Intelligent completions were introduced over a decade ago to address completions and reservoir management challenges arising from highly-deviated, extended-reach, multi-targeted, or multilateral wells. Recent advances in exploration and drilling technology are enabling the oil and gas industry to target reservoirs with stratigraphic and depositional complexities in deepwater, subsalt, arctic, and other extreme environments, resulting in the need to develop a new generation of intelligent completion tools. These reservoirs also may be characterized by HPHT, extreme HPHT, or ultra-HPHT environments with multiple components contributing to the uncertainty of recovery.This paper describes how the requirements of current and future reservoir environments and a decade of operational experience have shaped the functional design and qualification of a new-generation Interval Control Valve (ICV) for intelligent completions. The new-generation ICV has higher pressure and temperature tolerances to cater to the new harsher environments while simplifying its operating mechanism and improving inflow performance and debris tolerance. The qualification program included metal-to-metal seal qualification, life-cycle testing, API 14A SCSSV class II-sand slurry based tests, flow coefficient (C v ) test, seal stack qualification, and erosion testing. Descriptions of each qualification test, acceptance criteria and test results that demonstrate the capability of the new generation of ICV to perform in severe service conditions are presented in this paper.Some field applications of the new-generation ICV are also presented. Technologies, such as real-time ICV position feedback, have further aided in maximizing efficiency. Finally, the paper outlines the operational limits of the current design and discusses the design enhancements planned for the next-generation ICV.

Intelligent completions and electrical submersible pumps (ESPs) are realizing greater oilfield acceptance because of their capabilities to improve recoveries, especially in multi-zone wells where production can be controlled and optimized without intervention. Previously, when ESPs had to be removed for routine maintenance, the whole completion had to be pulled, which would require significant time, risk, and cost. Now, an electrical disconnect tool exists that enables ESPs to be changed out without requiring the lower intelligent completion to be removed. This paper discusses the equipment and methodology recently used in a trial test offshore Brazil to reliably disconnect an ESP in the upper completion from the lower intelligent completion that had two interval-control valves (ICVs) and two dual-sensor pressure/temperature gauges. The trial test required the disconnect sub to be disconnected from the receptacle, then reconnected again, followed by an ICV and gauge function test to prove the reliability of the wet mate connector in the electro-hydraulic disconnect tool. This paper highlights the successful case history of the new disconnect tool installed in January 2013 in the Carapeba field, offshore Brazil. The paper will discuss the technical aspects of the concept, the well-planning details, completion procedures, installation lessons learned, and tool design improvements that will be adopted for use in future wells. This installation will initiate the use of electrical disconnect tools for upcoming intelligent completions involving ESPs, sub-surface safety valves, or long horizontal sections that may require the lower completion to be installed on drill pipe.

Intelligent completions were introduced over a decade ago to address completions and reservoir management challenges arising from highly-deviated, extended-reach, multi-targeted, or multilateral wells. Recent advances in exploration and drilling technology are enabling the oil and gas industry to target reservoirs with stratigraphic and depositional complexities in deepwater, subsalt, arctic, and other extreme environments, resulting in the need to develop a new generation of intelligent completion tools. These reservoirs also may be characterized by HPHT, extreme HPHT, or ultra-HPHT environments with multiple components contributing to the uncertainty of recovery.This paper describes how the requirements of current and future reservoir environments and a decade of operational experience have shaped the functional design and qualification of a new-generation Interval Control Valve (ICV) for intelligent completions. The new-generation ICV has higher pressure and temperature tolerances to cater to the new harsher environments while simplifying its operating mechanism and improving inflow performance and debris tolerance. The qualification program included metal-to-metal seal qualification, life-cycle testing, API 14A SCSSV class II-sand slurry based tests, flow coefficient (C v ) test, seal stack qualification, and erosion testing. Descriptions of each qualification test, acceptance criteria and test results that demonstrate the capability of the new generation of ICV to perform in severe service conditions are presented in this paper.Field applications of the second generation valve have shown additional operational benefits not even considered during the design. Technologies such as real time ICV position feedback have further aided in maximizing efficiency by enabling the use of downhole or surface positioning. Surface positioning devices can choke flow by varying ICV positions. The use of surface positioning enhances reliability by reducing the number of tools required downhole. Finally the paper outlines the operational limits of the current design and discusses the design enhancements planned for the next generation ICV. IntroductionAdvances in exploration and seismic imaging technologies have opened up new opportunities for large, deepwater field developments in the Gulf of Mexico (GoM), offshore Brazil, Asia Pacific, and offshore West Africa. The Lower Tertiary Wilcox trend of the GoM alone has over a dozen industry discoveries to date with world-class reserve potential. These discoveries are predominantly subsalt reservoirs at water depths of 5,000 ft to 10,000 ft, with reservoir pressures over 25,000 psi at true vertical depths of 25,000 ft to 33,000 ft. Reservoir temperatures are in the range of 250°F-300°F.With a broad range of heterogeneous reservoir gross intervals from 1,000 ft to 3,000 ft and permeability ranges of 2 md to over 50 md, these fields may not be efficiently developed with the well completions technology used in today's GoM, offshore Brazil, etc. Most of today's completion tools are not ...

Physical designs of Transaction I and II telephones and Transaction III terminal are described and illustrated. All three sets feature new card reader designs and a click‐disk switch design. These designs are described in detail. Use of these designs in Transaction sets has helped to meet performance, reliability, and cost objectives.