Successful Deployment of Metal Expandable Annular Sealing Systems in High Extended Reach Wells

Abstract

The successful deployment of metal expandable annular sealing systems in extreme reach design wells completion. The design and engineering of this technology resulted in the development of a fit for purpose, state of the art equipment that overcame several challenges such as having the liner with full rotational capability to overcome the drag during the deployment while maintaining the full liner torque capabilities. The metal expandable annular sealing system was designed to provide high expansion in potentially washed-out wellbores and across formations where effective isolation may not be achieved by primary cementation due to low formation gradient or cement design challenges in horizontal wells. The design included a long multi element sealing system with built in redundancy. The multi sealing element system chosen for this application due to it being a full bore, rugged, all welded, metallic construction with a constant, high ∆p over full expansion range. The system is fully rotatable during deployment, it also allows for high-rate circulation because of its slim OD. The metal expandable annular sealing system was run in total or partial losses multiple times, and it was observed that circulation was gained after setting the metal expandable system. Furthermore, it was also confirmed that the system effectively provides zonal isolation by injecting into compartment and ensure that zone is completely isolated.