New system targets three main areas to improve operational efficiency and reduce operating cost: safety, reliability, and inventory and cost control.
In an operating environment governed by ever greater levels of efficiency, the industry is pushing to continu- ously lower the total cost of operations while simultaneously enhancing safety.
DynaStage is an entirely new concept for perforating and incorporates groundbreaking addressable and selec- tive technology and an improved mechanical design that completely eliminates potential human error. The system operates more efficiently than traditional per- forating guns and, with its additional safety features, allows other wellsite operations to run in parallel during perforating. This results in improvements in perforation quality and performance reliability, fewer misruns and lower inventory. The DynaStage system has successfully completed operations in multiple basins.
The system targets three main areas to improve operational efficiency and reduce operating cost: safety, reliability, and inventory and cost control.
Safety
A simple, intrinsically safe design eliminates the risk of inadvertent detonation from any stray, DC or voltage. The addressable and radio-frequency-safe firing system is built on a low-voltage, digital communication platform proven to successfully initiate on command during more than 300,000 perforating operations without a single safety incident.
This technology enables verification during all phases of the operation. All electrical connections and com- ponent functions can be checked and full functionality confirmed during assembly and pumpdown operations. Surface explosive handling and arming can be conducted in less time and in parallel with other operations. The design eliminates the need to hold the gun system at shallow subsurface depth during simultaneous oper- ations. Both factors reduce wait times at the wellsite.
Reliability
The design of the electronic system and simplified mechanical field assembly virtually eliminates misruns. DynaStage targets a 99.9% operating efficiency. One major design improvement covers the detonator to sys- tem assembly and wiring.
A traditional detonator is assembled into a sub requir- ing wiring and ballistic connections and a port plug with O-ring seals. Wiring connection issues and leaking O-rings are among the most common causes of perforating gun misruns. With DynaStage the detonator wires have been replaced with an injection-molded connector, eliminating crimped wire connections and the associated risks of wir- ing damage and poor electrical connections. The detonator also was relocated to the gun body, which allows the use of a much shorter, disposable perforating gun connector sub and eliminates the port plug. Field assembly is simplified to inserting the plug-and-go detonator and threading the guns together (See image).
Inventory, cost control
The DynaStage gun modules are shipped to the wireline customer as specified and fully assembled, except for the detonator. All preshipping operations are performed in the DynaEnergetics gun assembly line, which has been optimized for high-volume assembly, automated quality control inspection and electrical verification of the final product. The production line process mitigates the risk of human error typical in the manual redress, cleaning, wiring and assembly of conventional perforating guns. This new industry model reduces the wireline service provider’s inventory and overhead.
More than 7,500 guns have been run since the introduction of the 31⁄8-in. DynaStage system during the summer of 2015. A 23⁄4-in. system recently was released to support the trend toward smaller gun sizes, and a 33⁄8-in. system currently is being finalized.
Each stage run with the DynaStage system cut an average of 32 minutes of completion time. Improved downhole reliability also was achieved, with an average decrease in nonproductive time of 2 hours per 100 runs. A significant part of the improved reliability was a reduced need for onsite user interactions that often lead to electrical issues and misruns in conventional wired perforating systems.
The use of DynaStage resulted in fewer days on location and operator cost savings as high as six figures. The production success rate has been one mis- run per 420 runs for a perforating efficiency of 99.41%. DynaEnergetics continues to refine the system components, assembly process and operating procedures with the ultimate objective of attaining the 99.9% plus efficiency rate and zero safety incidents.
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