An operator was developing a High-Pressure High-Temperature (HPHT) field in the U.S. Gulf of Mexico (GOM). Completion design for the injector wells was cased-and-perforated, with no mechanical sand control. This led to the requirement for a tubing-conveyed perforating (TCP) system, featuring deep-penetrating (DP) charges which would meet specific performance requirements, in order to enable the wells to achieve injectivity targets.

A perforating system was therefore developed and qualified to meet these requirements. This was an integrated system development, including both mechanical and explosive components, with simultaneous attention to performance, reliability, and quality assurance in the eventual field environment.

The development program yielded a 4-3/4-inch carrier system, perforating charges, firing head, and gun hanger. All key components and systems were qualified in customer-witnessed testing, and demonstrated to meet or exceed operational function and performance requirements.

The pressure and temperature rating of the newly-developed system is 30,000 psi at 425 °F. Explosive train function reliability was demonstrated at 380 °F for up to 28 days. The newly-developed perforating shaped charge was confirmed to exceed the stringent penetration depth and casing hole diameter performance requirements at downhole conditions. The firing head offers operational flexibility by being configurable for up to 15 pressure cycles prior to detonation, with an adjustable initiation threshold pressure to reduce risk to the completion string. The gun hanger was customized and demonstrated to exceed load requirements, and reliably set and release, in a test configuration featuring operator-provided field casing.

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