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WellDynamics
Halliburton WellDynamics is the world's leading provider of intelligent completion technology to the upstream oil industry. Introduced in 1997, the WellDynamics SmartWell system technology was the industry's first intelligent well completion system and was designed specifically to remotely control and monitor specific reservoir zones without intervention. Today, Halliburton WellDynamics offers a broad complement of products and services that range from reservoir engineering studies to advanced completion design, zonal isolation and flow control, reservoir monitoring, and surface digital infrastructure solutions. SmartWell systems are designed to meet the demands of every intelligent completion in all global areas and environments. Halliburton WellDynamics has designed its product lines and solutions accordingly. Flow control solutions include interval control valves (ICV), lubricator valves (LV), packers, and downhole control systems. Permanent monitoring solutions include downhole gauges and flowmeters. Digital infrastructure solutions include a supervisory control and systems designed for manual, automatic, and integrated operation and electro-hydraulic control and monitoring systems. Optical fiber solutions include distributed temperature sensing (DTS) tools and software.
SmartWell Systems
A SmartWell completion system optimizes production by collecting, transmitting, and analyzing completion, production, and reservoir data; allowing remote selective zonal control and ultimately maximizing reservoir efficiency by: Helping increase production Commingling of production from different reservoir zones increases and accelerates production and shortens field life. Helping increase ultimate recovery Selective zonal control enables effective management of water injection, gas and water breakthrough, and individual zone productivity. Helping reduce capital expenditure The ability to produce from multiple reservoirs through a single wellbore reduces the number of wells required for field development, thereby lowering drilling and completion costs. Size and complexity of surface handling facilities are reduced by managing water through remote zonal control. Helping reduce operating expenditure Remote configuration of wells optimizes production without costly well intervention. In addition, commingling of production from different reservoir zones shortens field life, thereby reducing operating expenditures.
Reliability
Reliability is essential for intelligent completion systems, and Halliburton WellDynamics engineers reliability into all of its equipment. The company is ISO 9001 application certified and has developed processes to guide, monitor, and optimize system delivery and performance. In addition, Halliburton WellDynamics has a dedicated Reliability Assurance department that manages reliability tools and processes. Halliburton WellDynamics maintains a detailed database to track the field performance of each SmartWell system installation. The knowledge gleaned from this data is used to calibrate design predictions and optimize the design and production process.
WellDynamics
3-1
HS-ICV Valve
Halliburton WellDynamics' HS interval control valve is the next-generation downhole control valve designed for Halliburton WellDynamics' industry-leading SmartWell intelligent completion systems. The HS-ICV is designed for deepwater and high-pressure/high-temperature applications in which operating conditions are extremely severe. The HS-ICV's eight-position standard gas/liquid flow trims have been characterized to provide optimum production/ injection at various positions. Optional onboard sensors track the movement of the flow trim. These position sensors provide the operator with real-time feedback to confirm valve movements.
3-2
HAL30642
WellDynamics
Operation Hydraulically actuated, the HS-ICV is operated remotely from surface using Halliburton WellDynamics' reliable Direct Hydraulics, Digital Hydraulics, or SmartPlex downhole control system. The premium thermoplastic hydraulic chamber seals are designed to operate under high actuation pressures and over temperatures ranging from 40F (4C) to 330F (165C). The valve has also been subjected to a stringent qualification program, including temperature, pressure, debris, and erosion tests. The HS-ICV body has slots to accommodate two 1/4-in. dedicated instrument wires for position sensors and allows bypass of up to six 1/4-in. bare hydraulic control lines or instrument wiresall without compromising valve body rating or working envelope. Debris-Tolerant Design The HS-ICV has been designed and tested such that the flow trim will ensure complete metal-to-metal (MTM) seal integrity even when exposed to heavy wellbore debris. A onepiece valve mandrel design eliminates the potential for wellbore debris to be trapped inside the tool and consequently prevent valve movement. Proprietary MTM Seal The HS-ICV houses a proprietary metal-to-metal flank seal that enables the valve to unload at a maximum differential pressure of 5,000 psi without the threat of any valve damage. Any additional tubing or annulus pressure acts on the MTM seal to further ensure seal integrity, which has been rigorously tested and qualified at low- and highpressure (up to 10,000 psi) differentials. Pressure-Balanced Valve Mandrel A pressure-balanced valve mandrel design eliminates the need for a latch mechanism to hold the trim closed or the need to maintain hydraulic pressure on the close chamber to keep the flow trim shut. This balanced sleeve design also prevents drifting of the sleeve in the incrementally open position. The valve mandrel design also includes a shifting profile that allows the sleeve to be mechanically shifted in the event that hydraulic control has been compromised or if sleeve momentum is not achievable due to scale buildup inside the ICV.
Simple On/Off or Choking Applications The HS-ICV is designed for simple on/off applications or more versatile choking applications if used in conjunction with the Accu-Pulse incremental positioning module. For the choking application, the HS-ICV comes fitted with a standard liquid or gas flow trim, depending on the well application. These trims can also be customized to suit a particular well's injection or production philosophy. Tungsten carbide is the material of choice for these flow trims to combat the threat of erosion due to high flow rates. Position Sensor The HS-ICVs can be fitted with onboard position sensors which track the movement of the flow trim. These sensors provide the operator with real-time feedback to confirm remotely actuated valve commands. In dry-tree choking applications, the position sensor feedback can be used in conjunction with Halliburton WellDynamics' surface positioning technology to remotely position the ICV, eliminating the downhole Accu-Pulse module requirement. Shrouded Versions A shrouded configuration of the HS-ICV is available primarily for a two-zone stacked gravel pack application. The shrouds can also be shrink-fitted with a carbide insert when the valve is used in a stacked gravel pack injection application.
WellDynamics
3-3
IV-ICV Valve
Halliburton WellDynamics' infinitely variable interval control valve (IV-ICV) is a remotely operated control valve that controls flow into or out of an isolated reservoir interval. The IV-ICV is used where selective control over production or injection is required. The IV-ICV allows the operator to alter the flow characteristics of the zone without mechanical intervention. It is run in conjunction with the SCRAMS surface controlled reservoir analysis and management system. Features Infinitely variable choke positioning Seal locking mechanism that eliminates the requirement for hydraulic pressure to be maintained Incremental choke control can be achieved electro-hydraulically or hydraulically Mechanical override facility High integrity metal-to-metal (MTM) choke sealing Shrouded version available for stacked zone applications Flow area equivalent to tubing flow area Benefits Control of reservoir intervals without the requirement for well intervention Ability to alter flow characteristics of each zone Flow allocation capability through SAM sensor actuation module tool Operation The IV-ICV is controlled by differential pressure applied to the actuator piston. A minimum of 250 psi differential is needed to unlock the MTM seal and allow the choke to open. The choke can then be positioned incrementally between fully closed and fully opened. Seals The primary IV-ICV seal mechanism is a metal-to-metal spring-loaded apparatus, which provides high integrity sealing. The IV-ICV holds the MTM seal with a locking mechanism, eliminating the need for hydraulic line pressure to be maintained. The unique configuration of the seal mechanism provides increased preload to the MTM seal ensuring a tighter seal at higher differential pressures. The MTM sealing mechanism is capable of handling 7,500 psi differential in the closed position and 5,000 psi differential during opening. The choke mechanism incorporates a tungsten carbide element which has been field-proven in extremely corrosive conditions and has undergone extensive accelerated life testing to establish its limits in a wide variety of flow conditions. The flow wetted seal stacks consist of PTFE- and PEEK seal-based thermoplastic elements, which have been extensively tested in oil, water, and nitrogen to demonstrate thermal and pressure cyclic performance. The system has the ability to tolerate multiple shifts at the rated shifting pressure differential. Qualification Testing The IV-ICV has been successfully subjected to rigorous qualification testing. A brief summary of the tests carried out are as follows: Cv determination for complete tool Cv determination for commingled flow Qualitative and quantitative erosion testing Quantitative vibration testing Short-term erosion evaluation at high flow rates (86,000 B/D) to simulate stimulation effects; qualified to 57,000 B/D for shortterm high flow rate applications
HAL33639
IV-ICV Valve
3-4
WellDynamics
MCC-ICV Valve
The MCC-ICV is a multi-position valve that provides incremental flow control over individual reservoir zones, allowing optimization of reservoir architecture down hole and maximizing recovery. The Halliburton WellDynamics surface control systems provide accurate incremental control over the MC-ICV choke trim and can be tailored to fit the operator's needs. The MCC-ICV is fitted with a tungsten carbide flow trim to control erosion from aggressive downhole conditions. The valve is available in a range of sizes and thread configurations and can be coupled with either an automatic or manual control system to accommodate specific operational requirements. Nominal Well Conditions MC-ICVs have been specifically designed for use in wells with the following normal conditions: 5,000 psi maximum differential pressure Negligible H2S and CO2 BHT < 275F Moderate duty cycle (open/close with pressure differential) Features Simple cost-effective design Bonded nitrile seals Open/close functionality in the MC0-ICV Multi-position functionality with tungsten carbide flow trim in the MCC-ICV Manual override Benefits Cost-effective SmartWell system functionality in moderate service conditions Remote control of reservoir intervals without the need for well intervention
HAL33642
MCC-ICV Valve
WellDynamics
3-5
2 7/8
6.00 10,000 275** 4.660 2.313 2.20 1.716 3.28 10,000 330 17,500 10,000 275** 17,500 10,000 275** 8.279 7.125 3.560 4.562 16.38 4.240 3.28 5,000 275 4.660 2.250 3.98 1.870 6.00 3.750 11.04 2.780 3.28 6.00 5.850 2.750 4.62 1.990 3.28 6.00 6.00
Yes 5,000 TBA Yes 5,000 Yes Yes 5,000 Yes TBA 5,000 TBA Yes 1,000
5.800
5.030
No
N/A
HS Series
3 1/2
7.070
7.980
Yes
7.685
4 1/2
7 5/8 in. 39 lb
8.535
9.300
Yes
8.315
5 1/2
No
N/A
N/A
Yes
9.330
MC Series
2 7/8
Yes
5.500
3.800
No
N/A
3 1/2
5,000
5,000
275
5.468
2.750
5.94
2.558
6.00
11.87
Choke
Yes
1,000
No
N/A
N/A
No
N/A
Notes: Special ID valves are made to order. OD of valves will be bigger if a 3/8-in. bypass is required for chemical injection. Chemraz seals are standard on HS-series valves (70F to 330F). Cold array seal stacks (40F to 275F) are under development. HS-series valves are available in various metallurgy to suit well conditions. HS-series provides incremental positioning only in conjunction with an Accu-Pulse control module. HS-series choke trims can be customized to suit clients needs. HS-series 2 7/8-in. size choking valve is eccentric in design. MC-series valve is available as a standard where metallurgy, thread connections, flow trims, seals etc. The HVC and IV-series ICV is being phased out. Contact Halliburton for information on these products. *Pending qualification testing **Ultimate goal is to get the temperature rating of the HS product line to 330F. Please contact Halliburton for more details. Chemraz is a registered trademark of Greene, Tweed & Co., Inc.
3-6
WellDynamics
Shroud Size/Weight
Deflector Available
Version Available
Availability
Size in.
Type
The LV-ICV is available in different sizes and materials to suit specific well configurations.
LV-ICV Valves
Maximum Temperature F 280 280 280 Maximum Pressure (Ball Open) psi 7,500 7,500 7,500 Maximum Pressure (Ball Closed) psi 5,000 5,000 5,000 Maximum Hydraulic Chamber Pressure psi 7,500 7,500 7,500 Maximum Unloading Differential Pressure psi 1,000 1,000 1,000 Piston Area in. 3.360 3.980 4.670 Total Stroke in. 2.100 2.510 3.080 Hydraulic Chamber Displacement in. 7.050 10.000 14.400 Internal Flow Area in. 6.560 11.420 16.800
Notes: Valve OD will increase if a control-line bypass is required. Valve is available in various metallurgy. Valves use Chemraz, PEEK, and Viton seals. Please contact Halliburton WellDynamics for additional information. Chemraz is a registered trademark of Greene Tweed & Co., Inc. PEEK is a trademark of ICI Americas, Inc. Poly-Ether-Ether-Ketone. Viton is a registered trademark of DuPont Dow Elastomers, LLC-Fluorocarbon.
WellDynamics
3-7
sSteam Valve
Cyclic Steam Stimulation (CSS) and Steam Assisted Gravity Drainage (SAGD) are widely used enhanced oil recovery (EOR) methods for extracting bitumen or hydrocarbons in heavy oil reservoirs. To help optimize production in CSS and SAGD applications, Halliburton WellDynamics has developed the sSteam valve. The sSteam valve allows uniform or selective steam placement along the entire length of the horizontal section of the wellbore. This robust downhole technology is designed to handle high temperatures (500F) and moderate pressures associated with steam injection. The sSteam valve can be deployed as part of the production liner with or without zonal isolations. Features 500F temperature rating 3,000 psi working pressure High-temperature control-line fluid Metal-to-metal closure seal Remotely operated Benefits Permits uniform or selective placement of steam across the wellbore Places uniform steam chamber under variant reservoir and steam quality conditions Prevents steam breakthrough by selectively shutting off a valve
Metal-to-Metal Closure Seal Tubing Equivalent Flow Area Ports Open Line
HAL31791
sSteam Valve
3-8
WellDynamics
Operation Halliburton WellDynamics reliable Direct Hydraulics downhole control system uses hydraulic lines connected directly from the surface to remotely actuate the sSteam valve. Each of the two control lines required to operate the valve is connected to the open or close side of the valve respectively. If multiple valves are present, the close side is networked to a common close line, and the open side of each valve has a dedicated open line. A specially developed hydraulic control fluid is used to operate the valve.
This hydraulic control fluid retains its desired viscosity when subjected to the extreme temperatures of the CSS / SAGD environment. In the event of steam breakthrough, the sSteam valve can be selectively shut off, thus allowing efficient hydrocarbon recovery without the threat of injected steam being produced or the need to shut down production to cool the reservoir.
sSteam Valve
Tubing Size in. Maximum OD in. Minimum ID in. Length in. Top and Bottom Connection Service Maximum Working Temperature F Working Pressure (Internal and External) psi Test Pressure (Internal and External) psi Base Metallurgy Fastener Metallurgy Piston Area in. Total Stroke Open-Close in. Tensile Rating* lbf Compressive Rating* lbf Minimum Internal Flow Area in. Control-Line Bypass Variations *Based on 9.3-lb tubing 3.5
5.430
2.735
3,000
4.419
207,000
207,000
WellDynamics
3-9
sFrac Valve
Halliburton WellDynamics' sFrac valve is a remotely operated, downhole hydraulic valve that offers cost-effective multi-stage fracturing capabilities to operators working in areas with tight gas or difficult-to-produce reserves. Available in 3 1/2-in., 4 1/2-in., and 5 1/2-in. sizes, the sFrac valve can be installed with Swellpacker isolation systems or cemented in place with the casing string. Later in the life of the well, the sFrac valve can be used for re-stimulation or selective shutoff of unwanted water or gas. Features 10,000 psi rating Remotely operated Can be operated after being cemented in place Large ports to reduce erosion Large piston areas for debris tolerance Available in 3 1/2-in., 4 1/2-in., and 5 1/2-in. sizes Benefits Saves rig time and operational expense by selectively controlling high-rate stimulation in a single well without mechanical intervention Provides a full bore from the upper zone to the lower zone Does not require ball seats to be milled up after stimulation Allows the zones to be fractured in any order Allows shut off of water production later in the life of the well Allows re-stimulation with minimal workover Gives more contingency options for screenout during frac operations The sFrac valve enables operators to economically complete multiple intervals in a horizontal wellbore in low permeability sandstones, carbonates, gas shale, and coalbeds. It allows selective, high-rate, and precise placement of hydraulic fractures in a multi-zone well without the need for mechanical intervention. The sFrac valve can be casing-conveyed and cemented in place or deployed via production tubing. Feed-through mechanical packers or Swellpacker isolation systems are used to isolate cased or openhole intervals as required.
HAL32387
sFrac Valve
3-10
WellDynamics
Operation Halliburton WellDynamics' reliable Direct Hydraulics downhole control system uses hydraulic lines connected directly from the surface to remotely actuate the sFrac valve. Each of the two control lines required to operate the valve is connected to the open or close control port of the valve. If multiple valves are present, each valve's open port is networked to a common close line and the open port is connected to a dedicated open line. When there are enough sFrac valves to make the number of lines in a Direct Hydraulics system prohibitive, the SmartPlex downhole control system can be used. The SmartPlex system is a simple, multi-drop, electro-hydraulic control system that uses two hydraulic lines and one electrical control line connected directly from the surface to
actuate multiple sFrac valves in a single wellbore. It uses a passive multiplexing switching method to control each valve independently even though they are connected to the same control lines. Once stimulation has been completed, the sFrac valve operates as a production device, allowing full wellbore access. Zones can also be selectively shut off in case of water breakthrough during the later life of the well. In addition, the sFrac valve allows re-stimulation at a later date after production declines.
sFrac Valve
Tubing Size in. Maximum OD in. Minimum ID in. Length in. Maximum Working Temperature F 285 285 285 Internal and External Working Pressure psi 10,000 10,000 10,000 Maximum Hydraulic Pressure psi 10,000 10,000 10,000 Piston Area in. Tensile Rating klb Compressive Rating klb Minimum Internal Flow Area in. 5.94 10.67 16.97 Port Flow Area in. Maximum Unloading Differential psi 1,500 1,500 1,500
85 81 81
A002 (4140) metallurgy. Can be designed to meet NACE standards with reduced pressure and load ratings. Bypass for 8 1/4 in. Stainless steel fastener metallurgy
WellDynamics
3-11
Integral Element Anti-Extrusion System The packing element is multi-piece with NBR sealing elements. It incorporates an anti-extrusion system that provides high resistance to swab off, which permits increased running speeds and high annular circulation rates (up to 8 bbl/min) prior to setting. The system has been qualified through multiple thermal cycles using both water and nitrogen as test media. Load and Functional Performance All HF-series packers are ISO-14310 V0 or V3 rated.
HF-1 Packer
3-12
WellDynamics
Type
Casing OD in.
Maximum FeedThrough
Working Temperature F
7 29
75-275
5.995 3 1/2
2.315 2.750
32 33.7 7 5/8 39
3 1/2
5.905 6.570
2.750
7,500 7,500
7,500 7,500 10,000 75-275 4,500 for Tubing Set 6,500 for ControlLine Set
Nitrile Nitrile
3 1/2
6.430
2.750
10,000
43.5
8.515
7,500 7,500
75-275 75-275
V3 V3
47
4 1/2
8.440
7,500 10,000
75-275 40-300
5 1/2 3 1/2 53.5 4 1/2 5 1/2 71.8 60.7 10 3/4 65.7 4 1/2 5 1/2 5 1/2 7.890 9.430 9.330 8.300
7,500 7,500 (a) 7,500 (b) 10,000 7,500 7,500 6,000 (a) 7,500 (b) 5,000
Nitrile HNBR
V0 V3
V0 V0 V0 V3 V0 V3 V0 V0 V0 V3
4,500 for Tubing Set 6,500 for ControlLine Set 4,500 for Tubing Set 6,500 for ControlLine Set 6,500
11 7/8
71.8
4 1/2
10.550
3.688
5,000
5,000
75-275
Nitrile
V3
9 5/8
53.5* 62.8
4.562 3.788
10,000 10,000
100-350 100-220
Aflas
V0 V3
5 15,000 80-350
6,500
Aflas V0
Notes: Available in two setting options: tubing set or control-line set Available in three releasing options: straight shift and pull method, knock-out plug and pump method, punch and pump method Available in various metallurgy, elastomers and thread connections to suit well conditions Refer to individual specification sheets for additional details. *Pending qualification testing **Pending qualification - 8.5-in. special drift casing. Maximum casing ID 8.710 Contact Halliburton for additional information. Aflas is a registered trademark of Asahi Glass Company
WellDynamics
3-13
MC Packers
Halliburton WellDynamics MC packers, available for both production (MC-1) and isolation (MC-0) applications (no slips), are single-string, cased-hole, retrievable packers primarily designed for use in SmartWell completions in marginal or mature assets. Both MC production and isolation packers have the facility to feed through up to eight hydraulic or electrical control lines, allowing communication with other SmartWell equipment without compromising the integrity of the isolated zones. In some instances, the MC production packer has been used as an isolation packer below the primary HF-1 production packer. Features Simple, cost-effective design Feed-through for up to eight control lines Tubing set Nitrile and HNBR packing element Benefits Apply SmartWell technology in marginal or mature assets Maintain zonal integrity Perform high pressure/tubing pressure testing Achieve communication with laser tools Setting Mechanism Both MC production and isolation packers are tubing pressure set. Incorporating a hydraulically activated interlock system, the MC packers can be adjusted externally prior to running in the hole. The interlock system allows the packers to be run in highly deviated wells, eliminating the risk of presetting due to casing. Release Mechanism The MC production packer is released by the shift-and-pull method. Once the primary packer is released, the MC isolation packer can be retrieved simply by pulling it straight out of the well. Packing Element The MC packer is fitted with a state-ofthe-art nitrile and HNBR packing element similar to those used in Halliburton WellDynamics highperformance HF-1 packer. This element offers robustness and excellent sealing properties. Nominal Conditions The MC production and MC isolation packers are designed for use in wells with the following normal conditions: BHP < 5,000 psi Negligible H2S and CO2 BHT < 275F P 5,000 psi Reliability The MC production and isolation packers have been qualified to an ISO 14310 V3 rating.
HAL33643
MC Packer
3-14
WellDynamics
Type
Casing OD in. 7
Maximum FeedThrough
Notes: Packer is set only via the tubing. Packer is released via straight shift and pull method Metallurgy options: 4140 or 13Cr Thread connections: Vam Top Refer to individual specification sheets for additional details. *Pending qualification testing Contact Halliburton for additional information.
WellDynamics
3-15
HAL30650
3-16
WellDynamics
Size in. 4.75 (ECC) 4.80 (ECC) 5.00 5.80 6.10 7.125 7.20
Notes: Control lines are normally hydraulically spliced above and below the seal stack assembly. Control-line feed throughs are also available. Number of feed throughs or hydraulic splices or both depends on the size of mandrel. Seals are nitrile bonded 90 duro. Contact Halliburton for additional information.
WellDynamics
3-17
Auxiliary Flat-Pack Consisting of 1x Electrical Line 1x Hydraulic Line SAM Unit Infinitely Variable Interval Control Valve
Damaged or Broken Line Damaged or Broken Line Connection Re-established via SAM Unit
3-18
HAL30655
WellDynamics
Operation The link from the control equipment located outside the well to the downhole tools includes redundant hydraulic and electrical buses in the form of control lines and electrical conductors enclosed in a flatpack. The hydraulic control line provides the hydraulic locomotive force to the SAM sensoractuated module tool, which in turn, using solenoid valves, distributes this force to each side of the ICV piston. The electrical conductor allows transmission of power and communication signals from the well controller to all of the downhole tools by means of the multi-drop telemetry system. In order to simplify and increase the reliability of the cable to the downhole tool interface, the SCRAMS system adopts a signal-on power telemetry system. To further enhance the downhole system survivability, the redundant electric and hydraulic network is segmented (SegNet communications protocol).
If any failure, either electric or hydraulic, develops in any section of the network between surface and the downhole tools, the SegNet communications protocol provides the ability to steer around the failure, retaining full functionality of the complete SmartWell completion system. SAM Sensor Actuation Module The SAM tool provides the control and data acquisition functionality for the SCRAMS system. The SAM tool contains redundant electronics, each separately connected to individual flatpacks, a hydraulic manifold to distribute hydraulic power, and sensors for pressure/temperature measurement. The SAM tool is the active component of the SegNet infrastructure. Incoming electrical and hydraulic buses are terminated into the SAM tool and exit to provide communication to other SAM tools further down the completion string. Solenoid valve and electrical switches incorporated in the SAM tool allow isolation of any potentially faulty sections of the network connecting the next tool in the completion.
WellDynamics
3-19
Hydraulic In
SmartPlex Manifold
SmartPlex Clamp
Electric Out
Hydraulic Out
Three-Line Flatpack
3-20
WellDynamics
Application The SmartPlex downhole control system is applicable for any dry tree multi-zone completion requiring more than two valves. When compared to the Direct Hydraulics system, the SmartPlex system not only helps reduce the overall cost of an intelligent completion, but also reduces the complexity involved by minimizing the number of control lines required. The SmartPlex system is ideally suited for long horizontal, compartmentalized completions, in both cased or open hole, where selective control of each interval is desired. Typically this can be advantageous for selective stimulation control in tight gas applications or in combination with a choking ICV for drawdown optimization in production applications. Operation The SmartPlex system is a design that uses a simple passive electrical switching method. Each valve is coupled with a SmartPlex actuator module which allows selective and remote control of each valve. Control lines consisting of one electrical and two hydraulic lines run from surface and are networked to each SmartPlex module. A signal down the electrical line switches a solenoid at the desired module, allowing hydraulic communication between the surface control unit and the valve. By regulating the fluid volume in combination with a time-domain control method, valves can be incrementally positioned (choking) to allow for advanced reservoir management.
Qualification Testing The SmartPlex control system has successfully passed extensive in-house deep well simulation testing. The tool has been cycled more than 10,000 times at 300F (150C) at 10,000 psi internally and 15,000 psi externally. A three-valve system integration test with 10,000-ft control line was also successfully conducted.
HAL31805
The SmartPlex downhole control system provides a simple methodology for controlling up to 12 interval control valves.
WellDynamics
HAL32215
3-21
Each flow control device is paired with a decoder that is designed to respond to its own unique code and rejects all other codes or sequences. Using this method, the communication between the surface controller and the downhole tools maintains its integrityeven when conditions such as temperature changes, long control lines, fluids, and leaks can cause other hydraulic communication methods to fail. The Digital Hydraulics system controls simple open/close interval control valves (ICV) and lubricator valves (LV) to provide on/off flow control from each zone.
HAL30644
To More Decoders
3-22
WellDynamics
Surface Control The surface equipment for the Digital Hydraulics system, Halliburton WellDynamics' SmartWell Master supervisory application, is designed as part of the Digital Infrastructure system. A fully automated surface hydraulic system (SHS), controlled from a central location allows control of the Digital Hydraulics system from a local or remote control station.
The SmartWell Master application translates Digital Hydraulics system logic into standard central control room operations. This translation allows the operator to easily monitor and control multiple Digital Hydraulics completion systems as well as an individual zone within an intelligent well completion.
10,000 - 15,000 Land, subsea, platform, or TLP (currently qualifying for subsea) Any Halliburton WellDynamics ICV Synthetic hydraulic control fluid (currently qualifying for water-based control fluid)
WellDynamics
3-23
3-24
HAL30640
WellDynamics
Operation The Accu-Pulse module provides incremental movement of a suitable ICV flow trim by exhausting a predetermined amount of control fluid from the ICV piston. The capability to recharge and exhaust the same amount of fluid repeatedly allows the ICV flow trim to be accurately moved through up to 11 predetermined positions. The Accu-Pulse module can communicate with either side of the ICV piston. It can drive the ICV open or closed. This ability provides incremental positioning in one direction with the ICV being driven to a fully open or closed position when pressure is applied from the other direction. Reliability Testing Extensive reliability and integration testing is performed on the Accu-Pulse module to ensure accuracy and longterm performance. Long-Term Testing The Accu-Pulse module has been long-term tested for: High temperature up to 330F (165C) High pressure 10,000 psi Flow-induced vibration
High level of well control for internal gas lift, waterflood, and commingled flow
Accu-Pulse Module
WellDynamics
3-25
Auxiliary Components
Concentric Hydraulic Disconnect Tool
Halliburton WellDynamics' concentric hydraulic disconnect tool allows operators to disconnect from electric submersible pump (ESP) applications without having to pull the entire completionthereby saving rig time and costs. Compact in design, the concentric hydraulic disconnect tool also enables reconnection and isolation of the tubing and hydraulic umbilical to the lower completion when the tubing is redeployed. The concentric hydraulic disconnect tool features six hydraulic control-line channels that provide communication in a SmartWell intelligent completion system. All six channels are independent of each other. Applications ESP pump applications Safety valve replacement Plug and abandonment options One and two-trip completions Features Compact design Six hydraulic control-line channels (up to eight channels available) Seal technology compatible with water and oil-based fluids provides total isolation and prevents leakage between the tubing and annulus No J-slot mechanism Straight string Built-in debris protection sleeve Benefits Helps save rig time and associated costs Helps minimize risk and costs associated with workovers
HAL30643
Running Options Halliburton WellDynamics' concentric hydraulic disconnect tool can be configured on location to provide three modes of operation: Snap latch Snap in/snap out Anchor Snap in/rotate out to release Shear anchor Snap in/shear to release
3-26
WellDynamics
2.995
3.788
Upper and lower sections require concentric ID and OD 3 1/2 in. 9.3 lb/ft EUE 8 rd box or 9.2 lb/ft VAM top box 4 1/2 in., 10.5 lb/ft EUE 8 rd or VAM top 3 1/2 in., 9.3 lb/ft EUE 8 rd pin 7,500
Top Connection
Bottom Connection Body Working Pressure psi Body Test Pressure psi C/l Pressure psi Metallurgy Working Temperature F Bypass Ports Umbilical Hookup Tubing Seals C/l Fluids
7,500
8,000
8,000
7,500
7,500
AISI 4140 18-22 RC / 80,000 psi yield per PES Spec A-005 275 275
6 x 1/4 in. hydraulic lines on each end of the tool TBA Red oil (MIL-H-5606) and water based
WellDynamics
3-27
3-28
HAL30635
WellDynamics
Running Options The concentric electric disconnect can be configured on location to provide three modes of operation: Snap latch Snap in/snap out Anchor Snap in/rotate out to release Shear anchor Snap in/shear to release
Operation The concentric electric disconnect features one electrical control line and six hydraulic control-line channels that provide communication in a SmartWell intelligent completion. All seven channels are independent of each other.
WellDynamics
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Splice Subs
The Halliburton WellDynamics splice sub connector is a reliable, field-proven method of splicing two ends of flatpack to facilitate repairs or lengthening. The splice sub also helps protect the flatpack by securing it to the tubing. The splice sub incorporates a two-piece robust splice clamp with a key profile that locates into a groove machined in a specially designed crossover. This arrangement ensures that no vertical or rotational slippage of the clamp occurs during installation or retrieval of the tubing string. The crossover is made up directly to the tubing string. Application The splice sub is used in all SmartWell completion systems where a flatpack is deployed, including wells with chemical injection, fiber optics, and surface-controlled subsurface safety valve (SCSSV). Features Fully compatible with standard Halliburton WellDynamics FMJ metal-to-metal sealing fittings FMJs fitted to the splice sub are fully testable using a standard FMJ test kit All splice connections are set within the body of the sub for protection Benefits Enables the splicing of up to four lines within a single splice sub Allows free bypass of at least one bare control line Ease of assembly in the field Connections Halliburton WellDynamics FMJ connections are used to make the splice connection, and these are retained within the clamp body to protect the splices, flatpack, and control lines from damage. By using these metal-to-metal FMJ connectors, completed connections can be pressure tested to ensure integrity. The device also includes provision for bypassing at least one additional bare 1/4-in. control line for operation of a chemical injection valve or SCSSV. The splice sub is available to suit different tubing specifications and applications.
HAL33640
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Permanent Monitoring
Halliburton WellDynamics' permanent monitoring solutions include the following: ROC permanent downhole gauges FloStream Venturi flowmeter system EZ-Gauge pressure monitoring system
ROC Gauge and Cablehead Connection
HAL31448
Benefits Obtain continuous pressure and temperature data without the need for well intervention Enhance reservoir management Increase system reliability using stable pressure/ temperature measurements gained from state-of-the-art testing ROC Gauge Designs Quartz transducer Hybrid technology Maximum 200C operating temperature Multi-drop capability up to seven gauges at 30,000 ft downhole cable Dual sensor feed-through capability Improved shock and vibration performance 0.75-in. OD slimline design available
HAL32151
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Mechanical Arrangement The ROC gauge mechanical arrangement consists of all wetted parts manufactured from high-performance, NACE-compliant corrosion resistant alloys (CRA). Cable Termination The cable termination is provided with a pressure-testable, dual metal-to-metal ferrule seal arrangement for isolating the downhole cable outer metal sheath from the well fluid. Testing The complete ROC gauge (sensor and electronic boards) is independently calibration-checked in our calibration facility. A calibration certificate is included with each gauge and is provided before each installation.
New gauge designs are subjected to a Highly Accelerated Lifetime Test (HALT) program. This program is a series of controlled environmental stresses designed to ensure stringent criteria are met for thermal shock, mechanical shock, vibration, and thermal aging. During manufacture, all ROC gauges are also subjected to Environmental Stress Screening (ESS) to highlight any defect in functionality prior to installation at the wellsite. This screening method has proven to be far more effective than burn-in techniques. All gauges are further subjected to pressure tests at elevated temperatures during Factory Acceptance Testing (FAT). For more information on any of the details featured here, please email us at welldynamics@halliburton.com.
<1 sec
<1 sec
<1 sec
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<0.02
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Negligible
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ROC Gauge
ROC-150 Configurations 10K 16K 20K 25K 20K 25K ROC-175 ROC-200
HAL32155
3
Single Pressure/ Temperature Sensor + Feed Through
3
HAL32156
3
Dual Pressure/ Temperature Sensor
3
HAL32157
3
Dual Pressure/ Temperature Sensor + Feed Through
3
HAL32158
3
Dual Pressure/ Temperature Sensor Fully Redundant
3
HAL32159
3
Dual Pressure/ Temperature Sensor Fully Redundant + Feed Through
3
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Accuracy and Resolution Accuracy of +5% can be achieved, provided the limits of the Venturi flowmeter principle are not exceeded Resolution of <0.1% of full scale Operational Parameters The Venturi flowmeter mandrel can be machined to a specific profile or can incorporate a wireline-retrievable Venturi flowmeter section, which can allow for: Changing of the Venturi flowmeter should the flow rate change significantly Replacement should the Venturi profile become worn Removal of the restriction imposed should it become necessary to carry out some well maintenance operation below the flowmeter
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EZ-Gauge System Components Downhole Chamber and Sensing Point The downhole chamber and sensing point can be installed in a number of different ways. - Chamber and capillary tubing can be installed permanently by incorporating them into the casing and cementing into the well. Temporary darts isolate chamber while casing is run and cemented in place. - The downhole chamber can be built into the production string and can be placed above or below packer arrangements for monitoring annulus or tubing pressure. - For short-term applications, the chamber is attached to the end of a capillary tube that can be run in the well in a manner similar to wireline. The chamber is sized based on well operating pressure and temperature, the well depth, and the capillary tubing size used.
Capillary Tube Capillary tube size and type is determined by well pressures and conditions. Various tube sizes react differently depending on pressure range and changes. Surface Instrumentation The available surface instrumentation ranges from basic pressure readouts to advanced data acquisition devices with memory and real-time telemetry capabilities. The EZ-Gauge system can be used with something as simple as a dial gauge for general pressure display, or as advanced as a high accuracy quartz transducer system that stores and/or transmits data to a central storage and monitoring point.
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Digital Infrastructure
Halliburton WellDynamics' digital infrastructure system enables operators to: Monitor and control permanent downhole gauges (PDG) Remotely control and configure downhole interval control valves (ICV) Monitor and control surface sensors and instruments Connect to distributed control systems and other thirdparty systems for monitoring and control Provide remote power and communications for Halliburton WellDynamics' SmartWell and permanent monitoring systems where no infrastructure is available Interface with field controllers provided by a variety of vendors The digital infrastructure portfolio consists of the following electrical and hydraulic sub-systems and applications: SmartWell Master supervisory application Provides a central point of control and monitoring for SmartWell and permanent monitoring systems XPIO 2000 data acquisition and control unit Allows operators to monitor and control downhole gauges and topside instrumentation UACU+ system Larger variant of XPIO 2000 system that enables monitoring of up to 20 wells/40 gauges Surface hydraulic system Designed to supply pressurized hydraulic fluid to downhole SmartWell systems and provide automatic and manual control of downhole ICVs Subsea interface cards Allow users to monitor PDGs and control Halliburton WellDynamics' SCRAMS system completions in subsea applications. The cards reside in pods provided by subsea control system vendors Remote power systems Designed to support Halliburton WellDynamics' digital infrastructure data acquisition and control systems in areas where conventional power and, in some cases, communications are unavailable, unreliable, or cost-prohibitive SoftFlow data analysis and calculation application Provides well and zonal flow rate estimations Surface positioning system Provides control of downhole ICVs without downhole control devices The SmartWell Master application is based on the ICONICS GENESIS32 web-enabled human machine interface (HMI)/supervisory control and data acquisition (SCADA) software running on the Microsoft Windows operating system. Features Web-based HMI/SCADA visualization Modular tool suite for visualization, HMI, and SCADA GENESIS32 OPC-To-The-Core Technology system Visual OPC alarming and event notification OPC connectivity Extensive diagnostics and analysis capabilities Powerful data-mining technology Custom configuration utility International language switching and global aliasing Visual control replay traceability playback Benefits Control SmartWell downhole equipment from central location Interfaces with external systems, including third-party computers and distributed control systems
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External System Connectivity A custom external control module allows the SmartWell Master application to connect to an external system such as a third-party computer or DCS for control and data handoff. Resource locking is utilized to ensure control is available from either the SmartWell Master application or the external system. Both OPC and Modbus versions are available. Displays The SmartWell Master application features standard displays specifically designed for: Hydraulic supply modules Well control modules Permanent downhole monitoring Alarming Trending A well configuration panel, a standard feature on the lefthand side of the screen, shows which wells are configured for the project. A standard alarm banner, located at the bottom of the screen, displays the most recent real-time alarms which have been raised. Tabs at the top of the screen allow easy switching between displays. Various hardware configurations are available, including standalone PC and rack-mount server with retractable VDU/keyboard/mouse unit.
Modules The SmartWell Master application features several modules that can be enabled according to the operator's specific needs, including: HMI Historical data External OPC interface Remote client Alarms and events Microsoft .NET helper programs, such as calculation engines and external Modbus data link modules SmartWell System Configuration A custom configuration utility allows project-specific SmartWell systems to be built up in the SmartWell Master application by dragging and dropping standard functional modules. Trending Trending can be carried out in real time or configured from historical data.
Modbus is a registered trademark of Schneider Automation, Inc.
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Field/Project Information
Well Information
Zone Information
1. Field information (single or multiple) 2. Data management and quality 3. Define calculation parameters 4. Units of measurements
HAL32364
1. Well type 2. Well properties and architecture 3. Depth of sensors and ICVs 4. Well administration
Information Chart
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Benefits Provides incremental ICV position control from surface without the need for downhole control devices, thereby reducing system cost Provides ability to incrementally position an ICV in either direction (open or close) without the need to close the ICV first Requires less time to perform incremental moves than systems using downhole control devices for this purpose Provides a flexible and configurable number of discrete choke positions for an ICV Can be applied to new or existing direct hydraulics ICV installations controlled from an automated SHS
Surface positioning system calibration involves determination of downhole response delay through simulation software. Accuracy depends upon correct information about the well completion configuration and control fluid. Well condition changes require recalibration of the surface positioning system to maintain accuracy. The surface positioning method can provide incremental control of an ICV in a range of applications, such as: Auto-gas lift Waterflood Gas injection Commingled production
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Operating Information 110/250 VAC 10-36 VDC unit available 14W power consumption plus 1W per gauge for XPIO 10W power consumption plus 2W per PDGIC plus 1W per gauge for UACU+ -10C to 85C operation Gauges Supported ROC family of permanent downhole gauges SmartLog cost-effective gauges EZ-Gauge permanent pressure gauges Communication Ports 2 RS-232 1 RS-485 10-BASE-T option Port Usage Options One RS-232 dedicated to XPIO PC program Modbus RTU Modem support (radio/cell) TCP/IP via ethernet (optional) Inputs Five 4-20mA inputs (12-bit) One 16-bit A/D (tool current) Outputs Four 4-20mA outputs (16-bit) Two pressure-controlled relays Memory 4MB flash for data logging 2GB SanDisk CompactFlash option (standard on UACU+)
Enclosure NEMA-4 type water resistant Anodized aluminum 19-in. rack-mount option Variants XPIO 1 well/4 gauges XPIO-DT 2 wells/4 gauges XPIO-QT 4 wells/4 gauges XPIO+ 1 well/8 gauges XPIO-DT+ 2 wells/8 gauges XPIO-QT+ 4 wells/8 gauges UACU+ 20 wells/40 gauges UACU+ 19-in. rack 10 wells/20 gauges
HAL31424
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Hydraulic Systems
Halliburton WellDynamics surface hydraulic system (SHS) supplies pressurized hydraulic fluid to downhole interval control valves (ICV) located in the well. It also retrieves pressure and temperature data from Halliburton WellDynamics permanent downhole gauges (PDG). A standalone self-contained unit, the SHS consists of an electro-hydraulic unit capable of delivering pressurized fluid up to 10,000 psi to the SmartWell equipment. It is housed in a single stainless steel enclosure which includes one main hydraulic supply module (HSM) and up to six well control modules (WCM) with expansion capabilities. The digital infrastructure system features a range of surface hydraulic systems designed to meet every environment. The integrated system consists of the SmartWell Master supervisory application and an SHS consisting of a hydraulic supply module and one well control module per well. Data acquisition and control can be managed either locally (by keypad or portable device such as a laptop computer or PDA) or remotely. The automated system is an SHS which includes a hydraulic supply module and one well control module per well. Data acquisition and control can be managed either locally (by keypad or portable device such as a laptop computer or PDA) or remotely. The manual system consists of the same basic hardware as the automated system but does not provide for automated or remote control. Manually operated valves are used throughout. In subsea applications, SmartWell system control is provided by hydraulic functionality from the third-party subsea controls company. Features A variety of physical configurations for well type, number of zones, and completion details Modules that allow for remote control and monitoring by the SmartWell Master supervisory application Benefits Supply pressurized hydraulic fluid to downhole interval control valves Retrieve pressure and temperature data from PDGs
Hydraulic System
Modules The basic SHS contains the following modules: Hydraulic supply module Well control modules Automated systems, in addition to the hydraulic supply and well control modules, contain: Hydraulic control unit Well control units The SHS is designed for hazardous area applications, including IEC/Cenelec Zone 1 (ATEX category 2). Automated systems can be controlled and monitored remotely by the SmartWell Master supervisory application or from a third-party computer by the Modbus system over TCP/IP communications to the programming logic controllers (PLC) in the hydraulic control and well control units. In one-well cabinets, the HSM and WCMs are combined into a single unit. For automated systems, hydraulic control and well control units are also combined.
Modbus is a registered trademark of Schneider Automation, Inc.
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The hydraulic control unit/well control unit firmware, developed in IEC 61131-3 standard language, automates the sequences and levels of pressure required to operate the SmartWell completion, and receives feedback from the ICV movement from surface sensors. Surface Hydraulic System Enclosure Features 316 SS, IP56/NEMA4X Removable latching doors Sloped drip pan 4X lifting eyes, multi-lift capable Ventilation louvers Ergonomic design Plexiglass doors Durability for harsh environments Hydraulic Supply Module (HSM) The hydraulic supply module (HSM) provides control fluid to the well control module at the required pressure and cleanliness. Material selection for some HSM components may change according to the type of pressure and control fluid used. The HSM contains the tanks necessary to store and filter control fluid. For optimal performance of downhole equipment, all HSM designs are provided with a recirculation capability for managing control fluid cleanliness. Although the standard product contains two tanks and two pumps, several variationsincluding one tank and one pumpare available, depending on the number of wells and operational philosophy. The HSM provides all the electrical/hydraulic connections for connection to the well control modules. The HSM controls and manages system operation manually (switches) or automatically (pressure transmitters and PLC). In automated systems, the hydraulic control unit houses the PLC and its accessories. The hydraulic supply module consists of: Clean supply reservoir (typically 95 L) Return reservoir (typically 220 L) Main hydraulic supply pump Recirculation pump Accumulator (up to 10,000 psi) Filters (1m, NAS1638, Class 6) Relief valves Tubing/fittings (up to 10,000 psi rated) Hydraulic control unit junction box
Well Control Module (WCM) A well control module (WCM) provides a means of applying pressure sequences to hydraulic control lines and therefore a way of manipulating the downhole tools. Pressurization and venting of the control lines are achieved by manual or automatic supply/block/vent of directional control valves. Designed for both reliable performance in the target environment and for quick installation for future expansion, well control modules are interchangeable modules that can be combined with the same cabinet for multi-well applications, providing a flexible base for future expansion. In automated systems, each WCM is controlled by a dedicated well control unit which can be fitted with an optional permanent downhole gauge interface card (PDGIC) module for communication with downhole gauges in the well. The number of hydraulic lines required to operate a particular SmartWell completion system is dependent on the chosen control system (Halliburton WellDynamics Digital Hydraulics or Direct Hydraulics systems) and the number of downhole valves in the well.
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Additional external ports are included for connecting chart recorders and an external hydraulic supply. A well control module contains the following components: Solenoid directional control valves (DCV) Pressure transmitters (24VDC, 4-20mA) Hydraulic pressure gauges (up to 10,000 psi) Three-way manual control valves Relief valves and bleed valves External connection bulkhead Well control unit junction box (with optional PDGIC)
Physical Configurations Halliburton WellDynamics surface hydraulic system comes in various physical configurations, depending on well type, number of zones, and completion details. For example: Six-well cabinet Two-well cabinet Four-well expansion cabinet One-well cabinet Portable unit Both automated and manual versions of the surface hydraulic system are available.
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Functional integration testing of the card in the iCon pod was carried out at Aker Solutions premises in Aberdeen, U.K. The card has also been deployed in the iCon pod on major projects. Dril-Quip Dual Gauge Interface Card The Dril-Quip dual gauge interface card is the same card, 9670-6050, used by FMC. It was qualified in Houston, Texas, with the Dril-Quip subsea control system provided by Perry Slingsby. Intelligent Well Interface Standard (IWIS) Card Halliburton WellDynamics' IWIS card for monitoring of permanent downhole gauges has been qualified with VetcoGray, Cameron, FMC, and Aker Solutions and has been qualified to IWIS environmental stress screening (ESS) standards with tests for: Sine swept vibration Random vibration Physical shock Thermal soak IWIS Features Support for ROC family of downhole gauges Secure downloadable firmware allowing software upgrade in the field Supplied with 6HP front panel that can be optionally fitted by the customer IWIS Benefits Enables downhole gauge system for a subsea completion where the subsea control system is provided by any IWIS compliant supplier
IWIS systems are based on transparent communications between the IWIS card in the subsea pod and the intelligent well computer (IWC) located topside. Consequently, it is essential that a Halliburton WellDynamics IWC be provided to communicate with any Halliburton WellDynamics IWIS subsea card. Subsea SCRAMS Card Halliburton WellDynamics offers a subsea interface card for subsea SCRAMS installations. This card, installed in the subsea pod, communicates with the electronic board within the downhole SCRAMS tool. The subsea SCRAMS card has been implemented with Aker Solutions, VetcoGray, and FMC.
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9670 - 6010
9670 - 6050
9670 - 6000
9670 - 6040
9550 - 6140
9670 - 6060
DHI109/ 100016417 Standard Eurocard 100 160 mm 2x DIN41612 male 24 VDC 10%
DHI204/ P6000041999 (FMC) Standard Eurocard 100 160 mm DIN41612 male 24 VDC 25%
8W
8W
8W
7.5W
8W
4W
9W
3W
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-20 to + 70C 6g, 20-2000 Hz 3-axis 6-axis, 30g 11ms, 1/2 sine RS485
-20 to + 70C 6g, 20-2000 Hz 3-axis 6-axis, 30g 11ms, 1/2 sine RS485
-20 to + 70C 5g, 20-2000 Hz 3-axis 6-axis, 30g 11ms, 1/2 sine RS485
-7.5 to + 70C
-25 to + 70C 5g, 20-2000 Hz 3-axis 6-axis, 30g 11ms, 1/2 sine
-10 to + 50C
-20 to + 70C 5g, 25-1000 Hz 3-axis 6-axis, 30g 11ms, 1/2 sine
RS485
RS485
RS232
RS422
Modbus RTU
Modbus RTU
Modbus RTU
Modbus RTU
Modbus RTU
Hypertac is a registered trademark of Smiths Interconnect. Modbus is a registered trademark of Schneider Automation, Inc.
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