SPE 58778
Pressure-Actuated Isolation Valves for Fluid Loss Control in Gravel/Frac-Pack
Completions
D.W. Worlow, SPE; L.V. Grego, SPE, British-Borneo Exploration, Inc.; D.J. Walker, G.R. Green, and B.E. Smith, SPE,
OSCA Inc.; and M.E. Harris, SPE, Harris Tool and Specialty Co., Inc.
Copyright 2000, Society of Petroleum Engineers Inc.
This paper was prepared for presentation at the 2000 SPE International Symposium on For-
mation Damage Control held in Lafayette, Louisiana, 23–24 February 2000.
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Abstract
A new, mechanical fluid loss control system, integral to the
base pipe of gravel pack screens, has been developed for
'smart' completions. This system allows for positive fluid loss
control through all phases of well work once the gravel/frac
pack is in place including the running of the isolation tubing
stinger through the upper screen assembly of stacked comple-
tions. The isolation valves are opened for production without
wireline intervention by hydraulically opening the zonal isola-
tion sleeve of the 'smart' completion and applying pressure
down the tubing. A new screen coupling system has also been
developed to allow fluid returns during gravel/frac pack op-
erations when the pressure actuated valves are run. To date,
this system has been designed, tested, and successfully run in
two deepwater subsea completions (3200' WD).
Introduction
Fluid loss to high permeability sandstones has long been rec-
ognized as a major contributor to formation damage, increased
completion/workover costs, and well control/safety concerns.
Over the past 20 years, several systems (both fluid and me-
chanical) have been developed to minimize or eliminate fluid
losses during completion operations.1
The ability to sequentially deplete multiple zones from a
single wellbore without a major recompletion operation sig-
nifcantly enhances the economics of the well. The develop-
ment of mechanical isolation systems utilizing wireline
sleeves for gravel packed completions allowed multiple selec-
tive completions to become commonplace in the shallow wa-
ter Gulf of Mexico. Selective completions in a deepwater
subsea well, however, were not generally economic attractive
due to the high intervention cost associated with shifting
sleeves. The development of ‘smart’ completion technology
has eliminated this well intervention cost and has made deep-
water subsea selective completions economic in some cases.
‘Smart’ completions, however, create some unique challenges
for fluid loss control and zonal isolation for the upper zone(s)
of deepwater selective completions.
Completion Design – Allegheny Field
The development economics of the Allegheny Field (Green
Canyon 254) favored the use of ‘smart’ completion technol-
ogy and dual gravel/frac packed completions. The production
tubing is landed in a sealbore below the upper zone, thus pro-
viding zonal isolation under flow the same as a conventional
dual completion (Fig. 1). Zone selection is accomplished by
shifting the 4-position dual zone isolation valve (DZICV) to
the desired position by hydraulic pressure from the TLP.
The lower zone(s) were designed to be frac pack com-
pleted utilizing a conventional, isolation tubing/wireline sleeve
system to provide zonal isolation and fluid loss control after
frac packing. The upper zone(s) were designed to be high-rate
water pack (HRWP) completions. The unique challenge in
designing the upper completions was the selection of a post-
HRWP fluid loss control system. Pumpable fluid loss systems
were not considered a workable option due to the difficulty in
completely removing the fluid loss material. Also, pumpable
systems would have required a considerable increase in time
and expenses associated with rigging up and performing
coiled tubing operations on a floater. Existing wireline sleeve
systems could not be used due to the inability to mechanically
open sleeves after landing the production tubing. The ex-
tended period of time (±48 hrs) required to land and test the
hanger, pump packer fluid, and set the production packer that
the upper zone(s) would be open to fluid loss was deemed
unacceptable, therefore, use of frangible flappers and ‘ball
dropper’ devices were dismissed.
2 D.W. WORLOW, L.V. GREGO, D.J. WALKER, G.R. GREEN, B.E. SMITH, M.E. HARRIS
Pressure-Actuated Isolation Valves
A design team was formed with the goal of designing a me-
chanical fluid loss control system that met the following crite-
ria:2
• positive fluid loss control and zonal isolation after
HRWP treatment
• full opening ID large enough for production isolation
tubing and not restrict screen size selection
• unaffected by pressure differentials from OD to ID
• 10,000 psi burst and collapse
• actuation without mechanical intervention
• reliable and 100% redundant
The results of the design team involved the development of
an internally pressure-actuated valve (PAV). Due to the ge-
ometry of the wellbore, the PAVs were designed to be an inte-
gral part of the screen base pipe assembly. The design incor-
porates a unique lock ring mechanism to handle a pressure
differential from the OD to the ID. A mechanical spring is
incorporated to drive the valve open once the internal actua-
tion pressure (ID to OD) is released (Fig 2).
The PAVs are run in the well in the locked closed position
and actuated by an applied pressure differential from the ID to
the OD. This pressure differential actuates the PAV by
shearing set screws and disabling the lock ring placing the
valve in the unlocked closed position. Releasing the internal
pressure allows the spring to shift the valve in open position.3
Important features of the PAVs are as follows:
• External pressure (OD to ID) differential creates a
force on the inner sleeve trying to drive it to the open
position. The lock ring at the nose of the valve pre-
vents movement of the sleeve and transmits the force
into the valve body. This is necessary to avoid un-
wanted valve opening during HRWP/frac pack opera-
tions.
• Actuating the sleeve with internal pressure differential
(ID to OD) shears the set screws and retracts the lock
ring mechanism but does not open the valve. At this
point the valve is unlocked but maintains pressure in-
tegrity. This feature allows multiple valves to be ac-
tuated, and subsequently opened, simultaneously.
Without this feature, the first valve to open would
cause the internal pressure differential to decrease and
no other valves would open.
• The mechanical spring that opens the valve also pro-
vides enough force to maintain the valve open. The
inner sleeve is designed to protect the spring from any
well/treatment fluids to ensure mechanical integrity.
SPE 58778
• The valve contains a slight piston area bias which
means the wellbore must be in near pressure balance
with the reservoir to open (not actuate) the valve. Un-
derbalancing the wellbore will create an additional
force to assist opening the valve.
• The valve is designed with an internal profile in the
sleeve to allow actuation with a collet shifting tool.
Screen Communication Coupling
The individual joints of screen with closed, screen wrapped
PAVs will not allow circulation through the screens. There-
fore, it is required to incorporate standard screen wrapped
sliding sleeve(s) into the screen assembly to permit circulation
through the screens during pumping operations. These sliding
sleeves will be ‘sacrificial’ in that once they are closed on the
trip out of the hole with the service tools, they cannot be
opened again.
One option would be to place one of these standard sleeves
per joint of screen in the assembly. This would cause a ‘dead
spot’ in the each joint of screen assembly under production
and would require diversion (additional turbulence and pres-
sure drop) of the hydrocarbons in the base pipe/screen annulus
to the nearest PAV. To minimize the number of ‘sacrificial’
sleeves to be run in these completions, the design team devel-
oped the screen communication coupling (SCC).
The SCC consists of specially designed slotted end con-
nectors on the base pipe of the screen and an internal mandrel.
With the SCC in place, fluid can return through the screen by
entering the wire wrap and proceeding down the base
pipe/wire wrap annulus to the slotted connector. At the slotted
connector, the fluid enters the slot and then travels down the
internal mandrel/base pipe annulus to the next slotted con-
nector where it enters the base pipe/wire wrap annulus of the
next lower screen joint. This process repeats itself for every
joint of screen until the fluid can enter the open sliding sleeve
in the base pipe and return to surface via the washpipe (Fig.
3).4
Testing and Field Installation
Prototypes of both the PAVs and SCCs were constructed and
fully tested. Tests included PAV opening under axial loads
and flow tests to measure pressure drop in base pipe/wire wrap
annulus at various flow rates. Upon analysis of the testing
results and proof of the reliability of the system, screens were
ordered for the upper zones of two wells at Allegheny.
The basic screen joint consisted of three PAVs coupled to-
gether to form the base pipe of the screen joint with SCC slots
cut at each end. The bottom two joints of screen consisted of
two PAVs and one standard sliding sleeve (two ‘sacrificial’
sleeves were required in order to avoid hydraulic lock due to
the service tool space-out). The PAVs were pinned to actuate
at approximately 2500 psi differential pressure.
SPE 58778 PRESSURE-ACTUATED ISOLATION VALVES FOR FLUID LOSS CONTROL IN GRAVEL/FRAC-PACK COMPLETIONS
Make-up of the screen joints in the field differed from
normal screen make-up only by the insertion of the inner
mandrel of the SCC by hand and the stabbing of the next
screen joint over the upper end of the mandrel. Make-up and
running of the screen and packer assembly were uneventful.
The screens were snapped into the lower GP packer and the
upper GP packer was set with the screens in neutral position.
The HRWP treatments were performed without event and
screenout was induced by taking returns through the screens.
The service tool was pulled from the screen assembly closing
the ‘sacrificial’ sleeves and GP port closing sleeve. The well-
bore was then pressure tested to 500 psi to ensure pressure
integrity of the system. The service tool was then pulled out
of the hole. If pressure integrity did not exist, the contingency
plan was to trip in the hole with the colleted shifting tool on
pipe and open the PAVs manually. A sized carbonate pill that
would seal off on the inside of the wire wrap screen was the
contingency fluid loss control plan.
The production packer and tubing was run without any
fluid losses. A 9.0 ppg packer fluid was reversed circulated
into the well and the production packer was set. The DZICV
was then shifted to the ‘upper zone only’ position to provide
pressure communication to the PAVs. Tubing pressure was
applied to provide ±3500 psi differential at the PAVs (1500
psi over the shear pin values) and held for 15 minutes. The
pressure was bled off on surface and the PAVs opened. The
opening of the PAVs was confirmed by pumping into the for-
mation.
Conclusions
1. A positive, fluid loss control system has been designed,
tested, and successfully installed which requires no me-
chanical intervention to actuate and open.
3
2. In conjunction with the development of the PAVs, a
screen communication coupling system has been de-
signed, tested, and installed which allows for a continuous
fluid path for circulation through screens with closed
PAVs/sleeves/unperforated base pipe.
3. Although developed for use in completion intervals where
there is no future mechanical avenue for manipulation of
the valves, the PAV/SCC system can be utilized in other
completion types eliminating mechanical intervention re-
quired to open standard sleeves.
Acknowledgements
The authors wish to thank the management of British-Borneo
Exploration, Inc. and OSCA, Inc. for their support in this proj-
ect and permission to publish this paper. We also would like
to thank the various vendors, sub-contractors, field service
hands, and the crews of the Atwood Oceanic Hunter for a job
well done.
References
1. Ross, C.M., Williford, J., Sanders, M.W.: “Current Materials and
Devices for Control of Fluid Loss”, paper SPE 54323 presented
at SPE Asia Pacific Oil and Gas Conference and Exhibition, Ja-
karta, Indonesia, 20-22 April 1999.
2. Smith, B.E., Walker, D.J., Cornelius, C., Hallman, J., McCarthy,
S.: “New Deepwater Sand Control Strategies – Gulf of Mexico:
Reducing Costs and Enhancing Completion Efficiency”, pre-
sented at Deep Offshore Technology Conference and Exhibition,
Stavenger, Norway, 19-21 October 1999
3. Walker, D.J., Turner, D., Henderson, W.D., Ritter, M.: “Pressure
Actuated Circulating Valve”, U.S. Patent Application
#60/097,449
4. Walker, D.J., Turner, D., Traweek, B.: “Method and Apparatus
for Controlling Fluid Flow in a Well”, U.S. Patent Application,
#60/116,619
4 D.W. WORLOW, L.V. GREGO, D.J. WALKER, G.R. GREEN, B.E. SMITH, M.E. HARRIS SPE 58778

Figure 1 - Typical "SMART" Completion at Allegheny

Water Depth -- 3,226' RKB - MSL -- 99.0'

10K SpoolTree @ 3,311'

Production Tubing
3-1/2" 10.20#, 13Cr85, VAM Ace

9-5/8" 53.50#, P-110 Tie-back

CI
Chem Inj Mandrel @ 7,937'

SCSSV SCSSV @ 8,001'

TOL - 9-5/8" 53.50# @ 9,546'

11-3/4" 65.00#, P-110 10,032'

CI
Chem Inj Mandrel @ 12,XXX'

DZICV Operation Packer Set Sub @ 12,XXX'

PSS
Position Lower Zone Upper Zone
1 open isolated
2 isolated isolated 9-5/8" HF-1 Pkr @ 12,XXX'
3 isolated open
4 open open
DZICV w/integral DHPT

TOL - 7" 38.00#

9-5/8" 53.50#, P-110

7" 32-38# GP Pkr
2-3/8" 4.70# Isolation Tubing 4" 54K SOSJ
w/ATR seals

4" 13Cr, 0.008 ga screen w/3 PAVs per jt

2 - 2.813" ID sliding sleeves

7" 32-38# GP Pkr

4" 54K SOSJ

4" 13Cr, 0.008 ga prepack screen

2-3/8" 4.70# isolation assembly
w/1.875" ID sliding sleeves

7" 26-38# Sump Pkr

PBTD - Cmt Retainer

7" 38.00#, P-110
SPE 58778 PRESSURE-ACTUATED ISOLATION VALVES FOR FLUID LOSS CONTROL IN GRAVEL/FRAC-PACK COMPLETIONS 5

Figure 2 – Pressure Actuated Valves

6 D.W. WORLOW, L.V. GREGO, D.J. WALKER, G.R. GREEN, B.E. SMITH, M.E. HARRIS SPE 58778

Base Pipe
Screen Slot
Fluid
Flow

Coupling

Slot
Fluid
Screen Flow
Base Pipe

Figure 3: Screen Communications Coupling