Expandable Liner Hanger Installation in Middle East Exploration Well - South Arabic Gulf Offshore

Abstract This document will capture the experience of Expandable Liner Hanger successful installations for an Offshore Exploratory Well in South Arabic Gulf considered the first well profile in the Area to contain 4 different cemented Liner sizes starting from 16" Liner to 9-5/8" (with possibility of 2 contingency Liner Sizes 7" & 4-1/2"). In a challenging sour environment and complicated well design, the Expandable Liner Hanger system was selected as a proven reliable technology recognized worldwide. The document will discuss the challenges in design and execution phases to reach the required TD of the well, exceeding 20,000 ft, to explore 2 main 4 ways structural closures. Liner Hanger implementation in the well was a key point to reach the required depths without jeopardizing the well design. Procedures to run, install and cement the expandable liner hanger in place capturing all lessons learned and implementing the required risk assessments was a result of collaboration between engineering and operation teams to plan and prepare for all contingencies resulting in a smooth execution. Expandable Liner Hanger helped to set and cement all casing shoes at planned depths in a complex well design offering a high capability of reaming while encountering high Pressures, high flow rates & high torques with no risk for premature release or premature set which is not feasible with a Conventional Liner Hanger system. 16"x20" Liner was installed through multiple kicks overcoming more than 75 tight spots (either with SOW, rotation or ream down) and cemented. 13-5/8"x16" Liner with single trip tieback system - designed and built for the project - that enabled minimizing the large OD length of the hanger system in 13-5/8″ × 16″ whilst also providing the tieback operation flexibility through a 20ft stroke system to surface was successfully installed. 13-3/4"x13-5/8" faced Intensive reaming down for more than 48 hours while slacking off all Liner weight & facing high torques with high flow rates/pressures. Finally, 9-5/8" Liner and 20 ft tie back to surface was successfully installed. Utilizing the Expandable Liner Hanger as a reliable system in such challenging well allowed us to exploit all its potential. Continuous Improvements in Planning through execution phase within the simulations (Torque and Drag, Surge & Swab, wellCat simulations) and in the rig installation procedures resulting to mitigate risks and providing improved reliability, enhanced operational capabilities, and well integrity assurance.