Optimum Upper-Completion System
Discover premium performance Optimal performance for the most extreme conditions
Drilling
Evaluation
Completion
Cased-hole completions Production
Intervention
• • • • •
Downhole control valves Flow control Hydraulic flow control Packer systems Safety systems
Optimax surfacecontrolled subsurface safety valve
Discover the Optimum upper-completion system When the stakes are high, count on Weatherford to deliver. From the high pressures and high temperatures encountered in deepwater to the corrosive conditions of natural gas storage wells, extreme environments can adversely affect completion equipment, undermine safety and necessitate costly workovers. Drawing on more than three decades of cased-hole completion experience, we developed the Optimum upper-completion system to mitigate the elevated risk, and potentially expensive consequences, of performance failure in such harsh environments.
OptiPkr™ removable production packer
Leveraging advanced design features The Optimum upper-completion system features premium components designed to withstand extremities and to work in tandem with one another. Interventionless completion design. Our system incorporates the groundbreaking radio-frequency identification (RFID) operated setting module that uses radio transmitters and receivers to control packer setting, as well as the opening and closing of sleeves, which reduces cost and enhances safety. Modular system. From modular packers and safety valves to flowcontrol devices, each component works in-sync to provide the maximum results. In addition, we offer several deployment and setting methods, customizable metallurgies and elastomers, and pressure and temperature variations—all ensuring that the design is custom-built for your wellbore.
Uniset® flow control
OptiSet valve
OptiSleeve sliding sleeve
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© 2011 Weatherford. All rights reserved.
OptiBarrier isolation valve
Optimum Upper-Completion System
Engineered for premium performance Discover the difference our Optimum upper-completion system and our completions expertise can make on your toughest wells. Our premium system is suited for various applications including but not limited to: Deepwater. As operations continue to move into deeper water depths that are further from shore, the challenges have become more complex geologically and logistically along with the continued need to focus on safety and environmental concerns. Operators need to complete wells quickly with reduced nonproductive time. Today’s high-cost deepwater projects require the reliability of the Optimum upper-completion system and its capability to adapt to changing reservoir conditions with minimal intervention. Gas-storage wells. The Optimum upper-completion system can withstand the corrosive conditions in gas-storage wells and the extra stress caused by the cyclical nature of gas-storage projects. From our large-bore tubing-mounted safety valve to the robust large-bore premium OptiPkr™ production packer to the OptiSet interventionless packer-setting valve, each component is designed to work together to ensure life-of-well performance. High-H2S/CO2 environments. The presence of hydrogen sulfide (H2S) and carbon dioxide (CO2) and the corrosive nature of these environments greatly increases operational risks, including the health and safety of workers, communities and the environment. The Optimum completion system’s metallic components and elastomers are designed for reliable service and to endure the chemicals and processes required to complete and produce wells in these harsh environments. High-pressure/high-temperature environments. The hotter and the more pressure in the wellbore, the need for reliable completion equipment increases. With the Optimum system’s premium components and certified pressure and temperature ratings at or above 10,000 psi (69.9 MPa) and from 350° to 650°F (177° to 343°C) in some cases, you can be assured that the Optimum system improves reservoir recovery. Unconventional resource plays. From heavy oil to gas shale, the Optimum upper-completion system has the performance envelope to provide the returns you expect.
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Designed for the life of the well
The Optimum upper-completion system optimizes casedhole completions and life-of-well performance in even the most extreme environments—providing multiple benefits, including but not limited to the following. Long-term reliability. The use of premium upper-completion components designed to work together in an integrated system minimizes the risk of performance failure and the potentially costly consequences. Greater efficiency. The system’s durable design and the capability to procure all of your upper-completion components from a single source contribute to operational efficiency. The modular design enables standardization, thus reducing inventory and lead times. Reduced costs and enhanced safety. The system’s optional RFID-enabled technology remotely actuates downhole tools. A radiotransmitting tag is dropped down the tubing and communicates instructions to various tools in the completion string, eliminating the need for well intervention, which controls completion costs and preserves asset values. In addition, the interventionless completion design minimizes personnel requirements, further reducing risk and enhancing safety.
Maximized ROI. Added together, these benefits can significantly improve your bottom line during the course of a well’s life.
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© 2011 Weatherford. All rights reserved.
Optimum Upper-Completion System
Weatherford has two of the largest research‑and‑development (R&D), testing and training facilities in the industry. Based in Houston, Texas, USA, our Technology & Training Center houses the world’s most advanced safety-valve engineering lab and three hot cells that simulate downhole conditions. Our Aberdeen facility is Europe’s foremost research, testing and development center for offshore well services. This facility includes two fully operational drilling rigs and test boreholes.
© 2011 Weatherford. All rights reserved.
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Value-added expertise Backed by Weatherford’s strong commitment to internal training and research and development, we align our service performance to your business drivers. Whether the objective is safety, economics, operational efficiency or all of the above, our global team of completion specialists is well equipped to support your completion operations. Highly trained personnel. Our efforts to provide you with valueadded completion expertise begin with hiring talented engineers and support personnel, but they do not end there. We provide our completion specialists with ongoing classroom training to supplement their field experience. Commitment to excellence. To ensure the safety of our personnel and clients, we encourage a culture of excellence through our Enterprise Excellence Process (EEP). Our EEP addresses everything from total technical integrity assurance for product/service delivery to continuous process improvement in our day-to-day activities with our clients. Collaborative approach. Recognizing the important role that collaboration plays in the success of a project, we work closely with your completion teams to develop a thorough understanding of your wells and objectives. We have completions engineering teams in the Eastern and Western Hemispheres to provide more localized support. Also our dedicated Premium Completion Center in Houston, Texas, serves as a global resource for our completion specialists in the field. Project execution and management. Quality, reliability and efficiency are built in through a global network of Weatherford manufacturing and services facilities. While at the wellsite, installation success comes from the knowledge and the experience that only an industry leader can provide. Our operational project management system provides the structure for applying this experience with safety and efficiency. Research and development. With one of the strongest patent portfolios in the oilfield services industry, Weatherford is committed to enhancing existing products and to developing new ones. Our global network of R&D facilities brings you state-of-the-art completion technology and custom-engineered equipment. Our R&D efforts related to the Optimum upper-completion system are ongoing, and we look forward to unveiling new design features as they materialize.
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© 2011 Weatherford. All rights reserved.
Optimum Upper-Completion System
Discover premium design The Optimum system consists of an integrated array of highly durable upper‑completion components, including an interventionless removable production packer, subsurface safety valve, multiple downhole control valves and flow-control equipment.
Optimum Upper-Completion System OptiPkr™ removable production packer
OptiSet valve
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Large-bore removable packer No mandrel movement during packer setting Interventionless setting modules Modular design to meet operational objective ▪▪ Qualified to ISO 14310 V-0
▪▪ Holds pressure from above for interventionless packer setting ▪▪ Self-filling ▪▪ Capable of multiple-pressure cycles
Optimax series subsurface safety systems
OptiSet FL isolation valve
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▪▪ Minimizes fluid loss to the formation
Industry-leading reliability Nonelastomer rod-piston design Tubing and wireline retrievable models Ultradeep set and slimline version available
OptiBarrier isolation valve ▪▪ Contains fluids during completion ▪▪ Unique, opposing dual-curved flappers ▪▪ Bidirectional sealing
OptiSleeve sliding sleeve
Uniset® premium flow controls
▪▪ One connection to minimize leak paths ▪▪ Chemically inert nonelastomer seals for exceptional sealing in hostile environments ▪▪ Available in up-to-open or down-to-open
▪▪ Simplicity of design eliminates the need for complex manipulation downhole ▪▪ No-go principle minimizes the taper effect
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Production packer system OptiPkr™ removable production packer system. Weatherford’s OptiPkr production packer is designed for maximal flexibility and durability. It offers the robustness of a permanent packer, while maintaining the flexibility of a retrievable packer. Tested to ISO 14310-V0 standards, the highly modular OptiPkr system can handle extreme downhole pressures and temperatures. It is a removable (for higher tensile loads) production packer that can be converted from hydraulic to hydrostatic, to RFID-set, as needed. In addition it is significantly shorter than more conventional retrievable packers, which helps reduce risks in highly deviated wells. The OptiPkr packer is also ideally suited for subsea environments, in which packer reliability is critical. With few components, its simplicity further enhances reliability. RFID technology. Available with the OptiPkr system, Petrowell’s RFID technology uses small, encoded tags and downhole readers to automate packer functions. As such, it can render the OptiPkr system truly interventionless, enhancing efficiency, minimizing personnel requirements, and consequently reducing cost and risk.
Seals anchored
Seals floating
Thru-tubing cut extension
No-seals premium threads
Shear-release ShearShearShearShearShearmodule Release Release Release Release Release Module Module Module Module Module
ShearShearShearShearRelease Release Release Release Module Module Module Module
OptiSet OptiSet OptiSet OptiSet OptiSet OptiSet Packer-Setting Packer-Setting Packer-Setting Packer-Setting Valve Packer-Setting Valve Valve Valve Valve valve
OptiSet OptiSet OptiSet OptiSet Packer-Setting Valve Packer-Setting Valve Valve Packer-Setting Valve Packer-Setting
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© 2011 Weatherford. All rights reserved.
RFID module
Hydrostatic module
Intervention set
Optimum Upper-Completion System
600
Number of TRSSSV2 Failures
500 400 300 200
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Middle
With the best mean time before failure (MTBF) rate in the oil and gas industry, Optimax valves are tested to standards that exceed API 14A, helping ensure their reliability in the field.
Consolidated Service Life (Valve Years)
700
e/We
Our Optimax safety valves are available in tubing- and wireline‑retrievable versions with pressure ratings of 5,000, 10,000 and 15,000 psi (34, 69 and 103 MPa); sizes ranging from 2 3/8- to 7‑in. tubing; and a 350°F (177°C) temperature rating.
800
Europ
Optimax surface-controlled subsurface safety valves (SCSSVs). If surface controls fail, Weatherford’s Optimax series SCSSVs protect wellsite personnel, equipment and the surrounding environment. The Optimax series’ design incorporates nonelastomeric dynamic seals in a rod piston, providing longer well life and lower frictional forces. In addition, this unique design provides reliable service for a vast majority of well conditions.
To date, Weatherford’s Optimax valves have experienced zero failures in the field.1
Asia/ Pacif ic
Subsurface Safety Valves
Information is current as of December 2010. For a current list of our reliability statistics, visit our website at weatherford.com. Tubing-retrievable subsurface safety valve 3 Commonwealth of Independent States (formerly the USSR) 1
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Key Features Self-equalizing flappers. All Weatherford SCSSVs incorporate a metal-to-metal hard seat and a nonelastomeric resilient seal in the flapper designs. This dual seal provides redundancy in gas applications. The design of the optional through-the-flapper equalizing system is based on years of industry experience in the design and use of self-equalizing valves. Rod-piston design. The multiseal rod-piston stack incorporates metalto-metal seals for accurate sealing engagement and accurate control. The strength of the design ensures best-in-class service, reducing costs and providing longer well life.
© 2011 Weatherford. All rights reserved.
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Downhole Control Valves OptiSleeve sliding sleeve. Operated with a shifting tool, the tubing-mounted OptiSleeve sliding sleeve enables the opening and closing of apertures between the tubing and annulus to regulate flow from producing zones. Its applications include isolating producing zones during installation of the inner string, circulating completion or kill fluids, and injecting water into select zones for waterflooding. The OptiSleeve sliding sleeve’s nonelastomer seals and proprietary sealing threads help ensure sealing integrity in hostile environments. It is rated for temperatures up to 350°F (190°C) and pressures up to 10,000 psi (69 MPa). OptiBarrier isolation valve. The OptiBarrier valve contains fluids from above and below during completion operations. Its multiple functions include isolating the reservoir from completion fluids while running or retrieving the upper completion. Run in hole and tripped to close, the valve is equipped with unique, opposing dual-curved flappers that enable bidirectional sealing, thereby enhancing sealing integrity and providing a true downhole barrier. Simple and easy-to-operate, the unique flapper design offers a larger ID than conventional ball valve designs.
OptiSet valve. Installed below the packer, the OptiSet valve enables interventionless packer setting, enhancing operational efficiency and safety. Additionally, it is self-filling (tubing-to-tubing), which eliminates the need for—and cost of—a separate auto-fill sub. A built-in contingency feature, the valve’s APIqualified aluminum flapper can be dissolved with acid in the unlikely event that the shear mechanism fails, minimizing the potential for nonproductive time. OptiSet fluid-loss (FL) isolation valve. The OptiSet FL isolation valve is used to minimize fluid loss to the formation when completing a well. Like the OptiSet valve, the OptiSet FL valve is equipped with an API-qualified aluminum flapper that can be dissolved with acid as a contingency measure.
Flow Control Uniset® flow-control system. The core of the Uniset system is completion optimization. The system consists of multiple, highperformance flow-control accessories, including anti-blowout devices, equalizing assemblies, plugs and standing valves that optimize well-completion designs. The Uniset system uses nipples for simple, reliable, low-cost well completion and servicing, as well as bridge plugs for redundant well plugging later in the field’s life. The flexible working monobore design results in a well design that enables thrutubing retrievable bridge plugs to be run into the liner, yet still enables the use of landing nipples in the upper completions. The integrated system is rated for temperatures up to 400°F (204°C) and pressures up to 20,000 psi (138 MPa).
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© 2011 Weatherford. All rights reserved.
Optimum Upper-Completion System
© 2011 Weatherford. All rights reserved.
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Optimum Upper-Completion System
Discover premium performance
Discover how Weatherford’s interventionless Optimum upper-completion system can help you avoid performance failures in harsh environments. Contact your local Weatherford representative, or visit weatherford.com
weatherford.com
© 2011 Weatherford. All rights reserved.
7362.00
Weatherford products and services are subject to the Company’s standard terms and conditions, available on request or at weatherford.com. For more information contact an authorized Weatherford representative. Unless noted otherwise, trademarks and service marks herein are the property of Weatherford and may be registered in the United States and/or other countries. Weatherford products named herein may be protected by one or more U.S. and/or foreign patents. For more information, contact
[email protected]. Specifications are subject to change without notice. Weatherford sells its products and services in accordance with the terms and conditions set forth in the applicable contract between Weatherford and the client.
