First Field Application of Novel Open-Hole Isolation System: An Expanding Metal Alloy Packer Transforming to Rock-Like Material
Authors: Arias Rommel E. , Hababi Ali H. , Saber Ahmed , Shakeel Muzzammil 
Published: September 2024

Hydraulic fracturing is a common stimulation technique to increase hydrocarbon productivity in low permeability formations. Well completions are equipped with various components to achieve the required stimulation objectives. Open-hole packers are a key component in well completions to compartmentalize the wellbore and achieve hydraulic open-hole isolation. A reliable sealing element is critical to achieve isolation and deliver an effective treatment distribution across the compartments. Elastomer-based open-hole packers may not be suitable in certain downhole conditions due to challenges during deployment phase, exposure to high differential pressures, tubing cooling effects and irregular boreholes. This paper presents an innovative, transformational non-elastomeric solution that can provide open-hole isolation in extreme downhole conditions.

The new non-elastomeric open-hole isolation technology discussed in this paper is an engineered metal alloy that transforms into a rock-like material upon activation. This technology overcomes multiple challenges that occur during deployment, stimulation and production phase of a hydraulically fractured well. The principle involved in this technology is utilizing a chemical reaction that occurs between the metallic alloy sealing element and downhole fluids, resulting in expansion of the sealing element. The newly designed metal alloy packer underwent comprehensive testing to qualify for 15,000 psi differential pressure rating and up to 500,000 lbs. of anchoring force. The packer has been validated in accordance with API 19OH-V1 requirements Comprehensive studies were performed in this study to capture chemical transformation of metal alloy to a reliable sealing element.

This paper also discusses the successful deployment of the new open-hole isolation packer in a long horizontal well. The engineered metal alloy open-hole packer was successfully installed in a horizontal producer well consisting of tight gas carbonate formation with more than 4,000 ft of reservoir contact. The completion string consisted of seven open-hole packers along with other multi-stage fracturing completions including frac sleeves and toe initiation sleeve, run in on an expandable liner hanger. The 15K open-hole multistage completion system successfully reached target depth after overcoming various tight spots through the long open-hole lateral. All metal alloy open-hole packers were activated by displacing filtered brine into the wellbore. Rig-less stimulation operations were successfully performed proving excellent sealing and anchoring capability of the new open-hole packer. The chemical transformation of metal into a rock-like material was achieved in the field providing necessary zonal isolation during simulation. It was also established that the new open-hole packer has the capability of withstanding high differential pressures and anchoring loads as validated by the testing. The ability to rotate and circulate as needed also provides additional flexibility during deployment.