Flexible and robust through the life of well, Fuzion-H technology enables safe and cost-effective ESP replacement
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Replace the ESP located in the upper completion 2.5 years after installation
Middle East
In September 2023, Halliburton successfully completed workover operations to replace underperforming electric submersible pumps (ESPs) on two Middle East operator wells. Both onshore wells included intelligent completions with Fuzion-H hydraulic downhole wet-mate connectors, which provide a reliable method to disconnect and reconnect the upper and lower completions. The team retrieved the upper completion by disconnecting the male and receptacle subs in the 3 1/2-inch Fuzion-H connector, without removing the three-zone SmartWell® lower completions. Connectivity to the lower completion was re-established during run in hole with the new upper completion and ESP.
The operator required an economical solution to replace the ESPs in each well and maintain the production optimization benefits of the SmartWell completion. Without Fuzion-H technology, ESP replacement introduces additional risks, which the operator wanted to avoid. Removing the entire completion necessitates costly intervention operations and a means to combat fluid loss in each zone, along with the challenges typically associated with workover.
Understanding the likelihood and challenges of ESP replacement, Halliburton designed the intelligent completions with Fuzion-H hydraulic downhole wet-mate connectors run in 9 5/8-inch casing. The hydraulic connectors enable replacement of any part of the upper completion, such as a non-functioning ESP, safety valve or other component, without recovering the entire lower intelligent completion. Fuzion-H technology facilitates reliable disconnection and reconnection to ensure SmartWell hydraulic system functionality pre- and post-workover.
9 5/8 and 7-inch casing sizes
workovers performed successfully
NPT
The Halliburton team performed workover operations and replaced the ESPs in both wells successfully with zero NPT. Post-workover, the SmartWell® system retained full functionality. Because the existing lower completion components remained in place and available for use, the already-installed interval control valves (ICVs) could provide full reservoir isolation during workover, which helped reduce health, safety and environment (HSE) exposure, save time, and optimize operation costs.
The Fuzion®-H electro-hydraulic downhole wet-mate connector enables multi-trip hydraulically-controlled completions.
The Fuzion® suite of wet-mate connectors facilitates removal of the upper completion from the lower completion without using destructive intervention methods.
