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Xpandable AZIP Packer ensures effective zonal isolation

Openhole horizontal oil producer well successfully recompleted with AZIP Packers combined with active ICDs in Libya.

Saltel Xpandable Steel Packers in Lybia 

The Packers were successfully expanded and set with 5,000 psi. The workover was effective and allowed recompleting the well with ICDs and Xpandable AZIPs. The client benefitted from effective means of shutting off watered out zones, reducing water inflow and getting control of the well production.

Field mature wells characteristics

With known reserves of 43.1 billion barrels of oil equivalent (36.7 billion barrels of oil, 37.7 trillion cubic feet of gas, 0.1 billion barrels of natural gas liquids), the Basin ranks 13th among the world’s petroleum provinces.

Aging horizontal wells from this field tend to face excessive water breakthrough. The client experienced a similar case in one of his open hole porosity producer wells. Production tests showed a severely reduced oil rate of 210 barrels of oil per day (BOPD), and they noticed an increase in the water cut from 50 to 80% on natural flow. The field, as any other carbonates reservoirs is facing similar challenges:

  • Permeability variation along the wellbores
  • Multi-fractures and/or tight reservoirs
  • High water mobility rates

The above reservoir challenges typically lead to the following risks;

  • Unbalanced production profile
  • Early water breakthrough
  • Internal cross-flow and under-production
  • Un-swept regions with oil bypassed

The client well performance charts showed Water Cut (WC) increased up to 75% with oil production declined from to 348 BOPD over one-year well life.

Completion Design Philosophy and Objectives

The philosophy of the proposed new generation of Inflow Control Devices (ICD) completion designs, is to incorporate Schlumberger lessons learned and best practices of ICD technology, resulting in systems that are efficient to deploy, that address reservoir challenges and allow intervention where necessary to reduce water cut.

This proposed completion design also allowed the client to improve reservoir sweep efficiency, optimize oil production and increase recovery factor.

Preference has been given to field-proven equipment and technologies, the Schlumberger design approach and associated technologies leverage confidence gained through the use of proven technology. There were no solution gaps or engineering/qualification requirements necessary to meet the client’s challenges.

Therefore our completion design objectives could be summarized as follows:

Reservoir Management

  • balanced inflow profile along the entire horizontal section
  • improve sweep efficiency
  • maximize oil recovery

Production Optimization

  • decrease rate of high-mobility fluids
  • delay early water breakthrough
  • Isolate “shut-off” watered out zones

  

 

Active ICDs combined with openhole packers for drastic water cut resorption

Schlumberger recommended a workover to recomplete the well with active in-flow control devices (ICD) and open hole packers, to reduce drastically the water cut, and take control of the production. The following recompletion string was recommended:

  • 5in x 7in Liner hanger with Liner top packer
  • 5 Saltel Xpandable AZIP-W 4.5in
  • 12 Premium Port ICDs

Setting depths

 

Successful Open Hole Packers installation

Associating Xpandable Steel well Packers with active inflow control devices was a worldwide first materialized and field-proven effective in Libya.

 

Xpandable ECP allows completing cementing operations

ECP Campaign - multiple stage cementingExternal Casing Packers (ECP) successfully isolated thief zones, enabling two-stage cementing operations, onshore Argentina

Thief zones encountered downhole are commonly due to fractured or highly permeable formations. These loss zones disrupt the circulation during cementing, and can jeopardize the wellbore. Being partial or total, they can also lead to lost circulation, costing several hundreds of millions of dollars each year in lost or delayed production, remedial cementing, or in solving drilling issues.
To limit the potential effect of lost circulation, the operators commonly lessen the density of the cement slurry, constrain the friction pressure while pumping, or resort to multiple stage cementing operations. This third alternative consists in combining open hole annulus packers with stage collars, to avoid the thief zone.

An operator in Argentina (Anticlinal Grande field) conducted a multiple-well drilling campaign and required external casing packers (ECP) to perform 2-stage cementing operations. They encountered frequent losses zones while drilling, and needed a cost-effective solution to secure the annulus integrity and cement successfully back to surface.

Selecting Saltel Xpandable Steel ECP

Schlumberger recommended Saltel Xpandable Steel Packers. The packers were to be set either in openhole and had to withstand tough RIH conditions in deviated and under gauged holes. The possibility to rotate and put weight on the packer during RIH was also essential. 

Saltel Xpandable ECP is specially designed for stage cementing applications.
10 Xpandable ECPs 5.5in were run and installed as annulus barriers in 9.2in open hole, to isolate the thief zones and allow a second cement stage above the packer. The maximum depth of the wells was 8,200 ft [2,500 m], and the setting depth goes from 1,968 to 5,577 ft [600 to 1,700 m].

The cementing campaign recorded 100% success with Saltel Xpandable Steel Packers. The 10 packers isolated the troublesome lost circulation zones, and allowed resuming cementing operations. The cement could be pumped back to surface through a stage collar above the ECP.

High Temperature patch installations in California

 

Successful High Temperature patch installations in Californian thermal wells

Casing repair with Saltel High Temperature PatchSaltel Industries successfully completed the installation of 3 patches, to repair leaking casings in 2 cyclic steam stimulation (CSS) wells, for an operator in the US, Ca.

The client was looking for a remedial solution displaying strong resistance to maximum 380 degF [193 degC] temperature, during steam injection cycles.

Saltel suggested Saltel Patch with high temperature design, qualified under max 480 degF [250 degC], ensuring continuous resistance up to 450 degF [230 degC]. 

1st well – 2 patches

Both patches (8-5/8in, Ultraslim, 19.6 ft [6 m] long) were installed in 8-5/8in casing.

  • Top patch was installed to cover 58-61 ft [17.68 - 18.59 m] leak interval.
  • The bottom patch was installed over 711-714 ft [216.71 - 217.63 m] leak interval.

The second patch setting is one more confirmation of our the patch through patch capacity.

A solid pressure test confirmed the leaks were isolated with success.  

2nd well – 1 patch

7in Ultraslim, 19.6 ft [6 m] long) set in 7in casing at 120 degF [49 degC] temperature. The patch was set over 406-408ft [123.75 - 124.36 m] leak interval.

 

Saltel Patch was much appreciated for its easy conformance to irregular geometries and its ability to be set gently against fragile tubulars, while offering strong sealing characteristics.

The Saltel PTT (Pressure Test Tool) was then deployed to immediately confirm with the same crew the correct isolation of the leaking zone.

The installation was a complete success with field tickets rated “excellent”. The client is glad of this first experience with Saltel high temperature patch technology.

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Zonal isolation allowing selective acid stimulation

Compartment isolation between sliding sleeves, prior selective acid stimulation

Acid Stimulation with Saltel Azip PackersObjectives

  • Effective isolation prior to performing selective acid stimulation
  • Enhance production rates from fractured carbonate reservoir.

Challenges

Guarantee sufficient robustness to:

  • withstand tough run in hole (RIH) conditions (tight spots) due to high dogleg severity (DLS)
  • allow limited and controlled push/pull/rotation in case of a tight spot.

Context

The oil producer well was drilled in 2017 in the Bekhme formation of Tawke Cretaceous reservoir,
in Iraqi Kurdistan.

The client requested an alternative to traditional swell packers for isolating compartments between sleeves during acid stimulation.
The completion would include:

  • Robust metal expandable packers designed for high DLS (up to 28°/100 ft)
  • Sliding sleeves (SSD) for selective acid stimulation and clean-up.

A selective acid stimulation would be conducted after the rig had moved out, to counteract the relatively poor initial stimulation treatment (limited coiled tubing acid wash).

Proposed solution

To provide reservoir compartmentalization in high DLS and tight spot environment, Saltel AZIP Packers were used to create a solid metal barrier against the 6-1/8in formation.
The short length (4ft) of sealing element enabled to pass the kick-off point, while the 5.5in RIH OD ensured a smooth entry through the restriction.

 

 

 

 

 


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First Saltel Patch installed from a semi-submersible rig

 

Set offshore (North Sea) from a semi-submersible platform without active Heave Compensator, the Patch successfully isolated a leaking coupling.

OS Saltel Patch during RIHSaltel Patch successfully isolated a leaking coupling, in a 10-3/4in - 60.7 ppf casing. The patch had to be set from a semi-submersible rig giving no guarantee of accurate positioning at depth, due to the heave. The rig did not have an active heave compensation system available (to maintain the BHA at a constant depth).

A customized (6mm steel thickness) 10-3/4in Patch - 5m long was selected, to maximize the differential service pressure rating. The semi-submersible rig was constantly moving up/down, (no active heave compensator) which would have resulted in an inaccurate positioning of the BHA for each expansion step and in uncontrolled forces transmitted downhole on the Patch and the BHA.

The solution to meet such challenge was to modify the setting process by adding a no-go approximately 60ft above the BHA, landing on the tree wear bushing to position and anchor the Patch. The tools were then POOH, and the distance between the no-go and the setting tool was adjusted for the next steps.

Once positioned at the right depth, the Patch was successfully installed.
A total of 8 expansion runs was performed and a final drift run (#9) was done to confirm the Patch drift ID was >8.75in [222 mm].
Once the Patch was set and drift ID confirmed, the well was pressure-tested. The test was solid: <0.5 psi loss per min, versus 3 psi/min before the Patch setting.

 

 


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AZIP installation in Venezuela

Successful Annulus Zonal Isolation Packer installation

Saltel zonal isolation packer in latin americaSaltel AZIP installation in Venezuela has been a success. The client needed to isolate 2 producing zones with shale between, in the Boscàn field. They realized most of the water produced and fine migrations were generated from upper Boscan and the shale zone.

The openhole packer, a 51-2in AZIP-C 0-1 has been set below the shale to isolate the upper section and produce from the lower Boscàn only to increase the production and reverse the decline of the field production.

The AZIP was 8in OD, it has been run through a 9.625in 47ppf casing and successfully installed in a 10in underreamed section at 9,599 ft depth using a straddle setting tool as part of a standalone completion including Quantum packer and Facsrite sand control screens.

 

Zonal Isolation AZIP Venezuala

 

 


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The two first Saltel Patches ever installed in Australia

Saltel Casing Patch installed after a cement squeeze treatmentThe 2 first Saltel patches (Total Sealing, 0.11in [3 mm], 19.68 and 26.24ft [6 and 8m] long, have been deployed successfully in two Coal Seam Gas (CSG) wells, in Australia.

 The objective was to cover the cement squeeze area with a casing patch in each well, to restore integrity in the 7in production casing. The patches were installed after the cement remediation jobs (Perf. & Cement Squeeze).

 The setting went as per job program, and post-setting pressure tests confirmed the new barriers efficiency (1,000 psi [68.94 bar], less than 2% pressure loss over 10min).

The wells are now being completed and put in production.

 

Case study - Frac port isolation with saltel PreFRAC patch

 

  

 The client had a frac port prematurely open at stage 30 (total 36 stages). The upper ports were milled to 116 mm / 4.56 in. to allow access to port 30. The client then completed a clean-up trip to set the casing patch to fully restore well integrity to continue on fracturing the remainder of the well.

The purpose of the patch was to restore well integrity and resume fracturing operations. Once the patch set, the largest ball size required was 3.250 in [82.55 mm] OD. Having heavier pipe weight uphole 75.44 lbs/ft [34.22 kg/m] and lighter casing weight in the zone to seal was a criticial challenge for the job.

The well was killed using 7% KCl water. Saltel Industries ran a 5-1/2in Reinforced patch to seal stage 30 (Leaking frac Port). When set, the patch had a Drift ID of 4.19 in [106.49 mm] allowing the largest frac ball (3.250 in OD) to easily pass through it. The top of the patch was set in 4.89 in [124.26 mm] casing nominal ID, then had to be pressed out over the restricted 4.56 in frac port ID, then pressed back into 4.89 in casing nominal ID. Once fully set, the patch was pressure tested to 20 MPa and held solid, allowing the frac to commence.

 

 


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Successful off-bottom cementing campaign

100% success rate recorded on 75 wells completed and fractured.

The client has numerous oil fields under development in Western Siberia. Featuring low depletion reserves, these fields have a strategic importance, since they are a significant part of client’s overall oil production. The client found an effective way to reduce the drilling time by switching from standard design (12-3/4in surface pipe with a 9-5/8in conductor casing, followed with 7in production string, and 4.5in liner with MSF equipment), to new well design (two-string horizontal well: 12-3/4in surface pipe with a 9-5/8in conductor casing, connected to a 7in-5.5in combined production string, for wall lining, installation of MSF equipment and further operations). As a result, this change excludes an entire stage in the drilling cycle.

Saltel Steel ECP-C off bottom cementingThe client was then looking for a reliable and solid External Casing Packer (ECP) to perform off-bottom cementing. In addition the packer must be more robust than conventional inflatable packer to sustain tough running conditions and pass thru obstructions, usual situation due to geology in the Priobskoye Oil Field (called the Pearl of West Siberia), one of the largest fields in Russia by oil reserves.

 

The client selected Saltel Steel ECP-C 7in (Crimped design) for its extraordinary solidity during RIH, and disruptive slack-off weight capacity.

Combined with a cementing port, the ECP-C is run as part of the production string just above the crossover between 7in and 5.5in strings. The Packer is expanded with 2,700psi to seal against 8.66in Open Hole.

 

After expansion, the ECP expansion port permanently closes. Then the cementing port can be hydraulically opened ; Cement is pumped through and supported by the ECP-C. After closure of the cement port, the casing integrity is restored. allowing high internal pressure to be applied (HP stimulation).

 


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Successful Patch through Patch Operation

 

 

Successful Patch through Patch operation to cover off-depth perforations

After previous split casing repair with Saltel Patch, a second patch was successfully installed to isolate off-depth perforations.

 

patch thru patch operation USA first patch (17.5m 5.5in reinforced) was set last November 2017 at 3,000ft across a split casing. The patch was combined with a cement squeeze to increase its mechanical resistance to frac pressures). Amongst the many original qualities of this expandable steel patch is the large ID, making it possible to run perforating guns, plugs, or other tools through the set Patch. During the wellbore preparation prior to a frac,the perforating gun fired off depth below the first patch.

 

In January 2018 a second patch (The 150th in the US since the beginning, 6m 5.5in slimline) was run through the first Patch and set to seal off the unwanted perforations.The well was then fractured in 52 stages, at  5,670psi. An average of 365,000lbs of sand were pumped in each stage. This job illustrates the capacity of the patch seal effectively with high pressures, repeated pressure cycles, high flow rates and large volumes of fluid and sand (Total 8,627 tons), while still leaving access to the well below.

 


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Crossover repair with Saltel Patch Argentina

 

 

Saltel Patch run with coiled tubing, successfully isolates a leaking crossover, allowing to resume Plug'n'perf stimulation.

The context

In a new well, a leaking crossover (5in to 4.5in) at 9,548ft [2,910m] was precluding to continue performing plug and perf stimulation program. Setting a 4.5in reinforced patch (external differential service pressure rating 1,500 psi) to isolate the leaking crossover implied significant collapse concerns, with 4,000 psi external pressure. A preparatory resin squeeze job successfully sealed the crossover (after multiple attempts) and enabled the patch operation.

Job Objectives

The purpose of the patch was then to reinforce the resin, allowing to apply high internal pressure during the plug & perf stimulation.

 Saltel patch run with coiled tubing repairs leaking crossover 2

The solution

Saltel patch run with coiled tubing repairs leaking crossover

A 4.5in Reinforced Patch was selected to cover the crossover. Due to well control contingency, the conveyance was Coiled Tubing (CT). Being the 1st patch setting with CT + downhole tension sub in Argentina, a test run was performed, prior to rigging up the patch. 

 

 

The result

The patch was successfully set in 18 steps and drifted at 3.3in. The client was able to pressurize the well at 12,000psi. The client then carried on 4 fracturing stages with limline Plugs - 3.18in OD [81mm], pressuring up to 12,000psi in the well head. 

benefits

 


  

Saltel Expandable Steel Patch features:

■ Patch through Patch
■ Small run-in diameter
■ Simple setting process
■ Minimum reduction in ID, Large through passage
■ Simple top-down setting process: if difficulties occur the tools can always be easily retrieved, redressed, & the job completed
■ Fast feasibility study, job evaluation & proposal
■ Short lead times, a skilled operations team available worldwide
■ Proven technology (Over 600 patches set worldwide)
■ 97 % success ratio
■ Adapts to casing ID, even if out of round, corroded or deformed
■ Fits both to vertical and horizontal sections

 


 

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Successful Sand Screen repair, Offshore Caspian Sea

 

Screen repair to eliminate sand production with Saltel Patch, set on Coiled Tubing - Offshore Caspian sea 

 

The context

In an open-hole gravel pack completion (5in #18), two sand producing zones were localized thanks to permanently installed optical fiber.

48 (157ft) and 24m (79ft) needed to be sealed, but the riser length limited the maximum possible patch length to 14m (46ft). It was decided to overlap the Patches to provide an effective solution over the entire length.

The solution

 Inflatable packer qualification

Saltel Industries Expandable Steel Patch Technology is a unique solution which uses an inflatable Packer to expand the steel patch. This gives a high expansion ratio and means Patches can be overlapped (or Patch run through a previous Patch) to mold to the exact ID of the damaged screen.

Patches set on Coiled Tubing

The patches and setting BHA were conveyed on intelligent Coiled Tubing, to provide pressure from surface. The behavior of the CT at this depth in a horizontal well was the main uncertainty of this job (stick and slip, downhole movements,…). In order to monitor downhole movements and the forces applied on the patch and the BHA during the setting, the CT supplier developed a tension compression sub.

The CT MHA also included a CCL module (for positioning), and pressure and temperature sensors.

The result

A test run (consisting in running in the BHA without patch and inflating an inflatable packer) was performed to:

  • Confirm possibility of progressive pick up of the CT to compensate for its elongation under pressure, and validate calculated values
  • Measure the transition between up and down movements downhole 

Then four patches were set overlapped to cover the bottom zone, and two patches overlapped for the top zone; 150 pressure cycles were performed in a total of 12 days offshore (including mob./demobilization) without issue.

Start-up of the well was performed.

There were several World Wide Firsts on this operation

  • A 4-1/2in Patch was successfully set in 5in 18ppft casing, showing the versatility and expansion capacity of the Expandable Steel Technology
  • 6 Patches of 14m (46ft) were set in the same well, with 4 overlaps
  • Screen repairs at over 4,000m (13,300ft) on CT (horizontal well)

 

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Saltel Expandable Steel Patch features:

■ Patch through Patch
■ Small run-in diameter
■ Simple setting process
■ Minimum reduction in ID, Large through passage
■ Simple top-down setting process: if difficulties occur the tools can always be easily retrieved, redressed, & the job completed
■ Fast feasibility study, job evaluation & proposal
■ Short lead times, a skilled operations team available worldwide
■ Proven technology (Over 600 patches set worldwide)
■ 97 % success ratio
■ Adapts to casing ID, even if out of round, corroded or deformed
■ Fits both to vertical and horizontal sections

 

 


 

 

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3 Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

 

 

ECP installed in P&A application - MEA

 

 

Successful Steel ECP installation in Plug and Abandonment application - Middle East

 

saltel ECP Qatar

 

The context

The client had challenging Plug & Abandonment requirements to isolate the water producing lower zone of a multilateral well, in 5-3/4in horizontal openhole section to produce oil flow rate from upper layer, and assess the reservoir quality to unlock future development opportunities.
The application required an isolation packer, part of a P&A kit, to isolate the water zone prior running upper completions. A large expansion ratio was necessary, however traditional inflatable packers were disqualified since they are subject to damage while RIH through high deviated holes and crossing sidetrack cut windows.
Schlumberger provided a robust alternative that enabled circulation and rotation during RIH, with very high torque capacity. Solid anchoring performance of the product once set was also mandatory, allowing to launch a mechanical release overpull in contingency plan mode of hydraulic release mechanism.

Challenge

Set an effective open hole plug after running in agressive conditions (cycles of overpull, rotation, circulation) through a cut window.

Solution

Saltel Steel ECP-W [welded] 4.5in was selected as a “rapid response” solution with custom connection design, and for its robust qualities.
Steel Expandable Casing Packers can rotate during running in hole, pass through cut windows with no integrity risk concerns on its packer element. The strong anchoring capabilities of this technology, and the slim RIH OD, facilitate its deployment.

Result

 

  • The ECP was successfully set at 3,400 psi [234 bar].
  • Allowing rotation while RIH, the packer successfully withstood crossing cut windows without damage.
  • It took several attempts to release the setting tool and the ECP confirmed its robustness, withstanding multiple cycles of overpull (~60klbs), rotation and circulation without being affected.

 

 

 


 

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3 Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

 

Leaking DV tool repaired with Saltel Patch

 

During the first fracturing stage, a leak was discovered in the DV tool. A Saltel Patch successfully covered the DV tool at 2,000 m [6,500 ft] depth and restored well integrity, enabling continued fracturing operations.

The DV tool developed a leakwhile fracturing the first stage. It was unsuccessfully squeezed multiple times.

The solution was to cover the DV tool and its collars with a patch. The program required a patch with ≥ 8,500 psi internal pressure rating, and > 3,000 psi external pressure rating.

Saltel rig

The solution

A 26-ft, 5.5-in extra-reinforced patch was selected. The patch was set in just over 3 hours, fully drifted at 4.25in, and pressure tested at 8,500 psi. 

The patch was set in 3h15 and fully drifted at 4.25 in.

The result

As an alternative to the unsuccessful squeeze cementing attempts, the patch effectively sealed and molded to the inner shape of the DV tool to isolate it, and restored well integrity.

The fracturing operations resumed and the remaining 33 stages of the well were successfully fractured at 8,500psi with 80bbl/min flow rate. The patch succesfully withstood the 8,500 psi Frac pressure.

  

 


 

Saltel Expandable Steel Patch features:

■ Patch through Patch
■ Small run-in diameter
■ Simple setting process
■ Minimum reduction in ID, Large through passage
■ Simple top-down setting process: if difficulties occur the tools can always be easily retrieved, redressed, & the job completed
■ Fast feasibility study, job evaluation & proposal
■ Short lead times, a skilled operations team available worldwide
■ Proven technology (Over 600 patches set worldwide)
■ 97 % success ratio
■ Adapts to casing ID, even if out of round, corroded or deformed
■ Fits both to vertical and horizontal sections

 

 


 

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3 Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

Successful stage tool repair with Saltel Patch

Ensuring well integrity, enabling Fracturing the well, leaving sufficient ID for the largest frac ball, and withstanding 8,900 psi [613 bar] frac pressure

The context

The client well had a frac port that was stuck in the open position. To resume fracturing operations, a casing patch had to be set inside the well to isolate the stage tool and restore well integrity.

The stage tool was milled out to drift ID 3.794 in [96.39 mm], the Patch needed to leave access for a 3.375in [85.73 mm] ball, yet still withstand high fracturing pressures of 8,900psi for multiple fracs with 2,000 tons of proppant.

Challenge

stage tool repair2 2Saltel Patch was to restore well integrity so the customer could continue fracing the 20 stage well program. The largest ball size required to pass our set patch measured 3.375in [85.73mm]

Solution

39.47ft long patch x 4.5in x 0.118in (reinforced)
Elastomer thickness 0.059in, RIH OD 3.504in

Saltel Patch Installation

stage tool repair1 1Saltel then ran a 4.5-in reinforced patch to seal the open frac port, taking just under 5 hours to anchor and fully set it. The remaining drift ID was 3.438 in [87.33 mm], allowing the largest frac ball of 3.375-in [85.73-mm] OD to easily pass the set patch.
After the patch was fully set, it was pressure tested to 25 MPa [3,600 psi] against the toe port for 15 min, enabling the fracturing operation to resume.
The patch saw 100 tons of proppant per stage for a total of 2,000 tons pumped past the patch. This job was a major success for the client because the well was stimulated without losing stages below the patch.

Result

The patch was successfully installed across the milled out Stage Tool. It was set and drifted using our 83.82mm OD drift ring to ensure the patch was fully set without any restriction. It was then pressure tested to 25MPa prior to starting fracturing phase. All 20 stages below the patch were stimulated at 8,900 psi [613 bar] without issue and withstood the high pressures and pump rates without leaking nor bursting.

 


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Saltel to ATCE 2017

atce2012

Saltel Industries is part from Annual Technical Conference & Exhibition (ATCE) next 09-11 October 2017. You are welcome to our booth #2559, we will present the latest developments of our Steel Packers and & Patches.

Venue

Henry B. Gonzalez Convention Center - San Antonio, Texas, USA

Expandable Steel Technologies

Saltel Steel Packers

Saltel Steel Packers can meet numerous technical expectations in various applications such as Annulus IntegrityCement BackupStage Cementing, Deep Offshore Annular Isolation, Acid StimulationSandscreen Isolation and Shale Fracturing.  Saltel Packers are slid onto the completion casing and fixed by Welding or Crimping (patented). Applying hydraulic pressure in the completion casing, expands the packer's metallic sleeves. The plastic deformation of the steel sleeves, creates a solid and permanent annular well isolation, whose sealing efficiency is ensured by a thin layer of HNBR (swelling and non-swelling).

  

Saltel Patches

Saltel Patches fit for Production Optimisation (Perfs shut-off), Well Maintenance & Repair (damaged casings), New well applications (Frac Port, DV Tools, or sliding sleeves repair), and Enhanced Oil Recovery (EOR) applications (SAGD, CSS remedial applications). Saltel Patches are expanded using a high pressure inflatable packer and pushed against the casing. Once the setting tools are extracted, a pressure resistant inner lining is left inside the well.

 

Saltel to MIOGE 2017

Saltel Industries is exhibiting to MIOGE 2017, 27-30 June, Crocus Expo, Moscow

Mioge 17

 

 

Saltel exhibit team is looking forward to meeting you up there. We will present our latest developments on both Saltel Steel Packers and & Saltel Patches.

You need an invitation? send us your request to marketing @ saltel-industries.com

 

Saltel Patch enables modifying Injection profile in a water injector well

 

The context

modifying injection profile ALGThe injector well was completed with 41/2in tubing and liner. This well was injecting in two different reservoirs. Both modelling and empirical data concluded that injection in the top reservoir pushed the gas cap to the oil producer wells, without providing meaningful pressure support. The client requested an Expandable Steel Patch to modify the injection profile.

 

The job objectives

Improving the injection in the lower reservoir with Saltel Patch was modelled: this would yield a 300Mbbl increase in cumulative production by 2020, decreasing gas oil rate (GOR) and improving the reservoir pressure support.

 

The solution

modifying injection profile ALGA 41/2in Saltel Reinforced Patch was selected and installed on ACTive coiled tubing.

 

The results

The patch was installed in 27 steps, and less than 5 hours. It was effectively drifted at 3.445in [87.5mm] during the setting process. The patch sealing efficiency stopped the injections in the top reservoir and successfully modified the injection profile, according to client’s latest data.

 

 

 

 

 


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Improving Primary Cementing, Western Europe

 

Improving Primary Cementing with Saltel Steel Packer

Annulus Zonal Isolation Packer as preventive barrier to avoid risk of channeling

 

 

Challenge

Solution

Results

Run 5in liner through 7in casing and set the Annulus Zonal Isolation Packer (AZIP) in 7in underreamed openhole section

Use Saltel Steel AZIP during cement setting to isolate the trouble zones and optimize cement sheath.

The AZIP 5in was successfully set in 7in underreamed section, in 40 minutes. The casing cement was successful and showed no signs of channeling.

Germany offshore 01

Prevent from channelling issues 

An operator encountered cement issues in an offshore field with different formation pressures. Crossflow and channeling during cement setting were predicted and needed annular isolation at 4,800m depth to separate the two zones and avoid possible communication.

 

 

Run a 5in liner through 7in casing and set the packer in 7in underreamed openhole section

Improving primary cementing with zonal isolation packerThe packer, crimped onto a 5in liner, was run through a 7in casing. After pumping cement the packer was then expanded into the cement and set in 7in openhole section using 240bar [3,625 psi] casing internal pressure. The setting took 40 minutes and made an effective barrier to close off the annulus while the cement set, avoiding the risk of crossflow or channeling.

Completing cementing operation with no issues

The cementing operation was completed with no issue. The well displayed no migration issue in the annulus, and the client successfully resumed drilling and well construction operations.

 

 

 

 

 


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Successful casing reinforcement campaign with Saltel patch

Successful casing reinforcement campaign with Saltel patch allowing hydraulic fracturing operations

The Contextweak point BIS

North Dakota - Prior to starting hydraulic fracturing operations, the casing inspection outlined 7 weak spots in 5 different wells, due to drilling operations. Despite no leak was detected, logs indicated the casing thickness did not allow using frac treatments as per initial plan. The client had the choice between using a fracturing string or setting a casing patch to increase the internal pressure rating of the damaged casings.

The client preference was to restore the full casing integrity. This would allow keeping maximum internal diameter (ID) to implement the fracturing program, without increasing the friction losses with a tie-back system. The casing patch operation still needed though to be competitive.

 

IMG 3926 CopyThe solution

Saltel Patch (7in Ultraslim) was selected for its better set ID (5.69in). It was determined that the mechanical reinforcement of the patch inside a 7in - 32 lbs/ft casing was over 2,500psi; pressure above which stress is transmitted on the back side of the patch, to the casing.
A patch setting campaign was awarded after the success of the solution field tested in a well.
Five patches (Length 4m -13ft) were selected to cover the 1ft weak sections and one patch (11m - 36ft), to cover two weak spots in the same run.

The patches had to be set back to back to increase the efficiency of the operations, and keep the costs down.

 

The result

The 7 patches were successfully installed (one day/patch operation). The wells were pressure tested to 9,500psi.The client was able to successfully fracture the wells without casing failure.

 

Saltel Expandable Steel Patch features:

■ Patch through Patch
■ Small run-in diameter
■ Simple setting process
■ Minimum reduction in ID, Large through passage
■ Simple top-down setting process: if difficulties occur the tools can always be easily retrieved, redressed, & the job completed
■ Fast feasibility study, job evaluation & proposal
■ Short lead times, a skilled operations team available worldwide
■ Proven technology (Over 600 patches set worldwide)
■ 97 % success ratio
■ Adapts to casing ID, even if out of round, corroded or deformed
■ Fits both to vertical and horizontal sections

 

3 Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

 

 

Saltel Industries at HFTC 2017

Saltel 17HFTCSaltel Industries is taking part in SPE Hydraulic Fracturing Technology Conference (HFTC).

HFTC, one of SPE’s most popular events, will take place at the Woodlands Tx, 24-25 jan. 2016. HFTC is a great opportunity for oil and gas operators, to catch up with our isolation packer technology, meeting both fracturing and refracturing downhole requirements.

Saltel exhibit team is looking forward to presenting our latest developments on both Steel Packers and & Steel Patches.

Visit us on booth #107.

Patch over perforations before drilling operations

Saltel Patch enables cement repair and provides fullbore access to continue drilling

 

  

Setting of a customized Saltel Patch over casing perforations at 560 ft (170 m) allowing drilling BHA to pass through a 12 ft/4 m 9-5/8 in patch customized with a thinnest sealing element.

Context
In a new well, the cement between the 9-5/8 in casing and the wellbore was incomplete, the client had to perforate the casing to re-cement. The major concern of the client was to cover the perforations and then being able to pass thru with the directional drilling BHA (2° bent angle motor on a 8-3/8in drill bit).

Analysis
The casing is a 9-5/8in - 36 lbs/ft, with a nominal ID of 8.921 in (226.59 mm). Setting a standard 9-5/8 in Ultraslim patch was not possible, due to the small ID of the set patch.
R&D analysis led to manufacture a customized 9-5/8 in Ultraslim patch. The thickness of the sealing element was reduced to 1.5 mm (0.0509 in) instead of 2.25 mm (0.088 in).
The expansion was done in 2h, on a 24h drilling Rig. The patch was positioned by wireline, and pressure tested up to 1.500 psi (10.3 Mpa) solid for half an hour.
The 8-3/8in drill bit and 2° tilt angle passed through the patch (drift ID 8.411in / 213.63 mm) with slight dragging (8,000 lbs) and the well was successfully drilled as planned.

Result
The perforations were successfully sealed and the drilling BHA passed through the patch. The client resumed Drilling Operations.

Conclusion
With a customized analysis from Saltel Industries R&D Dpt, we can get an adequate ID and match the client requirements. In this specific case, the Saltel Expandable Steel Patch (Saltel Patch) was the only product able to meet such expectations.

 

 


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Successful Perforations shutoff with Saltel Patch in Ecuador

Three Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

3 Saltel Patches 7in were successfully installed to shut off producing perforations. This operation allowed converting the well from oil producer into re-injector well.

The client expectationsSaltelPatchInEcuador 1

The Patch had to meet 2 important requirements agreed with the client:
■ Maximum differential service pressure rating
■ Maximum Internal Diameter
Once installed, Saltel Patch successfully met these downhole requirements.

 

 

 

 

 

 

 

SaltelPatchInEcuador 2The solution

■ This job was the first in Ecuador
■ The job was completed in 110 hours without issue
■ The Patches were run through a 9-5/8 - 7in liner hanger, without issue
■ Setting depth: 9,600 ft [2,926m]
■ Setting temperature: 225°F [107°C]

The result

The patches were successfully installed, and the job was a success. Saltel Industries run 3 different patches with different lengths (8, 9, then 6meters-long patches) in the same well.

 

 

 

 


 

Saltel Expandable Steel Patch features:

■ Patch through Patch
■ Small run-in diameter
■ Simple setting process
■ Minimum reduction in ID, Large through passage
■ Simple top-down setting process: if difficulties occur the tools can always be easily retrieved, redressed, & the job completed
■ Fast feasibility study, job evaluation & proposal
■ Short lead times, a skilled operations team available worldwide
■ Proven technology (Over 600 patches set worldwide)
■ 97 % success ratio
■ Adapts to casing ID, even if out of round, corroded or deformed
■ Fits both to vertical and horizontal sections

 

3 Expandable Steel Patches set in the same well to shut off perforations, leaving large ID and strong collapse pressure ratings

Saltel to IPTC 2016

Saltel Industries is exhibiting to IPTC 2016, 14-16 Nov 2016, at Bangkok Convention Centre - Centralworld.

IPTC2016b

Saltel exhibit team is looking forward meeting you up there.

We will present our latest developments on both Saltel Steel Packers and & Saltel Patches.

Visit us on booth #D11

 


Saltel to ADIPEC 2016

 Adipec2016 01

Saltel Industries is part from Abu Dhabi International Petroleum Exhibition & Conference (ADIPEC), taking place at Abu Dhabi National Exhibition & Conference Center, next 7-10 November 2016. You are welcome to our booth #9330E, we will present the latest developments of our Steel Packers and & Patches.

 

More than 140% increase in oil production with Saltel Patch in DRC

 

Context

The client, one of the largest independent oil company, expected to shut off 7in casing perforation sets producing gas, over 15 wells on an onshore oil field in a remote area in Central Africa.

 

The Gas produced was originally used for artificial lift purpose (Natural Gas Lift & Artificial Gas Lift) and the client decided to switch artificial lift method from gas lift system to Sucker Rod Pump (SRP) system. For this, they required Saltel Patches in 15 wells, to shut off casing perforations, which were producing gas from the Turonian formation.kinkasi3

 

Job Objectives

  • Isolate gas producing Turonian formation
  • Isolate existing perforations in the 15 wells with Saltel Patch
  • Cost savings: Switching from gas lift to SRP mechanical activation would enable stopping gas compressors on the tank farm, meaning strategic opex cost savings

Solution

Fifteen 7in Slimline patches, with variable lengths (adjusted locally) as per client needs. A 14-month campaign completed in 5 mobilizations.kinkasi2

 

Results

Successful campaign using Saltel Patch to reduce opex cost isolating gas production in 15 producer wells.

  • No accident recorded during the Casing Patch Campaign.
  • No down time due to Saltel Industries.
  • All the patches were successfully set.
  • A global increase of 148% in the production was observed on the 15 wells

Benefits

  • Turonian successfully isolated
  • +148% increase in oil production
  • Drastic opex cost savings

kinkasi 01

 

 

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Saltel to SPE ATCE 2016

 ATCE2016 01

Saltel Industries is part from Annual Technical Conference & Exhibition (ATCE) next 26-28 September 2016. You are welcome to our booth #6017, we will present the latest developments of our Steel Packers and & Patches.

Expandable Steel Technologies

Saltel Steel Packers

Saltel Steel Packers can meet numerous technical expectations in various applications like Annulus IntegrityCement BackupStage Cementing, Deep Offshore Annular Isolation, Acid StimulationSandscreen Isolation and Shale Fracturing Saltel Packers are slid onto the completion casing and fixed by Welding or Crimping (patented). Applying hydraulic pressure in the completion casing, expands the packer's metallic sleeves. The plastic deformation of the steel sleeves, creates a solid and permanent annular well isolation, whose sealing efficiency is ensured by a thin layer of HNBR (swelling and non-swelling).

  

Saltel Patches

Saltel Patches fit for Production Optimisation (Perfs shut-off), Well Maintenance & Repair (damaged casings), New well applications (Frac Port, DV Tools, or sliding sleeves repair), and Enhanced Oil Recovery (EOR) applications (SAGD, CSS remedial applications). Saltel Patches are expanded using a high pressure inflatable packer and pushed against the casing. Once the setting tools are extracted, a pressure resistant inner lining is left inside the well.

 

Saltel Industries to exhibit to ONS 2016

Offshore North Sea (ONS 2016) will be taking place at Stavanger forum - Stavanger, Norway next 28Aug- 1st Sept 2016.

See original image

Saltel Industries will be part from this event. Saltel exhibit team is looking forward meeting you up there.

We will present our latest developments on both Saltel Steel Packers and & Saltel Patches.

Visit us in Hall 2, booth #220.






 

Saltel to exhibit at 2016 URTEC

urtec2016Saltel Industries will be exhibiting to the Unconventional Resources Technology Conference (URTEC).

 

URTEC 2016 will take place at Henry B. Gonzalez Convention Center, San Antonio Tx, 01-03 August 2016.

 

 

Saltel Industries exhibit team is looking forward to presenting our latest developments for unconventional applications (shale fracturing, completion module repair / damaged frac ports) on both Saltel Steel Packers and & Saltel Patches.

Visit us on booth #939.

 

Press Release - Successful off-bottom cementing operation

Saltel Steel ECP demonstrates unusual resilience despite severe RIH conditions

Run through tight spot, stuck and worked for several hours before pull out of hole, checked intact on the surface then successfully re-run and installed

Saltel Industries records another success running an external casing packer in a Coal Seam Gas well, despite very difficult run in hole conditions. Due to downhole restrictions, the expandable steel ECP has been worked for several hours before being pulled out of hole. Once at surface the ECP was checked intact whereas any other annulus packer would have suffered material damages!

Following a successful 2-wells campaign for one-stage and two-stage cement jobs, this 7in Expandable Steel External Casing Packer (ECP) was successfully installed, and allowed to perform off-bottom cementing above a pre-perforated casing section. It was the last from a field trial campaign of 3 Saltel Steel ECPs.

Saltel ECP pulled out of hole after have been stuck and worked for several hours downhole

Photograph of Steel External Casing Packer (Saltel Steel ECP) after pull out of hole preceding the 2nd run: No damage indicating the product has been run through tight spot

 

For previous operations, the operator regularly encountered frequent loss zones while drilling and needed to perform stage cementing operations. The Packers had to be set either in Cased or Open Hole and had to withstand both difficult running conditions in deviated wells, and under gauged holes. The 3rd packer was run in hole through a tight spot. Nevertheless both installation and off-bottom cementing operation were successful. This provided sufficient guarantees on Expandable Steel ECP technology:

  • Saltel Steel ECP’s sturdiness; the ECP displays an extraordinary robustness, allows running in hole in difficult conditions.
  • Saltel Steel ECP has proved a relatively easy to run and easy to set product, conforming itself to any stage cementing configuration, and every situation (depth, hole size, deviation…)
  • The successful consecutive installations outline Saltel Steel ECP’s reliability (sealing effectively regardless of what happens, and improving the annulus integrity)

 More details about the ECP installation

During the first run, the packer went through a tight spot but elements above the packer were stuck. The string has been worked for 12 hours, attempting to pull all the equipment out of hole.

When pulling the casing back to surface, the SES ECP showed no signs of deformation and looked "good as new” as per client words.

Finally, Saltel Steel ECP was run back and successfully set in nominal 8-3/4in Open hole. The Cement job went well with full cement return. The possibility to rotate and put weight on the packer during RIH has been capital.

About Saltel Industries

Recently acquired by Schlumberger, Saltel Industries is an upstream Oil Service Company developing, manufacturing and marketing innovative solutions for downhole applications. Specialized in high performance composite elastomers, and stainless steel plastic deformation, Saltel Industries focuses on 2 main Business Segments: Expandable Steel Packers, and Expandable Steel Patches.


For more information, please contact

Franck NDJALI ETENO                                                                                                     
Communication & Marketing Manager                                                              
This email address is being protected from spambots. You need JavaScript enabled to view it.
 

 

Schlumberger Acquires Saltel Industries

Unique expandable steel technology solutions strengthen Completions technology portfolio

hist6

HOUSTON, June 1, 2016—Schlumberger announced today the acquisition of Saltel Industries, a France-based engineering, manufacturing and service company that offers expandable patches and steel packers technology for the oil and gas industry.

Read More

Successful OpenHole Multistage Fracturing

 Successful OpenHole Multistage Fracturing Operations with Saltel FracPackers

Context

  • A Gas producer horizontal well with openhole multi-stage completion (ball-drop sleeves) 4-1/2in 13.5 lb. /ft. P110 run in 6-1/8in openhole.
  • The client selected a combination of 2 different Isolation Packers: 15 Hydromechanical Isolation packers (competition) with 5 Saltel Expandable Steel FracPackers located at the toe.

Solution

FracPacker is a patented metal expandable packer specially designed for OH multistage frac operations. Saltel Industries provided five 10k 4-1/2in ISO 14310 V3 qualified to 10,000psi (68.9Mpa) differential pressure. The FracPackers came set on 10ft Pup Joint (4-1/2in 13.5ppf P110), with pin-box LT&C connections.

The short length of the packer (3.3ft) combined with its reduced intial diameter (5-1/2in) facilitated the Running In Hole. The Saltel FracPackers were first run to depth from 12,675ft (3,850m) to 13,800ft (4,200m) in the horizontal section, then successfully expanded a couple of months later with the frac fleet.

Saltel FracPackers ready to be run in hole

Results

  • The FracPackers installation was a success.
  • The FracPackers enabled successful Shale Fracturing Operations.
  • Frac pressure of the zones varied between 5,945psi and 7,395psi (41MPa to 51MPa)
  • 335m3 to 454m3 of frac sand have been pumped in the intervals

Conclusion

Checking both pressures and rates of each frac treatment in the intervals isolated by the Saltel FracPackers showed a solid annular isolation. Following this success, the Operator decided to run 36 FracPackers in a full Openhole multi-stage frac completion end of 2015.

 

 

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ONS invitations

10 invitations available for ONS 2016. Ask for yours now!

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Case Study: ECP Valve Repair, Permian Basin

 

ContextSaltel Patch ECP Valve Repair Permian

On a Plug & Perf horizontal well, an external casing packer valve (ECP valve), set at 4,860 ft, had been derated to 6,000 psi by the manufacturer while the formation would require 6,800 psi fracturing pressure.
The client had planned to run plugs with an outer diameter of 4.425in for the stimulation operations with a possibility to switch to a 4.3in plug.
Concerns about setting a casing patch were about the internal diameter (ID) reduction for the plugs to pass through and the cleanout operation to remove the plugs and start to produce.

 

Solution

The solution was to cover the External Casing Packer to make sure its valve would not see the frac pressure using a 5.5in Slimline patch.

The Saltel Patch IDs regarding a 5.5in-20 lbs/ft casing (Nominal = 4.778in / Drift = 4.653in) are 4.427in / 4.296in and would not be sufficient to allow 4.3in Plug OD to pass through.

The client ran a caliper log to define exactly the internal diameter of the casing, in order to have a better projection of the real patch ID. The Caliper log showed a minimum of 4.744in, that gave a Patch ID of 4.391in drift.
The patch was set in 3 hours and fully drifted up to 4.350in Just after pull out of hole (POOH), the well was successfully pressure-tested up to 9,800 psi.

A plug with an ID of 4.425in was ran later but tagged as predicted on top of the patch. The client decided to run 4.3in plugs for the stimulation operations.

 

Result

All the perforation guns & plugs went through the patch without any issue. All 13 stages of the well were successfully fractured up to 7,000 psi.
4.5 MM lbs of sand - 67,000 bbls of fluid with 36,000 gals of 15% HCl were successfully pumped through the patch. Retrieving the patch from the hole by fishing or milling was not necessary. All the plugs had been milled out successfully with a 4.25in bit, drilling out one plug at a time and applying sweep and short trip to minimize any tagging/dragging issue.
This job was a major success for the client that applied this same remedial solution for others wells on the pad having issues with DV Tools.

 

 

 

 


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Case Study: Successful stage cementing with Saltel ECP

 

Context

A 2-well campaign was conducted using Saltel Industries Expandable ECPs.

The client encountered frequent losses zones while drilling and needed to perform onestage and two-stage cementing operations.

The Packers had to be set either in Cased or OpenHole and needed to withstand difficult running conditions in deviated wells and under gauged holes. The possibility to rotate and put weight on the packer during RIH is therefore essential.

Solution 

SES ECP is a proprietary expandable steel packer specially designed for stage cementing applications. SES ECP 7in is a robust, simple and cost-effective barrier providing reliable ground for stage cementing operation.

  • Simple setting process compatible with operator’s current string design and procedures
  • Quick installation time
  • Can be worked in doglegs or tight spots
  • Can be rotated while RIH
  • High sealing capability in cased hole or openhole

Saltel Expandable ECP Australia

Results

1st Well – Two-stage cement job
The 1st packer was successfully expanded in the vertical cased section of a deviated well at 300m - 984.2ft. Packer has been set in a 9-5/8in 36ppf casing (ID 8.921in). Cement has been pumped above the packer and circulated back to surface.

2nd Well – One Stage cement job
The 2nd packer was placed at the very bottom of the string for a one-stage cement job above a loss zone. The casing was worked for 6 hours attempting to go through under-gauge hole (String weight UP/SO, 70klbs/26klbs). When pulling the casing back to surface, the SES ECP showed no signs of deformation. It was run back and successfully set in nominal 8-3/4in Openhole (with potential washout). 

Benefits

  • Compatible with any stage cementing configuration
  • Robust design allows RIH in under-gauge hole
  • Simplified running & setting
  • No risk of premature expansion
  • Cement successfully pumped to surface

 

 

 


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Case Study: first patch set in New Zealand

 

Context1st ses patch in New Zealand

In a 9 year-old well, a communication between the 5-1/2in production casing and the 9-5/8in annulus had to be located then shut off.The objective was to cover and seal off the hole using a Saltel Expandable Casing Patch, allowing the completion to be run through the patch.

 

 

  

Solution

Split Casing

The depth of the leak was not known before the job; a 5.5in Reinforced SES Patch was selected in case the damaged zone had been located deep in the well, which would have require a high collapse pressure.A multi finger caliper log allowed to locate the hole in the production casing 25.7m below the Tubing Hanger.The patch and setting BHA were conveyed with 2-7/8in tubing on a service rig and positioned by tubing tally.

 

 

Result

The patch was rigged up, positioned, installed in 12 expansions, and drifted at 4.331in without issue in less than 3 hours. It was then pressure tested solid at 1,550psi for 10min. Finally the completion was set back into the well. 

 

Water-well turbidity reduction in a slotted screen

 

Context

In a 1600ft well, a 4ft-long zone produced turbid water above a given pumping rate. Length of the stainless steel screen -1300ft- raised concerns on the possibility to efficiently treat this area. Indeed, turbidity could travel along the gravel pack and contaminate the main flow. 

Length of the patch was studied as to allow the maximum turbidity-free flow at an acceptable pumping rate, taking into account possible fluid-level change caused by patch-induced pressure losses. Also, the screen geometry (0.23in thick with 0.08in oblong slots) questioned the possibility of expanding and anchoring the patch without damaging the strainer.

Solution

test patch in strainerIt was decided to set a 40ft patch to steady the flow behind the patch and thus prevent the production of turbid water. Saltel Industries performed shop tests on an identical slotted screen and determined that the patch could be anchored with no damage to the slotted-casing, if less than 650psi was transmitted to the casing.

The key points in order to avoid screen damage were:

  • an accurate positioning of the expansion packer when expanding (to avoid the contact of the inflated packer with the screen)
  • the pressure monitoring (to avoid applying too much pressure to the  screen through the patch).

Settings

Positioning of the patch was made by pipe tally since water was too trouble for video positioning. The patch has been expanded in 17 steps.

Result

turbidity vs flowrateVideo check confirmed the good setting of the patch and it has been observed that the screen has not been expanded above or below the patch.
The client was satisfied by the solution since the patch increased the turbidity threshold point, enabling production gain of 125 US barrels per hour with no turbidity. Also, for a given pumping rate, no fluid level drop was observed compared to previously.

Case Study Tubing Repair in a Gas Well Patch set with Coiled Tubing

 

Context

On a gas producer well, a leak was detected between the 4.5in #13.5 production tubing and the 7in casing. It was located with a thermo-log at a collar at 988m (3240ft). The major concern for the customer was to repair the zone and be able to run a downhole safety valve (storm choke) with an OD of 84mm (3.31in) through the repaired zone.

Solution

patch set with coiled tubingThe workover of the Cr13 tubing string would have been very expensive and a tubing patch was determined to be the most reliable and cost effective solution. In order to cover the collar with a reasonable sealing length, a 6m (20ft) 4.5in reinforced patch was selected. The patch was conveyed using a 1-3/4in Coiled Tubing with optical fiber inside. Due to unpredictable CT behavior under pressure (elongation, helical buckling), a tension-compression sub was added in the BHA, to enable real time monitoring of the forces applied on the setting tool and the patch. It was also equipped with temperature and pressure sensors. The initial positioning of the patch was performed with a GR-CCL log. Prior to the patch operation, the well was killed with 1.27sg CaCl2 brine.

Result

The patch was successfully set and drifted real time with the 3.4in OD setting tool (86.36mm, on 2m60=8.5ft long). After the POOH, a slick line gauge (OD=87mm=3.425in) was run through the patch without weight variation. The safety valve was then run through the patch and the well put back in production. No pressure increase in the 7in annulus confirmed the patch sealing capability. This job was a major success for the client and saved a costly workover.

 

 

 

 


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Saltel Industries at 2016 SPE HFTC

Show 8876Saltel Industries will be exhibiting to the SPE Hydraulic Fracturing Technology Conference (HFTC). HFTC, one of SPE’s most popular events, will take place at the Woodlands Tx, 8-11 February 2016. Saltel Industries exhibit team is looking forward to presenting our latest developments on both Steel Packers and & Steel Patches

Visit us on booth #106.

A new Application (Pipeline Repair) for SES Patch

Saltel Industries and Atteris have combined their expertise and technology to develop a range of new pipeline repair methods. This game changing technology is based on internally repairing a pipeline defect using Saltel Industries’ proven Expandable Steel Technology, combined with standard deployment techniques and equipment.

 Read More

 

New Case study Water well rehabilitation with SES Patch

Context

After galvanic corrosion of the casing by the downhole pump, rehabilitation was needed in a 2,600ft water well. The main concerns were the possibility of contamination of the well by exterior tools and the patch material compatibilities regarding drinkable water. Perfect isolation of the casing was also to be achieved.

Solution

Before running 430ft of new liner (OD = 11.4in) in the corroded casing, a SES-Patch was welded at the bottom of it. An Inflatable Packer was then run in the liner to expand the Patch. Once expanded, the SES Patch holds the liner and makes the seal. The rubber groove technology developed by Saltel Industries allows an anchoring force of 26,400lb for a 20ft Patch. This technology, combined with specially machined rubber sleeves also assures sealing and dielectric union. For environmental concern, the setting 

tools were entirely dismantled prior to the setting and each part was cleaned then greased with food-grade products. After reassembly, the tools were heavily circulated with chlorinated water.

Setting

patch schematic water well rehabilitation with ses patch

The patch was set and drifted at 11.96in.

 

 

 

 

Resultliner and patch water well rehabilitation with casing patch

The rehabilitation operation of the well could then continue and the well went back on production. The client was very satisfied with the technology and the result of the job

 

 

 

 

 

 


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