WELL INTEGRITY TESTING
Our purpose built pumping and measurement systems provide the customer with vital information on the integrity of their wells. The systems are supplied to meet the customer’s individual requirements. These range from simple pressure recording systems to complete pumping and well integrity diagnostics packages.
- Annulus liquid levels
- Annulus top up volumes
- Tubing to annulus, annulus to annulus leak rates
- Annulus fluid identification/origin
- Annulus gas cap volume
- Annulus gas leak off rate
Liquid levels are established using our digital Echometer. The meter consists of a microprocessor controlled dual channel amplifier/recorder and a gun/microphone wellhead attachment. The gas gun generates an acoustic pulse which travels through the wellbore gas. This pulse reflects from tubing collars and the liquid level. The microphone converts acoustic reflections to an electrical signal.
ANNULUS TOP UP VOLUMES
Our purpose built containerised packages provide a complete one stop shop solution for annulus top up and testing operations. The IR air driven compact pumping system (approx. 1m x 1m x 1m) has been specifically designed for annulus top up operations. The ATEX certified unit has high volume, low pressure and high pressure, low volume outputs. Other pumping systems are available for higher pump rates.
Liquid treatments including biocides and oxygen scavenger are injected via a chemical injection pump or by pre-mixing. Chemical injection dosing can be regulated and automated depending on the specific requirements of the customer.
The metering skid comprises of multiple flowmeters and pressure transducers records volumes, rates and pressure of each specific job. Generally, one skid is used to record the volume and rate injected into the annulus and a second skid is used to establish returns by measuring the flow rate, density and pressure of the annulus fluid. A sample port on the return line allows access for fluid sampling where annulus fluid identification and origin analysis is required.
TUBING TO ANNULUS, ANNULUS TO ANNULUS LEAK RATE DETERMINATION
The leak rate is established by recording tubing head and annulus pressures simultaneously during the integrity test. The pressures can be recorded in memory mode or real time using the IRL hazardous area logger. The logger is also used to record flow rate and density during the annulus top up operation.
ANNULUS GAS CAP AND BLEED OFF MEASUREMENT
Accurate annulus gas cap volumes and gas bleed off rates are established using the IR annulus gas metering skid. The IRL designed equipment can measure very low gas rates at low pressures and higher gas rates at high pressure. Annulus gas cap volumes are calculated using the rate, volume and density of the measured fluid.
WHITL / KRONOS TM
In much the same manner as the chart recorder revolutionised pressure testing, the WHITL will change the method in which test and monitoring operations are undertaken.
This ATEX zone 0 rated equipment package including intuitive software means that significant time savings can be made across all aspects of the test or monitoring operation.
Tests can be preconfigured prior to mobilisation offshore and stored in the display unit thus reducing set up time and simplifying dataset identification and reporting. When at the well the compact WHITL is easily deployed with the connection of 4 hoses and a single cable. The hand held battery powered unit displays the inputs from 4 pressure transducers and a single flow meter. The unit displays instantaneous confirmation of pressure and trend identification both graphically and numerically. The included flow meter input allows for the logging of inflow rates and top up volumes for confirmation of test parameters. The integral battery pack is sized to allow over 12 hours of operational time with a recharge time of less than 12 hours to give sufficient capacity to cover an entire shift without the need to recharge or power down to conserve battery power.
The accompanying software package reduces the time required to interpret data and produce a report. The use of “wizards”, guide the user through the download and report generation process. With provision to allow technician comment, indication of a pass or fail and a date/time stamp the WHITL transfers a pdf report and an excel spreadsheet of the complete date set. Further supporting the traceability of the test process is a protected empirical data file, detailing the test data, calibration details and date/time information to show that report data is authentic.
The arrival of the WHITL brings with it a new level of insight and ease to testing. Its adaptability and intuitive use makes the WHITL the ideal instrument for multiple testing and monitoring functions. Its rugged design makes it equally at home in a work shop or a well bay allowing technicians to use a single system in any work environment.
- WELL INTEGRITY
- WELLHEAD MAINTENANCE
- EQUIPMENT CERTIFICATION TESTING
- CONDITION MONITORING
- PRESSURE TESTING
- ANNULUS INTEGRITY TESTING
- INFLOW TESTS
- ATEX/IECEX RATED Ex ia T4 IIB (INTRINSICALLY SAFE ZONE 0)
- BATTERY POWERED > 12 HOUR CAPACITY. RECHARGE TIME < 12 HOURS
- MONOCHROMATIC, BACKLIT DISPLAY SCREEN FOR USE IN LOW LIGHT ENVIRONMENTS
- NUMERIC & GRAPHICAL DISPLAY OF MEASURED INPUTS
- 4 PRESSURE CHANNELS (AVAILABLE PRESSURE RANGES FROM 0-3 BARG THROUGH 0-700 BARG). ACCURACY OF 0.05% FS & RESOLUTION OF 0.02% FS
- FLOW METER INPUT WITH FLOW RANGES UP TO AND OVER 3000 LITRE/MIN. ACCURACY & RESOLUTION DEPENDANT ON METER SELECTED
- UP TO 100 TEST CONFIGURATIONS STORABLE WITHIN DISPLAY UNIT
- LOGGING SAMPLE RATE AT 1 SECOND AND DISPLAY UPDATED EVERY 3 SECONDS. INTERNAL STORAGE FOR OVER 1 YEAR OF DATA
- DISPLAY UNIT WEIGHT 1.5KG & TOTAL PACKAGE WEIGHT LESS THAN 25KG
- INTUITIVE OPERATION
- ACCOMPANYING SOFTWARE FOR TEST CONFIGURATION, ANALYSIS & REPORTING
- TRACEABLE ENCRYPTED DATASET
- GENERATES PDF FORMAT REPORTS ALONG WITH EXCEL DATA SET
The introduction of KronosTM software to the WHITLTM hazardous area data logger is the next step in the evolution of pressure testing. The system maximises the efficiency of the testing process by eliminating the reliance on “Rule of Thumb” practices. The auditable results from KronosTM defines whether a pressure test meets the acceptance criteria of the equipment under test. Additionally, an absolute pass/fail result means that there is no requirement to repeat the test.
The KronosTM test configuration function provides a means for test characteristics to be programmed based on the requirements of the equipment under test.
Max Press. Loss
Max Press. Build Up
Amount of averaging applied during pumping operations to smooth out pump discharge spikes
Once created, test configurations are saved in a database for future use and can be edited as requirements change. KronosTM also brings a dedicated pumping mode with adaptable smoothing to remove pressure and flow spikes associated with certain pump configurations.
KronosTM can simultaneously monitor 5 inputs, 4 pressure and 1 flow, with each channel running different test types. In operation the WHITLTM / KronosTM shows the technician test status and gives immediate feedback on when a test is active and if it will pass or not. A clear indication is provided for a positive test, in the event of a test failure the system rearms to allow the option of repeating the test.
Test information is recorded and input directly into the test reporting software upon conclusion of operations. Test type, parameters, status, start/finish pressure and times are all displayed for confirmation. Reports provide a numeric and graphic representation of testing and are output in a protected .pdf & Excel compatible format for ease of distribution.
APPLICATIONS FOR WHITLTM & KRONOS TM INCLUDE:
- WELL INTEGRITY
- WELLHEAD MAINTENANCE
- EQUIPMENT CERTIFICATION TESTING
- CONDITION MONITORING
- PRESSURE TESTING
- INFLOW MEASUREMENT
- INFLOW TESTING
- PUMPING OPERATIONS
- FLUID TRANSFER
- BOP TESTING
- API 53 PRESSURE TESTS
- COMPLETION VERIFICATION & TESTING
- WELL WORKOVERS
We have identified opportunities for improvement in the provision, operation and installation of measurement equipment. Historically, measurements have relied on readings taken from level indicators, stroke counters, chart recorders and basic flowmeters. IRL introduced new technologies to improve accuracies and to record data.
The focus of our application engineering team is to source technologies, improve upon existing practices of measuring process variables and bring innovation and improved efficiency to existing methods of measurement. The team have designed and executed operations across the whole spectrum of well intervention from chemical injection, downhole leak rectification to annulus gas cap bleed off/top ups. Beyond this, operations have been successfully performed in the purging of hydrocarbons from subsea umbilical lines and the installation of temporary rig board water supplies.
We have made significant advances in the field of downhole leak detection and sizing through static pressure modelling analysis using only surface measurement instrumentation.
LEAK SEALING TECHNOLOGIES
SEALMAKER SERVICES – LEAK SEALING TECHNOLOGY
Our sealants activate based upon pressure differential and shear within a leak site, causing the chemicals to transform from a liquid to a solid, within the leak point, repairing the system to full operational capacity quickly, efficiently and permanently.
Solutions are designed to seal a large number of leak profiles including, well head, hanger, tubing, casing, packer, umbilical and pipelines. Each leak profile is independently assessed to determine viability. If the leak can be sealed a solution is engineered and applied to enable the client to continue operations quickly and efficiently.
The sealant solution activates with differential pressure generated at the leak site, the excess solution remains in liquid form within the system or until it is flushed. The shear effect generated by the pressure differential causes fibrillations that knit together, bonding with the inner surface of the leak site and creating a chemically resistant seal. Inert to production fluids, the seal is capable of withstanding pressures up to 15,000 psig bi-directionally at temperatures of up to 5000 F (2600 C).
Adjusted to suit the application, Intervention’s leak sealing solutions are available in three forms.
The standard form is a flexible high strength dynamic sealant.
CRYSTALLINE CASING REPAIR SYSTEM
The Crystalline Casing Repair System (CRS) has a high leak rate capability forming a solid mass at the point of differential, (the leak site), allowing for normal production operations.
Enviroplug is a derivative of the standard form that provides a self-displacing highdensity micro molecular sealant.
Intervention work closely with the client using current and historical data to assess the leak profile. Once assessed and validated Intervention can deploy a team of qualified personnel and equipment to implement an engineered solution to seal the leak.
- Chemically inert to production fluids and downhole chemicals
- High strength seal capable of withstanding pressures bidirectionally up to 15,000 psig
- Suitable for temperatures up to 5000 F (2600 C)
- Flexible and dynamic
- Restores integrity to full operational condition
- Restores lost production safely and efficiently
- Dramatically reduces work-over costs
Whether the operation is subsea or at surface our wide range of pumping equipment will provide the most efficient and cost-effective solution for our clients requirements.
For all types of pumping operations, our in-house engineering team will plan and execute your job from start to finish. Furthermore, with IRL’s reputation as the premier flowline and flow measurement provider you can be sure to receive a high quality service.
ANNULUS TOP-UP AND TESTING UNITS
Intervention’s annulus top-up system for annulus integrity testing utilises our air driven dual pump system and purpose-built chemical injection pumps. This allows us to inject and mix your top-up fluid on site saving clients on costly chemical transportation.
Intervention can also monitor the wellhead and tree test ports throughout annulus top-ups to detect any anomalies in the tubing/casing hanger seals.
This combined with the required metering, recording and measurement package for each specific job provides the complete solution for your annulus integrity testing operations.
SCALE INHIBITOR/TREATMENT SYSTEMS
Scale build up can block flow by clogging perforations and can form a thick lining in production tubing. There may also be the potential to coat and damage down-hole completion equipment such as safety valves and gas-lift mandrels.
Intervention’s diesel and electric driven, high pressure, reciprocating plunger pumps are designed and built for hazardous area zone 1 & 2. The pump packages are designed to deliver fixed or variable flows at a range of pressures allowing IRL to meet a large variety of treatment requirements.
Intervention’s fleet of high rate pumps are ideally suited to performing injectivity trials on water injection wells.
Either static or multi rate testing can be carried out using our zone 1 & 2 electric or diesel driven pumps which are ideal for these types of tests.
Coupled with IRL’s market leading experience in flowmetering and datalogging we can provide the ideal package for injectivity testing.
TEMPORARY SERVICE WATER PUMP SYSTEMS
Our temporary service water pump systems can be tailored to fit your exact needs and are mounted in DNV frames. Intervention’s systems are capable of lifting high volumes of water from sea to deck level and are suitable for all types of offshore structures.
ULTRA LIGHTWEIGHT MODULAR TRIPLEX PUMPING SYSTEM
Pumping and well integrity operational requirements often fall between the flexibility of pneumatic driven pump units and the high pressure/high rates delivered by cement pumps.
Intervention Rentals have developed an ultra lightweight compact modular fluid pumping system. The system is capable of delivering fluid at over 3 BPM and pressures of 5600 PSI with a max lift weight of 1.5 Tonnes per skid (2 skids only). The modular ATEX pump system comprises of a lightweight diesel power pack and a triplex pump. An electric submersible pump can easily be added to the system for sea water operations. The rates available from the system allow top up operations to be completed considerably faster than if using pneumatic pumps. Packaging the engine and pump in individual skids reduces the lifting weight to 1.5 Tonnes each. The unit’s innovative fluid recycling system means that delivery rate and pressure can be controlled individually giving previously unattainable levels of control from a diesel pump. This control and rates available allow it to be used for well kill operations at a rate of 2 BPM at 1650 PSI. Further expanding this versatility is the ability to change the pump plungers in the field to tailor the delivery characteristics to a variety of tasks.
Our submersible units can be used to transfer high and low viscosity fluids from subsea pipelines, storage cells and voids. The fluids are pumped to storage tanks on Intervention vessels or platforms prior to filtration operations and subsequent disposal. Each system is custom built to meet the customer’s requirements and can be operated remotely from a well intervention vessel or platform.
The pumps are capable of lifting fluid with viscosities of over 6000 centipoise from the seabed to a designated storage facility on surface. Pumps are controlled by specially designed hydraulic power packs which allows the operator to regulate the flow rate.
As part of our bespoke approach Intervention can also provide all the surface hardware required for transferring fluid to the tanks including, hoses, reels, flowline, chokes, valves, tanks and hydraulic hose cutters.
IRL are known as the go to company for intervention flow measurement. Our highly accurate flow meter calibration facility allows us to verify the performance of our flowmeters. For pumping operations we can offer accurate volumetric and fluid density measurements by using our range of flow measurement equipment. IRL can offer solutions to most flow measurement applications including mud, slurry, brine, oil, water, chemicals, natural gas, nitrogen and compressed air.
SUBSEA ANCILLARY EQUIPMENT
IRL provide a range of stand alone equipment on a rental basis, for example subsea pressure gauges, SPAMM’s, crossovers, high pressure hoses and flowline equipment.