Integration into the Sandface Tool System for Gravel and Frack-Pack Installations with a Fiber Optics Wet-Mate Connector System

Abstract

Abstract Operators have always sought the capability to monitor pressure, temperature, and flow across the sandface in gravel and frack-pack (and stand-alone screen) completions in real time in order to optimize production, and gain advanced notice of remedial needs. In most sandface completions, the lower completion contains the screens, and the completion is performed in two stages: the service tool string is run first to perform pack operations, and the second stage "mates" the upper completion string to the lower completion. The unique capabilities of fiber optics sensing techniques such as Distributed Temperature Sensing, Point Pressure and Temperature, Array Temperature Sensing, and Distributed Acoustic Sensing can provide the desired production and reservoir information across the sandface. However, accomplishing this requires a fiber optics wet-mate connector system to link the fibers in the lower and upper completions. Weatherford had run a fiber optics wet-mate connector system in Oman in April 2005, and a key driver for the new connector system was to use a lower profile connector to maximize the production flow area with Halliburton's gravel and frack-pack completion technology. The design essentials for the 9 5/8-in. × 4 ½-in. to 5-in. system, and required field operations for successful deployment are described in the paper along with the development and qualification process performed in laboratory, and test well conditions completed in May 2013. These were to ensure that the two key challenges of alignment and debris management had been successfully resolved. The final System Integration Test (SIT) for qualification was run at approximately 3,000 ft, and witnessed by a major operator. Subsequently, a demonstration SIT in the same well was witnessed by multiple operators in November 2013. The mechanical and optical measurements taken during the qualification process will be presented to demonstrate that the desired production/reservoir information can be provided.