Operator reduces rig time with remote barrier valve

Overview

An operator in development of its first horizontal well in the Tengiz field sought a safer and more reliable method to set a liner hanger in the lower completion. The well included a long ~5,249 ft (1600 m) horizontal section and required operations in high-pressure/high-temperature (HP/HT) conditions with elevated H₂S levels. Traditionally, the operator used a ball-drop method to land a ball on seat and create the barrier necessary to set the liner hanger. However, the extended lateral and heavy oil based mud (OBM) environment introduced significant difficulty to pump the ball to seat, increased the risk of excessive pump rate requirements, and created potential for nonproductive time (NPT) if the ball failed to land successfully..

To address these challenges, the operator worked with Halliburton to implement a remotely operated solution intended to reduce dependency on ball‑drop operations and allow the completion to run open ended. Halliburton recommended deployment of the eRED® (electronic remote equalizing device) valve as an integrated barrier in the completion. This approach would help the operator set the liner hanger and establish an ISO 14310 compliant barrier without introduction of the risks associated with conventional methods.

Integration of the eRED® valve into the lower completion as a shrouded subassembly, programmed at the workshop, and its deployment in the open position to support self-filling while run in hole (RIH), the operator gained a method designed to provide more control and predictability when closing the completion toe and setting the liner hanger. After pressure-based activation and a timed closing sequence, the valve helped establish isolation, supporting safer and more efficient completion activities.

Challenge

In this horizontal well operation, the standard ball-drop method introduced several operational risks. The long lateral and heavy OBM environment made it difficult to maintain sufficient pump rate to carry the ball to seat. Failure to land the ball would create costly rig time while the crew attempted contingency options. Deployment of the completion string closed-ended increased the risk of swabbing the well while RIH, particularly given the high deviation.

In addition, the HP/HT environment, combined with elevated H₂S exposure, required a barrier solution capable to maintain functional integrity throughout a broad temperature and pressure range. The operator sought a method that would:

• Allow the completion to be deployed open-ended to reduce RIH risk
• Reduce dependence on ball drop operations
• Provide a reliable barrier for liner hanger installation and subsequent tests
• Support contingency planning in case of downhole uncertainty

Solution

Halliburton recommended deployment of the eRED® valve to replace the conventional ball-drop approach. The valve was made up to a three-way crossover and preinstalled in the completion subassembly. Before shipment to the rigsite, the team programmed and tested the electronics in the operator’s workshop to ensure functional integrity under expected downhole conditions.

The eRED valve was RIH in the open position to allow the completion to self-fill during deployment and reduce swab risk through the long horizontal section. After total depth was reached, the valve was triggered using hydrostatic pressure. This activation initiated a programmed timer sequence that closed the valve after the necessary delay, at which point the operator set the liner hanger.

Once the liner hanger was set and the lower completion and packer were pressure tested, the crew issued a final pressure command to shut down the valve electronics and lock the valve in the closed position. In this state, the eRED valve served as the permanent toe barrier, in accordance with ISO 14310 standards, to support the remainder of the completion program.

Result

The remotely operated eRED valve helped improve operational safety, reliability, and efficiency for the operator’s first horizontal well in the Tengiz field. The valve performed as programmed after exposure to temperatures that ranged from –25°C during rigsite storage to 128°C downhole, and pressures of 11,800 psi hydrostatic and 14,300 psi absolute. Its open position deployment allowed fluid bypass to maximize the capability to reach setting depth and minimize swabbing risks.

Elimination of a ball-drop operation helped reduce the risk of associated failure and helped the operator avoid unplanned rig time. Once closed, the valve acted as an ISO 14310 compliant barrier and allowed early shutoff of the completion toe. The reliable remote closing functionality reduced operational uncertainty in the HP/HT environment and help improve overall well execution efficiency.