2014 DEVEX CONFERENCE 6-7 MAY 2014 – ABERDEEN, SCOTLAND, UNITED KINGDOM

Introducing High Temperature and High Pressure Sand

Control Technology with Fluid Loss Prevention

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Sean Gaudette, Nick Carrejo, Bradley Kellogg, Jason Barnard

Baker Hughes Inc.

Introduction of High-Strength Disintegrating Metallics HSDM

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• 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)

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• 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)

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• 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

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• 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

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• 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

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• 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

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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

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• 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

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• 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

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• 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

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• 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

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HSDP

HSCM

XPFS