Cytadel ZX Electronically-Actuated Packer
The Baker Hughes Cytadel ZX™electronicallyactuated packer is a gas-tight, annular casing packer with an electronic trigger mechanism used to provide a new level of wellbore integrity, improve safety, and reduce risk. It does this by creating a mechanical barrier to potential annular flow paths that may occur during wellbore construction, completion, production, and well abandonment operations. The modular design of the Cytadel ZX packer incorporates V0-rated, gas-tight sealing technology for critical land, unconventional gas, continental shelf, deepwater, and deep well applications. The packer acts as a barrier that stops sustained casing pressure, even after downhole conditions compromise the sealing integrity of cement. It provides a secondary barrier that eliminates gas migration and reduces the likelihood of SCP-related blowouts.
The Cytadel ZX packer is the first V0-rated packer to utilize a modular electronic trigger mechanism, eliminating the need for pressure or pipe manipulation to set the packer. This interventionless actuation method simplifies installation by reducing the amount of downhole data that must be considered when setting the packer. In shallow applications less than 1,200 ft deep (365.76 m), an intrinsically safe signal generation system sends preprogrammed vibration sequences from the rig floor to the tool as a means of activation. An alternative activation method for shallow and deep applications alike utilizes a magnetic signal carrier or customized casing wiper plug with a specific magnetic signature to initiate the packer’s setting timer. Pre-programmed contingency timers and surface-generated hold commands provide an additional means of operational control in both product variations.
Because there are no flow paths through the Cytadel ZX body, the packer maintains pressure integrity and eliminates the potential for fluid communication between the casing and annulus. In addition to addressing short-term safety and environmental risks associated with wellbore construction, completion, and production operations, the elimination of sustained casing pressure (SCP) significantly reduces the costs associated with plug and abandonment operations. Furthermore, the packer’s ISO 14310 V0 rating satisfies the regulatory requirement for a mechanical barrier in the annular flow path.
The Cytadel ZX packer also incorporates proven ZX™seal technology, which has delivered unsurpassed pressure and temperature ratings, and rugged dependability in wellbores around the world. By combining our advanced seal technology with the industry’s only electronic trigger mechanism in a V0-rated packer, Baker Hughes delivers a safe, reliable packer system to provide a mechanical, annular seal between casing strings.
Applications
•Conventional oil and gas
•Unconventional hydrocarbons
•Land and deep water
•Continental shelf beginning at 200 ft (60.96 m) below the mudline
•Deep set wells
•Long-string casing completions
•Annular isolation above previous casing shoe
•Wellbore integrity
Features and Benefits
•ZX seal technology
–Eliminates SCP and bleed-off costs
–Offers 99.5% reliability with more than 40,000 runs
–Carries ISO 14310 V0 rating
•Solid-body packer mandrel with tubular connections
–Matches performance of the casing, ensuring wellbore integrity
–Eliminates flow paths between the casing and annulus
•Electronic trigger to set the packer
–Takes one trip
–Eliminates the need for pressure or pipe manipulation
–Enables actuation from the rig floor
–Saves rig time
Operators rely on cement to provide annular isolation.
In deepwater wells, where safety and environmental concerns are critical to success, operators have relied on cement alone to protect against dangerous sustained casing pressure (SCP). While using cement to isolate zones and seal wells from formation gases is standard in the industry, downhole conditions can make achieving a complete hydraulic annular seal with cement alone difficult. Even small leaks can lead to dangerous levels of SCP inside the casing. While operators have traditionally tried to repair unsuccessful cement jobs with annular squeeze operations, results have been mixed. Wells exhibiting even small SCP levels must be monitored and vented to bleed off dangerous pressure in the casing.
Unsuccessful cement jobs can:
1.Increase SCP and risks to personnel and the environment
2.Raise the risk of blowouts
3.Increase rig time
4.Lead to costs for bleeding off pressure
5.Delay production
6.Require additional reporting
Stop dangerous sustained casing pressure.
The Cytadel ZX™ electronically-actuated packer creates a gastight annular seal to provide an added layer of protection against SCP buildup caused by insufficient cement. This secondary barrier eliminates gas migration and decreases the risk of SCP-related blowouts.
Why chance it? Cut HSE risk
The Cytadel ZX packer is run as part of a long-string completion and is positioned to isolate the casing-to-casing annulus. At the conclusion of the cementing operation, the Cytadel ZX packer is remotely actuated from the surface. Once set, the packer provides an ISO 14310 V0-rated annular seal, creating a permanent gas-tight barrier. The packer features industry-recognized zero-extrusion ZX™seal technology that has proven reliable in 99.5% of more than 40,000 applications. Its solid-body design eliminates ports and O-rings, so it can be deployed without negatively affecting casing integrity.
The V0-rated ZX seal eliminates dangerous casing pressure and offers industry-proven reliability.Delivering safe, environmentally sound deepwater wells is not a choice. It is a requirement. It is a responsibility. And it takes commitment.
The Baker Hughes Cytadel ZX electronically-actuated packer is the only packer that enables you to:
•Eliminate SCP, bleed-off costs, and related production interruptions with ISO 14310 V0-rated, industry-proven, zero-extrusion ZX seal technology
•Stop flow between the casing and annulus, reduce the risk of SCP-related blowouts, and maintain casing integrity with the solid-body packer mandrel
•Activate the packer remotely and reduce rig time with the electronic trigger mechanism
CASE HISTORY
Cytadel ZX packer stopped dangerous gas migration in offshore wells near Sakhalin Island
An offshore operator near Sakhalin Island, Russia, had experienced fluid loss on several wells in the area during completions, resulting in inconsistent cement jobs. Some of the wells required multiple annular squeeze operations to establish effective seals, adding rig time, driving up costs, and increasing HSE risks. SCP caused by gas migration is a serious safety and environmental hazard, and the operator understood that casing and cement alone would not prevent gas migration and dangerous SCP.
The operator targeted two initial wells that were prone to seismic activity and exhibited potential for channeling and cracking in the cement barrier. During cementing, fluid loss was extensive. It was clear that, without an additional barrier system, gas migration would be a significant issue
in the well.
After cementing was complete, the Baker Hughes team remotely activated the Cytadel ZX packer, setting the V0-rated packing element in the outer annulus between the reservoir and the surface. Backside pressure tests on both wells confirmed the packers had established a gas-tight barrier.
Neither well has recorded SCP since packer installation.Deploying the Cytadel ZX electronically-actuated packer helped improve well control, eliminated SCP and related bleed-off costs and complications, and satisfied the operator’s firm commitment to HSE.
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