Cytadel ZX Electronically-Actuated Packer Eliminated SCP ... · PDF filecompleted cementing...

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Results n Provided a V0-rated annular seal using remote actuation n Eliminated SCP and bleed-off costs n Reduced likelihood of blowout and HSE incidents n Increased efficiency with remote electronic actuation n Future-proofed the well for eventual P&A operations Background and challenges n Offshore well near Sakhalin Island, Russia n Operating temperatures ranging from 28°F to 107°F n Operator needed to prevent gas migration between 24-in. outer casing and 18 5 /8-in. inner casing to eliminate potential for SCP n Well design required setting a packer without mechanical intervention Baker Hughes solution n Deployed Cytadel ZX electronically- actuated packer in two wells at 492 ft and 1,200 ft n Proven V0-rated technology created a permanent annular seal between production zones and the surface n Solid-body design maintained casing integrity An offshore operator near Sakhalin Island, Russia had experienced fluid loss on several wells in the area during completions, resulting in inconsistent cement jobs. Some of the wells required multiple annular squeeze operations to establish effective seals, adding rig time, driving up costs, and increasing health, safety, and environmental (HSE) risks. The operator needed a way to mount a secondary barrier on long-string casing (ruling out mechanically-actuated packers) and did not want to risk seal failure (eliminating available hydraulically-actuated packers because of the inherent potential leak path through the hydraulic cylinder). The job required establishing a permanent gas-tight annular seal between 24-in. outer casing and 18 5 /8-in. inner casing to eliminate sustained casing pressure (SCP), reduce HSE risks, and satisfy expected Russian SCP and surface- bleed regulations. The Baker Hughes team worked with the operator to develop and deploy the Cytadel ZX electronically-actuated packer, which provides an ISO 14310 V0-certified annular seal without using mechanical intervention. The packer features industry-recognized zero-extrusion ZX seal technology that has performed flawlessly in 99.5% of more than 40,000 applications. Its solid-body design eliminates the need for ports and O-rings, which means it can be set without negatively affecting casing integrity. To accommodate various environments, the Cytadel ZX packer can be remotely actuated with surface vibration, by using an automated timer, or Cytadel ZX Electronically-Actuated Packer Eliminated SCP and Reduced HSE Risk Location: Sakhalin Island, Russia CASE HISTORY | bakerhughes.com

Transcript of Cytadel ZX Electronically-Actuated Packer Eliminated SCP ... · PDF filecompleted cementing...

Page 1: Cytadel ZX Electronically-Actuated Packer Eliminated SCP ... · PDF filecompleted cementing operations. After the packer was set and inner string was removed from the casing, the operator

Resultsnn Provided a V0-rated annular seal using remote actuation

nn Eliminated SCP and bleed-off costs

nn Reduced likelihood of blowout and HSE incidents

nn Increased efficiency with remote electronic actuation

nn Future-proofed the well for eventual P&A operations

Background and challenges nn Offshore well near Sakhalin Island, Russia

nn Operating temperatures ranging from 28°F to 107°F

nn Operator needed to prevent gas migration between 24-in. outer casing and 185/8-in. inner casing to eliminate potential for SCP

nn Well design required setting a packer without mechanical intervention

Baker Hughes solutionnn Deployed Cytadel ZX electronically-actuated packer in two wells at 492 ft and 1,200 ft

nn Proven V0-rated technology created a permanent annular seal between production zones and the surface

nn Solid-body design maintained casing integrity

An offshore operator near Sakhalin Island, Russia had experienced fluid loss on several wells in the area during completions, resulting in inconsistent cement jobs. Some of the wells required multiple annular squeeze operations to establish effective seals, adding rig time, driving up costs, and increasing health, safety, and environmental (HSE) risks.

The operator needed a way to mount a secondary barrier on long-string casing (ruling out mechanically-actuated packers) and did not want to risk seal failure (eliminating available hydraulically-actuated packers because of the inherent potential leak path through the hydraulic cylinder). The job required establishing a permanent gas-tight annular seal between 24-in. outer casing and 185/8-in. inner casing to eliminate sustained casing pressure (SCP), reduce HSE risks, and satisfy expected Russian SCP and surface-bleed regulations.

The Baker Hughes team worked with the operator to develop and deploy the Cytadel ZX™ electronically-actuated packer, which provides an ISO 14310 V0-certified annular seal without using mechanical intervention. The packer features industry-recognized zero-extrusion ZX™ seal technology that has performed flawlessly in 99.5% of more than 40,000 applications. Its solid-body design eliminates the need for ports and O-rings, which means it can be set without negatively affecting casing integrity. To accommodate various environments, the Cytadel ZX packer can be remotely actuated with surface vibration, by using an automated timer, or

Cytadel ZX Electronically-Actuated Packer Eliminated SCP and Reduced HSE RiskLocation: Sakhalin Island, Russia

CASE HISTORY| bakerhughes.com

Page 2: Cytadel ZX Electronically-Actuated Packer Eliminated SCP ... · PDF filecompleted cementing operations. After the packer was set and inner string was removed from the casing, the operator

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Model of 185/8-in. Cytadel ZX packer seal module

by dropping a magnetic signal carrier from the surface. The operator targeted two initial wells with expected operating temperatures of 28°F to107°F (-2°C to 42°C) for deployment. These were the first two wells in a set of eight that were prone to seismic activity and exhibited potential for channeling and cracking in the cement barrier.

Once onsite, the Baker Hughes team stabbed the packer into the casing string in the first well, ran a diagnostic routine to test all electronics, and set the contingency timer as a backup for the planned surface vibration actuation. The operator ran the packer to the planned depth at 492 ft (150 m) and conducted the cementing job. Fluid loss during cementing was extensive. It was clear that without an additional barrier system,

gas migration would be a significant issue in the well. The Baker Hughes team sent the surface vibration signal downhole to trigger the packer. The onboard packer electronics detected the activation sequence and started the setting process. After allowing sufficient time for the packer to set and retrieving the inner string from the casing, the operator performed a 150-psi (10-bar) backside pressure test. Annular pressure remained constant for the duration of the half-hour test, indicating the packer had successfully established a gas-tight barrier.

On the rig floor of the second well, the team repeated the preparation, testing, and contingency timer setting procedures on the Cytadel ZX packer. The operator tripped the packer into position below the mud line at

its planned depth of 1,200 ft (370 m) and completed cementing operations. After the packer was set and inner string was removed from the casing, the operator tested the seal with 218 psi (15 bar) of pressure applied over half an hour, once more verifying a gas-tight barrier. Neither well has recorded SCP since Cytadel ZX packer installation.

SCP caused by gas migration is a serious safety and environmental hazard. In the case of these two Sakhalin Island wells, the operator understood that casing and cement alone would not prevent gas migration and dangerous SCP. Deploying the Cytadel ZX electronically-actuated packer helped improve well control, eliminated SCP and related bleed-off costs and complications, and satisfied the operator’s commitment to HSE.

CASE HISTORY