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The MaxForce® Flow Ultra-Kleen Perforating Technology was selected as a finalist for the 2015 World Oil Awards.

The MaxForce® Flow Systems consist of UltraKleen and Low Debirs Zinc, each with an increased flow area of 6¾-in. 18-spf. The increased flow area enhances both conventional and flux-based completion approaches. Maximizing the flow area reduces the pressure drop across the perforations and the effective force on the individual sand grains, resulting in less screen washouts and less potential for sand production. This is all without sacrificing fishing ability in heavy wall casings.

The high-pressure rating of the MaxForce Flow System is ideal for:

• Deep water
• Sand control completions
• Stimulation completions
• Gravel pack, frac pack, or high-rate water pack
• Natural completions

With a proprietary charge tube design, the 6¾-in. 18-SPF MaxForce® Flow Ultra-Kleen System family provides an almost debris-free operation, even in severe doglegs and high-angle wells. The 6¾-in. 18-SPF Big Hole MaxForce Flow Ultra-Kleen System helps ensure that debris created from shaped charges is minimized, containing larger debris pieces within the gun system for safe, clean perforating without sacrificing flow area. The system also reduces dynamic transient forces during the perforation event, which safeguards the completion and tubing-conveyed perforating string.

Benefits

• Has the lowest amount of debris that exits the carrier during and after the perforating event
• High-pressure rating that is suited for deep water
• Delivers high-flow area of 13.04 sq. in./ft
• Reduces dynamic transient forces during the perforation event
• Reduces risk of screen washout by reducing pressure drawdown and flow rate per perforation
• Reduces risk of sanding production due to drag from fluid or gas turbulence
• Reduces risk downhole for mechanical problems related to charge debris during stimulation treatments
• Shot phasing that limits stress contrast and helps prevent tunnel-to-tunnel stress failures
• Maximized gun size without sacrificing the ability to fish in heavier wall casings

Applications

• Provides an exceptional effective perforation solution focused on: – Deep water – Sand control completions – Stimulation completions – Gravel pack, frac pack, or high-rate water pack – Natural completions
• Can eliminate potential costs associated with sand production without mechanical segregation techniques
• Can eliminate potential issues associated with perforating debris

CASE STUDY

MaxForce® Flow Ultra-Kleen Gun System delivers unsurpassed flow area with lowest gun debris in the Gulf of Mexico

A Gulf of Mexico operator, facing a deepwater high-pressure well challenge, needed a perforating solution to perforate at bottomhole pressure greater than 21,000 psi (1,448 bar) at a depth of more than 30,000 ft (9,144 m) total vertical depth (TVD). Under these extreme downhole conditions, standard perforating solutions were not an option. The operator was concerned about the dynamic transient load that a gun system could exert on its completion string during the perforating event. The perforating system could not exceed the pressure limitations of other downhole tools and equipment. The operator also needed a gun system that produced maximum flow area and limited debris that could cause operational issues during the frac-pack operation.

The operator approached Halliburton for a solution. The Halliburton Global Engineering and Technology team designed and modeled a unique solution to meet these challenges. Halliburton’s innovative 6¾-in. 18-SPF Big Hole MaxForce® Flow UltraKleen Gun System, designed with Dynamic Transient Control, was the solution. The gun system is rated to 25,000 psi (1,724 bar) and 425°F (218°C). It was designed for optimum performance in deepwater and high-pressure wells, allowing Halliburton to perforate the well within the limits of operator’s requirements. With a confirmed official API 19B Section 1 and 5 Test, the MaxForce Flow Ultra-Kleen Gun System leads the industry both in hole size and lowest debris. It delivers a high-flow area of 13.04 sq. in./ft, in a 97 /8-in 62.8 lb/ft Q-125 casing test, and lowest debris of 16 g/ft, which allows for the best frac-pack completion. The gun’s system design prevents shock loading from dynamic transient forces during the perforation event, which protects the completion and tubing-conveyed perforating string.

The perforated interval was from 30,710 ft (9,360 m) to 30,815 ft (9,392 m) MD, and had a temperature of 245°F (118°C) and pressure of 21,174 psi (1,460 bar). The MaxForce Flow Ultra-Kleen Gun System fired and functioned successfully. After the guns fired, the well was monitored and reversed out. No debris was spotted on the shakers. The sump packer was retagged at the exact original tag mark on the pipe. With no indication of movement and fill, the gun was pulled out of the hole. The completion and tubing-conveyed perforating string were retrieved to surface with no incidents (i.e., sticking, bending, etc.), with physical confirmation of all shots fired and minimum lost debris as designed. The entire job was also completed with no nonproductive time (NPT) or safety issues.

Through effective communication and planning with the operator, the job was successfully executed as proposed. The MaxForce Flow Ultra-Kleen Gun System successfully perforated the well under these extreme conditions, while meeting all the client’s expectations and addressing all their concerns.

CHALLENGES

• With its bottomhole pressure greater than 21,000 psi (1,448 bar) and perforation depth at more than 30,000 ft (9,144 m) TVD, the operator was concerned about exceeding pressure limitations and the dynamic loading of other tools and equipment downhole during perforation event.
• Operator required a gun system that would produce maximum flow area and, at the same time, be debris free to enhance and ensure the fracpack operation could be completed without NPT.

SOLUTIONS

• The 25,000 psi (1,724 bar) 6¾-in 18- SPF Big Hole MaxForce Flow UltraKleen Gun System was utilized. This system was developed for optimum performance in deepwater and high-pressure wells, and designed with Dynamic Transient Control to address dynamic loading concerns.
• The MaxForce Flow Ultra-Kleen Gun System was selected for its delivery of the maximum flow area and lowest debris in the industry, ensuring the best environment for frac-pack completions.

RESULTS

• The gun system performed as designed to prevent shock loading from dynamic transient forces during perforation event, safeguarding the completion and tubing-conveyed perforating string.
• Confirmation of the bottomhole assembly (BHA) was done upon retrieval from the wellbore. No incidents (i.e., sticking, bending, etc.) occurred. No debris was spotted on the shakers. The entire job was completed successfully as designed with no NPT or safety issues.