Swell Technology 4-1 Swell Technology Swell Technology Swell Technology is 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. HAL22167
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Swell T
echn
ology
Swell TechnologySwell Technology is 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.
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Swell Technology 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 390°F (200°C).
• 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.
4-2 Swell Technology
Swellpacker® Isolation System
The Swellpacker® isolation system 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.
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.
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 customer’s 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
End rings 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.
The Halliburton K2 end ring 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.
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Swellpacker®
Isolation System
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K2
End Ring
Swell Technology 4-3
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.
InstallationTo 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.
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
• 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