In this special section E&P highlights some of the latest products and technologies for shale and examines how they will benefit companies in their ongoing search for improved production and more effective operating techniques.

 

Editor’s note: The copy herein is contributed from service companies and does not reflect the opinions of Hart Energy.

 


 

DRILLING

 

DRILLBIT PROACTIVELY MITIGATES STICK/SLIP, IMPACT LOADING

In the Delaware Basin in Texas, an operator was experiencing erratic drilling performance in 12¼-in. intermediate sections running through interbedded shale, limestone and salt, driving up nonproductive time (NPT) and costs. Based on the operator’s challenges, Baker Hughes, a GE company, proposed using a Terr- Adapt adaptive drillbit to improve drilling performance and reduce NPT by proactively mitigating stick/slip and impact loading. It incorporates self-adjusting depth-of-cut control elements to mitigate torsional instability—which can lead to stick/slip—and to absorb sudden impact loads from formation variations. The TerrAdapt bit completed the 1,023-m (3,355-ft) section in one run, increasing ROP by 27% compared to ROP on offset wells drilled with standard PDC bits. ROP averaged 168 ft/hr, and the surface torque generated by the TerrAdapt bit was 45% lower on average and 90% more consistent. bhge.com

VALVE PROTECTS DRILLING SYSTEMS AGAINST DANGERS OF OVERPRESSURIZATION

CORTEC’s CRV26 Pressure Relief Valve (PRV) is designed to offer users the safety, reliability and rapid response functions required to meet modern drilling challenges. The CRV26 has been engineered to protect drilling systems against the dangers of overpressurization and is the first of its kind of be rated to 10,000-psi systems. Automated PRVs provide the highest level of accuracy and reliability and are automatic or manually resettable for thousands of cycles. Applications in the field include fracture system relief, mud pump relief and managedpressure drilling. uscortec.com

TECHNOLOGY HELPS REDUCE DRILLING FLUID WASTE

Cubility’s MudCube is a compact, lightweight solids control solution that uses a vacuum-based/ rotating screen filtration system. Enabling the MudCube to be rapidly and inexpensively installed on shale rigs and well pads, Houston- based Stage 3 Separation (S3S) has incorporated the MudCube into its mobile and modular S3S Performance Platform for onshore shale operations. Additional analytics also is under development to further improve the MudCube. The MudCube meets the cost and operational challenges of returns-focused shale operators. This includes rapid deployment on well pads, limited space and manpower requirements, and fast mobilization/demobilization. The MudCube and its separation capabilities result in more drilling fluid recycled back to the mud tanks and less waste. MudCubes also can process 100% of the circulating volume, immediately increasing performance with up to 80% more drilling fluid processed than other technologies, which is critical given the extremely high flow rates of the latest shale drilling rigs and the need for immediate returns. cubility.com 

FLUID END REDUCES OPERATING STRESSES IN PUMPING APPLICATIONS

Gardner Denver’s next-generation fluid end helps operators extend the life of their pressure pumping equipment by reducing operating stresses in pumping applications. Using proven Falcon Technology, Redline Packing and Thunder elements, the service-friendly design reduces maintenance time for valve, plunger and packing changes while also extending life. Additionally, Falcon Technology eliminates alignment requirements for suction covers and requires no special tooling to install, reducing nonproductive time. Features of the next-generation fluid end include optimized internal chamber and seat deck geometry that reduces stress; 3.5 times or more fatigue life over competing products; utilizes standard Gardner Denver internal components; and has direct interchangeability with the previous generation. Additionally, a new front face design improves structural integrity and distinguishes next-generation from older-generation fluid ends. gardnerdenver.com

RPMs HELP TACKLE DATA VOLUMES AND VAST GEOGRAPHY

Ikon Science offers new rock physics models (RPMs) and RPM templates for unconventional shale reservoirs in RokDoc. One of the key links in the chain for quantitative interpretation in unconventional settings is rock physics, which can be used to explain relationships between seismic attributes and reservoir parameters. RPMs can be calibrated using log and core data and then organized into RPM templates to provide the necessary framework for log and seismic derived property analysis in terms of important organic mudrock parameters such as total organic carbon (TOC), porosity and effective stress. The end result is an ability to tackle huge data volumes and vast geography, making systematic and repeatable workflows that can be rolled out across basins. Robust rock physics modeling gives us the ability to quickly create and test scenarios, capturing uncertainties and allowing us to consistently rank opportunities across portfolios, leading to faster decisions and more reliable well placements and completions, thus maximizing the ultimate recovery. ikonscience.com

REDUCE WELLBORE PLACEMENT UNCERTAINTY

MagVAR In-Field Referencing and Multi-Station Analysis corrections strongly reduce the wellbore placement uncertainty by up to 60%. Applying these methods significantly increase the separation factors between new wells drilled in congested fields. With increased separation factors, fewer wells will require dispensations and less collision risk will be encountered. Thus, increased separation factors further improve the safety of drilling campaigns in congested unconventional environments. To increase the separation factor between a planned wellbore and its offset wells, the new wellbore can sometimes be moved or shortened. However, any such modifications of the well plan can result in sub-optimal drainage, stranded reserves and sub-optimal field development. magvar.com

AUTOMATED DIRECTIONAL DRILLING CALCULATIONS HELP IMPROVE PERFORMANCE

The Motive Bit Guidance System improves directional drilling performance. This improvement is provided by taking on tasks that are better performed by a high-performance computer and leaving the tasks that are better performed by a human to the driller. The core functionality is to provide turn-by-turn steering instructions and feedback directly to the driller. The decisions are supported by automating standard directional drilling calculations that were previously done by the directional driller, but done automatically, continuously, faster and with more detail than is humanly possible for timely decisions. The system also provides a tremendous amount of additional analysis of the data, performs forward modeling of the bit position in real time, improves communication between the rig and office, and automates and improves directional drilling reporting. The Motive Bit Guidance System has guided the drilling of more than 450 wells, resulting in better consistency, reduced drilling times, less tortuous wells and improved production potential. motivedrilling.com

HIGH-PERFORMANCE EMULSIFIER INCREASES WELLSITE EFFICIENCIES

New technology and improved drilling efficiencies have increased asset value in unconventional shale. In the Eagle Ford, maintenance of asset values requires engineering solutions that allow continuous improvement and sustained profitability. The OptiMul HP high-performance emulsifier achieves target fluid properties at reduced product concentrations. The operator evaluated eight extended-reach wells: four wells used a conventional emulsifier technology while the other four wells used OptiMul HP. The OptiMul HP wells handled solids loading better, greatly reducing fluid loss control agent requirements. In the drilling fluids program, an overall total cost reduction of more than 35% was seen on a well-to-well basis. newpark.com

TOOL MEASURES FORMATION RESISTIVITY WHILE DRILLING

The Tolteq symmetric propagation resistivity (SPR) tool from National Oilwell Varco (NOV) employs an array of symmetrically placed transmitters and receivers to measure formation resistivity while drilling. When run in conjunction with the Tolteq iSeries MWD platform, the SPR tool’s resistivity measurements can be transmitted in real time for geosteering applications. The tool measures attenuation and phase shift between two receivers and correlates those measurements with formation resistivity using an efficient inversion algorithm, providing borehole- compensated formation resistivities with multiple depths of investigations and vertical resolutions. One of the shortest LWD resistivity tools on the market, the SPR tool’s robust mechanical design and advanced electronics minimize phase and attenuation noise, thus increasing measurement range and accuracy. The tool also provides better delineation of bed boundaries during well placement operations and improves the estimate of total hydrocarbon in place. nov.com

DRIVING TORQUE DRAMATICALLY DOWN

Substantially reducing downhole heat and friction under extreme conditions drives operational results sharply upward. Field-proven at hundreds of drillsites, ProOne’s Nitro Drilling Fluid Treatment next-generation lubricant delivers 70% friction reduction and reduces torque by 15% to 50%. With long lateral drilling’s resurgence, this treatment not only reduces torque but uses considerably less product than ordinary lubricants. Numerous case studies include a torque reduction from 15,550 ft-lb to an average 8,500 ft-lb at a California site; reduced torque to allow completion of the longest lateral in New Mexico history; and a 40% drop in torque was accompanied by reducing trips and drillbit changes and a 12% ROP increase in Texas. pro1energy.com

SOLIDS CONTROL SYSTEM REDUCES WATER USAGE WHILE IMPROVING DRILLING

The QMax MUDSTRIPPER solids control system recycles and reduces water used in drilling with clear water or brines by up to 50%, while also reducing drilling costs by up to 40%. The system, which can process up to a 850-gal/min flow rate without any interruption in drilling operations, allows higher penetration rates, lower disposal costs, smaller rig site locations and minimal fluids waste disposal. Traditional solids control equipment on the rig removes large cuttings using shakers and then passes the underflow through the MUDSTRIPPER where a flocculant is added. As fluids pass through a settling chamber, the flocculated solids settle, leaving clear fluid. Solids are transferred to a small cuttings pit or portable collection tank, and the clear fluid is available for reuse. qmax.com

AUTOMATED DRILL RIG TECHNOLOGY IMPROVES SAFETY, EFFICIENCY

For rig providers, drill time is a top key performance indicator (KPI). To optimize the number of days it takes to drill a hole, rig owners need to keep downtime to a minimum and operate at peak efficiency. Rockwell Automation works with rig providers, like Nabors Industries, to help automate and modernize drill rig technology to improve efficiency and safety. Nabors’ rigs leverage Rockwell Automation Integrated Architecture based on ControlLogix control systems, PanelView human-machine interfaces and information solutions to capture data in real time and contextualize and display the data as useful information in a central location. Nabors’ operators and technicians can view KPIs like ROP, directional path, torque and other parameters. With real-time rig performance, Nabors can support and service its rigs and global customers immediately. rockwellautomation.com

SYSTEM PRODUCES A REAL-TIME IMAGE SURROUNDING THE DRILLBIT

DrillCam is an integrated real-time system for imaging and predicting ahead of the drillbit and around the well. It uses multiphysics measurements both downhole and on the surface to produce a real-time image surrounding the drillbit similar to what the doctor sees while operating an ultrasound. The DrillCam system enables controlled geosteering through the reservoir’s pay zones as well as predictions of lost circulation and hazardous drilling zones, which have a huge business impact on discovery, recovery and cost efficiency. saudiaramco.com

ENABLING BETTER WELL PLACEMENT IN SHALE ENVIRONMENTS

The Schlumberger xBolt accelerated drilling service eradicates surveying wait time and costly trips out of hole, while enabling better well placement in shale environments. The MWD tool integrates a configurable telemetry system into a single tool—either ultrafast electromagnetic or robust mud pulse, or both with a dual telemetry option. The service also can change telemetry modes in less than one minute, effectively eliminating trips. In addition, the multitelemetry service provides a well placement solution for accurate geosteering decisions owing to its high-density azimuthal gamma ray functionality. During a recent shale operation in the Midcontinent region, the service quadrupled data transmission rates and improved signal reliability to eliminate relogging. slb.com

TOOL PROVIDES AT-BIT MEASUREMENTS BACK TO THE SURFACE

Scientific Drilling’s BitSub provides a cost-effective geosteering solution. Placed between the motor and the bit, the always-rotating BitSub utilizes the company’s WiSci technology to communicate with the MWD tool and provide at-bit measurements back to the surface. This battery operated tool has onboard sensors for static and continuous inclination, focused natural gamma ray and tri-axial vibration, and is designed to work with any downhole motor. Along with total natural gamma ray, the tool provides either four or eight sector gamma ray borehole images in real time and 16 sector images in memory for structural dip processing. The primary application is geosteering, geostopping and improved in-zone net-to-gross wellbore position, utilizing the immediate knowledge of wellbore deviation and formation changes. scientificdrilling.com

LINER HANGER SYSTEMS ALLOW LONGER LINER RUNS, LARGER COMPLETION TOOLS

Seminole Services LLC offers metal-formed liner hangers to advance shale drilling and completion operations through well construction and well integrity tools. Designed specifically for shale operators, the company’s recently developed 4½-in.-by-7-in. PowerScrew liner hanger allows longer liner runs, larger completion tools and priority placement of pressure-activated equipment in a production string. The tool was created to minimize reliability risks while offsetting costs associated with other expandable hangers and long-string casing designs. Also, with the company’s mechanical setting process, safety risks from high-pressure, high-compression loads and cone extraction have been engineered out of the tool, creating more value than cost savings alone. seminole-services.com

THIRD-GENERATION TOOL STABILIZES BIT LOADING

Drilling efficiency is the key to unconventional success. The autonomous Anti Stick-slip Technology (AST) of Tomax is installed close to the drillbit and will stabilize the loading of the bit within 20 ms. Together with the reduction in tool damage, the efficiency advantage compared to surface controls has driven a fivefold increase in AST use every year since 2015, even through the downturn in oil prices. The tool is designed for minimal friction through curvatures with an ability to absorb more energetic, high-frequency torsional vibrations compared to previous generation tools. tomax.no

CUTTER SCOOPS SHALE, INCREASES EFFICIENCY

In the Delaware Basin concave SCOOP cutters developed by Varel Oil & Gas Drill Bits have significantly enhanced penetration rates. The first regional run of a PDC bit equipped with the nonplanar, shaped cutters drilled the lateral in the Bone Spring Formation’s shaly sand at 71.1 m (233.4 ft) per hour compared to an offset average of 54.1 m (177.5 ft) per hour. The achievement follows similar performance of prototype cutters in the fine-grained sandstone, shale and conglomerate of Oklahoma’s Oswego Formation. The shaped cutters produce a variable back rake described by the radius of the concave surface—as the cutter shears deeper into the rock, the concave face presents a progressively higher effective back rake. The resulting increase in efficiency achieves greater ROP for an equivalent weight on bit. varelintl.com

 


 

COMPLETIONS AND WATER MANAGEMENT

 

COMPANIES PARTNER TO BEGIN RECYCLING PRODUCED AND FLOWBACK WATER

Aqua Terra Water Management and DeNora Water Technologies have partnered to begin recycling produced and flowback water at Aqua Terra’s saltwater disposal injection facilities. The DeNora technology recycles water from gathering facilities or disposal wells to lower producers’ costs and potentially eliminate the use of freshwater for fracturing. Through a complete inner loop system, this partnership will reduce truck traffic and the carbon footprint of trucked water making roads safer. Aqua Terra partners with producers to provide infield disposals and pipelines to further reduce truck traffic. The use of pipelines tied to injection facilities reduces producers’ costs providing higher rates of return on projects. With the current drought in operating regions, this partnership and technology is designed to help save aquifers throughout the industry. aquaterrawatermanagement.com, denora.com

SILICA DUST CONTROL FRACTURE SAND COATING TECHNOLOGY

Respirable crystalline silica dust control continues to be an ongoing challenge for the hydraulic fracturing industry. One engineering control that effectively addresses this problem is ArrMaz’s SandTec, a chemical coating technology for fracture sand. Field results prove that SandTec reduces respirable silica dust by up to 99% and below the U.S. Occupational Safety and Health Administration’s permissible exposure limit and action level across the hydraulic fracturing supply chain. SandTec simplifies fracture sand logistics and does not occupy valuable real estate on the fracturing site. It is compatible with a wide variety of fracture fluids and is environmentally friendly. arrmaz.com

PERFORATING SYSTEM ELIMINATES MISRUNS, NPT

The GameChanger perforating system from C&J Energy Services features a semi-disposable gun assembly designed to increase efficiency and reliability by eliminating the misruns and resulting nonproductive time (NPT) associated with traditional gun systems. Compatible with all manufacturers’ shaped charges, the port-free design eliminates pinch points that can damage electrical connections, has no port plugs that can get lodged in the well and significantly decreases the chance of flooded guns. Addressable switches provide real-time confirmation throughout the downhole descent and, with no wires running between guns, the GameChanger system provides a high level of confidence in the wellbore. Using the compact C&J top sub and plug shoot sleeve, the system reduces the length and weight of the gun string, which requires less rigup equipment and provides safer onsite handling. cjenergy.com

INCREASE PRODUCTION, EUR FROM SLICKWATER FRACTURING OPERATIONS

New to the CARBO suite of proppant and fracture technologies, CARBOAIR is a high-transport, ultralow-density ceramic proppant technology with chemically engineered internal porosity, designed to increase production and EUR from low viscosity slickwater fracturing operations. 
CARBOAIR features superior conductivity in comparison with equivalent sized sand, ensuring it is a viable proppant in low viscosity fluids. As a result of its physical characteristics, increasing fracture length while pumping equivalent mass of CARBOAIR (due to its weight advantage) or increasing fracture networks of complexity (because the proppant can turn the corner more easily) are significant benefits. To date, CARBOAIR has been pumped in tail-in applications in three major basins in the U.S. and in an openhole gravel pack in Trinidad. carboceramics.com

 

TENSION TOOL ENABLES SAFER TUBING SETTING

D&L Oil Tools’ ProTension safe tension tool ensures complete well control at all times when setting a tubing string in tension using standard field procedure. While tension is pulled into the tubing string using ProTension, there is no need to remove the BOPs or to overstretch the tubing, which is the case when using low line slips. Ideally suited for long reach horizontal, multistage stimulated oil wells, which will eventually require artificial lift, ProTension is installed between the tubing hanger and the production tubing. Once the tubing hanger is landed, isolating the annulus, tension is pulled into the tubing string and safely locked into place without losing well control. The tool allows complete rotation of the tubing when setting downhole tools. dloiltools.com

FORMATION TUNED SHAPED CHARGE INCREASES STAGE COMPLETION SUCCESS RATE

DynaEnergetics’ HaloFrac formation tuned shaped charge was recently featured as part of an 18-month case study. The charge boasted a repeatable 20.3% overall improvement in stages completed while reducing treating pressure by about 10% on average for a major E&P company operating in the Permian Basin. The HaloFrac cylindrical jet design features equal entry hole performance and optimized tunnel “halo” geometry intended to address some of the most difficult challenges associated with inconsistent fracture rates, pump delay (pumping times) and break down pressure. The robust spherical fracture network created by the HaloFrac shaped charge has enabled the E&P company to realize more than a four times increase in stage completion success rate when compared to neighboring offset wells. dynaenergetics.com

ELECTRIC FRACTURING EQUIPMENT OFFERS FUEL SAVINGS UP TO 95%

Evolution Well Services will soon release the second generation of 100% electric fracturing equipment to the North American market, planned for the third quarter of 2018. Like the first generation, the fleet is powered by a single 36-MW gas turbine that is fueled 100% from the customer’s field gas. Upgrades include a custom turbine mobilized in less than 24 hours, five trailers removed from the footprint and an increase in power density with 6,000-hp electric motors, scheduled to be 7,000 hp for subsequent fleets. The fleet design solves many of the challenges faced by conventional assets. At about 82 dB, sub Tier IV standard emissions and 100% removal of diesel, noise and environmental concerns are mostly eliminated, with fuel savings of 90% to 95% as an added bonus. evolutionws.com  

FLEXIBLE PUMPING ASSETS LOWER UNIT COST

Trailer-mounted horizontal pumps reduce the unit cost of water transfer, flowback, saltwater disposal, water injection and fracture hit protection pumping operations. Horizontal pumps, when integrated with hydraulic jet pumps or gas-lift systems, create robust artificial lift systems. GR Energy Services has proved that, when compared to conventional systems, horizontal pumps, hydraulic jet pumps and/or gas-lift integrated systems reduce operating costs by eliminating gas locking and solids handling issues that cause workovers. grenergyservices.com

DISSOLVABLE ALLOYS WORK IN WIDE RANGE OF CONDITIONS

Luxfer MEL Technologies (formerly Magnesium Elektron) produces SoluMag dissolving magnesium alloys for use in dissolvable fracture plugs and balls. The SoluMag family of alloys allows the tool designer to apply the best combination of mechanical and corrosion properties for the application. SoluMag alloys are being used in plug-and-perf and sliding sleeve applications as dissolving fracture plug components and fracture balls in North American oil and gas wells. The wide range of SoluMag dissolving magnesium alloys were developed to give the designer, service company and operator the confidence that the material will work in downhole conditions predictably given the wide range of conditions. Giving the user the data on how this material performs in the range of operating conditions will allow the completion to go predictably. luxfer.com

MULTISTAGE FRACTURING SYSTEM PREVENTS PROPPANT FLOWBACK

The Bullmastiff from National Oilwell Varco (NOV) is an openhole ball-drop-activated multistage fracturing system that incorporates proppant and formation debris control. The system uses sand screens, which are exposed post-fracture, to prevent proppant flowback. By using a mechanical method of sand control, the Bullmastiff enhances well economics over a well’s life cycle by reducing surface facility requirements and improving production efficiency. The Bullmastiff also incorporates a ball-drop-closable sleeve, which allows open sleeves to be closed without the loss of ball-drop stages for the completion. Screen subs are activated during milling operations and securely locked in the open position. Pumping operations using the Bullmastiff are similar to traditional openhole ball-drop operations, allowing the operator to maintain the stage count. Unlike with standard openhole completions, the Bullmastiff does not put the casing at risk of exceeding the collapse pressure of the casing between the packers. nov.com

 

MODULE REMOVES SUSPENDED SOLIDS, OIL AND DISSOLVED ORGANICS FROM WASTEWATER

OriginClear’s Electro Water Separation with Advanced Oxidation (EWS:AOx) water treatment technology removes suspended solids, oils and dissolved organics from the dirtiest wastewaters, offering oil and gas operators a cost-efficient and effective means of managing and reusing produced water onsite.
Through a demonstration project on a field belonging to the Sinopec Group, OriginClear used a pilot system equipped with its EWS technology to remediate hydraulic fracturing flowback water for onsite reuse. The EWS module demonstrated its ability to abate major contamination factors found in produced water, reducing chemical oxygen demand by more than 90%, ammonia by more than 80% and total suspended solids by more than 95%. originclear.com

 

COMPLETE RESERVOIR COVERAGE WITH TRUE LIMITED ENTRY STIMULATION

Sliding sleeve technology transformed the completions industry nearly two decades ago, and innovation has steadily continued to reduce intervention and risk during stimulation, reduce operating time and cost, and maximize stimulation efficiency. Packers Plus’ TREX QuickPORT IV sleeve represents an evolution of sliding sleeve technology for cemented liner completions. Multiple sleeves are grouped within a stage to mimic plug-and-perf limited entry stimulation, while erosion resistant nozzles ensure even distribution of stimulation fluid through each entry point in the cluster. Recently, 80 QuickPORT IV sleeves were run in a single well by an operator in the Permian Basin. Grouped in four-sleeve clusters to cover the first 20 stages of a hybrid completion, the QuickPORT IV limited entry stages were stimulated in under 70 hours of pump time, saving the cost associated with downtime as well as mitigating the operational risk of intervention in the toe stages. packersplus.com

PROTECTED RUPTURE DISK ENSURES OPERATIONS

Rubicon Oilfield International recently commercialized its HydraSTART STV II toe valve technology. Operators require an accurate and reliable valve to initiate the pump down process of their completion. These valves utilize a rupture disk that protects a piston and atmospheric chamber. When the rupture disk bursts, the well pressure acts against the piston forcing it to shift open into the atmospheric chamber, ultimately opening the sleeve. It must perform after being cemented through and remaining in the well environment, sometimes exceeding 149 C (300 F), for months. The HydraSTART STV II design increases reliability by protecting the rupture disk and increasing force to open the valve through an industry-leading piston size. The design has proven reliable in more than 20 runs including in Haynesville Shale. rubicon-oilfield.com

RESEARCH, VISUALIZE OPTIMAL WATER SUPPLY CHAIN AND TRADE EXCESS CAPACITY

Sourcewater.com is an online database and marketplace for water sourcing, recycling and disposal. With new well stimulations using as much as 1 MMbbl of water per fracture, reliable and cost-effective sourcing and disposal of water has become one of the key constraints on upstream energy growth. Sourcewater enables operators and service companies to research, visualize and acquire the optimal water supply chain and trade excess capacity. Sourcewater obtains its data from user listings, public permit filings, satellite imagery analytics, outbound data collection and Internet of Things sensor feeds. The company has more than 100,000 Permian Basin water source and disposal listings, many with price, volume, flow rates, water quality and dates available. The company has recently introduced its satellite analytics identifying every Permian fracture pit and added a geographic information system map interface. sourcewater.com

MONOLINE FRACTURING MANIFOLD SYSTEM MINIMIZES NUMBER OF FLOWLINES

SPN Well Services, a Superior Energy Services company, offers a monoline fracturing manifold system specially designed for multiwell pads and used in conjunction with high rate fracturing treatments. Monoline is suitable for use on oil and gas wells across the U.S. and is ideal for fracturing treatments with maximum pressures and rates of 15,000 psi and 100 bbl/min, respectively. The system reduces the overall hazards associated with rigging up multiple wellheads by minimizing the number of flowlines, reducing personnel onsite and minimizing tripping and hammering hazards. Monoline rigup is faster, cleaner and more simplified when compared to zipper manifolds or manual valve rigups, and the system’s small footprint means that it is ideal for use in tight locations, leaving more room for fracturing equipment. SPN Well Services’ Rentals product line is a new service line, formed in 2017, that offers BOP and accumulator packages; manifolds; valves, tees and flow crosses; flanges; and other rental items needed in today’s drilling, completion and production oil and gas segments. spnws.com

SAND CONTROL DEVICE PREVENTS PROPPANT FLOWBACK

Sand or proppant can create challenges for oilfield operators when they flow back into the wellbore after a fracturing treatment has been completed. The result is higher operating costs due to proppant settling in casing, potential erosion of critical surface equipment as well as sand fill cleanout and facility damage, all of which can lead to reduced production and heightened safety concerns. Stage Completions has created a sand control device called the Xand-X that is designed to be used in combination with the SC Bowhead II sliding sleeve. It is deployed by being pumped down after flushing the fracturing treatment in each stage. Once pumped down, the device lands in front of the open ports and is used to prevent any proppant flowback from occurring. stagecompletions.com

DECREASE TIME FOR A PACKER TO SWELL, HOLD DIFFERENTIAL PRESSURE

Swellable packers have been a mainstay in the shale toolbox for several years. TAM International improved upon the tried and true by creating FastSwell, a modification to existing technology that drastically decreases the time it takes for a packer to swell and hold differential pressure. By adjusting the exposed surface area of the packer, the swell times are faster and more precise. Time is money in the oil and gas industry. This new technology allows users to begin subsequent operations much sooner. In addition, it can provide a much more reasonable swell time in colder temperatures or challenging fluids. tamintl.com

DIVERTER SYSTEM SEALS ALL HOLES, REGARDLESS OF SHAPE

Thru Tubing Solutions’ SlicFrac diverter system is an intrawellbore diverter utilizing Perf Pods to selectively divert frack to virgin formation efficiently stimulating the entirety of each stage. Perf Pods were designed to seal both circular- and irregular-shaped holes, providing the ideal solution for new completions and refracturing operations. Utilizing the wireline pod tool to deploy pods downhole in the wireline bottomhole assembly allows the operator to reduce the total number of bridge plugs used, while maintaining the advantages of closer stage spacing and/or additional clusters. A “Pod out” or complete seal between stages verifies full coverage of the previous stage as well as provides the ability to pressure test the casing prior to perforating new clusters. The risk of a preset plug can be drastically reduced, along with post-fracture completion costs and associated resources. thrutubing.com

 

WATER TREATMENT SYSTEM ENABLES PRODUCED WATER REUSE AT WELLHEAD

Veolia Water Technologies has developed a transportable, modular water treatment system that enables produced water reuse at the wellhead. ShaleFlow consists of three modules that can treat up to 10,000 bbl/d, eliminating the need for transporting freshwater to the site and produced water for disposal. The process uses proven technologies to remove suspended solids and oil and grease to less than 5 mg/l; H2S, iron and manganese to less than 1 mg/l; and bacteria to nondetectable levels. The effluent water quality is suitable for reuse in fracturing and completion operations. Treatment steps include dissolved air flotation, nutshell filtration and a filter press. System performance is guaranteed when operated by Veolia. The transportable system is designed to be moved as the field is developed. veoliawatertech.com

COMPOSITE FRACK PLUG LEAVES MINIMAL MATERIAL IN WELLBORE

When completing shale wells, operators commonly use the plug-and-perf (PNP) method to minimize downtime and start production as soon as possible. The new Minima composite frack plug mills up in as little as five minutes, enabling a more efficient PNP process. As one of the shortest plugs in the industry, the Minima plug leaves minimal material in the wellbore. Compared to standard frack plugs, the Minima plug deposits 40% less cuttings, which eases cuttings removal. Additionally, the plug holds pressures up to 10,000 psi and sustains temperatures up to 121 C (250 F). weatherford.com 

 


 

PRODUCTION

 

NEW ALGORITHM TARGETS OPTIMAL GAS INJECTION RATE

Determining the optimal gas injection rate for a well has traditionally been an inaccurate procedure, delivering an accuracy of only 8% to 15%. Apergy developed an algorithm designed to hunt for the optimal gas injection rate and continually tune it to ensure the well is operating within the optimal range. The Apergy algorithm is set up at the surface as part of the company’s controllers with a bottomhole pressure (BHP) gauge in the bottom of the well. The reading from the pressure gauge enables the monitoring of the BHP and the managing of the gas injection rate through the control valve, which increases or decreases the gas injection rate. To date, wells using this algorithm have experienced maximum BHP drawdown, which yields greater production and recovery from unscheduled downtime. apergy.com

PMM ELIMINATES INDUCTION LOSSES

Operators are looking for new ways to increase electric submersible pump (ESP) system efficiency and lower lifting costs. Baker Hughes, a GE company’s new Magnefficient permanent magnet motor (PMM) improves efficiency by lowering ESP system energy consumption. The Magnefficient PMM eliminates induction losses, lowering system power consumption by 20% and reducing motor power loss by as much as 67%. The Magnefficient motor has demonstrated positive results in the field and extended the applicability of ESPs into situations that weren’t previously practical. Eight PMMs have been installed in applications ranging from waterfloods and unconventional oil and gas wells in North America to high-temperature and mature fields in Latin America. Some of the units have been running continuously for more than 800 days, and each installation has achieved an efficiency rating of more than 90%, with no reported failures. bhge.com

SYSTEM PROFILES HYDROCARBON PRODUCTION IN A FRACTURED WELL

The latest technological advancement by Core Laboratories’ ProTechnics division addresses the industry challenge of accurately profiling hydrocarbon production in a well. FlowProfiler EDS provides an engineered delivery system to precisely place oil tracers with proppant into the fracture network. The carrier bead, chemically engineered to bond with ProTechnics’ tracers, provides an engineered delivery structure. The system is precisely injected throughout all proppant-laden fluid of specific stages during a completion. Available in 40/70 and 100 mesh, varied sizing aligns the technology with specific operator objectives and stimulation designs. Already widely utilized in diagnostic programs, FlowProfiler EDS is rapidly being adopted across all major basins in the U.S. and Canada. corelab.com 

MULTIPHASE FLOWMETER PROVIDES REAL-TIME FLOW MEASUREMENTS IN SHALE FIELDS

The modular, compact Roxar multiphase flowmeter provides inline, real-time flow measurements in shale fields and capital investment savings at the well pad of up to 50%. Through improved algorithms and a new operator interface, the meter is specifically designed for unconventional fields and can be used for flowback measurements, well testing and allocation. Other benefits include advanced field electronics and high-resolution sensors; flexible sizing for varying production rates; and no moving parts for reduced maintenance. The Roxar meter addresses challenges such as the need for real-time well monitoring and accurate flow rate and fluid information in the often unpredictable flow regimes of shale fields as well as the need for a smaller reduced footprint, minimal maintenance and lower costs. In a deployment on the Permian, an independent operator has seen significant capex savings from the meter in production infrastructure costs, more efficient well pad operations and accurate well allocation. emerson.com

ARTIFICIAL LIFT SYSTEM OFFERS BETTER VISIBILITY INTO OPERATIONS

Oil and gas producers are continuously looking to get the most from their existing assets and wellheads as efficiently and cost effectively as possible. Fortunately, new technologies and capabilities available in the digital oil field provide a means to do just that. A combination of low-cost sensors, onsite controllers, intelligent assets and information tools allow oil and gas producers to gather more data and have better control of their artificial lift systems. The Rockwell Automation OptiLift artificial lift systems, including the rod pump controller, virtual flowmeter and net oil computer, help producers realize three primary business benefits in their wellhead applications: better visibility into operations, optimized production and asset performance, and reduced operating costs. rockwellautomation.com

SERVICE IMPROVES OPERATIONS WITH NEARLY REAL-TIME CONFIRMATION OF DOWNHOLE EVENTS

The Schlumberger WellWatcher Stim stimulation monitoring service improves fracturing and acidizing operations with nearly real-time confirmation of downhole events that can affect oil and gas production but may not be evident from conventional surface pressure response. In multistage wells it is common to find only 60% to 70% of perforations or perforation clusters contribute to production. The causes of this mediocre performance vary from reservoir quality to completion and stimulation effectiveness. With minimal setup time and location footprint, the WellWatcher Stim service can verify actuation balls landing on a seat, ports shifting, fluid entering the reservoir and fluid diversion. This means operators can ensure each stimulation job is pumped as designed to optimize stage contribution. If the service determines that a zone is understimulated, the treatment can be pumped again immediately. Otherwise, the poor stimulation response might not be apparent until days or weeks later. slb.com 

EFFICIENCY IN GAS-LIFT OPERATIONS INCREASED

A new Digital Intelligent Artificial Lift (DIAL) gas-lift production optimization system from Silverwell is improving gas-lift operations through a data-driven on-demand approach, enabling more efficient production with less intervention. DIAL installations encompass fully qualified, tubing conveyed surface-controlled multirate gas-lift units, rated to 10,000-psi burst, 6,000-psi collapse and 125 C (257 F). Each unit includes up to six independently actuated orifice valves and onboard pressure and temperature transducers. DIAL eliminates uncertainties. It enables more production from enhanced lift efficiency to accelerate return on investment; less intervention with a reduction in opex and risk; more data through the increased insight afforded by multiple in-well sensors; and less uncertainty with the potential for improved production management decisions through the deployment of an integrated gas-lift optimization system. silverwellenergy.com

CHEMICAL ADDITIVE UNITS MIX MULTIPLE CHEMICALS PRECISELY, ACCURATELY

SPN Well Services, a Superior Energy Services company, provides chemical additive units for applications such as coiled tubing, workover, snubbing, drilling and acid pumping/mixing. These units have the ability to mix multiple chemicals precisely and accurately, while maintaining individual flow rates critical to the quality of the fluid system. Chemical additive units mix and pump at variable rates/pressures and feature twin centrifugal pumps with stainless components for corrosive chemicals, six variable rate chemical additive stations and two 10-bbl mixing tanks with mixing paddles. Utilizing a wireless mobile acquisition  system, all relevant data associated with fluid mixing and pumping is captured and multiple data streams provide duplicative backup, ensuring operators have access to all the vital information they require. spnws.com

IMPROVE PERFORMANCE OF ‘HUFF AND PUFF’ EOR IN SHALE OIL RESERVOIRS

The effective distribution of injected gas in multizone horizontal wells and the ability to keep the gas in the reservoir to maintain energy can greatly affect the recovery efficiency of EOR in shale oil. The use of advanced completions can improve the distribution of gas injection and control premature production of gas in the soaking period of the EOR process for shale oil wells. Passive inflow control devices are used to balance the distribution of gas injection along the length of the wellbore,  while autonomous inflow control devices (AICD) restrict the early back-production of gas and increase the contact time. As an active flow control device, AICDs deliver a variable flow restriction in response to the properties (viscosity and density) of the fluid flowing through it. tendeka.com

LONG-STROKE PUMPING UNIT ACCELERATES TRANSITION TO HIGH-PERFORMANCE ROD LIFT

The latest Weatherford Rotaflex long-stroke pumping unit helps shale operators to accelerate the transition to high-performance rod lift and even eliminate intermediate lift methods. All new for 2018, the unit adds numerous features that improve lift efficiency, including a purpose-built 350-series gear reducer and enhanced top drum. Even in the deep, high-angle or high gas-to-liquids wells that shale operators routinely face, the latest Rotaflex unit was redesigned to further increase uptime, reduce the total cost of ownership and streamline maintenance. With stroke lengths up to 366 in. (9.3 m), the unit increases system efficiency and energy savings, substantially lengthens sucker rod and downhole pump longevity, and reduces cycles, reversals and the risk of downhole failure. The design simplifies inspections and repairs, encloses moving parts and offers easy access to major components. weatherford.com