Incorporation of an Annular Expandable System: Effective Reservoir Isolation Within the Production Liner with Full Losses During Cementing

Abstract Depletion in legacy Gulf of America (GoA) reservoirs increasingly challenge conventional cementing operations. This paper presents a successful deployment of a Metal Expandable Packer (MEP) system to achieve zonal isolation in a deepwater well experiencing total losses during the production liner cement operation. The MEP restored casing integrity, enabled effective isolation between two productive sands, and eliminated the need for costly remedial cementing. Field data, cement bond logs, and injection tests validate the system's performance, offering a replicable solution for similar high-risk environments. Drilling and completing deeper targets have extended oil field lifespans but have added increased complexity to the well construction process, one of which is not providing effective annular isolation due to lack of proper cement placement. For field A, the operator experienced severe losses in previous wells. The risks were assessed, and it was determined that the incorporation of the MEP in their production liner would increase the success of effective annular isolation. Understanding the downhole conditions was critical for the design parameters of the MEP, i.e. restoring the casing specifications of burst/collapse of 17,500 psi, minimizing restrictions to decrease Equivalent Circulation Density (ECD) during the cementing operation among others. Once selected, detailed job planning, risk-assessment, and operational procedures were reviewed with the multi-disciplinary teams, i.e. cementing, drilling, liner hangers, etc. Once the drilling was completed, the logs enabled the analysis for the proper placement of the MEP, isolating the two productive sands. The MEP was run as part of the 9 7/8" liner and ran to bottom with rotation. The cementing operation was initiated, and full losses were experienced immediately after the cement was starting to be lifted. The cementing operation experienced challenges to bump the cement displacement plug, preventing pressure build up from surface to set the MEP, which led to the contingency setting mechanism, using a retrievable bridge plug. A detailed review of the contingencies was done between the operator and the service company, and the MEP was set by utilizing a retrievable bridge plug and pressurizing against it. The MEP was set above the loss zone providing support to the remedial cement job performed through an Annular Cementing Sleeve (CC), thereby reducing the risk of additional losses. The ultrasonic bond log confirmed the cement losses and the lack of cement across the MEP depth. After the sliding sleeves were open, an injection test confirmed the effective isolation of the two pay zones. The MEP is qualified under the strictest American Petroleum Institute (API) standards (API11D1), and it does not reduce the casing specifications, maintaining the casing integrity while providing life of well isolation of the pay zones. Cement bond logs of Field A will be presented, showing the benefit of incorporating the MEP in the production liner. Support data, value solutions, and operational best practices from this deployment will be shared in this paper, high lighting cost benefits and risk mitigation.