Completion Barrier Glass Plug with Integrated Bypass Sleeve

In order to optimize Completion installations by eliminating Intermediate Completion, reducing rig time, and preventing fluid loss, a project was initiated to develop a barrier glass plug with bypass capability. The plug allows self-filling of the tubing while running in hole and circulating of fluid to displace the wellbore. Once the bypass is closed using a pressure key applied from surface, a V0 certified barrier is established. A glass plug with an integrated bypass sleeve was developed to allow pumping through the plug. To develop the plug, multiple technologies from existing plugs with proven track record were incorporated. To close the bypass sleeve an Electronic Counter system, known as E-Trigger, was utilized. A pressure key is programmed in the E-Trigger Software. Once the pressure key is applied, the bypass sleeve will close. To open the plug, a Mechanical Balanced Counter System was utilized which requires pressure cycles to activate. Once the Balanced Counter is fully cycled, the glass will break and the plug will open. Utilizing barrier glass plug with bypass capabilities in the lower Completion will eliminate the requirement to use an intermediate completion to isolate the well and displace the well to brine. Once the sleeve is closed it will prevent fluid loss to the formation after placement of the filter cake breaker. The plug can then be used to set production packers hydraulically, pressure test production tubing, and allow for the safe installation of Christmas Trees. To verify the performance envelope and functionality of the plug, an erosion test was performed where 10 barrels per minute flowrate was achieved for a total volume of 10,000 barrels using water based mud. With the substantial volume pumped, no indication of erosion was seen after the test. The bypass sleeve was then closed and the plug was pressure tested and qualified to ISO 14998 V0. The current technologies available in the market does not allow for high flowrate pumping and remote closure of barrier glass plugs after the pumping operation. Therefore, incorporating the barrier glass plug with bypass capabilities in the lower completion will result in significant savings by reducing the completion components in the string and reducing rig time.