Abstract
Enhancing gas productivity is linked to multistage stimulation (MSS). Choosing a cemented over uncemented solution is driven by factors such as operational efficiency, drilling practices, and isolation techniques. Swellable and mechanical packers have been used widely. A new packer type, an expandable steel packer, has been qualified recently, the expandable steel packer combines the strengths of mechanical and swellable packers and will provide an option for openhole completions.
The 4.5-in. expandable steel packer design was optimized to meet most demanding applications with the following characteristics: reduced running outside diameter (OD) to 5.6 in., premium assembly technique by crimping, double sleeve pressure self-compensation, and use of nickel alloys for sour environment. After the design of the packer was completed, the 4.5-in. expandable steel packer was qualified according to the API Spec 19OH (API 2018) standard protocol at 15,000 psi with thermal variation between 320°F and 68°F. The packer was tested in a casing with inside diameter (ID) of 6.5 in.
The test casing had an ID of 6.5 in. whereas nominal hole size ranges from 5.875 in. to 6.125 in. It was chosen to simulate a washout and considering the calculated maximum expansion ratio for the steel to verify the 15,000-psi pressure rating capability. The test casing was built with a heat exchanger, high-pressure pump, and pressure and temperature sensors.
The packer was expanded inside the dummy well with all the measuring instruments in place. Expansion pressure signatures were observed as predicted. The analysis of the packer setting pressure curves showed expansion initiation and full casing ID contact. The liquid differential pressure test from each side of the packer proved the internal pressure compensation performed as expected. No leak was observed during the pressure steps of 15.000 psi held for 15 minutes while cycling the temperature from 320°F to 68°F and back to 320°F.
The expandable steel packer utilizes a unique double-sleeve system for self-pressure compensation during ball-drop stimulation operations. The packer expandable sleeve is protected during deployment by the end fittings. Expandable steel packers exhibit robustness during running in hole, enable setting on demand, have a high expansion ratio, require no de-rating vs. hole size, and have low sensitivity to thermal variations.