Installation of WFV using high expansion Well Key® for new well stimulation and production
WELL TYPEOil / gas producer
SHORT TERM DELIVERY6 weeks from order to delivery
Welltec® proposed incorporating the 4-1/2” Welltec® Flow Valves (WFV) with multiple flow area (choking) configurations. These would enable the client to retain maximum control of the dual zone completion without having to make major alterations to their previous, single zone well design. In addition to multiple choke settings, the WFV is ISO14998 V3 qualified to 8,000 psi burst at 135°C and can be manufactured with varying specifications to meet operators’ needs. It is operated via a reliable, e-line conveyed toolstring consisting of the Well Tractor®, Well Stroker® and Well Key®.
Within six weeks of initial discussion, five WFVs with three different, customer specified flow areas (chokes) were delivered for the operation. Additionally, the Well Stroker and Well Key HEX (High Expansion) implemented within this same time period to function within the 4-1/2” WFV after passing through a 2.75” restriction in the previously planned upper completion.
The two zones were separated by hydraulically set packers. The lower completion was run on a 4-1/2” frac string with the planned purpose of facilitating the fracing operation before being pulled and replaced by the upper completion. The lower completion and frac string were run to TD without incident. But prior to the frac operation the 3rd party frac sleeve failed to open despite multiple attempts using coil-tubing. Welltec used Computation Fluid Dynamics (CFD) modeling to evaluate the option of fracing through the WFV and determined the valves function would not be affected by this operation.
Deciding to proceed with this option, the Well Tractor, Well Stroker and Well Key HEX were used to quickly open the WFV within the oil zone. The operator then continued with the planned frac without having to pull the completion or resort to other, alternative deconstructive solutions.
A proppant frac was initiated through the WFV using x-linked fluids and proppants. A total of 723 bbls was pumped up to maximum surface pressure of 7,100 psi (490 bar).
After completion and clean-up of the oil zone, Welltec opened all three WFV’s in the shallower gas zone on a single descent. This allowed the operator to evaluate the full flowing gas production prior to determining their desired choke settings. The three, different flow configurations on each of the WFVs across the gas zone gave the operator multiple options to choke the flow as desired for optimum production.
This was the world’s first installation of Welltec’s Flow Valves and demonstrated the flexibility and ease by which it can be ordered, delivered, deployed and operated.
Within six weeks the WFV’s were manufactured and delivered along with the modified Well Stroker and Well Key HEX. Shortly thereafter they were run in this new well completion and performed flawlessly, despite being subject to unplanned contingency operations.
First WFV installation.
First prop frac through a WFV.
Three WFV’s opened in one run.
First job using newly modified, high expansion Well Key® HEX.
The Well Key® (HEX) High Expansion version provides operators with the ability to pass through small restrictions and still actuate hardware in large liners.
The Well Tractor® was regarded as a revolution in the industry when it was introduced in the 1990’s. It enables operators to extend the reach of traditional e-line deployment into highly deviated and horizontal wells.
The Well Stroker® can push or pull multiple times in the same run irrespective of the depth and deviation. It delivers up to 100,000 lbs of axial force downhole using a bi-directional hydraulic ram.