Wireless Control and Monitoring; The Next Generation Downhole Completions

Abstract

Abstract Dynamic downhole well production management has been historically limited to cabled intelligent completion systems. This paper introduces a new technology that provides wireless communication, control, monitoring and autonomy while being retrofittable for existing downhole well completions. The technology has been field deployed in three variants to address different challenges: remediate failed safety valves, restore downhole monitoring and provide flow control at a given interval. The field application of this technology has proven the feasibility and long-term performance of this wireless command, control and monitoring system under downhole conditions. It has also demonstrated the cost and CO2 savings of retrofitting versus recompletion. The tool is designed to be deployed or retrofitted in an existing completion and record downhole data, responding to wireless commands from surface or operating autonomously in response to a change in a well's flowing conditions. Most variants were deployed via slickline intervention with the option to retrieve later in the well life. The intelligent safety valve is a fully autonomous system, API14A qualified, device that enables the safe production of wells with failed downhole safety valves. This valve was installed in both oil and gas wells to restore production under a variety of challenging production conditions. The intelligent control valve was installed to provide commanded flow control of a long lateral with a late life risk of water. The wireless gauge was trialled for retrofit to replace a failed downhole gauge and allow continuous downhole measurements in wells without existing gauges. We will review the field applications of this wireless technology and discuss the challenges overcome through application. The production of five wells was restored by retrofitting the wireless intelligent safety valve. The valve successfully operated under a variety of challenging conditions including cyclic loading, gas lift, velocity string and slug production. The intelligent control valve successfully actuated to provide zonal isolation on a subsea well without intervention. The wireless gauge provided pressure, temperature and gauge diagnostics on a daily basis while recording shut-in data at high rates to capture valuable transients during well shut in. This data was compared with existing downhole gauges as part of a trial to validate the technology. The retrofit ability of this technology significantly reduced environmental impact and overall project costs. This is the first publication that describes widespread application of this technology to address industry challenges. This is one of the only wireless control and command technology that does not rely on repeaters. The two-way communication method utilizes pressure perturbations in the production fluids to transmit downhole data or tool commands. The communications protocol allows for communication with multiple devices in the well and independent of depth.