Multi-Stage Cementing With Metal-to-Metal Supported Packers for Effective CCA Prevention

Abstract Casing-to-casing annular gas migration is among the most severe problems at gas wells and may occur during drilling or well completion. The possible consequences are diverse and not always immediately detectable. However, severe surface complications, such as gas flow or pressure at the wellhead, may necessitate well abandonment. Thus, elaborate measures are required to secure wells integrity. The current abstract meets this need by elucidating real-life solutions to prevent casing-to-casing annulus pressure in gas wells. The abstract intends to describe multi-stage cementing through metal-to-metal supported packer (packoff stage tool (POST) also known as differential valve (DV Tool) to prevent casing-to-casing annulus pressure in gas wells. A case study methodology was selected to enable a detailed assessment of the said phenomenon within the Middle East field applications. The proposed technical approach was divided into the foundation, pre-field, field, and reporting phases. The field deployment showed outstanding DV Tools performance in preventing casing-casing annulus pressure while performing multi-stage cementing. Consequently, data and information were collected in the field phase and compiled into meaningful insights within reporting stage. The case study identified the tool's successful development research and application for the drilling equipment and services. The obtained results indicated the feasibility of successfully isolating multiple zones in gas in 9 5/8-in and 13-3/8-in casing sections, followed by multi-stage cementing (ideally two-stage) to separate lost circulation zones. In this case, correctly placing cement up to the surface level is crucial to provide an extra annular barrier to prevent casing-to-casing annular gas migration. The innovative approach presents the state-of-the-art in preventing casing-to-casing annular pressure in gas wells in Gulf Cooperation Council countries. This research is among the first attempts to summarize the success of using multi-stage cementing with a metal-to-metal supported packer to address the said problem. Thus, the provided information should establish an essential reference for future studies and facilitate the global adoption of similar solutions within the oil and gas fields. The results of field trials and case studies further demonstrate the effectiveness and economic viability of this approach, validating its potential to transform CCA prevention strategies and elevate wellbore performance to unprecedented levels.