Swell packer technology

Swell Packer Update

October 6th 2003
Contents

• Rubber Swelling
• Swell Packer
• Constrictor
• Testing
• Installations
• Application
Rubber swelling
• Thermodynamic absorption rubber/oil
• Continued expansion until equilibrium
• Swelling pressure 3-6bars
• Reduced mechanical properties, no degradation
• No degradation at 190C
• No swelling in water based fluids

Swelling pressure measurement

Dimensions and design
• Fully flexible OD/base pipe dimensions
• Small clearance (7.9-8.15” OD–8.5” hole)
 Estimated/correlated ΔP
8.15”
200
180 4.5" base pipe
160 5.5”
5.5" base pipe
140 6.625" base pipe
120
DP (bar)

7" base pipe

100
6.625”
80
60
40
20 7”

8.5 9.5 10.5 11.5

Hole ID (inch)
Swell Packer for Oil Based Mud
• OBM dummy run 7500m in Statoil well 18hrs
• 3 layer construction
• Several installations

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 i ffus 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
Constrictor Alternative to Gravel Pack
TM

• 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 Alternative to Gravel Pack
TM
Testing-Autoclave
• Testing with temperature and crude
• 98% WC circulation
• Regains integrity after failure
– Erosion testing
• Model packers and full size
– Round, oval, different lengths, sand surface
Testing, Laboratory
• Crude oil, 45API→bitumen
• Crude up to 190°C
• Chemicals (acid, heavy brine…..)
• Friction
450

400 150C 24h Acetic acid

350

300
% Swell

250

200 Swell
150

100

50 HNBR
0
0 5 10 15 20 25 30 35 40 45

API
Splice less cable feed through

PS! Better
installation tool
designed shortly
Splice less cable feed through
• Competent formation
• One string
• No cable splicing at packers
Advantages
• Self repairing, continues to expand
• Rugged construction
• Set at BHST
• Logistics/setting
• No rig time, wash pipe, tools,
pumping
• No environmental impact
Installations and running tests
• 28 wells, 150 packers installed
• Milled window with dummy run
• Collapsed hole
• 1600m in open hole at Rogaland Research
 Corrosion cap
Completion fluid for the screen section:
1,25 s.g. Na/K-COOH formate mud

Template funnel Norsk Hydro Grane

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
NaCl Brine
18 5/8" casing shoe
10 3/4" tie-back string

10 ¾” top PBR

ZXP packer
10 3/4" liner

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
Date Co mp leted : 4th July 2003

Shell
Well No : SF-37 Location : SFJT-B
Wellhead Type : Cameron Triple Wellhead + Single X’Mas tree All Depth in Ft. AH.BTHF
Tubing : 3.1/2” 9.2# L80 K.Fo x (Conventional S/String ) Maximu m Dev. : 63.4° @ 4426’-6784’ ahbthf
M in Status

Malaysia
Depth Long String
ID

3.1/2”Flow Coupling 2.910

516 3.1/2” TRSCSSV 2.813 Closed
13.3/8” Casing Shoe
@ 949’ 999 3.1/2” SPM 2.875 BKR-5

1659
2100
3.1/2” SPM
3.1/2” SPM
BKR-5
BKR-5
SF-37 Final Completion
Diagram
DKO-2
2635 3.1/2” SPM
3105 3.1/2” SPM
DM Y

3606 3.1/2” SPM DM Y

2.750 Closed
Top of 7” PBR
3696’
3669 3 1/2” SSD
– 6-18” Open Hole
7” Seal stem located 6.250 7.000
3700
with half mu le shoe – 5,7” Packer OD
3866 3 1/2” SSD 2.750 Closed
– 3-1/2” Lower completion
9.5/8” Casing Shoe
@ 3985’

4015 Swell Packer 2.992

4041 3 1/2” X-Nipple 2.750 No Plug

Predrilled Tubing 2.992

4354
4379
Swell Packer
3 1/2” X-Nipple
2.992
2.750 No Plug SF37:
Blank Tubing 2.992
4478 Swell Packer
Predrilled Tubing
2.992

2.992
SF-37's water cut has come
4655 Swell Packer 2.992 down from ~95% to 0! This is
No Plug
4680
very good proof of the packers
3 1/2” X-Nipple 2.750
Blank Tubing 2.992

5298 Swell Packer 2.992 working!

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
Shell Malaysia
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
Tubing : 3.1/2” 9.2# L80 K.Fox (Conventional S/String ) Maximum Dev. : 61.5° @ 4403’-7416’ ahbdf

SF-38 Final Completion

Min Max
Depth Long String ID OD
3.1/2”Flow Coupling 2.910

13.3/8” Casing Shoe

594 3.1/2” TRSCSSV 2.813 5.000 Diagram
@ 1051’ 781 3.1/2” SPM + BKR-5 2.875 5.620
1440 3.1/2” SPM + BKR-5
2006 3.1/2” SPM + BKR-5
2446 3.1/2” SPM + DKO-2
2855 3.1/2” SPM + DMY 1500 BOPD against 1400 promised
Top of 7” PBR 3170 3 1/2” SSD 2.750 4.281
@ 3195’ 0% water cut Sand = 2 pptb
3200 7” Seal stem located with half 6.250 7.000
mule shoe 545 psi FTHP (so there's plenty of
3430 3 1/2” X-Nipple 2.750
room to bean up from current
9.5/8” Casing Shoe 3.905
@ 3484’
3610 Swell Packer No.1
Sand Screens
2.992 5.700 28/64")
4234 Swell Packer No.2
3 1/2” SSD 2.750 4.281
ZONE-1A
4259 Blank Tubing
Swell Packer No.3 2.992 4.000 GOR = 238 scf/STB
4305
Blank Tubing
ZONE-1B 4516 Swell Packer No.4 2.992 5.700 The GOR is VERY encouraging
Blank Tubing 4541 3 1/2” SSD
Min ID:2.992, Max. OD: 3.900 4565 Swell Packer No.5 2.992 5.700
because there is a gas sand
ZONE-2 Predrilled Tubing 2.992 3.900 present.
Blank Tubing 5290 Swell Packer No.6
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 This GOR is LOWER than many
ZONE-3
6250
Predrilled Tubing
Swell Packer No.8 2.992 5.700
Rev. 2 wells with more expensive
Blank Tubing
Min ID:2.992, Max. OD: 3.900
6275 3 1/2” XN-Nipple 2.635 3.905 completions.
6347 Swell Packer No.9 2.992 5.700
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’
 Shell SF Rev3 Budget versus EFC
66

Malaysia
70
60

Well Cost RM'000

47
50 SF 39
-29% SF 38
Cost 40
30
SF 37

Performance 20
10
-
Budget EFC

SF Average well cost comparison Savings on:

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

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 Shell
Malaysia
SF Rev.2 and Rev.3 Benchmarking
Cost per foot (Rm/ft) comparison
5000
Budget
4500
Actual (EFC)
4000

3500
+2% -29%
RM per ft

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
 Shell
Conclusions Malaysia
– Significantly Cheaper Wells
– Installation relatively easy
– Production / Packer working very encouraging
– Can do even cheaper
 Shell
Malaysia
Statoil Heidrun - Zonal Isolation in Gravel Pack

• 900m horizontal water pack

• 8.5” hole, 5.5” screen, 2ea 7.9” SP
• First well completed
• Second well on plan for October 2003
Statoil - Snorre B
• 900m horizontal water pack
• 8.5” hole, 5.5” screen, 2ea 7.9” SP
• First well Installed September 2003
• Production start October 2003
DONG zonal separation

• SC lower completion
• March 2003 & May 2003
• Option for future water
shut off

• OBM 7,75* 8,5”