Check-valve ICDs save 20 hours of rig time and approximately USD 1 million

An operator deployed sand screens equipped with ResFlow™ check-valve ICDs to maximize operational efficiency during a stand-alone screen completion. The check valves eliminated the requirement for a washpipe for circulation, cleanup, and openhole hydraulic packer setting, saving significant rig time and costs.

Openhole hydraulic packer setting complicated screen completion

An operator offshore Canada had planned to complete an openhole interval of 4,134 ft [1,260 m] with LineSlot™ direct-wire-wrapped screens equipped with inflow control devices (ICDs). Two openhole hydraulic packers would provide critical zonal isolation.

In preparation for setting the packers, polished bore receptacles (PBRs) had to be installed above and below each packer. Subsequently, isolating and setting the packers required a dedicated run with molded seal assemblies and washpipe before applying pressure from surface.

Check-valve ICDs minimized rig time, cost, and risk

To streamline operations, SLB proposed using ResFlow check-valve ICDs, which eliminate the need to deploy washpipe. The check valve assembly—comprising a ball, plate, and ceramic nozzle—can be dropped in to replace a standard ICD nozzle assembly within the ICD housing without any design changes to the screens.

During procedures such as fluid circulation to the toe of the well or application of pressure in the string to set hydraulic packers, the check valve helps ensure completion string hydraulic integrity. The ball is pushed against the nozzle, closing the check valve and preventing outward flow from the basepipe into the annulus through the nozzle.

Later, when the pressure is released or pumping stops, the ball drops back onto the plate. The ICD controls the flow of hydrocarbons during production in the same way as a conventional ICD. Eliminating washpipe reduces costs and improves operational efficiency, safety, and logistics.

Operator achieved zonal isolation and saved about USD 1 million

The 4,682-ft [1,427-m] lower completion was run in with 31 screen joints, each equipped with four check-valve ICDs. Subsequently, 5,000-psi [34-MPa] pressure was applied to set the packers; the ICDs successfully held the pressure.

The streamlined process saved the operator 20 hours of rig time and approximately USD 1 million. This was the first application of ResFlow check-valve ICDs in setting openhole hydraulic packers. The operator has since used this solution in a second well in the same field.