Falcon* multistage stimulation system isolates zones and enables them to be treated continuously during matrix acidizing stimulation or hydraulic fracturing treatments in horizontal, deviated, and vertical wells. The system uses swellable or hydraulically set packers between zones for isolation. Balls with gradually increasing diameters are dropped from surface to enable treatment of successive zones.
Flow-through circulating and hydraulically actuated frac valves
The flow-through circulating valve enables circulation while the system is being run in the hole. When the liner reaches the desired position, a ball is dropped from surface and pumped down until it lands on the ball seat, permanently closing the circulation valve. Pressure can then build up to set the hydraulic packers and actuate the hydraulic frac valve, enabling communication with the first fracture zone.
Hydraulically set and swellable packers
Falcon system packer elements are engineered from a complex polymer suited for high-pressure applications to achieve sealing during stimulation as well as production. Hydraulically set packers use pressure to activate a positive-lock mechanism that expands the packer element, sealing against the formation.
ResPack* swellable bonded-to-pipe packers are designed to swell on contact with fluid—water or oil. The elastomer is bonded directly onto the basepipe. An integral delay mechanism engineered into the polymer minimizes the risk of premature swelling and setting without the need for any additional exterior coating. The packer has no moving parts.
Ball-actuated frac valve
Progressively larger balls are dropped from surface to seat in and shift open the ball-actuated frac valves, establishing communication with the zones of interest. The frac valves use spherical ball-seat geometry to prevent stuck balls during fracturing and the consequent loss of production from the zones below. Use of ELEMENTAL degradable technology frac balls eliminates the need to flow back or mill the balls after fracturing because they degrade predictably and fully at bottomhole conditions.
Liner-top packer
With a full range of liner hanger assemblies and liner-top packers within the Falcon system portfolio, a fit-for-purpose solution can be provided for the deployment of stimulation systems and securing of the system in the well. The liner-top packer elements are ISO 14310 V3 qualified. The liner hanger system can be deployed via a mechanical right-hand-release running tool (RRT), hydraulic collet running tool (CRT), or latchdown tool. Optional sealing bores of various lengths are available for liner tieback in latched or unlatched seal assembly applications.
Liner hanger and packer
A. PV-3 weight-set liner top packer
Holds HPS hydraulic pocket-slip liner hanger
1.ISO 14310 V3 qualification?
2.TBR tieback receptacle for tying in fracturing string
3.Hold-down slips to prevent upward movement of liner
4.Large fluid bypass area that aids inhole cleaning and reduces circulation time
5.Integral mandrel and setting adapter to permit transmission of high torque from running string to liner
6.Maximum OD of 8.445 in [214.5 mm]
B. HPS hydraulic rotating pocket-slip liner hanger
Hangs heavy liners while rotating
1.Tongue-and-groove pocket slip design that minimizes running interference and stress and eliminates cone collapse
2.Reduced burst pressure on casing
3.Enhanced cement integrity and well stability and safety
Falcon packer options
C.Hydraulic-set openhole packer Isolates adjacent stages being stimulated
1.Setting pressure of 2,400 psi [16.54 MPa]
2.Full gauge protection
3.Antiswab elements and barrier rings on both sides of element that prevent extrusion
4.Internal lock ring that permanently retains setting force in element after packer is set, permitting multiple pressure reversals
5.Design that allows multiple packers to be set simultaneously
D. ResPack* swellable bonded-to-pipe packer
Isolates adjacent stages being stimulated
1.Available for a wide temperature range, from 100 to 365 degF [37 to 185 degC], and with a differential pressure rating of up to 15,000 psi [103 MPa], the highest psi/ft rating in the industry
2.Built-in swelling delay mechanism that reduces risk of premature setting
3.Elastomer bonded directly onto basepipe; no moving parts; durable, self-healing construction
4.Suitable for all fluid types
Falcon valves
E. Ball-actuated frac valve
Allows communication to be established with each zone to be fractured
1.Antirotational device that enables easy milling of balls and seats
2.Large exit ports to maximize flow area
3.Reclosable feature with ability to close the sleeve before and after milling the seats
4.Multiple-ball seats for increased flow rate
5.Millout ID of 3.75 in [95.25 mm]
Frac ball and ball seat
The spherical ball seat geometry promotes ball flowback and prevents stuck balls during fracturing. All balls flow off seats at <500 psi [<3.447 MPa] back pressure, the lowest in the industry.
1.Magnesium balls that are light, strong, extrusion resistant, and easy to mill
2.Balls with nonlinear increments based on engineering calculation of load forces for every stage
3.Optional ELEMENTAL degradable technology frac balls, which eliminate the need for interventions to remove frac balls, saving time and costs
4.Segmented seats for easy millout into small pieces
F. Hydraulically actuated frac valve
Allows communication to be established with first fracture zone at toe after close of flowthrough circulating valve
1.Only one valve per system, situated above flow-through circulating valve
2.Setting pressure of ~5,500 psi [~37.92 MPa]
3.Large exit ports that increase flow area, allowing high flow rates
G. Flow-through circulating valve
Allows fluids to circulate while system is run inhole and then closes to isolate internal casing from annulus
1.Activation pressure of 1,500 psi [10.34 MPa] by ball dropped from surface after system reaches TD
2.Ball seat sizes that are easily interchanged at wellsite to accommodate change in number of stages being stimulated without new valves needed
3.Elimination of piston force on liner assembly during initial fracture
APPLICATIONS
Horizontal, deviated, and vertical wells for
–multistage fracturing
–isolated matrix acidizing treatments
–stimulation when a well has casing integrity issues
–stimulation of sandstone, carbonate, and shale plays
BENEFITS
1.Single-trip installation that reduces rig time and operational risks
2.Improved efficiencies due to modular design that accommodates multiple configurations and last-minute modifications
3.Reduced costs with elimination of wireline and coiled tubing operations
FEATURES
1.ELEMENTAL* degradable technology frac balls, which eliminate the need to flow back or mill frac balls after fracturing operations
2.Seat geometry that promotes ball flowback at lower pressures during fracture cleanup
3.Drillable seats for fullbore access and increased production output
4.Reclosable ball-actuated frac valves for zonal shutoff after fracturing
5.Delayed swelling of swell packers for reduced risk of premature setting.
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