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2014 DEVEX CONFERENCE 6-7 MAY 2014 – ABERDEEN, SCOTLAND, UNITED KINGDOM
Introducing High Temperature and High Pressure Sand
Control Technology with Fluid Loss Prevention
1
Sean Gaudette, Nick Carrejo, Bradley Kellogg, Jason Barnard
Baker Hughes Inc.
Introduction of High-Strength Disintegrating Metallics HSDM
2
• Low Density, composite metal
• High-strength with Ultimate Compressive Strength greater than 52 ksi
• Currently used as tripping balls
• 10+ ksi pressure ratings
• Dissolves away in brine or with acid
• Degradation characteristic
• 3 formulations, varying in rate of corrosion
• Rate of corrosion ranges from
• Low – 1 mg/cm²/hr
• Medium – 60 mg/cm²/hr
• High – 150 mg/cm²/hr
Application of HSDM to Current Drill-in Liner Systems High-Strength Disintegrating Plugs (HSDM)
3
• Current Perforating assemblies for drill-in liners
are explosive in nature and leave behind
significant amounts of ferrous and metallic
debris.
• HSDP can be installed Drill-in liners and
dissolves in 24-48 hours in brines and 1-2
hours in HCL
Application of HSDM to Sand Control Technology Extreme Pressure Frac Screen (XPFS)
4
• XPFS adds sand control to the drill-in
liner HSDP concept via a bonded bead
matrix installed in a larger plug
• Filters 85%-90% of all particles larger
than 53 µm
• Burst and Collapse of the HSDM wafer is
approximately 15,000 psi
Corrosion Testing of HSDM
5
• 1” X .5”OD test samples of HSDM
• Samples tested in fluid at 200°F (93 °C)
• Rate of Corrosion determined by:
Δ weight(mg)÷average surface area (cm²) ÷
Δ time, (hr) Pre-Test Post-Test
Testing of HSDP
6
• Thread adhesive was used to install plugs in 2-
7/8” pipe at 6ft-lbs and exposed to 3% by vol.
sodium chloride (NaCl) at 200° F for 24 hrs.
• Pressure ratings determined by exposing HSDP
installed in 3-3/4” pipe to increasing pressures
until failure.
• Seal integrity verified against ballooning effects
by installing 12 HSDP per foot in a 72” long 4-
1/2” OD pipe after 1 week in fresh water.
Testing of XPFS 1 ½” and 1” sizes
7
• Finite element analysis performed on plug body
models
• Plugs installed into 30,000psi working pressure
fixture and brought to failure in burst and
collapse in fresh water at ambient
temperatures. 1 ½” XPFS
Assembled Test Fixture
Results and Discussion HSDM
8
Fluid Type BHT °F ROC mg/cm²/hrFlowback Water 275°F 10.68
Frac Fluid 250°F 0
Broken Frac Fluid 250°F 7.391
Flowback Water 265°F 3.457
Flowback Water 170°F 139.121
Flowback Water 170°F 102.149
Flowback Water 150°F 42.743
Oil-Based Drilling Mud 160°F 0
Oil-Based Drilling Mud 180°F 0
Oil-Based Drilling Mud 260°F 0
Water-Based Drilling Mud 160°F 0
Water-Based Drilling Mud 180°F 0
Water-Based Drilling Mud 260°F 0.587
1% HCl Ambient 57.371
5% HCl Ambient 2342.809
10%HCl Ambient 4556.338
15% HCl Ambient 5763.451
28% HCl Ambient 9306.017
Summary of Results
Results and Discussion HSDP
9
• Individual 3/8” HSDP hold Pmax of 7,200psi
• Ballooning effects cause no failure of HSDP
seal below 2,000psi differential
Results and Discussion XPFS
10
• 45 ft-lb and 90 ft-lb installation torque for 1” and 1 ½” XPFS
• Final design of 1” XPFS burst near 13,000psi and collapse above
19,000psi with no pressure reversals
• Lessons learned incorporated into 1 ½” design and FEA now
predicts 20,000psi ultimate burst and collapse but not yet
confirmed by testing
BETA Testing HSDP
11
• Two 37’ pipe sections drilled 1 port per foot with a 30° rotational
offset resulting in 62 HSDP installed at 6 ft-lb
• 3,000 ft-lb peak and 1,500-2,000 ft-lb average torque
• Max pressure differential of 500 psi
• Retrieved and showed
no observable plug
failures
Conclusions
12
• HSCM
• Hydrochloric acid produces a significant corrosion rate that
increases as the concentration of HCl increases
• HSDP
• Can maintain pressure integrity up to 7,200 psi
• Drill-in liner using HSDP is a feasible alternative to solid
liner requiering tubing or wireline perforation and produces
well debris
• XPFS
• can maintain pressure integrity up to 15,000 psi
• Drill-in liner using XPFS is a feasible alternative to solid liner
which requires tubing or wireline perforation and sand
control
Questions
13
HSDP
HSCM
XPFS