers installed in 8 wells in OBM

OH carbonate frac
Draw down test of integrity
Norsk Hydro, Grane
Statoil Heidrun gravel pack
Statoil Snorre B smart well
Statoil Gullfaks Sat smart well
Shell Nigeria 3 zone smart well
Shell Malaysia OH isolation
Shell North Cormorant TTRD
 The end

(Or just the end of the

beginning…….)
 • Can use OBM - hole stability
• Avoid annular flow – no plugging
• Robust screens
• Eliminate gravel pack - cheaper

Repeat unit
Liner hanger

Swell Packer
Sand screens

Constrictor
Shell North Cormorant
Cementing problems
Slim hole sidetrack
Intermittent blank and preperforated
Oil based mud
110°C
Dogleg in window 18deg
 TTRD Achievements 2003
Past Achievements: Improvements Improvements: Improvements:
• Max KOP 12344 ft • ROP – Bits/Agitator •Mud (Micromax) • SqueezeCrete success
• Max OH 3200 ft • Directional Control •Higher MWs >700pptf • Zonal isolation with
• Hole sizes 4.5” to 5” • Casing Exits • Well Control Swelling packers
• Liner size 2 7/8” 3.5” • Equipment Mngmnt • New philosophy • Eliminate clean-outs
• Bi-centre bit tech
• Mud (Micromax) • Cementing • Eliminate perforating
• Slotted 2-7/8” Liner Well Complexity
• Well Control (Radar) • A annulus isolations
• K-Formate Mud
• Abandonment • Spacers improved
• ARC3 Real Time
PWD • Cleanout improvements

CN-18S5 Well Cost

CN-29S3
CN-13S1/2
CN-17S1
CA-28S3 CN-24S2 CN14S2
BB-14S2 CN-18S6 CN32S4 CN24S3

PAST TTRD wells First 2 wells 2003 Second 2 wells 2003 Fifth well 2003 Tomorrow
CN24s3 – A Step Change in TTRD design

Swelling Packers Technology (EWS)

CN24s3 - A first in UK North Sea and in
TTRD application
¾Eliminate cementing of 2-7/8” liner and
subsequent clean-out of liner
¾Potential for more effective zonal
isolation in small hole sizes with high
drawdown/differential pressures
¾Elimination of cement debris following
clean-up saving £350k – 1,000k per
TTRD well (15-30% of total well cost)
¾Potential to eliminate perforating
¾£400k – 750k per TTRD well for CT
¾Provide a step change in economics
¾30-100% increase in VIR for slim holes
 North Cormorant 12 Day Wells
CN24s3 – 5th Well of TTRD campaign producing 90% OIL
HIGHLIGHTS
•Milled Dual Exit Window in one successful run.
•SqueezeCrete slurry exceeded expectations for cement repair
•Excellent performance - Shoe to shoe drilling - 3.9 days Avg ROP 48fph
•New technology
9BHA design – 17.5deg DLS achieved with motor & agitator
9Micromax-weighted OBM. Lower ECD’s and virtually NO sag!
9Swelling packers for zonal isolation – cut down on rig time and good zonal isolation

•Swelling packers – Eliminated cementing & CT perforating

•Good hole conditions through use of PWD tool.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30

Lost Time
12750

NORTH CORMORANT
13000
TODAY
TTRD with swelling
• Twist-off in NMDC – however successfully fished in one run! 13250

packers completion
13500

• Minor environmental discharge (0.6m3 oil) to sea 13750

Drilled Depth (feet)

14000 EXPECTATION
EXPECTATION AFE CN24s3

consequential to OBM taken through production facilities 12d wells

12d wells Actual CN24s3
14250
Possible with today's technology

14500

• CT had to be used with N2 in order to lift the well offline 14750

15000

TODAY’S REALITY – 12 DAY WELL TIMES 15250

15500

Swelling packers – A Step change in performance

 Completion fluid for the screen section:
1,25 s.g. Na/K-COOH formate mud

Template funnel

Template
Shale intervals:
2190-2240 m MD 3149-3166 m MD
2290-2330 m MD 3196-3213 m MD
2456-2480 m MD 3238-3274 m MD
10 3/4" SC-1 plug @ 300 m MD (upper barrier) 2514-2575 m MD 3310-3402 m MD
2723-2767 m MD 3425-3429 m MD
2802-2895 m MD
30" casing shoe
1.06 s.g

18 5/8" casing shoe

NaCl Brine
Value:
Reduced cost 800kUSD/well compared to ECPs
10 3/4" tie-back string

10 ¾” top PBR 2 less runs

Reduced risk for installation failures
ZXP packer
10 3/4" liner
Increased production by reduced plugging
Verified by PLT
Swell Packers RA tracer sub RA tracer sub
13 3/8" casing shoe Silver-110M Cobalt-60
on screen joints
Top screen PBR @ 2014,76 m MD

Bullnose @ 3539 m MD
2 screen joints

Liner hanger / ZXP - packer

FBIV @ 2055,26 m MD (closed pos.)
1.25 S.G. NaCl POLYMER
10 3 /4" casing shoe BRINE

7" blank pipe 4 Swell Packers mounted on 7" screen section

one joint of 7" blank pipe 9 1/2" open hole to TD @ 3540 m MD
Case 1: Swell Packers in Grane
• Emulsion
• 19API crude
• Demobilize shale particles in annulus
• Pressure isolation of screen annulus
• 800kUSD/two runs saved/well
• “Heaven compared to inflatables” (NH rigrep)
 SABAH SHELL PETROLEUM CO. LTD
FINAL WELL COMPLETION DIAGRAM @ a.h.bthf
Well No : SF-37 Location : SFJT-B Date Co mp leted : 4th July 2003
Wellhead Type : Ca meron Triple Wellhead + Single X’Mas tree
Tubing : 3.1/2” 9.2# L80 K.Fo x (Conventional S/String )
All Depth in Ft. AH.BTHF
Maximu m Dev. : 63.4° @ 4426’-6784’ ahbthf
SF-37 Final
Depth Long String

3.1/2”Flow Coupling
M in
ID
2.910
Status
Completion Diagram
516 3.1/2” TRSCSSV 2.813 Closed
13.3/8” Casing Shoe
@ 949’ 999 3.1/2” SPM 2.875 BKR-5
– 6-18” Open Hole
BKR-5
1659
2100
3.1/2” SPM
3.1/2” SPM
BKR-5 – 5,7” Packer OD
DKO-2
2635
3105
3.1/2” SPM
3.1/2” SPM DM Y
– 3-1/2” Lower completion
3606 3.1/2” SPM DM Y

3669 3 1/2” SSD 2.750 Closed

Top of 7” PBR
3696’

3700 7” Seal stem located 6.250 7.000

with half mu le shoe

9.5/8” Casing Shoe

@ 3985’
3866 3 1/2” SSD 2.750 Closed
SF37:
4015 Swell Packer 2.992

4041 3 1/2” X-Nipple 2.750 No Plug SF-37's water cut has come
4354
Predrilled Tubing
Swell Packer
2.992
2.992
down from ~95% to 0! This is
4379 3 1/2” X-Nipple 2.750 No Plug
very good proof of the packers
Blank Tubing 2.992
4478 Swell Packer 2.992 working!
Predrilled Tubing 2.992

4655 Swell Packer 2.992

4680 3 1/2” X-Nipple 2.750 No Plug

Blank Tubing 2.992

5298 Swell Packer 2.992

Predrilled Tubing 2.992

5366 Swell Packer 2.992

5375 3.1/2” Bull nose 2.992

6 1/8” Open hole

TD: 6784’
 SABAH SHELL PETROLEUM CO. LTD
FINAL WELL COMPLETION DIAGRAM@ ah.bdf
Well No : SF-38 Location : SFJT-B Date Completed : 15th July 2003
Wellhead Type : Cameron Triple Wellhead + Single X’Mas tree All Depth in Ft. AH.BDF @ 71 ft elevation SF-38 Final
Tubing : 3.1/2” 9.2# L80 K.Fox (Conventional S/String ) Maximum Dev. : 61.5° @ 4403’-7416’ ahbdf
Depth Long String
Min
ID
Max
OD
Completion
594
3.1/2”Flow Coupling
3.1/2” TRSCSSV
2.910
2.813 5.000 Diagram
13.3/8” Casing Shoe
@ 1051’ 781 3.1/2” SPM + BKR-5 2.875 5.620
1440 3.1/2” SPM + BKR-5 1500 BOPD against 1400 promised
2006 3.1/2” SPM + BKR-5
3.1/2” SPM + DKO-2
2446
2855 3.1/2” SPM + DMY
0% water cut Sand = 2 pptb
Top of 7” PBR 3170 3 1/2” SSD 2.750 4.281 545 psi FTHP (so there's plenty of
@ 3195’
7” Seal stem located with half 6.250 7.000 room to bean up from current
3200
mule shoe 28/64")
3 1/2” X-Nipple
9.5/8” Casing Shoe
3610
3430
Swell Packer No.1
2.750
2.992
3.905
5.700
GOR = 238 scf/STB
@ 3484’ Sand Screens
4234 Swell Packer No.2
4259 3 1/2” SSD 2.750 4.281 The GOR is VERY encouraging
ZONE-1A Blank Tubing 2.992 4.000
4305 Swell Packer No.3 because there is a gas sand
Blank Tubing
ZONE-1B 4516 Swell Packer No.4 2.992 5.700 present.
Blank Tubing 4541 3 1/2” SSD
Min ID:2.992, Max. OD: 3.900 Swell Packer No.5
ZONE-2
4565 2.992 5.700 This GOR is LOWER than many
Predrilled Tubing 2.992 3.900
Blank Tubing 5290 Swell Packer No.6 Rev. 2 wells with more expensive
5316 3 1/2” X-Nipple 2.750 3.905
Min ID:2.992, Max. OD: 3.900
5535 Swell Packer No.7 2.992 5.700 completions.
ZONE-3 Predrilled Tubing
6250 Swell Packer No.8 2.992 5.700
Blank Tubing
6275 3 1/2” XN-Nipple 2.635 3.905
Min ID:2.992, Max. OD: 3.900 Swell Packer No.9 2.992 5.700
6347
ZONE-4 Predrilled Tubing
6855 Swell Packer No.10 2.992 5.700
3.1/2” Bull nose 2.992 4.000
6 1/8” Open hole
TD: 7393’
 SF Rev3 Budget versus EFC
66

Cost 70
60

Well Cost RM'000

47
SF 39
Performance 50
40
-29% SF 38
SF 37
30
20
10
-
Budget EFC

SF Average well cost comparison Savings on:

- Liners
25
21 Budget - Cement
Well Cost (RM Million)

EFC
20 - Cleanout
-26% 16
15 - ESS (now Poromax)
- Scraper runs
10
- Perforation runs
5 - Packers
0 - Completion equipment
Well cost Rev2 Well cost Rev3
 Cost Performance

SF Rev.2 and Rev.3 Benchmarking

Cost per foot (Rm/ft) comparison
5000
Budget
4500
Actual (EFC)
4000

3500
+2%
RM per ft

-29%
3000

2500

2000

1500

1000

500

0
SF-31 SF-32 SF-33 SF-34 SF-35 SF-36 SF-37 SF-38 SF-39 Avg Avg
Rev2 Rev3
 Conclusions
– Significantly Cheaper Wells
– Installation relatively easy
– Production / Packer working very encouraging
– Can do even cheaper
 Snorre B Well D-4H Drawing: 1
Completion schematic Date: 18.09.2003
File: D-4Hcomplettering skisse.ppt
Rev: 3

Value: Packer depths: Casing depths:

13 3/8”: 380 – 2178 m MD
7” DHSV Sand production expected
Prod. Packer: 3192 m MD in perforations at water onset
Iso. packer #1: 3586 m MD Liner depths:
@ 606 m MD Reduced erosion risk
Iso. packer #2: 4116 m MD
of smart well equipment
9 5/8” liner: 2111.5 – 4273 m MD
No down hole operations
Iso. packer during installation
#3: 4611 m MD 7x5 1/2” screen: 4347 – 4973 m MD
Long packers ensure efficient sealing
TOC = 3013 m MD Tubing:
Clamps
Verified by downhole gauges 7”, 13 Cr-80, 29 lbs/ft NSCC
5 ½”, 13 Cr-80, 20 lbs/ft Vam Top
5 ½”, 13 Cr-80, 23 lbs/ft Vam Top
4 ½”, 13 Cr-80, 13.5 lbs/ft NSCT

IP @ 3586 m

IP @ 4116 m
PP @ 3192 m

IP @ 4611 m
7”
t ub
in
g
Swell Packers

5 ½” 5 ½” 5 ½” 4 ½”

Sone #1 Sone #2 Sone #3 Sone #4

Lunde
Case 2: Down hole test
• 8,15” OD WBM, 7” perforated liner
• 8-1/2” Open hole
• Coiled tubing deployed test plug
• Successfully inflow tested
• February 2003

P
Case 3: Isolation in Carbonates (1/3)
2380 meters horizontal reservoir section

9-5/8” Casing Shoe 8-1/2" Hole

WBM, 7.9” OD
5-1/2” preperforated liner
Case 3: Isolation in Carbonates (2/3)

3-1/2” Inner isolation

WBM 4,4” x 3-1/2” - 4m SSD (OD - 3.92”, ID - 2.31”)
string (2.992” ID)
Case 3: Isolation in Carbonates (3/3)

9-5/8” Casing Shoe

8-1/2" Hole

3.5" tubing 5-1/2" Perforated liner

Liner – Annulus Isolation

Tubing – Liner Isolation Isolated and controlled production interval
 Hole ID DP [bar] %
Swell Packer simulations Differential pressure profile 5.73 246 30
5.742 0 1 20.0 % 5.77 196 40
300
5.753 1 1 22.0 % 5.80 156 48
For: 5.765 1 2 24.0 % 5.83 116 4000 57
Date: 5.776
250 1 2 26.0 % 5.87 76 69
3500
By: 5.788 1 2 28.0 % 5.93 36 85

Differential pressure [bar]

Differential pressure [Psi]

5.799 1 3 30.0 % 3000
200
5.811 1 3 32.0 %
Input 5.822 2 4 34.0 % 5.99 16 2500 102
Pipe OD 5.000 in 127 mm 5.834
150 2 4 36.0 %
Packer OD 5.625 in 143 mm 5.845 2 5 38.0 % DP [Psi] 2000
5.856 2 5 40.0 % 3567
100 1500
Down hole viscosity 1.50 cP 5.868 2 6 42.0 % 2842
Hole ID 6.000 in 152.4 mm 5.879 3 6 44.0 % 22621000
Operational pressure 50 bar 5.890
50 3 7 46.0 % 1682
5.902 3 7 48.0 % 1102500
5.913 3 8 50.0 % 522
Output 0
5.924 4 9 52.0 % 0
Final OD (20bar DP) 6.031 in 153.2 mm 5.70
5.935 5.75
4 95.80 5.8554.0 % 5.90 5.95 6.00

Volume swell % at Hole ID 106% 5.946 4 10 Hole ID56.0

[in] % 232
Time to fully set max DP 35 days 5.958 5 11 58.0 %
Time to operational pressure N/A days 5.969 5 12 60.0 %
Time to first seal 15 days 5.980 5 13 62.0 %
DP at "Hole ID" 212 psi 15 bar a 5.991 6 13 64.0 %
6.002 6 14 Swell profile
66.0 %
6.013 6 15 68.0 %
Input 6.024
30
7 16 70.0 %
Cable OD 0.25 in 6.350 mm 6.035 7 17 72.0 %
Number of cables 2 Insufficient rubber thickness 6.046 8 18 74.0 %
25
6.057 8 19 76.0 %
Pressure calculations are based on failure pressure of a 3m long element, modified with 20% safety factor. 6.068 8 20 78.0 %

Time to swell [days]

A longer packer will enable higher differential pressure but exact correlations are not mapped. 6.079
20 9 21 80.0 %
Timing of swelling process will vary dependent of fluid circulation and is based on WBM construction. 6.090 9 22 82.0 %
Timing of swelling in gas may be estimated by EWS 15
OBM construction will take longer time. 6.101 10 23 84.0 %
EWS advise designs with differential pressure exceeding simulated limitations also allowing for washouts. 6.112 10 24 86.0 %
10
6.122 11 26 88.0 %
Oil Field Units SI Units 6.133 11 27 90.0 %
Temperature 280.4 °F 138 °C 5

Base pipe wt 12.6 ppf 18.8 kg/m

Base pipe length 19.7 ft 6 m 0
Element length 9.8 ft 3 m 5.70 5.75 5.80 5.85 5.90 5.95 6.00 6.05 6.10 6.15 6.20
Packer weight excl pipe 26.2 lbs 11.9 kg Time to seal
Packer mass 274.3 lbs 124.5 kg Hole ID [in]
Time to fully set
Packer volume 0.357 ft^3 0.010 115%
Splice less cable feed through
• Competent formation
• One string
• No cable splicing at packers