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.
The ability of cement to achieve a pressure seal across the reservoir section for the life of a well becomes ever more difficult to achieve because of increasing depths and more complexity in well design and operations. Mature fields with depleted zones combined with the desire and ability for extended reach wells exacerbates the challenge of delivering a cement-only, fit-for-purpose liner. To address this challenge, an operator and service company have joined forces to design, develop, and qualify a hydraulically expandable metal well annular barrier (WAB) assembled on the outside diameter (OD) of a liner while maintaining full-bore inner diameter (ID). Intended initially for use in Norway's Valemon field, the operator is also exploring options for other applications in the Snorre and Brage fields, also offshore Norway. This paper discusses the design, development, and qualification of the metal WAB, including: review of the design, material selection to achieve the required expansion, the unique outer seal design to deliver the pressure differential requirements, and intended applications to date. The final qualification process exceeds the industry-established guidelines in ISO standard 14310 (which defines requirements for packers and bridge plugs for the oil and gas industry).
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