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Case study - DV Tool & ECP Valve Repair, USA

 

  

On a Plug & Perf frac well, 7 in. casing on the vertical section with a 4.5 in. liner below, the annular casing packer was under-rated and the pressure test during the toe prepping operation created a leak on its safety valve, challenging the fracturing operation.

The objective was to cover the leaking ACP and the DV tool positioned directly above, considered as a potential weak point. Due to the high formation pressure, the patch needed a high collapse resistance. After drill out, the DV tool has a larger ID than the casing (7.4in) representing 20% more than the Nominal Casing ID. The patch has to withstand up to 17% deformation to make the seal against the casing ID. High pressure from the well pressure test and fracturing pressure will hydroform the patch to mold the inner profile of the DV Tool.

 A 40 ft (12 m) 7 in. Reinforced patch was selected for its high expansion ratio in the DV tool larger ID and for its collapse resistance. 

The Patch was positioned by wireline. A pup joint was placed in the work string above Saltel’s tools and the position correlated from the well gamma ray log with a CCL/GR.

Set in 2h & 45min, the Patch has been successfully pressure tested up to 9,600 psi

 


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Primary cement backup

Improve primary cementing, preventing gas or water channeling in cement

Improving primary cementing

 

Annulus cementing is essential as a primary well barrier to secure the environment, and ensure the efficiency of high pressure stimulation operations below.

Efficient primary cementing can be difficult, particularly when there is potential crossflow, a tight borehole, or a risk of gas migration.

Proposed solution

Using a high pressure steel barrier to seal the annulus while the cement is setting will prevent crossflow or channeling, support the cement to keep it in place, eliminate any gas migration, and help to centralize the casing. A steel packer run on the casing can be expanded into the wet cement to eliminate these potential problems and ensure cement and annulus integrity..

Saltel Steel ecp C 

Available Product Range

Product line Saltel Steel ECP-C Saltel Steel AZIP-C 1-0
Features Mounting Crimped
Valve system Lock valve closing permanently packer expansion port and trapping fluid inside   packer Lock valve closing permanently packer expansion port + Annulus compensation valve (one side)
Sealing System Deformable steel sheath with elastomer seal
Benefits Reliability Life of well valve system Life of well (Sweet and Sour environment)
Performance High DeltaP achieved with moderate setting pressures Self energized High pressure differential from one direction Unaffected by temperature variations

 

 

 

Open Hole Ball-Drop Multi-Stage Fracturing

Provide immediate efficient seal, whatever the fluids or the temperature cycles*

 *FracPackers not available in Europe

 

Openhole isolation is challenging, especially with irregular borehole geometries. With the high flow rates used during hydraulic stimulation, the temperature can drop in elastomer sealing elements, causing thermal contraction and leaks. 

 

 

MULTI STAGE FRACTURING

Proposed solution

Saltel Steel FracPacker has no moving parts and is set almost instantly by pressuring-up the casing.

The strong mechanical structure will allow the string to be rotated, reciprocated and together with the large clearance will avoid any damage running in hole. The self-centralization will reduce the number of centralizers.

The steel packer will also be able to self-adapt to irregular borehole geometry, and to re-energise as soon as pressure is used in the interval. A pressure compensation system improves the seal as the frac pressure increases.

 

 

 

  

Product line Saltel FracPacker 10,000 psi Saltel FracPacker 15,000 psi
Features Mounting Welded Crimped
Valve system Safety closing valve
Sealing System Deformable steel sheath with elastomer seal
Benefits Reliability Gentle settting, avoiding frac initiation at packer position
Performance Self energized High pressure differential from one direction Unaffected by temperature variations

 

 

 

 

Saltel Industries, a Schlumberger company

Saltel Industries develops, manufactures and operates Expandable Steel Patches and Expandable Steel Annulus Packers.

Casing Patches allow restoring well integrity and optimizing the production in both mature and new wells applications. Designed for perforation shutoff, the technology is also suitable for damaged or corroded completion repair.

Saltel Expandable Steel Packers are permanent and reliable annular barriers, preventing from migrations in the annulus, for Shale Fracturing, Multistage Cementing and Cement Integrity.

  

Off-bottom cementing above uncemented openhole completion

Ensure high pressure resistant annular barrier before OHMS fracturing operations or above screens with Saltel Steel Packers

off bottom cementing above hp uncemented completion 01Annulus cementing is essential as a primary well barrier to secure the environment, and ensure the efficiency of high pressure stimulation operations below.

Effectively placing primary cement above an uncemented completion can be difficult. This is particularly challenging when the well will be subjected to high pressure stimulation (fracturing) and a complementary high presssure annulus barrier is required below the cement.

 Proposed solution

Saltel Steel Packer combined with a stage collar or a DV Tool is run as part of the production string. The Packer can be set inside the previous casing shoe, or in the open hole below. The cement is pumped through the stage collar and placed above the expanded packer.

After closure of the cement port, the casing integrity is restored, allowing high pressure stimulation to be performed. The packer acts as an additional barrier to both seal the annulus and protect the cement.

Saltel Steel ecp C 

Available Product Range

Product line Saltel Steel ECP-C Saltel Steel AZIP-C 1-0
Features Mounting Crimped
Valve system Lock valve closing permanently packer expansion port and trapping fluid inside   packer Lock valve closing permanently packer expansion port + Annulus compensation valve (one side)
Sealing System Deformable steel sheath with elastomer seal
Benefits Reliability Life of well valve system Life of well (Sweet and Sour environment)
Performance High DeltaP achieved with moderate setting pressures Self energized High pressure differential from one direction Unaffected by temperature variations

 

 

Saltel Steel Packers

 

The Expandable Steel Annular Isolation Packers are slid onto the completion casing, and sealed by welding or crimping. Hydraulic pressure is applied in the completion casing to expand the metallic sleeves up to the contact with the formation or casing it is set in. As a result, the stainless steel sleeves plastic deformation creates a solid and permanent annulus seal. Compared to existing solutions, our Annular Isolation Packers come with a drastically quicker and positive setting procedure compared to fluid-inflated packers, with more effective (high pressure) sealing features than elastomer swelling packers. The Expandable Steel Annular Zonal Isolation Technology brings new assets to the completion market in various applications such as Shale Fracturing*, Multistage cementing, Cement integrity and Replacement, Acid stimulation, and Zonal Isolation

Click to access your requested application on the image below

Stage CementingStage CementingAnnulus IntegrityAnnulus IntegrityZonal IsolationZonal IsolationMulti-Stage FracturingMulti-Stage Fracturing  

 


*Saltel FracPacker is not available in Europe. For more information please contact us

 

Saltel Patch for Enhanced Oil Recovery & damaged casings

Perforations shut off (water or gas) or ICD isolation with Saltel Expandable Steel Patch

Saltel Patch eliminates or reduces water or gas production without restricting the wellbore access. It seals the perforated zone without restricting the production from the neighboring perforations.

An innovative setting process with high pressure inflatable packer, contrasting with traditional cone setting.  

25 patch applications web

 

▲Enhanced Oil Recovery (EOR) applications, including water and gas shut-off, modifying injection profiles, ICD isolation

▲Restoring casing integrity applications, including repairing short lengths of damaged casing or tubing, damaged sand screens and leaking couplings.

 

 

   



 

 

Damaged or corroded completion repair

Parted casing, leaking coupling, corroded casing/tubing or sand screen repair, with Saltel Expandable Steel Patch

Saltel Patch is an excellent inner lining solution for repairing old or damaged casing, whether it’s corroded or eroded, twisted, burst or bent. It perfectly seals the damaged zone, ensuring maximum nominal and drift ID after setting. Saltel Patch provides 100% effective sealing, even in out of gauge or worn casings.

An innovative setting process with high pressure inflatable packer, contrasting with traditional cone setting.

▲Restoring casing integrity applications, including repairing short lengths of damaged casing or tubing, damaged sand screens and leaking couplings.

▲Enhanced Oil Recovery (EOR) applications, including perforations shut off, water and gas shut-off, and modifying injection profiles

 Run on tubing or CTU, Saltel Patch is expanded downhole using an inflatable packer to create a high pressure inner lining inside the casing.

    

Damaged Casing

 

DAMAGED CASING

Read More..

    

Damaged Tubing

 

DAMAGED TUBING

Read More..

    

Damaged Sand Screen

 

damaged sand screen

Read More..

    

Leaking Couplings

 

LEAKING COUPLINGS

Read More..




    

Pïpeline Repair

 

pipeline repair

Read More..





 



Saltel Industries Site Map

 Saltel Industries Site Map

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Cost Efficiency

Saltel Industries is organized to optimize the time and costs required for introducing new products to the market by deploying strict methodology.  This makes it possible to reduce uncertainty as much as feasible.

With its agility and high level of professionalism, Saltel Industries can develop, qualify and introduce new technologies to the market in a short time and at an optimized cost.

  • Agility makes it possible to offer innovative solutions by quickly adapting to customer requirements using short decision-making processes and a rigorous yet flexible project management system.
  • Structural costs which are lower than those of the large groups make it possible to develop and put new technologies on the market at distinctly lower cost.
  • The right to fail and to experiment helps the R&D teams make new developments possible with complete peace of mind. In a small organization, the concept of individual careers comes after the communal objective of technological success.
  • Professionalism must be at the same level as in large companies. Qualification processes are necessary to guarantee equipment operability and the safety of personnel.
  • Financial prudence and adaptability to customer requirements.  This is essential. As a priority, financial resources must be devoted to products which optimize customer needs and company objectives.

Saltel Expandable Steel Standard Casing Patch

Casing Patch front

dhetSES Patch is a permanent solution used to repair a zone of damaged tubing or casing, to shut-off unwanted perforations, to seal a leaking sliding sleeve, or other remedial operations. This expandable short length of tubular is made from high quality stainless steel with an elastomer outer skin and a profiled sealing system, the SES Patch is run on tubing, drill pipe, or coil tubing. At depth the Patch is expanded using a high pressure inflatable packer, and pushed against the casing to activate the outer seals. The setting tools are extracted to leave a pressure resistant inner lining inside the well.

  

Running Procedures

The Down hole expansion tool is positioned inside the Expandable Steel Patch. The inflatable packer section is then inflated enough to grip the inside of the Patch (not enough to start expansion). The assembly is Run In Hole to the setting zone. The packer is inflated using pressure from surface to expand the top of the Patch, anchoring it in place. The packer is then deflated, run in 3 ft / 1 m, and the next section is expanded. This is repeated as often as necessary until the full length is expanded, and BHA is pulled back to surface.

 

Challenges

  • Life of the well solution
  • Seal effectively in oval, out of gauge or irregular borehole
  • Repair damaged or corroded casing
  • Seal off leaking couplings or separated pipe

 

Applications 

25 Appli patch 600

 

 

Features & Benefits

  • The high expansion ratio enables running the Patch with a large clearance, avoiding sticking problems while running in hole
  • A real time setting controller verifies the ID of the set Patch during the operation. Any anomaly can be immediately detected and corrected.
  • Tubulars primarily made from 321 stainless steel
  • Outer skin in hydrogenated nitrile (HNBR) profiled to ensure a good seal
  • The Patch will set effectively in any intermediate diameter within its range
  • Seals effectively even with ovalisation up to 25% 
  • A second patch can be run through a previous Patch and set below (except in heavy weight casing / thick Patch, see products specs)
  • Leave large ID access to the well below for most standard tools

 

 

Saltel Expandable Steel Standard Casing Patch

Casing Patch front

dhetSES Patch is a permanent solution used to repair a zone of damaged tubing or casing, to shut-off unwanted perforations, to seal a leaking sliding sleeve, or other remedial operations. This expandable short length of tubular is made from high quality stainless steel with an elastomer outer skin and a profiled sealing system, the SES Patch is run on tubing, drill pipe, or coil tubing. At depth the Patch is expanded using a high pressure inflatable packer, and pushed against the casing to activate the outer seals. The setting tools are extracted to leave a pressure resistant inner lining inside the well.

 

 

Running Procedures

The Down hole expansion tool is positioned inside the Expandable Steel Patch. The inflatable packer section is then inflated enough to grip the inside of the Patch (not enough to start expansion). The assembly is Run In Hole to the setting zone. The packer is inflated using pressure from surface to expand the top of the Patch, anchoring it in place. The packer is then deflated, run in 3 ft / 1 m, and the next section is expanded. This is repeated as often as necessary until the full length is expanded, and BHA is pulled back to surface.

 

 

Challenges

  • Life of the well solution
  • Seal effectively in oval, out of gauge or irregular borehole
  • Repair damaged or corroded casing
  • Seal off leaking couplings or separated pipe

 

Applications 

25 Appli patch 600

 

 

Features & Benefits

  • The high expansion ratio enables running the Patch with a large clearance, avoiding sticking problems while running in hole
  • A real time setting controller verifies the ID of the set Patch during the operation. Any anomaly can be immediately detected and corrected.
  • Tubulars primarily made from 321 stainless steel
  • Outer skin in hydrogenated nitrile (HNBR) profiled to ensure a good seal
  • The Patch will set effectively in any intermediate diameter within its range
  • Seals effectively even with ovalisation up to 25% 
  • A second patch can be run through a previous Patch and set below (except in heavy weight casing / thick Patch, see products specs)
  • Leave large ID access to the well below for most standard tools

 

 

DV Tool Repair, USA

 frac port repair with ses pre-frac patch Zone USA

Application: onshore, 5.5in 17lb/ft casing

Date of the job: February 2013

Context

Oil producer well

DV tool Repair

5.5in 17lb/ft casing  (ID= 4.892in / 124,26mm)

DV tool to repair @ 7 306ft / 2226,87m

Downhole temperature 130°F / 54°C

Conveyance: 2.375in 4.6lb/ft tubing

 DV Tool  

Objectives

Leaking DV tool Isolation

Allow fracking of subsequent zones with pressures up to more than 14,500 PSI

Leave maximum clearance for frac plug.

Solution

SES Pre-Frac Patch 5.5in, Slimline, Stainless Steel

Patch length 19.73ft / 6,02m before expansion

RIH OD= 4.390in / 111,50mm

Operational Characteristics

Set Patch ID= 4.415in / 112,5mm

Expansion Pressure 4 622psi / 319bar

Patch length 18.98ft / 5,79m after expansion

Expansion duration: The patch was set in 12 steps

Results

Good and safe job, the client was very satisfied with our work ethics and safety. Excellent job performance for efficient results: no problem with the frac or retrieving the plug afterwards. The SES Pre-frac Patch was successfully set.

 

BTN read_more

Case study Slotted liner repair in SAGD well

 

 Carte canada

Application type: Slotted Liner Repair

Liner: 8 5/8" x32lb/ft slotted liner

Patch ID after setting: 7.38in | 187,57mm

Temperature: 150°C | 302 °F

Depth: Approx 500m |1568ft vertical depth

Patch setting pressure: 262bar | 3799psi

 

Operation objectives 

  • Repair a partially damaged slotted liner without introducing borehole restriction nor physical obstruction.
  • Temperature resistant SES Patch setting in HT environment.

Result:

The 8.5/8in Ultraslim SES Patch was successfully positioned with a tubing tally. The SES Patch was set in 15 steps thanks to a 6.25in Inflatable Packer, in a horizontal well.

 

 our solution ses patch

Casing Collar Repair


 

OBJECTIVES

Damaged casing couplings repair

Seal off collar leak

 casing collar repair  

CHALLENGES

Install an effective pressure resistant watertight seal inside casing which might be shifted
Ensure maximum internal diameter (ID)

our solution ses patch Ask us for a job evaluation

CASE HISTORY

Location: Canada

Casing: 5,5in

Depth: 620m / 2035ft

Downhole temperature: 20°C / 68°F

Patch set length: 12,3ft / 3,7m

 Casing collar leak Canada

OBJECTIVES ON OPERATION 

A 5,5in Ultra slim SES Patch was run and expanded successfully with a 3,75in inflatable packer. The SES Patch was set in 8 steps and drifted with a 4.53in/115.2 mm gauge ring on the DHET.

RESULT

Normal operations resumed on the well after setting the SES Patch.

Board of Directors

Thibaut Guignard

TGuignardGeneral Manager

Thibaut GUIGNARD joined Saltel Industries in 2016, few months after Schlumberger acquired the company.
Prior to joining the company, Thibaut was in charge of Schlumberger Completions Operations in Brazil.
Thibaut joined Schlumberger in 2000. He started his career as a Mechanical Design Engineer in Rosharon, and has held various positions for Schlumberger Downhole Testing and Completions, both in technology centers and in the field, mainly in Americas & Africa.
Thibaut holds an Engineering degree from "Arts et Métiers Paris Tech" Grande Ecole, France, and a MSc. in Mechanical Engineering from Georgia Institute of Technology.

Nicolas SALTEL

Nicolas SALTELVice President Americas

Nicolas SALTEL began his career in Paris as Product Engineer / CAD Manager for a big aerospace company. He achieved previously a Master of Science at Bristol University (UK), after a Bachelor in Mechanical Engineering.
Nicolas joined Saltel Industries in 2005 to manage the Manufacturing department at its early days. He took care of the deployment of a CAM and a MRP software to allow its growth. Over a 10 year time period, the Manufacturing sector changed from a craft industry to a highly industrialized and organized Production line. From machining to pressure testing, the highly integrated manufacturing system is still focused on Quality.
He is now based in the US to make the link with the US market in order to promote the innovative technology of Saltel Industries' Products and services, and adapt the company's offer to the needs of the customers.

Benjamin SALTEL

Benja SaltelVice-President, TSO Manager & Saltel Patch Product Champion

Benjamin SALTEL started with the company at its inception in 2004. After developing the Inflatable Packers range of products, Benjamin and the R&D team developed the Expandable Patch Technologies and associated setting tools. As Métier Coordinator, Benjamin introduced Technical, Calculation, Quality and HSE Best Practice in the company. He deployed the PLM from research to the manufacturing process, and is co-author of 16 patents awarded or pending. Benjamin graduated from "Arts et Métier ParisTech" Grande Ecole (Mechanical Engineer). He moved to the US to become Country Manager (2014-2015), a job which includes the management of our operational base in Midland. Benjamin came back to HQ in 2015, as Vice President Europe & CIS.

James LEIGHTON

JLeightonVice President Marketing & Technology

Before joining Saltel Industries in 2009, James LEIGHTON was the Managing Director of Bretagne Innovation, and responsible for coordinating innovation support in Western France,. His first role with Saltel Industries was to develop the use of Inflatable Packer Expandable Steel Technology in the oilfield. James has an extensive experience of the O&G industry, previously serving as Marketing Director of Drillflex after several years as the Division Manager of Petrometalic. He started his career in the Middle East with Halliburton after graduating from Newcastle University in England in 1979. James is the author of several SPE papers and articles, recently co-author of 4 patents awarded or pending for the use of expandable technology for remedial applications, as well as 12 other international patents. He holds an MBA from Rennes. In 2014, James was promoted EVP for America & Pacific.

Yoann RIOU

thumb yoann riouVice President, MEA, RCA, EAF

Yoann RIOU joined Saltel Industries as a Project Engineer in 2004. He initially worked on the development of the Inflatable Packer Expandable Steel Technology, including the technology watch, marketing development, and operational procedures. He is co-author of seven patents awarded or pending for the use of expandable technology. Previously an operations engineer with Drillflex, then Schlumberger, Yoann started his career in 1994 working in the R&D team developing the Patchflex technology. In 2008, he was promoted to International Operations Manager for Saltel Industries. In this role, Yoann was in charge of the flying squad (operations engineers), job feasibility evaluation, and the organization of the equipment and procedures for Saltel Industries’ field operations around the world. He recently took the position of Vice President for the Middle East and Africa.


Damien LEVEUGLE

DLeveugleManufacturing & Supply Chain Manager

Damien LEVEUGLE holds a PhD in analytical chemistry in "Ecole Centrale Paris". For 13 years prior to joining the company, he held various positions in IT as project manager in several different business environments including mobile phone technologies, mail order selling, and international parcel delivery. With a solid experience in systems interfacing, team coordination and process management, he joined Saltel Industries in 2012 as IT manager. Since then, he has gradually taken the responsibility of QHSE, Organization Systems and most recently, Supply Chain.

Anne-Sophie FLECHELLE

AFlechelleChief Financial Officer

Anne-Sophie FLECHELLE graduated from Tours/Poitiers Business School (major in Audit). She started her career as an auditor for 3 years and joined Roullier Group after as a controller. Anne-Sophie spent 10 years at Roullier and held various positions in controlling. She joined Saltel in 2015.

Celine TEVELS-FOURNIER

CTevelsHuman Resources Director & QHSE Manager

Céline TEVELS-FOURNIER joined Saltel Industries in 2013. Prior to joining the company, Céline worked for eight years at Parker Hannifin, where she held various positions including Division Learning and Development Manager and HR Manager for Transair and for Northern Europe. Celine holds a MSc. in geology and geochemistry. She began her career with Schlumberger, initially on seismic survey vessels before moving to Communications and Human Resources.

Samuel ROSELIER

SRoselier Saltel Steel Packer Product Champion

Samuel ROSELIER graduated from “Ecole Centrale de Nantes” (Mechanical Engineer).
He worked for 5 years for the CEA (French Alternative Energies and Atomic Energy Commission). Samuel joined the R&D team in 2010. He developed the completions product range, then moved to a Product Champion position in 2014. Expertise: Expandable Steel Packers - Innovation and IP.