Swell Technology Systems

Swell Technology Systems

Swell Technology systems are based on the swelling properties of elastomers. The swelling process creates effective seals in both open and cased hole applications. Halliburton currently has three types of swelling elastomer systems. The first system uses elastomers that swell when exposed to hydrocarbon. This happens through a process known as diffusion and occurs as hydrocarbon molecules are absorbed by the rubber molecules, causing them to stretch. The packer swells as the hydrocarbon enters the rubber and is trapped in the crosslinked rubber matrix due to the natural affinity of polymer molecules and hydrocarbon. This process is not reversible. Mere trace amounts of hydrocarbons are sufficient to initiate the absorption process. The second system uses elastomers that swell upon exposure to water. The swelling process for this system is based on the principle of osmosis. Water will enter the rubber matrix and swell the rubber element. Since osmosis is dependent on the salinity levels of the elastomer and the surrounding fluids, changes in the downhole conditions can reverse the swelling process. The third system features a hybrid swelling polymer, which combines the capabilities of both oil swelling and water swelling polymers into a single compound. The fluids enter the rubber element via the same mechanisms as described above and has the ability to swell whether the well contains an oil-based or water-based fluid system. Swell Technology products are made by bonding the elastomer systems onto oilfield tubulars, and metal end rings are installed on each end of the rubber element. The end rings assist in increasing the differential pressure capability and guide the packer when being run into the hole. Packers can be tailor made for specialized applications, the element can be mounted on any size of basepipe, and the element OD and length can be adapted to suit the required purpose. The Swell Technology system portfolio also includes a range of slip-on pipe tools. These products have no moving parts and require no inflation to seal, removing the inherent risks of mechanical and inflatable tools. Customers simply make up or slip on Swell Technology products to their pipes where isolation points are needed to optimize the well.

Swell Technology Systems

HAL22167

4-1

Features and Benefits Sealing Swelling of the elastomer is not instantaneous. It is caused by the diffusion/absorption of liquid hydrocarbon or water, or both, into the elastomer. The time taken to achieve a complete pressure seal is dependent upon oil viscosity, element thickness, and temperature and salinity. The swelling time is engineered to ensure that the system can successfully be run to depth. The addition of slow swelling rubber layers and/or diffusion barriers can delay the onset of the swelling process as per individual well requirements. This enables running with tight clearances even in situations where the packer is exposed to swelling fluids while being run into the hole. The hardness of the set element is low, ensuring effective sealing in irregular wellbore shapes such as poor hole geometry and corroded casing. Set in permeable formation, a long packer element (5 to 9 m) seals more efficiently as it reduces bypass through the formation. The self-healing element will re-heal if damaged while running in hole or due to formation changes during production. If hole conditions are rough and the packer gets a cut, packer functionality is still maintained due to the expansion capability. If the seal should lose its effect due to formation erosion around the packer element or thermal shrinkage of the element, the Swellpacker systems will restart swelling to seal off any leak path. Rig Time An alternative to cementing, perforating, and cleanout operations when running pre-perforated assemblies or sand screens. No setting or manipulation operations are necessary. Openhole Swell Technology systems can transition from cased hole to openhole operations, reducing cost and formation damage. The system enables sand control with zonal isolation plus the isolation of shales. Robustness The chemical bonding of the rubber to the basepipe is stronger than the element itself, so it cannot be torn from the basepipe under normal conditions. The packers retain the strengths of the basepipe and can be rotated and jarred to bottom.

The packer is damage-tolerant. If hole conditions are rough and the packer gets a cut, packer functionality is still maintained due to its expansion capability. Swellpacker isolation systems can be delivered with any element length depending on the basepipe length. End rings located on either end of the swelling elastomer are an important component that assist in increasing the differential pressure capability and guide and protect the packer when run into the hole. Depending on the application and metallurgy requirements, the end ring design can be anchored to the basepipe using set screws, a crimping process, or welding. Temperature ratings up to 390F (200C). Risk Profile No mechanical interaction of downhole tools. No risk of damaging element by inflation. High reliability of equipment. Helps reduce rig time. No need for specialized personnel to run on rig.

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Swell Technology Systems

Swellpacker Isolation System

Todays oilfield requires operators to find simpler, safer, and more stable downhole technologies. The Swellpacker isolation system is an innovation that meets all of these criteria. The technology is based on the swelling properties of rubber in hydrocarbons or water, or in both. It swells up to 200%, sealing the annulus around the pipe to achieve effective zonal isolation. Once deployed, the rubber retains its flexibility, allowing the Swellpacker isolation system to adapt to shifts in the formation over time, retaining the integrity of the seal. Its self-healing properties make this a truly innovative technology for all zonal isolation applications. It is a bonded-to-pipe product that can be delivered with any element length depending on the basepipe length. Since the rubber is bonded to the basepipe, it is extremely robust and can hold significant differential pressures. The Swellpacker system can be used in cased or openhole environments. In some openhole applications, operators may be able to avoid cementing and perforating altogether, reducing the expense associated with these operations. By reducing well construction costs, saving rig time, and isolating producing zones, the Swellpacker system helps enable previously unachievable levels of oilfield performance.

Swelling Delay Systems

To ensure that the oil or water contained within the well fluid does not affect the packer while it is run into the hole, Halliburton has engineered several systems that can delay the swelling process. These systems enable control of the elastomer swelling process as the setting time can be tailored according to the customers needs, mitigating the risk of premature setting while optimizing the operating envelope. The swelling delay systems include polymers with built-in slower swelling properties and a variety of applied diffusion barriers. Customizing a design with either of these options, or using in combination, allows for creation of a well-specific engineered product.

End Ring Design

In addition to the elastomer compound development, Halliburton continues to innovate in all areas of Swellpacker isolation system design, including the end rings. These important components assist in increasing the differential pressure capability and guide the packer when run into the hole. Depending on the application and metallurgy requirements, the design can be anchored using set screws, a crimping process, or welding. Halliburton has developed the K2 end ring, which protects the rubber element while running in hole and further eliminates element extrusion once the packer is set. One of the benefits of this unique end ring is the ability to shorten tool length, while maintaining differential pressure. It also increases absolute differential pressure performance of the tools with testing performed to 15,000 psi across the packer.

Cementing Support
For well integrity issues, the Swellpacker isolation system can also be used to complement the primary cement job. The system provides comprehensive long-term zonal isolation, increasing the productive life of the well and minimizing the potential for an expensive workover operation. This combination of proven technologies provides an effective means to address both micro-annulus concerns and incomplete cement sheath issues.

HAL32568

HAL32569

Swellpacker Isolation System

K2 End Ring

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Swellpacker Cable System

The Swellpacker system can be delivered with a unique cable feed-through option that enables the passage of single or multiple control lines and flatpacks for downhole monitoring, chemical injection, and SmartWell completions without the need to cut the cables or lines. This removes the requirement for cable splices, control line cuts, and cable stripping, greatly reducing the risk of failure. It provides an annular seal in cased and open hole, and a seal around the control lines or flatpacks capable of holding differential pressure. Installation of the cables through the Swellpacker system is performed on the rig floor at the time of running the completion and requires no extra rig time. Applications Open and cased hole isolations Stimulation placement Open and cased hole straddles SmartWell completion systems Monitoring and chemical injection Water control Multilaterals Stand-alone screen sand control Compartmentalization for screen/ICD completions Gravel pack isolation Well construction Features Manufactured on any oilfield tubular Suitable for cased and open holes Robust construction No moving parts Spliceless cable feed-through option Self-healing, interventionless technology Can be run in most all fluid environments Multiple polymers available to provide oil swelling, water swelling, and hybrid swelling solutions Engineered swelling delay system Benefits No specialist operator required for installation Casing integrity is maintained
Swellpacker Cable System

HAL32625

Perfect seal for irregular borehole geometry Alternative solution to cementing and perforating in certain applications Complements cement to resolve well integrity issues Helps reduce operational risk Isolates producing zones more effectively Helps reduce well costs and rig time Cable feature increases system reliability by eliminating cable splicing and enables openhole SmartWell completions

Installation To install the systems, simply perform standard pre-job checks, then run in hole as part of the reservoir completion string or liner system. At that point, either produce the well to begin the swelling process, allow the current well fluid to swell the packer systems prior to operations, or circulate down the designed swelling fluid. The simplicity of the operation means that specialized installation personnel are not required. For the cable design, Halliburton provides the installation tool that fits easily on the rotary cable and installs the control cable or flatpack through the packer.

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Swell Technology Systems

Bonded-to-Pipe Tools
Operating Condition Run in Hole Fluid: Oil-Based Mud Run in Hole Fluid: Water-Based Mud Temperature Range Reservoir Fluid: Liquid Hydrocarbon Reservoir Fluid: Oil with High Water Cut Reservoir Fluid: Water Reservoir Fluid: Gas Condensate Differential Pressure Capability Time to Set Chemical Resistance Element Length Basepipe Tensile/Burst/ Collapse/Metallurgy Oil Swelling (OS) Design to suit applications All fluid systems 30 - 390F (0 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid Water Swelling (WS) All fluid systems Design to suit applications 30 - 390F (0 - 200C) Does not swell in hydrocarbons All fluid systems; swelling depends on temperature and salinity Wide range of fresh and saline water tested Requires contact with waterbased fluid for permanent seal Up to 10,000 psi (690 bar) Hybrid Swelling (HS) Design to suit applications Design to suit applications OS: 30 - 390F (0 - 200C) WS: 265 - 390F (130 - 200C) Wide range of crude oil tested. Swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid; water swelling depends on temperature and salinity Wide range of fresh and saline water tested Swells in traces of hydrocarbon fluid Up to 10,000 psi (690 bar) Comments Contact Halliburton for engineered delay system Contact Halliburton for engineered delay system Contact Halliburton for design and simulations

Contact Halliburton for design and simulations Salinity and temperature affect swell time Contact Halliburton for design and simulations Contact Halliburton for application-specific pressure ratings Contact Halliburton for application-specific simulations Contact Halliburton for application-specific questions Contact Halliburton for length requirement Can be built on any oilfield tubulars

Does not swell Swells in traces of hydrocarbon fluid Up to 15,000 psi (1032 bar)

Varies based on designs and well conditions Can be engineered for swelling delays of 1-20 days Common oilfield chemicals Application and basepipe dependent

Customer supplied or Halliburton purchased to match specifications

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Swellpacker Slip-On Isolation System

The Swellpacker slip-on isolation system is based on the swelling properties of rubber in hydrocarbons and/or water, swelling up to 200% to seal the annulus around the pipe for effective zonal isolation. This unique slip-on packer retains a full length internal seal against the pipe. Once deployed, the rubber retains its flexibility, allowing the Swellpacker system to adapt to formation shifts over time to maintain seal integrity. Its self-healing properties make it a truly innovative technology for all zonal isolation applications. The Swellpacker slip-on isolation system does not require basepipe to be supplied up front in the manufacturing process and is installed at the service location or rig site by sliding over the pin end of the casing or tubing joint. This allows storing and stocking of the tools, simplifying logistics, and reducing cost significantly. The system can be used in cased or openhole environments. In some openhole applications, operators may be able to avoid cementing and perforating altogether, reducing the expense associated with these operations. Cementing Support For well integrity issues, the Swellpacker slip-on system can also be used to complement the primary cement job. The system provides comprehensive long-term zonal isolation, increasing the productive life of the well and minimizing potential for an expensive workover operation. This combination of proven technologies provides an effective means to address both microannulus concerns and incomplete cement sheath issues.
Swellpacker Slip-On Isolation System

Slip-On Convenience Traditionally, swellable packers achieved high differential pressure ratings based on the area in contact with the casing wall or borehole. Element length is a key parameter for the contact area. The resulting differential pressure, and therefore the shorter slip-on designs, traditionally had lower pressure holding capabilities. Halliburton has developed shorter slip-on tools that can handle the higher differential ratings previously only achievable through a longer bonded-to-pipe product. One of those designs, the Swellpacker HPE (high performance element) slip-on isolation system incorporates the K2 end ring to protect the rubber element while running in hole and support the rubber during and after the swelling process. In addition, the next generation of the Lite family, the Swellpacker Lite II slip-on isolation system, has been redesigned to create a step change in slip-on tool capability. Swelling Delay Systems To ensure the oil or water contained within the well fluid does not affect the packer while it is run into the hole, Halliburton has engineered several systems that delay the swelling

process. These enable control of the elastomer swelling process as the setting time can be tailored according to the customers needs, mitigating premature setting risk while optimizing the operating envelope. The systems include polymers with built-in slower swelling properties and a variety of applied diffusion barriers. Customizing a design with either of these options, or using them in combination, allows for creation of a well-specific engineered product. Applications Swellpacker slip-on isolation systems can be key components in gravel packs for isolation and stand-alone screen completions to reduce fines migration. In reservoirs prone to sand production, the slip-on tool helps enable increased productivity and reduced well construction costs since it can be installed without specialized operating personnel. In completions using inflow control devices, slip-on tools are used to create shorter compartments for improved reservoir management.

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Swell Technology Systems

For many reservoirs using inflow control technology, the Constrictor slip-on isolation system can be an ideal device due to its simple design and reliable performance. One of the main applications for slip-on systems is with hydraulic stimulation operations. Halliburton horizontal completions provide operators with new options for completing horizontal multi-zone wellbores and enable highly accurate fracture placement with little to no intervention. The service allows operators to selectively access, isolate, and stimulate multiple payzones in a single wellbore with the option to close off one or more zones at a future date. This makes multi-zone stimulation possible in a shorter time interval, leading to reduced overall well completion costs.

Features Suitable for cased and open holes Install on any non-upset basepipe Robust construction No moving parts Self-healing, interventionless technology Can be run in most all fluid environments Multiple polymers available to provide oil swelling, water swelling, and hybrid swelling solutions Engineered swelling delay system Benefits No specialist operator required for installation Casing integrity is maintained Simplified logistics Permits last minute adjustments to placement

HA L32 576

Perfect seal for irregular borehole geometry Protect sand screens from plugging Alternative solution to cementing and perforating Helps reduce operational risk Isolates producing zones more effectively Helps reduce well costs and rig time

Constrictor Slip-On Isolation System

Installation Slide the slip-on system onto the basepipe, securing in place with Halliburton end rings. Run in hole with assembly. The tool simplicity means installation does not require specialist attention and can be fitted by personnel at the rig site.

Slip-On Tools
Operating Condition Run in Hole Fluid: Oil-Based Mud Run in Hole Fluid: Water-Based Mud Temperature Range Reservoir Fluid: Liquid Hydrocarbon Reservoir Fluid: Oil with High Water Cut Reservoir Fluid: Water Reservoir Fluid: Gas Condensate Differential Pressure Capability Time to Set Chemical Resistance Element Length Oil Swelling (OS) Design to suit applications All fluid systems 30 - 390F (0 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid Does not swell Swells in traces of hydrocarbon fluid Up to 5,000 psi (345 bar) Water Swelling (WS) Does not swell in hydrocarbons Design to suit applications 30 - 390F (0 - 200C) Does not swell in hydrocarbons All fluid systems; swelling depends on temperature and salinity Wide range of fresh and saline water tested Requires contact with waterbased fluid for permanent seal Up to 1,000 psi (70 bar) Hybrid Swelling (HS) Design to suit applications Design to suit applications OS: 30 - 390F (0 - 200C) WS: 265 - 390F (130 - 200C) Wide range of crude oil tested; swelling rate is a function of fluid viscosity Swells in traces of hydrocarbon fluid; water swelling depends on temperature and salinity Wide range of fresh and saline water tested Swells in traces of hydrocarbon fluid Up to 5,000 psi (345 bar) Comments Contact Halliburton for engineered delay system Contact Halliburton for engineered delay system Contact Halliburton for design and simulations Contact Halliburton for design and simulations Salinity and temperature affect swell time Contact Halliburton for design and simulations Contact Halliburton for application-specific pressure ratings Contact Halliburton for application-specific simulations Contact Halliburton for application-specific questions Custom lengths available on request

Varies based on designs and well conditions Can be engineered for swelling delays of 1-20 days. Common oilfield chemicals Standard lengths are 0.3 m, 0.5 m, and 1 m

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Swellpacker Side-Pocket System

The Swellpacker side-pocket system provides a reliable and effective means to avoid pulling the tubing string when side-pocket mandrels are too corroded or eroded for traditional dummy valves to properly isolate. The system allows the use of standard kickover tools with a standard running tool and is primarily run on slickline for installation. Its smaller diameter simplifies installation when compared with a conventional dummy valve and fits all industry-standard latches. The Swellpacker side-pocket system comes in standard 1-in. and 1.5-in. diameter sizes. With its ability to swell, the system can seal off even heavily flow-eroded or fluidcorroded pockets in the side-pocket mandrels, where standard dummy valves will leak. Custom solutions are also available for any non-industry standard equipment that may be in use. The Swellpacker side-pocket system takes advantage of the swelling properties of rubber in fluids containing hydrocarbons. It swells up to 200%, sealing off the gas flow areas inside the side-pocket mandrel. Once deployed, the rubber retains its ability to swell further, allowing it to adapt to further non-conformities in the pocket and retain future seal integrity. Extensive testing has shown the rubbers ability to swell into and seal in very heavily corroded surfaces. Application and Installation The Swellpacker side-pocket system is run on slickline with a standard kickover tool. Once in place, it swells in the presence of hydrocarbons and seals off the pocket in the side-pocket mandrel regardless of even the most severe erosion or corrosion that may occur. Once sealed off, remedial operations may be performed on the well.
HAL30857

858 L30 HA

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Swell Technology Systems

Features Suitable for all sizes of side-pocket mandrels Fits all industry standard latches Customizable for non-standard equipment No moving parts No specialist required for installation Predictable swelling in a wide variety of oil-based and synthetic-based mud environments Individual swell testing available if necessary Self-healing, intervention-free technology Benefits Eliminates the need to pull tubing in flow-eroded or fluid-corroded side-pocket mandrels Helps reduce production downtime for remedial operations Simple operation Helps isolate side-pocket mandrels more effectively

Swellpacker Side-Pocket System

Operating Condition Oil-Based Mud Water-Based Mud Temperature Range Reservoir Fluid: Liquid Hydrocarbon Reservoir Fluid: Gas Condensate Time to Set Chemical Resistance Differential Pressure Capability Range All fluid systems All fluid systems 32 - 320F (0 - 160C) Swells in hydrocarbon-laden fluids 2 - 100% Swells in gas condensate Varies based on design and well Common oilfield chemicals, H2S, CO2 Varies based on well and design Comment Single or multi-layered construction Single or multi-layered construction Contact Halliburton for application specific swell times No effect Contact Halliburton for application specific simulations

Swell Technology Systems

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SwellSim Software
The Swellpacker simulator, SwellSim software program, is used for selecting the most suitable design to meet specific customer requirements. Extensive testing on the expansion properties of Swell Technology systems has led to the development of the SwellSim software which can help predict the expansion ratio, differential pressure capability, time to first seal, and time to operational seal for a given basepipe OD, rubber element OD, and rubber element length in a given hole size. SwellSim software helps enable Halliburton to provide an engineered recommendation to our customers that delivers a fit-for-purpose and reliable solution. For our customers, this helps allow the utmost confidence that the selected product will meet their expectations. Based on actual test data, SwellSim software provides the user with the ability to look at a variety of designs (bonded to pipe, slip-on, cable bypass, etc.) and polymer types (oil, water, and hybrid swelling) in the proposed well environment. Inputting the well fluid characteristics and temperature allows the user to design and optimize the delay mechanism if necessary and tailor designs for special applications. Benefits Engineered recommendations Helps predict time to first seal Helps predict time to operational differential pressure Helps predict time to maximum differential pressure Helps allow for hole size variation Helps predict delay recommendation Helps identify potential failure modes Helps reduce downhole risks Helps reduce rig time SwellSim Software Legend Expansion ratio volume increase of packer element due to absorption of hydrocarbon Time to first seal when packer OD engages hole ID Time to operational differential pressure when packer reaches customer-specified differential pressure Time to maximum differential pressure when packer reaches maximum differential pressure capability

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Swell Technology Systems

SwellSim Software Output A differential pressure profile curve and a swell profile (time to seal and time to fully set vs. hole size) curve are automatically generated by the simulator. See the examples below for curves extracted from the simulator.

DIFFERENTIAL PRESSURE PROFILE

800 700
(bar)

11600
(psi)
50
Time to Fully Set: 5.5 in x 8.15 in x 9 m Time to Seal: 5.5 in x 8.15 in x 9 m

10150 8700 7250 5800 4350 5.5 in x 8.15 in x 9 m 2900 1450 9.20 9.40 9.60 9.80 10.00 10.20 0 10.40

600 500 400 300 200 100 0 8.60

Differential Pressure

8.80

9.00

Hol e ID ( in)

SWELL PROFILE
50 45 40 35
Ti me (days)

45 40 35
Ti me (days)

30 25 20 15 10 5 0 8.15 8.24 8.32 8.41 8.49 8.58 8.66 Hole ID (in) 8.75 8.83 8.92 9.00 9.09

30 25 20 15 10 5 0 9.17

Swell Technology Systems

Differential Pressure

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Well Construction
With the challenges presented by depleted or even overpressured reservoirs, it is becoming more difficult to achieve optimal zonal isolation using conventional methods. Complicated wellbore geometry has pushed the limits of technology in perfecting competent annular pressure confinement and isolation of multiple zones. Wells are being designed with more casing points to isolate depleted reservoirs before drilling ahead to higher pressure areas. The increased number of casing points dictate smaller annular volumes between casing and open hole or casing and casing. The smaller annular volumes make it more difficult to provide sufficient zonal isolation or sustained casing pressure prevention using current methods. More casing points can also lead to larger annular volumes in under-reamed openhole sections. With the move into deeper water and more severe environments, operators are requiring service companies to adapt to these ever changing conditions. The advent of swellable technology has presented a competent solution to many of the challenges that have been encountered. Swellpacker isolation systems, along with swellable elastomers in cement, are products that will change and adapt along with downhole conditions.

Swellpacker systems above top of cement

Swellpacker isolation systems on liner tiebacks Liner Hanger Swellpacker isolation systems below liner hangers

Swellpacker systems at shoe joints

Swellpacker isolation systems in production zones with cement

Swellpacker systems on shoe joint for Formation Integrity Test

HAL33105

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Swell Technology Systems

Swellpacker Systems Above Top of Cement Swellpacker isolation systems used above top of cement (TOC) will prevent pressure migration to surface (sustained casing pressure) from lower reservoirs without compromising the competency of the original cement job. The systems will help prevent sustained casing pressure if during the life of the well cement becomes de-bonded from the casing which could create channels for the pressure to migrate from the formation. Swellpacker TOC systems work independently from other operations regardless of conditions as long as a swell fuel is present. Swellpacker Systems at Shoe Joints Swellpacker systems used on the shoe joints will create a competent pressure seal and allow for a Formation Integrity Test (FIT) regardless of the tail cement condition. Swellpacker shoe joint systems are designed to swell in the drilling fluid. If there is insufficient mud cleanout in the shoe joint area, the contaminated fluid fuels the packer, prompting the system to swell. A formation integrity test can then be conducted to facilitate drilling ahead. If competent tail cementation is achieved, the Swellpacker shoe joint system does not activate. Swellpacker Systems Below Liner Hangers Liner hanger Swellpacker systems help provide a positive seal to isolate the openhole section from the surface. The Swellpacker systems are installed on a liner below a liner hanger inside the parent casing. The liner hanger Swellpacker system can be designed to swell either before the liner hanger is set, or after the liner hanger pack-off is energized. Using the liner hanger Swellpacker system can eliminate the need for liner top squeeze jobs, resulting in a substantial savings of time and money. The system can be employed with or without cement.
Swellpacker OBM System Liner Low-Pressure Zone

Open Hole

HAL33104

Swellpacker System Above Top of Cement

HAL33100

Swellpacker System at Shoe Joints

HAL33102

Swellpacker Isolation System Below Liner Hangers

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Swellpacker Systems in Production Zones with Cement Swellpacker systems when combined with primary cementing operations can provide comprehensive longterm zonal isolation, increasing the productive life of the well and minimizing the potential for an expensive workover operation. Incorporating Swellpacker systems in production zones with cement can also provide a reactive downhole means to address the micro-annulus that occurs when set cement debonds from the casing. The Swellpacker system will remain dormant while encased in the cement sheath. Once the micro-annulus opens up and liquids or gas attempt to flow through, the packer will swell to close the flow path. The swellable rubber will conform to almost any irregular geometry in the casing or cement. Swellpacker Systems on Liner Tiebacks Using Swellpacker systems on liner tiebacks provides pressure holding capability and also creates an enormous anchoring force for the liner tieback stringeliminating the need for cement to anchor the tieback string. Swellpacker systems are installed above the seal assembly and the tieback string is run in the hole to the tieback receptacle. After the seal assembly is pressure tested, it is then raised, and fuel for the swellable element is circulated to the proper place (if not in place already). The seal assembly is lowered back into the tieback receptacle, allowing the Swellpacker system to swell. Implementing Swellpacker systems frees up time and helps reduce cost because there is no cement, float equipment, or cement plugs to drill out before completing the well. Swellpacker Systems on Scab Liners Scab liners are placed in the well to simply provide a casing conduit from the lower liner to the upper tieback casing string. Cementing a scab liner in place is time consuming and can be risky. Using Swellpacker systems on scab liners helps reduce the risk of performing a competent cementing job in relative small annuli. Swellpacker systems will provide high-pressure sealing capabilities.
HAL33103

HAL33101

Swellpacker Isolation System in Production Zones with Cement

Swellpacker Isolation System on Liner Tiebacks

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Swell Technology Systems

Easywell Testing Facilities

Since the first introduction of the Swellpacker system in 2001, much has changed. Swell Technology systems have been accepted by a large number of operators worldwide. The growing complexity of well designs in harsher environments has increased the need for more diverse Swell Technology products and more rigorous testing on tools that are going to be commercialized. In order to support the research and development efforts required for product development, Halliburton has invested in laboratory facilities in Norway and the United States. At this center, Halliburton has the opportunity to consolidate key personnelproduct management, global technical support teams, and researchand enhance collaborative efforts with the customer during the design, testing, and qualifying stage. All standard tests, qualification testing, and customer/ project-specific tests can be performed at this facility, including swell speed testing at customer-specified conditions, full-scale differential pressure performance under both static and dynamic fracturing conditions, scaled (reduced size) packer testing, gravel pack testing, and friction testing. For customer-specific tests, the procedures are agreed upon between Halliburton and the customer before the test unit is built and the test is executed. These procedures contain the specifics of the test, timeline, reporting, and the testing budget. This facility is set up with digital logging and recording systems to accommodate the customers need to evaluate the technology. Remote witnessing of the testing is available upon request.

Research and Development Lab Stavanger, Norway

The main facility for Halliburton Easywell research and development opened in August 2008 and is located near Stavanger, Norway. The 8,000 ft laboratory has tripled the capacity of Halliburtons ability to design, test, and qualify new swellable technology products.

Halliburton Easywell Research and Development Lab

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Swell pressure testing is performed at an early stage in elastomer compound development. The objective is to verify swelling and internal pressure building in the elastomer, which indicates the differential pressure performance on full-scale tools. The swell speed test cell determines tool swelling speed at a specific downhole temperature. The fluid used can either be a sample supplied by the customer or a standard base oil. The primary advantage of this donut testing is to help determine the correct geometry, since the shape of the sample tested has a significant impact on the test outcome. All test results are subsequently used to update the SwellSim simulation software. Differential pressure testing is conducted in large autoclaves for full-scale tools only. Maximum pressure test pressure is 15,000 psi.
Swell Speed Test Cell

HAL31901

Differential Pressure Testing Area

The final test conducted on Halliburton Easywell tools before commercialization is the run-in-hole simulation or ruggedness test. In this test, full-scale tools are run through a milled window. The main objective is to test the robustness of the tools (both element and end ring) in a dry environment (no lubrication of any fluid).

HAL31905

Swell Pressure Testing Cell

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Swell Technology Systems

Support Lab - Carrollton, TX, United States

Halliburton's engineering test facility in Carrollton, Texas, has the capability to run full-scale swell speed testing and differential pressure testing. At the main facility, testing can be carried out up to 600F (315C) and up to 20,000 psi (1375 bar). The center's engineering test facilities also provide engineering analysis and support, high-temperature/highpressure testing, and tool pre-qualification to API and ISO requirements. The center includes two working test wells with rig accessories, slickline, and E-line operations as well as flow testing capabilities which allow Halliburton to simulate actual well environments before running new tools in a customer's well.
HAL17702

Carrollton Test Facilities

Swell Technology Systems

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Swell Technology Systems