Proactive Water Shut Off in Open Hole Gravel Pack Completions Using Thermally Deformable Annular Packers

Abstract Uncontrolled water production remains a significant operational and economic challenge in oil and gas wells, particularly in mature reservoirs, heterogeneous formations, and horizontal wells with multiple contributing intervals. In open hole gravel pack (OHGP) completions, water shutoff often appears straightforward in concept, by isolating the water producing zone and shifting the production profile, but in practice, this typically requires costly, logistically complex interventions after water breakthrough has already occurred. This paper presents a proactive water management strategy that incorporates Thermally Deformable Annular Packers (TDAPs) into the initial OHGP completion. These packers, cast with a specially formulated bismuth-based alloy, are positioned between screen sections and remain inactive during the early stages of production. When water breakthrough is detected, the TDAPs can be selectively activated using a downhole chemical reaction heater, triggering the alloy to melt and form a barrier in the annulus without the need for any heavy equipment, surface interventions or workover operations. By integrating the shutoff mechanism into the well's original design, operators gain the ability to control water production. This eliminates reliance on reactive remediation methods. The ability to isolate zones only when required adds a new dimension of flexibility, particularly valuable in water prone or sand producing formations. This paper details the system design, qualification testing program, and deployment methodology. Results from thermal activation, flow restriction, and high-pressure testing confirm the TDAP system's ability to deliver reliable zonal isolation and significant water flow reduction under realistic downhole conditions. These findings support the technology's readiness for field deployment and establish a new, more efficient standard for water control in complex completions.