Effectively managing resources encompasses accurate engineering of target formations and prudent execution of project capital. Attaining both requires employing current technologies and implementing efficient operations, especially with today's challenging drilling environments and economic climate. In multiple cases these objectives have been realized by combining solid expandable tubulars and swellable elastomers to effectively isolate zones without cementing. Swellable elastomers on openhole expandable systems installed in hard rock eliminated not only the need for cementing, but also for underreaming (usually a necessity when installing expandables). The dual technology, when coupled with coiled tubing, enabled isolating multiple zones while optimizing casing diameter to accommodate high-rate fracturing operations. This approach enabled implementing a flexible fracturing process for operational efficiency. In addition to drilling and completion applications, solid expandable tubulars and swellable elastomers provide a solution for challenges encountered when producing from mature reservoirs. A major challenge in reservoir management lies in controlling water production as the well life ages. An intervention project that combined solid expandable and swellable elastomer technology shut off unwanted water production that resulted in a sustained increase in oil production. This paper describes how the respective evolution of solid expandable tubulars and swellable elastomers provided a step change in technology. Applications and case histories will be cited to illustrate the resulting savings of time, money, and consumables, and exemplify the technology's efficiency, reliability, and cost effectiveness. Introduction In today's tumultuous economic climate, all well operations from drilling to recompletions/stimulations must, without exception, add value to the operator's bottom line. Adding value is particularly challenging when considering the application of new technology in well operations. In addition to adding value, any new technology considered must demonstrate high reliability to dispel concerns of equipment and installation risk. Solid expandable tubulars unquestionably fulfill these demands as their scope of application continues to grow. During the past ten years, solid expandable systems have demonstrated value as an alternative to conventional zonal isolation techniques. The increased system reliability has brought universal confidence throughout the industry. Even with a decade of successful applications, record-setting installations, and an increase in dependability, expandable technology continues to evolve to meet the ever-increasing needs of the energy industry.
Open hole, multi-stage (OHMS) fracturing systems were introduced in 2001. Since then, this technology has been credited with unlocking oil and gas reserves around the world that were previously dismissed as unavailable or uneconomic, enabling companies to maximize production in tight rock formations and mature oil fields. OHMS systems have been run in every type of formation from the much heralded shale gas plays in North America to the massive carbonate formations in Saudi Arabia and have also been used in offshore wells in the North Sea, Black Sea and West Africa. This paper focuses on the open hole packer used in OHMS systems to generate the annular compartmentalization necessary for effective multi-stage stimulation and production. This packer is a dual element, hydraulic-set, mechanical (DHM) packer and provides reliable open hole isolation with various benefits compared to swellable, inflatable and other mechanical packers including: 1) Reduced torque and drag due to their short length (average 5 ft) with only two short sections of rubber with a minimum running outside diameter, 2) Creation of two independent sealing points via dual elements, which together act like a single, 3 ft long seal with redundant sealing, 3) No need to formulate them for specific downhole fluids or wait for them to swell, 4) No thermal contraction such that the seal is not lost during stimulation, and 5) The rubber element does not reduce its durometer rating when set.Laboratory testing and field applications of the DHM packer are presented including HPHT, multi-laterals, proppant fracturing and acid stimulation with on and offshore case histories incorporating stand alone screens, acid jets, fracture ports and combinations thereof.
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