WellDynamics 3-1 WellDynamics 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 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. 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. 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.
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WellD
ynam
ics
WellDynamicsHalliburton 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
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 remotezonal 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.
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.
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
Flow Control Valves
Halliburton WellDynamics offers interval control valves (ICV) both with and without shrouds and deflectors:
• HS-ICV – Interval control valve for deepwater and high-pressure/high-temperature applications
• IV-ICV – Interval control valve at the core of Halliburton WellDynamics' SCRAMS® surface controlled reservoir analysis and management system
• MCC-ICV – Cost-effective valve with choking capability
• LV-ICV – Lubricator valve
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.
Features• Proprietary, debris-tolerant, metal-to-metal seal
• Customizable gas/liquid flow trim
• Can be used in simple on/off intervention avoidance applications or in more versatile advanced reservoir management choking applications with the Accu-Pulse™ module
Benefits• Remotely control flow into or out of the reservoir in
challenging environments such as deepwater and HPHT
• Eliminate the potential for wellbore debris to be trapped inside the tool and consequently prevent valve movement or impact sealing integrity
• Obtain real-time confirmation of remotely actuated valve movements using optional position sensors
• Unload at a maximum differential pressure of 5,000 psi without the threat of any valve damage—the highest unloading capacity in the industry
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OperationHydraulically 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 40°F (4°C) to 330°F (165°C). 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 wires—all without compromising valve body rating or working envelope.
Debris-Tolerant DesignThe 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 one-piece valve mandrel design eliminates the potential for wellbore debris to be trapped inside the tool and consequently prevent valve movement.
Proprietary MTM SealThe 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 high-pressure (up to 10,000 psi) differentials.
Pressure-Balanced Valve MandrelA 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 ApplicationsThe 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 SensorThe 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 VersionsA 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 tubingflow area
Benefits• Control of reservoir intervals
without the requirement forwell intervention
• Ability to alter flow characteristics of each zone
• Flow allocation capability through SAM™ sensor actuation module tool
OperationThe 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.
SealsThe 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 TestingThe 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 short-term high flow rate applications
PEEK is a trademark of ICI Americas, Inc. Poly-Ether-Ether-Ketone.
IV-ICV Valve
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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 ConditionsMC-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 < 275°F
• 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
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 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 (70°F to 330°F). Cold array seal stacks (40°F to 275°F) 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 330°F.
Please contact Halliburton for more details.
Chemraz is a registered trademark of Greene, Tweed & Co., Inc.
3-6 WellDynamics
LV-ICV Lubricator Valve
Halliburton WellDynamics' lubricator valve (LV) is a high-performance, remotely controlled, tubing-conveyed downhole lubricator system. The LV isolates pressure or flow above or below its position in the tubing string.
The LV can be used in any completion where pressure or flow isolation in the tubing string is required.
When included in a SmartWell® intelligent completion system, the LV can be used to control flow into or out of reservoir intervals. The LV can be controlled by any of Halliburton WellDynamics’ Direct Hydraulics, Digital Hydraulics™ systems, or SCRAMS® control systems.
The LV incorporates a ball with full open bore ID. Two control lines are connected to the LV, one at each side of the operating piston. Pressure applied to one control line opens the LV, allowing pressure or flow to pass through the ball. Pressure applied to the other control line closes the LV on the valve sealing surface for pressure integrity.
Because the ball seals on the same surface for flow/pressure from above and below, the LV-ICV pressure integrity is fully testable from surface.
Features• Full bore ID
• Deep set capability
• Minimal moving parts
• High force actuation for both open and close operations
Benefits• Helps ensure pressure integrity from above and below
• Helps control reservoir intervals without the requirement for well intervention
The LV-ICV is available in different sizes and materials to suit specific well configurations.
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 (500°F) 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• 500°F 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 offa valve
Open Line
Splice ProtectionSleeve
Metal-to-MetalClosure Seal
Tubing EquivalentFlow AreaPorts
CommonClose Line
CommonClose Line
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3-8 WellDynamics
OperationHalliburton 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 Sizein. 3.5
Maximum ODin. 5.430
Minimum IDin. 2.735
Lengthin. 53.5
Top and Bottom Connection 3.5-in. 8 rd 9.3-lb EUE Box × Box
Service Steam
Maximum Working Temperature°F 500
Working Pressure (Internal and External)psi 3,000
Test Pressure (Internal and External)psi 3,000
Base Metallurgy A005 (4140)
Fastener Metallurgy Stainless Steel
Piston Areain.² 5.15
Total Stroke Open-Closein. 4.419
Tensile Rating*lbf 207,000
Compressive Rating*lbf 207,000
Minimum Internal Flow Areain.² 5.87
Control-Line Bypass 6 × .25-in. lines
Variations 2 Position / Open-Close
*Based on 9.3-lb tubing
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. sFrac™
Valve
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OperationHalliburton 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.
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
Zonal Isolation Packers
HF-1 Packer
Halliburton WellDynamics' HF-1 packer is a single-string, retrievable, cased-hole packer that features a facility for bypass of multiple electrical and/or hydraulic control lines. Available for use as both the top production packer or as one of many lower packers isolating adjacent zones, the HF-1 packer includes a specialized slip configuration and additional body lock ring, which allow it to operate under higher loads and greater pressures than standard production packers.
Features• Hydraulically activated interlock
mechanism prevents premature setting
• No body movement during setting
• Premium thread connections
• NBR and HNBR element with anti-extrusion system
• Tailpipe can be left in tension or compression
Benefits• Less damage to casing using a multi-
cone, full coverage slip system
• Fully retrievable after installation
• Can be deployed with Halliburton WellDynamics SmartWell® system
• May be used as both top production packer and lower isolation packer
• Avoid damage to control line during setting
Setting MechanismsThe HF-1 packer has two setting and three release mechanisms.
• Setting Mechanisms
- Tubing pressure set
- Control-line set
• Release Mechanisms
- Punch and pressure release
- Shift and pressure release
- Mechanical shift release
The release mechanism is recessed and selective, allowing for passage of other toolstrings. Axial loads are supported in both directions so the tool cannot be released by tubing forces.
ConnectionsThe HF-1 packer is made up directly to the tubing string via integral premium thread connections. The internal mandrel also uses premium thread connections for continuity.
• Anti-pre-set mechanisms – The HF-1 packer incorporates a hydraulically activated interlock system and can be adjusted prior to running in the hole. The interlock system allows the packer to be run in highly deviated or horizontal wells, eliminating the risk of pre-setting due to casing drag.
• Tandem setting – The packer is designed for tandem setting with tailpipe in tension, compression, or neutral. The setting mechanism is independent of tubing movement or pressure induced tubing forces. Setting action will not impart loads on or damage any penetrations or lines.
PenetrationsProvision is made for the passage of multiple hydraulic and/or electrical control lines. All connections are sealed using Halliburton WellDynamics' proprietary FMJ connectors.
Elastomeric SealsMaterial for setting chamber seals and tubing to lower annulus is chosen based on application conditions.
Integral Element Anti-Extrusion SystemThe 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 PerformanceAll HF-series packers are ISO-14310 V0 or V3 rated.
Notes:Available in two setting options: tubing set or control-line setAvailable in three releasing options: straight shift and pull method, knock-out plug and pump method, punch and pump methodAvailable in various metallurgy, elastomers and thread connections to suit well conditionsRefer 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 MechanismBoth 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 MechanismThe 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 ElementThe MC packer is fitted with a state-of-the-art nitrile and HNBR packing element similar to those used in Halliburton WellDynamics’ high-performance HF-1 packer. This element offers robustness and excellent sealing properties.
Nominal ConditionsThe MC production and MC isolation packers are designed for use in wells with the following normal conditions:
• BHP < 5,000 psi
• Negligible H2S and CO2BHT < 275°F
• ΔP 5,000 psi
ReliabilityThe MC production and isolation packers have been qualified to an ISO 14310 V3 rating.
Notes:Packer is set only via the tubing.Packer is released via straight shift and pull methodMetallurgy options: 4140 or 13CrThread connections: Vam TopRefer to individual specification sheets for additional details.*Pending qualification testing
Contact Halliburton for additional information.
WellDynamics 3-15
Seal Stack Assembly
Halliburton WellDynamics' seal stack assembly isolates individual zones in SmartWell® intelligent completion systems in applications where it is not possible or desirable to use packers for isolation.
The seal stack assembly enables bypass of control lines to communicate with equipment installed lower in the completion string.
Typical applications are gravel pack or ESS completions where the seal stack assembly will stab into a polished bore to provide isolation between different reservoir intervals in the sandface completion. This ability is based on the use of a stack of robust bonded seal rings arranged along the assembly length.
The seal stack assembly allows up to six independent control lines to bypass, enabling control and monitoring of equipment below, such as interval control valves and permanent downhole gauges.
The device is capable of isolating zones with a differential pressure of up to 7,500 psi but, unlike the HF-1 packer range, has no load bearing capability.
Features• Simple effective design
• Multiple sets of bonded seals
• Bypass for up to six control lines
• Field-proven
Benefits• Installs above ICVs and permanent downhole gauges
• Isolates reservoir intervals without requiring a packer
5.00 5.076 4.945 2.313 80.000 275 10,000 7,500 10,000 2 7/8 in. 6.4 lb New Vam
5.80 5.770 5.876 2.945 88.923 275 10,000 7,500 10,000 3 1/2 in. 9.2 lb New Vam
6.10 6.050 6.176 2.945 72.220 275 10,000 7,500 10,000 3 1/2 in. 9.2 lb Vam Top
7.125 7.075 7.201 2.945 72.210 275 10,000 7,500 10,000 3 1/2 in. 9.2 lb Vam Top
7.20 7.150 7.276 3.813 107.210 275 10,000 7,500 10,000 4 1/2 in. 12.6 lb Vam Top
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
Downhole Control Systems
Halliburton WellDynamics’ downhole control systems provide a method of integrating the surface control system (either manual or automated) with downhole SmartWell® equipment.
SCRAMS® Surface Controlled Reservoir Analysis and Management System
The SCRAMS® system is a fully integrated control and data acquisition system that allows the operator to remotely control the wellbore and obtain real-time pressure/temperature data for each zone. This data feedback and accurate flow control capability allow the operator to optimize reservoir performance and enhance reservoir management.
The SCRAMS system is ideal for onshore, platform, and subsea applications and is typically used to control the IV-ICV valve for precise control of flow into or out of a reservoir interval.
Features• Can be used to control Halliburton WellDynamics’
infinitely variable hydraulic flow control valves
• Can be used for land, platform, or subsea applications
• Capable of interfacing with multiple subsea control vendors
• Infinitely variable control valve positioning
• Flow estimation derived from fundamental metrology
Benefits• Optimize reservoir performance by controlling multiple
reservoirs without intervention
• Enhance reservoir management through real-time data acquisition
• Remotely control the wellbore
• Obtain real-time pressure/temperature data for each reservoir interval
• Steer around faults for continued functionality using full redundancy capability
• Control multiple intervals from only one of the two electro-hydraulic flatpacks through multi-drop functionality
Primary Flat-PackConsisting of1x Electrical Line1x Hydraulic Line
Electrical Line
Hydraulic Line
Broken/Damaged Line
Damaged orBroken Line
Connection Re-establishedvia SAM™ Unit
ConnectionRe-establishedvia SAM™ Unit
Damaged orBroken Line
Infinitely VariableInterval Control Valve
SAM Unit
Auxiliary Flat-PackConsisting of1x Electrical Line1x Hydraulic Line
SCRAMS® Surface Controlled Reservoir Analysis and Management System
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OperationThe 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™ sensor-actuated 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
SmartPlex™ Downhole Control System
Halliburton WellDynamics’ SmartPlex™ downhole control system is an electro-hydraulic multi-drop system that provides simple and reliable zonal control of multiple valves in a single wellbore with a minimum number of control lines. The SmartPlex downhole control system uses two hydraulic and one electric line from the surface to remotely and selectively actuate multiple downhole flow control devices such as interval control valves (ICV). This makes a large number of tubing hanger penetrations unnecessary and reduces operational complexity and risk.
The SmartPlex system can control any flow control tool in the field-proven Halliburton WellDynamics portfolio.
Features• Three control lines for up to 12 downhole devices or four
control lines for up to 24 downhole devices
• Minimal use of only passive and no active electrical components
• System can remain pressured when operating any of the ICVs in the same direction, significantly decreasing ICV actuation times
• Can be deployed with non-integrated systems andfiber optics
• Supports “fail-as-is” device types
• Independent of tubing or annulus pressure
• Can be used to position ICVs in choking applications
Benefits• Helps reduce cost in multi-valve completions
• Faster activation time for valves
• Reduces rig time through greater facilitation of completion installation and retrieval
• Electro-hydraulic system provides high level of motive power to operate ICVs
• Allows the ICV to be closed in a single step
• Provides the ability to move the ICV from closed to any choking position in a single step
Three-LineFlatpack
Electric InHydraulic In
SmartPlex™Manifold
SmartPlexClamp
Electric OutHydraulic Out
Interval Control Valveor sFrac™ Valve
Three-LineFlatpack
Control Module withClamp Assembly
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ApplicationThe 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.
OperationThe 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 TestingThe SmartPlex control system has successfully passed extensive in-house deep well simulation testing. The tool has been cycled more than 10,000 times at 300°F (150°C) 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.
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The SmartPlex™ downhole control system provides a simple methodology for controlling up to 12 interval control valves.
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WellDynamics 3-21
Digital Hydraulics™ Downhole Control System
The Digital Hydraulics™ system is an all-hydraulic, multi-drop intelligent completion system that can direct any flow control tool in the Halliburton WellDynamics portfolio, providing simple and reliable zonal control for even the most complex reservoirs. The Digital Hydraulics system allows up to six flow control devices to be controlled from only three hydraulic control lines, making a large number of tubing hanger penetrations unnecessary.
Features• High activation forces for flow control devices in
both directions
• Three control lines for up to six downhole devices
• Four control lines for up to 12 downhole valves
• Can be deployed with non-integrated systems andfiber optics
• No setting depth limitations
• All-hydraulic system
• Supports “fail as is” devices
• Field-proven
• Independent of tubing or annular pressure
Benefits• Helps reduce control line costs
• Helps reduce rig time through greater facilitation of completion installation and retrieval
• Fewer connections through tubing hanger
OperationThe Digital Hydraulics system design uses the logical absence or presence of pressure (hydraulic code) to communicate between a surface controller and thedownhole tools.
Existing pressure greater than 2,000 psi is represented by a “1” and pressure less than 500 psi is represented by a “0.” Depending on the pressure in the wellbore, a sequence of 1s and/or 0s is communicated to the flow control devices within the Digital Hydraulics system.
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 integrity—even 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.
Control LinesFrom SurfaceControl LinesFrom Surface
To More Decoders
Pressure
Decoder 1
Decoder 2
ICV 1
ICV 2
No Pressure
Digital Hydraulics™ System
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Surface ControlThe 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.
Digital Hydraulics™ System
Number of Control Lines 3
Number of Double Acting Tools 6
Maximum Setting Depth No practical limitations
Temperature Rating°C 4 - 135
Surface Control System Automated or manual
Maximum Operating Pressurepsi 4,000 (6,000 test pressure)
Maximum Hydraulic Chamber Ratingpsi 10,000 - 15,000
Facilities Land, subsea, platform, or TLP (currently qualifying for subsea)
Control Devices Any Halliburton WellDynamics ICV
Working Fluid Synthetic hydraulic control fluid (currently qualifying for water-based control fluid)
WellDynamics 3-23
Direct Hydraulics Downhole Control System
The Direct Hydraulics downhole control system uses direct hydraulic control lines from the surface to remotely actuate downhole flow control devices such as interval control valves (ICV). The Direct Hydraulics system also provides on/off variable control of flow into or out of reservoir intervals and can be used in onshore, platform, or subsea applications.
Features• Can be used to control all Halliburton WellDynamics
hydraulic flow control equipment
• Provides all-hydraulic control
• Networking option helps reduce number of control lines required
• Operates as a closed-loop system
• Requires no setting depth
Benefits• Controls reservoir intervals without costly intervention
• Helps eliminate dependence on mechanical or pneumatic spring-return mechanism to open andclose ICV
• Use in onshore, platform, or subsea applications
OperationA typical Direct Hydraulics system includes an ICV, an Accu-Pulse™ hydraulic positioning module, and a zonal isolation packer such as the HF-1 packer. The ICV is a remotely operated control valve used to control flow into or out of an isolated reservoir interval. Hydraulic control lines are installed at the surface and are fed directly into the ICV piston. For control of a single ICV, two control lines are run from surface with one attached to the open side of the piston and the other attached to the close side. Pressure applied to one line, rather than to the other, drives the piston to the corresponding position. Since the piston is rigidly attached to the ICV opening mechanism, movement of the piston operates the valve. This feature can dramatically improve the ability to shift a sleeve which has been stuck due to scale buildup.
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Direct Hydraulics System
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Accu-Pulse™ Incremental Positioning Module
Halliburton WellDynamics' Accu-Pulse™ incremental positioning module is a complementary control module that provides incremental opening of a multi-position interval control valve (ICV). The Accu-Pulse control module allows the operator to control produced or injected fluid rates to the desired quantity, greatly enhancing reservoir management capabilities.
The Accu-Pulse module works in tandem with either Halliburton WellDynamics' Digital Hydraulics™ or Direct Hydraulics downhole control systems and with the HS-ICV multi-position valve.
ApplicationsThe Accu-Pulse module provides effective incremental control of an ICV in a range of applications, such as:
• Internal gas lift
• Waterflood
• Gas injection
• Commingled production
Features• Hydraulic, incremental control
• Ability to close valve from any position in one press cycle
• Provides up to 11 discrete positions with the appropriate interval control valve
Benefits• Enhanced reservoir management through control of
produced or injected fluids
• Helps provide accurate flow estimation and allocation
• Avoidance of reservoir drawdown
• High level of well control for internal gas lift, waterflood, and commingled flow
OperationThe 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 TestingExtensive reliability and integration testing is performed on the Accu-Pulse module to ensure accuracy and long-term performance.
Long-Term TestingThe Accu-Pulse module has been long-term tested for:
• High temperature – up to 330°F (165°C)
• High pressure – 10,000 psi
• Flow-induced vibration
Accu-Pulse™ Module
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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 completion—thereby 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
• Protects against extrusion and blowout with durable, high-performance seal
Running OptionsHalliburton 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
Concentric Hydraulic Disconnect Tool Front View
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Concentric Hydraulic Disconnect Tool
Size 3 1/2 in. × 7 in. 32 lb 4 1/2 in. × 9 5/8 in. 39 lb
Maximum ODin. 5.950 8.3
Minimum IDin. 2.995 3.788
Concentricity Upper and lower sections require concentric ID and OD
Top Connection 3 1/2 in. 9.3 lb/ft EUE 8 rd box or 9.2 lb/ft VAM top box 4 1/2 in. 15.1 lb/ft VAM top box
Metallurgy AISI 4140 18-22 RC / 80,000 psi yield per PES Spec A-005
Working Temperature°F 275 275
Bypass Ports
Umbilical Hookup 6 x 1/4 in. hydraulic lines on each end of the tool
Tubing Seals TBA
C/l Fluids Red oil (MIL-H-5606) and water based
WellDynamics 3-27
Concentric Electric Disconnect
Halliburton WellDynamics’ concentric electric disconnect allows operators to disconnect from the lower SmartWell® system completion without having to pull the entire completion string, thereby saving rig time and costs. Compact in design, the concentric electric disconnect enables reconnection and isolation of the tubing and hydraulic/electrical umbilical to the lower completion when the tubing is redeployed. The unique electric disconnect design offers the capability to connect/disconnect from an electrical line (I-wire connection) in addition to the standard feature for hydraulic lines. This feature also provides the ability to run permanent downhole gauges (PDG) as part of the lower completion.
Applications• ESP pump applications
• Safety valve replacement
• Plug and abandonment options
• One- and two-trip completions
Features• Compact design
• Six hydraulic control-line channels
• One electrical line
• Seal technology provides total isolation and prevents leakage between the tubing and annulus
• Straight string
• No J-slot mechanism
Benefits• Helps save rig time and associated costs
• Helps minimize risk and costs associated with workovers
• Protects against extrusion and blowout with durable, high-performance seal
Concentric ElectricDisconnect
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Running OptionsThe 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
OperationThe concentric electric disconnect features one electrical control line and six hydraulic control-line channelsthat provide communication in a SmartWell® intelligent completion. All seven channels are independent ofeach other.
Concentric Electric Disconnect
Size 3 1/2-in. x 7-in. 32 lb(3593 size designation)
Maximum ODin.
5.950 (Concentric)
Minimum IDin.
2.995 (Concentric)
Concentricity Upper and lower sections require concentric ID and OD
Top Connection 3 1/2-in., 9.2 lb/ft VAM top box (Upper half)
Metallurgy AISI 4140 18-22 RC / 80,000 psi yield per PES Spec A-005(Other materials may be substituted later)
Working Temperature°F (°C)
275 (135) Maximum
Bypass Ports 1/8-in. NPT with Swagelok® tube fittings(Others may be substituted to reduce OD)
Umbilical Hookup 1 × 1/4-in. electric line on each end of the tool6 × 1/4-in. hydraulic lines on each end of the tool
Tubing Seals TBA
C/L Fluids Red oil (MIL-H-5606) and water based
WellDynamics 3-29
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.
ApplicationThe 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
ConnectionsHalliburton 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.
Splice Subs
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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™ Permanent Downhole Gauges
Halliburton WellDynamics’ ROC permanent downhole gauges (PDG) help increase productivity through the life of the well or reservoir by providing reliable, real-time permanent monitoring of downhole conditions. Based on an industry-standard, field-proven resonating quartz crystal sensor, ROC gauges can be used for single or multi-zone monitoring applications. In multi-zone applications, variations of the standard gauge are available, along with dual, triple, and quad splitter block assemblies for multi-drop capabilities.
Halliburton WellDynamics has installed more than 1,000 ROC permanent gauge systems—both as standalone systems and as integrated components of a SmartWell® completion system—worldwide.
Applications• Life of well production monitoring
• Life of field reservoir monitoring
• SmartWell completion system optimization
• Artificial lift optimization
Features• Incorporates the most advanced high-temperature
electronics available in the marketplace
• Accurate quartz pressure/temperature sensor
• Designed for harsh environments up to 25,000 psi
• Dual-pressure testable metal-to-metal sealing arrangement on both gauge and cable termination
• Reduced OD gauge design
• Multi-drop capability on single tubing-encased conductor (TEC)
• Flow measurements for specific applications
• Hermetically sealed electron beam-welded design
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 200°C 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
HAL31448ROC™ Gauge and Cablehead Connection
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ROC™ Gauge Environmental Chart
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Mechanical ArrangementThe ROC™ gauge mechanical arrangement consists of all “wetted” parts manufactured from high-performance, NACE-compliant corrosion resistant alloys (CRA).
Cable TerminationThe 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.
TestingThe 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 [email protected].
Response Time to FS Step (for 99.5% FS) <1 sec <1 sec <1 sec <1 sec
Acceleration Sensitivity (psi/g – any axis) <0.02 <0.02 <0.02 <0.02
Drift at 14 psi and 25°C (% FS/year) Negligible Negligible Negligible Negligible
Drift at Maximum Pressure and Temperature (% FS/year) 0.02 0.02 0.02 0.02
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ROC™ Gauge
ConfigurationsROC-150 ROC-175 ROC-200
10K 16K 20K 25K 20K 25K
Single Pressure/Temperature Sensor
Single Pressure/Temperature Sensor +
Feed Through
Dual Pressure/ Temperature Sensor
Dual Pressure/ Temperature Sensor +
Feed Through
Dual Pressure/ Temperature Sensor
Fully Redundant
Dual Pressure/ Temperature Sensor
Fully Redundant + Feed Through
HAL32155
HAL32156
HAL32157
HAL32158
HAL32159
HAL32160
WellDynamics 3-33
ROC™ Gauge Mandrels
All Halliburton WellDynamics ROC™ gauge mandrels are sized to match the tubing string in which they are to be run in accordance with API 5CT. The gauge mandrel fully contains the ROC gauge assemblies within the mandrel body slots, protecting the gauges from damage. The gauge mandrels are machined from solid bar stock and are profiled to avoid snagging during run-in-hole operations. The gauge mandrels are also provided with premium threads to match that of the completion.
The gauges communicate with the production bore through ports in the sidewall. The gauges are mounted in custom-profiled locations on the mandrels, and a metal-to-metal seal with elastomeric backup seals provides a high-confidence permanent pressure seal between the mandrel and gauge.
All gauge mandrels are fully tested prior to delivery. This testing includes:
• NDT - MPI to ASTM E709:94
• UT wall to ASME V SA V88
• Gauge-mount pressure testing
• Bore burst testing as per API 5CT to match that of the tubing string
• High-pressure external testing on completed assembly
• Thread gauging and drift testing
FloStream™ Venturi Flowmeter
The Halliburton WellDynamics FloStream™ flowmeter incorporates a Venturi flowmeter profile and two high-accuracy ROC quartz pressure and temperature gauges. An optional third ROC gauge can be added to enable continuous calculation of downhole fluid density to be made.
Benefits• Accurate downhole flow rate measurement
• No moving parts mean high reliability
• Based on proven ROC permanent gauge technology
• Wireline-retrievable Venturi section option allows measurement of changing flow rates without a workover
• Absolute pressure measurement allows redundancy in pressure measurement and a wide flow rate measurement window
• Minimum pressure loss over whole system
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 ParametersThe 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® Permanent Pressure Monitoring System
Halliburton’s EZ-Gauge® permanent pressure monitoring system accurately monitors downhole pressure without downhole power, electronics, or moving parts. Using capillary tubing as the measurement mechanism, the EZ-Gauge system is a reliable, effective tool for long-term monitoring in extremely harsh environments where electronics willnot function.
Features• Capillary tubing negates need for costly downhole
electronics
• Durable pressure sensor is resistant to harsh environments
• No temperature limitations
Benefits• Check system accuracy without well intervention
• Interchange pressure acquisition systems on user needs
• Minimize drift and accuracy problems by calibrating pressure transducer at any time
• Validate system function through a series of chamber checks and purge techniques
• Run pressure system in conjunction with distributed temperature systems
• Run system as retrievable, permanent, or semi-permanent
OperationThe EZ-Gauge system utilizes a small diameter capillary tubing line connected to a downhole pressure chamber. The pressure chamber is placed downhole as an integral part of the completion or run on coiled tubing or spooled in the hole similar to slickline. A pressure transducer is attached to the capillary tubing at surface. The system is purged with a light, inert gas, usually helium.
Once the EZ-Gauge system is installed, the pressure at surface is corrected for the additional hydrostatic pressure of the helium gas column in the capillary tube. The hydrostatic correction includes an iterative process to calculate the helium density as a function of the entire well temperature and pressure.
This provides an accurate means of measuring downhole pressures without the inherent difficulties experienced when using downhole electronics.
EZ-Gauge® Permanent Pressure Monitoring System
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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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Chemical Injection System
Halliburton WellDynamics' chemical injection applications include:
• Scale
• Asphaltines
• Emulsions
• Hydrates
• Defoaming
• Paraffin
• Scavengers
• Corrosion
• Demulsifiers
There are two variations of chemical injection mandrels:
• Deep-set nipple mandrel – A robust one-piece machined design utilizing the same design criteria as the permanent downhole gauge mandrel for use in deepwater or critical applications
• Welded pup nipple mandrel – Designed for use in shallow set, non-deviated wells, or land applications
Features• Dual check valve (burst disk option available)
• Externally testable connections
• Welded construction check valve body
• Check valve material to suit application
Benefits• Subsea, platform, and land applications
• Cost effective
• Multi-line conveyance
Dual Check ValveThe Halliburton WellDynamics chemical injection systems include dual check valves, providing redundant checks (one hard seat and one soft seat). The connection to the chemical injection line uses primary and backup ferrules to provide improved sealing and physical strength. The check valve body is a welded construction to further reduce the possibility of tubing/annular leak.
The check valve is available in a variety of materials to best suit well conditions with externally testable connections to reduce makeup time.
Control Line, Chemical Injection Lines, and ClampsMulti-line conveyance is supplied as a standard service and includes all necessary spooler units, hydraulic slip rings, pumps, filters, and sheave wheels. Halliburton WellDynamics can provide full pump capability for operations during tripping in hole and for commissioning the well. Control lines and chemical injection lines are available in all common materials with tubing sizes and wall thicknesses to suitall applications.
The lines can be provided bare, encapsulated with other lines, or with a tubing-encapsulated connector (TEC) line. Lines are supplied fluid filled, flushed, and filtered to the required NAS standard. Cast steel or press steel clamps are used to protect the control lines.
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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 third-party 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 varietyof 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
SmartWell® Master™ Supervisory Application
Halliburton WellDynamics' SmartWell Master supervisory application for the digital infrastructure product line provides a central point of control and monitoring for SmartWell and permanent monitoring systems.
The SmartWell Master application is based on theICONICS 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 ConnectivityA custom external control module allows theSmartWell® 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.
DisplaysThe 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 left-hand 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.
ModulesThe 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 ConfigurationA custom configuration utility allows project-specific SmartWell systems to be built up in the SmartWell Master application by dragging and dropping standard functional modules.
TrendingTrending can be carried out in real time or configured from historical data.
Modbus is a registered trademark of Schneider Automation, Inc.
Hydraulic Supply Module Screen
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Well Control Module Screen
SmartWell® Configuration Utility Screen
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SoftFlow™ Virtual Flowmeter
Halliburton WellDynamics’ SoftFlow™ virtual flowmeter is a data analysis and calculation program that provides well and zonal flow rate estimation and allocation in real time.
Traditional asset production information is often based on data acquired intermittently from individual well tests. The SoftFlow application provides real-time estimates for continuous reporting of daily production on a per-well and/or per-zone basis. No additional equipment is required for a SmartWell® completion system.
The SoftFlow application draws information from downhole sensors as well as attributes from interval control valves (ICV), such as HS-ICVs used in SmartWell completion systems.
SoftFlow Application Requirements• Intelligent well completions with ICVs, annulus, and
tubing sensors for every zone
• Dynamic Field Data Management System (FDMS) interface to provide data and receive results from the SoftFlow application
• Standard Human Machine Interface (HMI) to configure the SoftFlow flowmeter for real-time operations and a computer to use the SoftFlow application offline
Features• Inputs can be configured for field and well levels
including well completion architecture, fluid composition (PVT tables), and ICV attributes
• Calibration for unique well conditions using well test data (shown to calibrate to 90% accuracy of actual flow rate measurements)
• Enables oil and water production scenarios (gas capability in future release)
• Configurable without well downtime or production interruption
• Calculation engine incorporates:
- Choice of analytical or numerical choke models to estimate and allocate subsurface flow rates
- Tubing performance, nodal analysis, and Inflow Performance Relationship (IPR)
Benefits• Asset Management
- Quickly helps identify wells with production problems and implements corrective actions to restore production
- Real-time reservoir information for asset optimization
- Helps improve production accounting and aids compliance with regulatory reporting requirements
• Real-Time Operations
- Enables production accounting in real time
- Real-time monitoring of individual well and asset performance
- Offers real-time well optimization (model, measure, and optimize)
- Allows viewing of zonal flow for commingled wells in real time
- Allows viewing of in-situ multi-phase flow estimates in real time
• Data Management
- Calculation engine tolerates erratic or missingsensor data
- Data analysis for back allocation (offline mode)
Field/Project Information
1. Field information (single or multiple)2. Data management and quality3. Define calculation parameters4. Units of measurements
1. Well type2. Well properties and architecture3. Depth of sensors and ICV’s4. Well administration
1. Zone PVT2. ICV Specification3. Node definition
Well Information Zone Information
Information Chart
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SoftFlow™ Screen Shot
SoftFlow™ Application Management System
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Surface Positioning System
Halliburton WellDynamics surface positioning system provides a methodology to incrementally control the downhole interval control valve (ICV) position in each zone through the Halliburton WellDynamics surface hydraulic system (SHS) without the need for downhole control devices. It is implemented by calibrating and moving ICVs from the surface with the help of an algorithm embedded into the SHS controller.
With this method, a specific pressure is applied for a specific time to one side of the ICV to cause it to move the desired increment, thus exposing or closing a number of flow ports. At the same time, compensating pressure is applied to other ICVs to keep them at their current position.
The surface positioning system is a reliable, cost-effective solution to move downhole ICVs to the desired choke open or close position without the need for reset.
Features• Implemented through algorithms embedded into the
SHS controller; no extra hardware is needed for the automated SHS
• Can be integrated into the SmartWell® Master™ supervisory application
• Maintains other ICVs in their current position by applying compensating pressures
• Can be used for wells with ICVs up to 10,000 ft deep; applications out of this range can be reviewed on a project-by-project basis
• Can be used for a well with a configurable numberof ICVs
• Can be used for completions with a common close line as well as independent open and close control-line configurations
• User-friendly interface
Surface Positioning of ICVs
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Surface Positioning Sequence
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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
SmartWell® Master Surface Positioning Screen
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Remote Power Systems
For circumstances in which conventional power is unavailable, unreliable, or cost-prohibitive, Halliburton WellDynamics offers a wide variety of remote power systems. Each system is designed to support Halliburton WellDynamics' digital infrastructure data acquisition and control systems, including:
• XPIO 2000™ series of data acquisition and control units
• Surface hydraulic system
• OptoLog® DTS CE fiber-optic system
Depending on site conditions and available resources, operators can choose from solar, wind, thermoelectric generator (TEG), engine generator-set (gen-set), or DC-UPS systems, either individually or in combination. Systems utilize existing local resources and enable wireless communication to remote locations. Offshore systems employ solar power with wind power backup.
The remote power systems employed by Halliburton WellDynamics are completely self-contained, pre-assembled, and tested prior to shipment and are specifically tailoredfor the electrical load and climatic conditions of each particular site.
ReliabilityHealth and safety margins are built into each remotepower system in order to ensure high reliability and continuous operation. Like all Halliburton WellDynamics equipment and electronics, the remote power systems are pre-wired inside custom enclosures and are fully factory-acceptance tested prior to shipment. Systems are warranted for five years.
Choosing the Appropriate Remote Power SystemAmong the most crucial considerations related to choosing an appropriate remote power system is the year-round availability of sunlight. Every remote power system must be able to perform reliably during even the most inclement weather. Accurate load information is also critical, particularly if communications equipment is included.
In general, solar photo voltaic (SPV) cells are the preferred method for providing remote power because of their simplicity, reliability, and cost-effectiveness. The solar-panel/battery combination is determined by accurately calculating the total power consumption of the data acquisition and control equipment and then sizing the system based on the worst weather conditions. A safety margin is included.
Solar Photo Voltaic (SPV) SystemsSPV systems convert sunlight to DC electricity and are the preferred choice in most circumstances. Solar power can be used in conjunction with wind, TEG, or gen-set systems.
Wind GeneratorsModern electrical windmills harness wind power that can complement solar power in conditions with intermittent sunlight. Regular maintenance and repair are required.
Thermoelectric Generators (TEG)TEGs burn natural gas and are extremely reliable when natural gas is readily available. They can also be a good supplement to solar power. A separator is normally required if the gas is “wet.”
DC-UPSDC-UPS is recommended for situations in which power is dirty, intermittent, or unreliable. Additional filtering and surge suppression are offered in addition to backup.
Engine-Generator Set (Gen-Set) SystemsGen-set systems use conventional fuel to charge a large battery bank. They can be used to supplant solar power and to charge batteries in temporary applications or in circumstances in which weather extremes make other options unattractive.
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XPIO 2000™ Data Acquisition and Control Unit
Halliburton WellDynamics' XPIO 2000™ data acquisition and control system allows operators to monitor and control downhole gauges and topside instrumentation. Acquiring data at a rate of 0.5 seconds per gauge, the XPIO 2000 system is available in a range of capacities, from 1 well/4 gauges to4 wells/8 gauges. A larger variant within the XPIO 2000 range is the UACU+, which extends capacity up to 20 wells/40 gauges for a single unit. The UACU+ is fitted with a permanent downhole gauge interface card (PDGIC) module for each downhole channel.
Downhole cable inputs are independent and fully isolated.
Features• Five channels of 4-20mA analog inputs (12-bit)
• Four channels of 4-20mA analog outputs (16-bit)
• 4MB of flash memory
• Modbus® RTU protocol support via RS-485 or RS-232 port, or via TCP/IP port
• Modem communications support via the RS-232 port
• Two relay contacts
• Communications programs that allow full configuration of the unit
Benefits• Control Halliburton WellDynamics' permanent
downhole gauges (PDG), including the ROC™ family, SmartLog™ gauges, and surface instruments
• Store and display data from PDGs and surface sensors
• Interface with external systems, including third-party computers and distributed control systems
Analog InputsThe XPIO 2000 system features five channels of 4-20mA inputs (12-bit) that are fully configurable using theXPIO 2000 PC program. Users can set the offset, span, and units of measure, and then can choose to monitor them on the display or log them into memory.
Analog OutputsThe XPIO 2000 system features four channels of 4-20mA outputs (16-bit). Users can select the pressure, temperature, span, and offset of a permanent downhole gauge, and the XPIO 2000 system will drive the translated value onto an output as it is decoded from down hole.
Modbus is a registered trademark of Schneider Automation, Inc.
Memory LoggingThe XPIO 2000 system comes standard with 4MB of flash memory. A SanDisk CompactFlash® card option extends the memory by 2GB.
The 4MB memory can hold pressure and temperature data from one gauge at one-minute updates for more than three months. The 2GB option extends memory capacity to hold pressure and temperature data from two gauges atone-second updates for more than a year.
Data is retrieved via an RS-232 port using the supplied PC program or by file transfer protocol (FTP) over the TCP/IP link and can easily be imported to other applications such as a spreadsheet. Data is logged to memory at a maximum rate of once per second.
Both the standard XPIO and UACU+ are available in NEMA4X enclosure and 19-in. rack mount versions. The 19-in. rack mount UACU+ has a 10-well/20-gauge capacity.
Serial CommunicationsThe XPIO 2000 system supports Modbus® RTU protocol via its RS-485 or RS-232 port or via its TCP/IP port. These interfaces are fully configurable in terms of parity, baud rate, etc. As a slave device, the XPIO 2000 system provides gauge data (i.e., pressure and temperature) that can be polled as well as data from any of the 4-20mA inputs. Time and date are also available.
Modem SupportThe XPIO 2000 system supports modem communications via the RS-232 port. Users may dial into the unit using the supplied PC program, or use the port to talk to the Modbus system over a radio modem, cellular modem, or regular modem.
Pressure-Controlled Relay ContactsThe XPIO 2000 system comes with two relay contacts (1/2A at 115VAC) which are controlled by software. When a selected gauge's pressure rises above or falls below a set pressure, the contact is closed. This feature is ideal for alarms and/or pump control.
Web-Installed PC ApplicationThe XPIO 2000 system comes with a web-installed application that provides for full configuration of the unit as well as data memory retrieval, real-time logging of data to the computer hard drive, and real-time data trending.
The application communicates with the XPIO 2000 system via a standard RS-232 port and runs on the Microsoft® Windows® 2000/XP/Vista operating system.
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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+
• -10°C to 85°C 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 is a registered trademark of Schneider Automation, Inc.
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
XPIO Data Acquisition and Control Unit
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Hydraulic SystemsHalliburton 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
ModulesThe 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 applicationor from a third-party computer by the Modbus® system over TCP/IP communications to the programming logic controllers (PLC) in the hydraulic control and wellcontrol 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 variations—including one tank and one pump—are 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 (1μm, NAS1638, Class 6)
• Relief valves
• Tubing/fittings (up to 10,000 psi rated)
• Hydraulic control unit junction box
Hydraulic Supply Module
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)
Well Control Module
Physical ConfigurationsHalliburton 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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Subsea Interface Cards
Halliburton WellDynamics offers a range of subsea interface cards that enable users to monitor permanent downhole gauges (PDG) and control SCRAMS® surface controlled reservoir analysis and management system completions. Each subsea interface card resides in the pod provided by the respective subsea controls vendor.
VetcoGray Dual Gauge Interface CardHalliburton WellDynamics' VetcoGray dual gauge interface card is compatible with the VetcoGray-type SEM2000 subsea control module, which features a single downhole channel that provides communications and power to the ROC™ family of gauges. It operates in either “Analog Gauge” or “Digital Gauge” mode.
The card has been subjected to an extensive environmental qualification program, including tests for:
• Temperature soak
• Temperature cycling
• Sine swept vibration
• Random vibration
• Non-operational shock
Functional card integration testing in the SEM2000 pod was carried out at VetcoGray's premises in Nailsea, U.K. The card has been deployed in the VetcoGray pod on major projects for various operators, including Statoil and ENI.
Cameron Dual Gauge Interface CardHalliburton WellDynamics' Cameron dual gauge interface card is compatible with the generic Cameron subsea pod. Featuring a single downhole channel that provides communications and power to the ROC™ gauge family,the card can operate in either “Analog Gauge” or “Digital Gauge” mode.
Cameron dual gauge interface card firmware includes a timeout feature on the gauge communications, ensuring the card will disconnect power to the downhole gauges if the pod processor has not communicated with the card for more than the timeout period. This feature is important in Cameron dual-SEM pods, where gauge outputs from the interface card in each SEM are connected together.
The card has been subjected to an extensive environmental qualification program, including tests for:
• Temperature soak
• Temperature cycling
• Sine swept vibration
• Random vibration
• Non-operational shock
The card underwent extensive integration testing to Cameron procedure X065418-07-01 at Cameron's premises in Celle, Germany.
FMC Dual Gauge Interface CardThe Halliburton WellDynamics' FMC dual gauge interface card is compatible with the FMC KS150 subsea electronics module. The card features a single downhole channel that provides communications and power to the ROC gauge family and can operate in either “Analog Gauge” or “Digital Gauge” mode.
The FMC card was subjected to an extensive environmental qualification program, including tests for:
• Sine swept vibration
• Shock
• Thermal cycling
• Thermal dwell
The card underwent extensive integration testing at the FMC premises in Kongsberg, Norway. An older card design, the FMC digital gauge interface card, is still used exclusively in Gulf of Mexico projects for a major customer. It has a single downhole channel providing communications and power to ROC digital gauges.
Aker Solutions Dual Interface CardHalliburton WellDynamics' Aker Solutions dual gauge interface card is compatible with the Aker Solutions iCon (formerly 5th Generation) subsea control module. It has a single downhole channel, providing communications and power to the ROC family of gauges and can operate in either “Analog Gauge” or “Digital Gauge” mode.
Unlike other interface cards, the Aker Solutions dual gauge interface card uses a Hypertac® edge connector rather than a DIN41612 Euro style connector. The card was subjected to electromagnetic compatibility qualification testing specific to Aker Solutions requirements, including:
• Emissions
• Immunity
• Electrical fast transients/burst immunity
Hypertac is a registered trademark of Smiths Interconnect.
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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 CardThe 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 byPerry Slingsby.
Intelligent Well Interface Standard (IWIS) CardHalliburton 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® CardHalliburton 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 cardhas been implemented with Aker Solutions, VetcoGray,and FMC.
