Achieving effective zonal isolation within long reach horizontal wells via conventional means, such as cement or swell packers, is becoming increasingly challenging to the industry. The longer step outs limit the Equivalent Circulation Density (ECD) due to frac/pore pressure limitations. Subsequent complex stimulation operations impose higher differential pressure (dP) across the packers. To address these challenges, a novel design was introduced, effectively creating an expandable metal, sleeve-type annular barrier that allows cementless completions and effective zonal isolation. The design of the new annular barriers, assembled on a full bore liner, minimizes the running outside diameter (OD) whilst delivering a high differential pressure seal even within a washed out hole. The qualification process was designed to meet the International Organization for Standardization ISO14310 V3 standard and to simulate the lifecycle of the packer during acid stimulation and later-life water management. The benefits to operators include increased reliability and certainty for success, both in the short-term and over the life of the wells. This paper reports recent implementation of the new annular barrier to meet the unique challenges of annular high pressure containment. Findings are supported by specific case examples, and the paper includes a discussion on design, application and performance.
Objectives/Scope: Focusing on a new way to complete and maintain wells, this paper will explain how a newly developed completion approach enables safer, more sustainable operations with higher production and recovery rates from a simple, durable and cost effective well construction. Methods, Procedures, Process: The approach, here referred to as the flex-well, concentrates on simplicity while providing all the components an operator requires to design and construct a completion that is fit-for-purpose; it can be as minimalistic or as intricate as the operator requires in order to accomplish maximum reservoir drainage. The flex-well has been engineered to provide a low total-cost-of-ownership solution that meets global operators' current and future drilling, deployment, and production challenges. The flex-well integrates intervention solutions through a full-bore completion designed for easy access and proactive adjustment. Diagnostic solutions that convey information to surface through wireline data retrieval allow operators to achieve a detailed understanding of well characteristics without permanent cables to surface. This understanding allows for better decision making to optimize and manage the reservoir for maximum recovery throughout the life of the well. Based on the operators data driven decisions production and stimulation valves can be adjusted through wireline interventions, eliminating the need for control lines to surface. With no lines to surface the well design offers complete flexibility for inclusion or addition of multilaterals for infill drilling. Results, Observations, Conclusions: The benefits, simplicity and design flexibility of the concept makes it applicable for operators across all resource plays, conventional and unconventional. However, some factors and conditions do enhance the attractiveness of the solution, such as when traditional cementing is challenged, when high-pressure differentials are present, or when full-bore liner design is desired. Novel/Additive Information: This new way of designing and intervening in oil and gas wells offers the industry a safer approach that results in fewer people required offshore, simpler procedures and operations, and less equipment deployed for shorter time.
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