SPE 166391

Open Hole Packers Provide Zonal Isolation for High Pressure Acid Stimulation
within a Chalk Reservoir
Authors: P. Hazel, SPE, Welltec; H. Singh, Total; J. Bårdsen, R. Vasques, R. Pearcy, N. Hannah, SPE, Welltec

Copyright 2013, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE Annual Technical Conference and Exhibition held in New Orleans, Louisiana, USA, 30 September–2 October 2013.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessar ily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
This paper overviews the design, development, qualification, and field trial deployment of a hydraulically expandable metal
packer that enabled a cementless, zonal, high-pressure acid stimulation program to be accomplished.
Achieving effective zonal isolation within long reach horizontal wells using conventional means with cement is
challenging to the industry. Achieving effective cement within long step outs is limited by the Equivalent Circulation Density
(ECD) (impacted by fracture/pore pressure) or by the inability to achieve effective cement (i.e., without channels/micro
annuli) simply due to the sheer length of the horizontal section of the well. Additional challenges are then imposed to achieve
zonal isolation within unconventional reservoirs or wells that require high-pressure stimulation.
These challenges spurred the design for a metal expandable packer for use in a cementless completion, assembled on a full
bore liner, and able to deliver a high annular Delta P seal in a worse case washed-out hole scenario.
Material selection to allow hydraulic expansion beyond the yield point of the expanding alloys (i.e., in the plastic region) is
a key design consideration for maximizing the post-expansion strength of the expandable metal packer. Continual design, test,
and result analysis enabled development of a unique, high-pressure seal between the metal expansion sleeve and the formation.
The qualification process was based on the ISO 14310 V3 standard, the industry standard for testing and qualifying plugs and
packers. This standard emulates the lifecycle of the packer during acid stimulation and later-life water management.
Field-proven zonal pressure isolation will be illustrated with real-time zonal pressure data from the field trial in an offshore
field. The well will demonstrate cement-less liner completion efficiency with sixteen expandable metal packers to achieve five
isolated, stimulated, and subsequently producing zones and three water shut-off zones.
In closing, the paper will summarize ongoing developments and how the open hole expandable metal packer is meeting the
unique challenges of annular high-pressure containment. The many benefits to operators include fast setting under surface
control with increased reliability and certainty for success.

Zonal Isolation Requirements for Field Trial

Zonal isolation requirements for openhole completions can be arduous. These requirements typically consist of maximum
pressure criteria, maximum pressure differential criteria, hole size requirements and installation and setting constraints. In
addition to these constraints, the requirements also included a need for an extremely long length of reservoir seal to minimize
the effects of acid channeling through an acid soluble reservoir during well stimulation, and packer movement and sealing
constraints during large temperature changes associated with wellbore stimulation. These design requirements were developed
with an operator for a field trial and included:
 Delta P capability of 8,000 psi during acid stimulation
 Delta P capability of 4,000 psi during water management
 Full Delta P capability from the drilled hole size out to a worst case hole wash-out of 10 1/2 in.
 Full sealing capability from ambient temperature to 125°C (257°F)
 Metal expandable sleeve reliability for robust deployment and life-of-well
 Long-length packing element with multiple seals, each capable of holding the full Delta P
 The expansion of the packers must be rapid and under surface control
 The effects of the cesium formate drilling mud, completion fluid, and produced fluids not to impact the metal
expandable packer
For the field trial, the reservoir section of the well is drilled with a 9 1/2 in. bit with a 7 5/8 in. nominal weight 51.20 lb/ft
heavy weight Q125 liner, the 9.2 in. running outer diameter (OD) full bore metal expandable packers are assembled on the OD
2 SPE 166391

of the liner, leaving the internal diameter (ID) of the liner unaffected. An inner completion is run with inflow control valves
(ICV) and associated cased hole packers and pressure sensors. A lower completion diagram is shown in Fig. 1. For the inner
string to be deployed, the 7 5/8 in. liner must remain full bore.
When deploying a double string completion, the CAPEX investment of an inner string is significant along with an
increased risk during deployment. The value of the inner string can only be realized if effective zonal isolation between the 7
5/8 in. liner and the open hole is achieved. Achieving effective open hole zonal compartmentalization through good isolation
enables:
 Selective stimulation to deliver maximum reservoir contact of acid to the formation
 Effective production management for the life-of-well through the ability to control production from each zone
 Reduces water cut to maximum reservoir drainage and minimize risk of scaling

Fig. 1—Lower completion schematic illustrating use of the 7 5/8 in. open hole metal expandable packers.

Each compartment of the 7 5/8 in. liner (Fig. 2) is comprised of two 5-m metal expandable packers, one slip joint, multiple
acid injection points, and an anchor. The long-length metal expandable packers were selected to maximize contact of the
sealing units/elements with the openhole and improve resistance to acid channeling. The anchors were positioned between the
metal expandable packers to ensure that the formation they were set in would not be exposed to the acid and render the anchor
ineffective. In addition, a slip joint was used in each zone to eliminate the thermal contraction and expansion forces acting on
the openhole packers during the acid stimulation. A pre-drilled 7 5/8 in. liner was run with dissolvable plugs installed,
enabling the liner to be run pressure tight for the hydraulic setting of the anchors, activation of the slip joint, and expansion of
the metal packers.

Fig. 2—Illustration of the 7 5/8 in. liner and inner string.

The inner string cased hole packers were positioned between the two expandable metal packers, each zone having one
surface-controlled valve to enable zonal acid stimulation and selective production capability.

Metal Expandable Packer Specifications

The objective of the acid stimulation program was to efficiently achieve maximum penetration of the wormholes within the
formation across the entire length of each zone. Therefore, it was imperative to have complete openhole zonal isolation to
divert the acid to the formation. The operator had previously tried various methods of both isolating the zones and achieving
maximum acid contact with the formation with limited success.
SPE 166391 3

The need for packer development was realized and a specification was jointly developed and agreed upon. The
specifications are summarized below and shown in Table 1:

Table 1—Metal Expandable Packer Specifications

Set within 9 1/2 in. open hole
Base pipe OD 7 5/8 in.
Base pipe material grade Q125
Packer set within max OD 10 1/2 in.
Nominal running OD 9.2 in.
Expansion sleeve length 5m
Packer seals/m 8
Max Delta P during injection 8,000 psi
Max Delta P during production 4,000 psi
Max service temp 135°C (275°F)
Min service temp 30°C (86°F)
Service environment Non NACE

Metal Expandable Packer Design and Functionality

The openhole metal expandable packer uses a metal outer sleeve mounted on the OD of the liner or casing (Figs. 3, 4, and 5).
One end of the expansion sleeve is welded to the casing (liner) and the other end of the sleeve is sealed against the outer
prepared surface of the liner string using sliding seals (piston seals). On the metal outer sleeve, surface pressure-activated
elastomer seal elements are housed within seal carriers. The metal outer sleeve is hydraulically expanded radially using well
fluids to make contact with the formation. The well fluid is communicated from the liner via ports within the liner wall.
During the hydraulic expansion, the metal outer sleeve yields (the yield pressure being a function of the material grade, wall
thickness, and the diameter) and then plastically deforms to conform to the openhole profile. The metal outer sleeve is
manufactured with a high ductility alloy that work hardens as it expands, increasing its resistance to collapse. The result is a
uniform expansion of the material that conforms to the borehole shape.

Fig. 3—Cross-section of the metal expandable packer mounted on the base pipe, pre expansion.

Fig. 4—Cross-section of the metal expandable packer mounted on the base pipe, post expansion.

Fig. 5— As-built metal expandable packer mounted on 7 5/8 in. base pipe liners.
4 SPE 166391

Many design iterations and bench tests of the metal expandable packer were performed. Detailed Finite Elemental Analysis
(FEA) models (Fig. 6) were run and evaluated to fine-tune the packer design. The FEA models were then validated and
verified with full-size models expanded to the maximum expansion geometry. The packer design was carefully selected to
ensure it provided a sufficient contact pressure and seal capability in the worst case borehole geometry.

Fig. 6—An FEA model showing post-expansion strains.

During the qualification tests, the behavior of the sleeve (i.e., strain, expansion pressure, time, temperature, fluid volume
etc.) is recorded and evaluated. An example plot is shown in Fig. 7.

Fig. 7—Pressure, strain and flow-rate/volume plot during expansion of the metal sleeve.

Operating modes. There are two operating modes for the metal expandable packer: injection/stimulation mode and
production or depletion mode. When in injection/stimulation mode, the pressure in the well bore is present in the well packer.
This pressure prevents the expansion sleeve from collapsing and increases the contact pressure between the formation and the
packer. Fig. 8 shows the packer in injection/stimulation mode.

Fig. 8—Injection/stimulation mode.

SPE 166391 5

When in production or depletion mode and with an adjacent zone shut in, the annular pressure on one (or both) sides of the
packer may be greater than the pressure within the packer. This pressure acts on the expansion sleeve trying to collapse the
sleeve inwards, and is carried by the strength of the sleeve post-expansion (a combination of steel grade, wall thickness, and
degree of work hardening). Fig. 9 shows the packer in production or depletion mode.

Fig. 9—Production or depletion mode.

Outer Seals. On the OD of the expansion sleeve, pressure-activated seal assemblies are attached (Fig. 10). The system is
designed such that the pressure used to expand the sleeve is also sufficient to energize the seal assemblies, creating a contact
seal between the nitrile rubber (HNBR) seal elements and the formation inner diameter, or the casing/liner if set within a cased
hole.
The initial contact seal is sufficient to seal at relatively low Delta pressures across the packer within the annulus. As the
annular Delta P increases in a zone (due to stimulation or water injection), the high pressure across the annulus is used to
enhance the contact pressure between the seal and the formation. This design enables the metal expandable packer to carry
very high Delta pressures (qualified for applications up to 10,000 psi).
One important design parameter is the temperature differential expected during stimulation. The seals are designed to cope
with the significantly higher thermal contraction of the elastomer as compared to the metallic parts. The initial contact pressure
between the packer and the formation can decrease significantly during thermal cycling. The problem has been evaluated with
an FEA model and empirically determined using multiple tests using the contact pressure information measured by strain
gauges. This let us create a set of design rules that has since been used successfully in other packer dimensions.

Fig. 10—Packer mounted on a base pipe indicating the pressure-activated seal assemblies.

Metallurgy. The system metallurgy takes into account the 28% HCl acid environment and the long-term corrosion
possibilities resulting from the cesium formate drilling fluid, completion fluids, stimulations, and the production environment.
Example materials used in construction of the packer are NiCr alloys, Duplex 2705, and HNBR. Weld procedures are
developed for all the welds which are approved by DNV.

Packer Qualification

Pressure testing. The qualification testing of the metal expandable packer was performed in a test pipe that simulated the
largest and smallest open-hole environments. A high-pressure pump was connected by a four-way manifold to an accumulator
which was used for expanding and conducting all pressure tests. The test jig and the pressure test setup are shown in Fig. 11.
6 SPE 166391

The pressure testing fluid was water. Pressure was monitored using electronic pressure gauges and was recorded during all
tests. The pressure was applied to three main areas. Liner pressure Pc is the pressure inside the liner, annular pressure P a is the
pressure on the travelling end of the annulus, and pressure Pb is the annular pressure on the fixed end of the annulus.
The packer test assembly was heated with heating blankets. The temperature was monitored at the OD and the inner
mandrel of the test jig.

Fig. 11—Packer installed on a test mandrel inside a test pipe.

The contact pressure between the packer and the test pipe was monitored using strain gauges during expansion. The strain
gauges were positioned on the OD, along the length of the test pipe at regular intervals. Axial load tests were performed with
the packer expanded and under different differential pressure scenarios. To test the packer for axial loads, the outer test pipe
was held fixed in a test jig and the load applied to the inner liner.
The ISO14310 standard establishes the pressure drop limit of 1% over 15 minutes for each test. However, the volume of
the test fixture is not taken in to account. For the metal expandable packer qualifications, both the pressure drop and a leak rate
were monitored for the 15-minute test interval. In addition to measuring the pressure status on the High Pressure (HP) annulus,
the leak rate across the metal expandable packer during the 15-minute pressure window was measured. To make a leak volume
measurement, a careful characterization of the accumulator was performed to clarify the relationship between pressure drop
and leak rate. The accumulator was initially charged to 11,000 psi. Then the pressure was reduced in 1,000 psi steps. The
drained water was then carefully measured, and a curve of discharge volume vs. pressure was plotted. In addition, an
isothermic theoretical equation of state for the nitrogen gas can be used to characterize the accumulator discharge vs. pressure.
The plot in Fig. 12 shows the theoretical behavior of the accumulator using the equation of state vs. the experimental results.

Fig. 12—Theoretical vs. measured discharge rate with pressure.

SPE 166391 7

With this information it is possible to determine the pressure drop across the metal expandable barrier as per the ISO14310
standard together with a leak rate across the metal expandable packer using the most stringent criteria depending on the
pressure test scenario. During the qualification tests, a 25 ml leak rate over 15 minutes was established as the pass criteria
during the 15-minute pressure hold period. The pressure drop limit was used to ensure a more efficient qualification process.
The metal expandable packer and test jig were heated to the reservoir temperature of 135°C and expanded into the test
pipe. The plot in Fig. 13 displays the data acquired during the expansion process into a test pipe with a 10 5/8 in. ID. On the
plot, the expansion pressure is displayed in blue. The metal expandable packer yields at approximately 4,000 psi with a clear
change in the slope of the pressure curve. The metal expandable packer contacts the ID of the test pipe at approximately 8,000
psi, the final expansion pressure agreed on with the operator was 10,000 psi.
The initiation of the expansion (yield) at 4,000 psi ensures that the metal expandable packer will not prematurely expand
when deployed, this pressure being greater than any possible fluctuations that could be expected within the well environment
during liner deployment.

Fig. 13—Data from the expansion process.

After the hot expansion, a series of hot (135°C/275°F) injection tests to 8,000 psi differential and production tests to 3,500
psi were performed before a cooling down cycle was applied to the test fixture. Once the fixture reached the required
temperature for the cold tests (25°C/77°F), the injection and collapse series of tests were repeated. Finally the fixture was
heated again to the required final hot test temperature before repeating the injection and collapse tests. The results of the fixed
end injection test are shown in Fig. 14. The blue curve represents the injection pressure at the fixed end to 8,000 psi (the
pressure was also applied to the bore). The pressure in the other annulus was set to 2,000 psi by a relief valve.

Fig. 14—Fixed end injection test.

Results. Both qualification tests in the minimum and maximum ID test pipes were performed successfully. During all the
qualification tests on the metal expandable packer, leakage rates were either zero or <25 ml.
The scope of the project was to qualify the metal expandable packer for sealing only. However, during the project axial
load tests indicated the metal expandable packer was capable of holding substantial axial loads. Therefore, further axial load
tests were performed to establish a greater load range. The metal expandable packer, when set within the drilled hole size of 9
1/2 in., was capable of holding loads beyond the test jig capability of 200,000 lbF. The axial load tests when set within the 10
5/8 in. ID test pipe are summarized in Table 2.
8 SPE 166391

Table 2—Axial loads on the large ID pipe.

Test No. Pa (psi) Pb (psi) Pc (psi) Fa (Klb) Fb (Klb)

1 8,000 2,000 8,000 80 0

2 2,000 8,000 8,000 180 0

3 0 0 0 200 0

4 8,000 2,000 8,000 0 200

5 2,000 8,000 8,000 0 100

6 0 0 0 0 200

Packer Testing Lower Completion Deployment

On completion of qualification, twenty metal expandable packers were manufactured in accordance with an agreed Quality
Control Plan (QCP). As part of the Factory Acceptance Test (FAT) procedure, all metal expandable packer assemblies were
pressure-tested with 1,500 psi internally and drifted internally and externally before shipment. The metal expandable packers
were mounted on Tenaris 7 5/8 in. 51.2# Q-125 TSH Wedge 521 Dopeless integral connection casing. This connection
required the top centralizer to be pre-installed during manufacturing. The centralizers were selected to minimize drag in the
open hole, provide high-flow bypass areas, and provide additional protection to the packer’s outer seals.
After completion of the FAT, the packers were shipped to their pre-job storage location in Stavanger, Norway using
specifically designed shipping protection to safeguard the 5-m sealing length of the packers. On location in Stavanger, bottom
centralizers were installed and both top and bottom centralizers were crimped in place (Fig. 15). Centralizers were installed as
close to the mounted packer assemblies as possible to ensure the centralizers gave the best protection to the packer, and to
ensure there were adequate handling lengths on either side of the packer assemblies. The centralizer crimping process deforms
the base pipe slightly; hence the packers were drifted again with a non-API 9.300 in. x 24 in. OD drift and an API 6.126 in. x
36 in. ID drift, respectively. The packers were then repacked in protective blankets and shipped offshore in standard 13.1 m
completion baskets.

TENARIS TM API 5CT

21 SF 7-5/8 52.20 01
TSH W563-RFB-DPLS

Fig. 15—Assembly drawing of packer with centralizers.

Deployment in the Well

The well was drilled with a 9 1/2 in. bit and the inclination of the well path was up to 94° with maximum dog leg severity of
3°/100 ft. Logging data indicated approximately 1,400 ft of pay divided into five zones. Two zones close to the heel were
water filled. From the log data available, an eight-zone openhole liner was selected enabling isolation of the water-filled zones
from the five oil-filled zones. Of the eighteen metal expandable packers mobilized, sixteen were run in hole to isolate the five
production zones and the three water zones. Two packers were run above the casing shoe and toe anchors to isolate Zone A
from the sump.
Caliper data (multi-finger caliper) showed the open hole was mostly in gauge, ranging from 9.7-10.0 in. well within the
packer specifications.
The packers were oriented such that the sliding end faced the planned stimulation zone. This orientation was to ensure that
if a small leak (one that could be chased with rig pumps) in the sliding end traveling seals was encountered during stimulation;
the acid would naturally leak to the stimulated zone, and thus have a negligible effect. Table 3 summarizes the packer
orientation with respect to each zone.
Table 3—Packer orientation by zone.
Zone Description Top Bottom Length (ft) Packer configuration
MD/RKB (ft) MD/RKB (ft)
Sump Sump 15,248 191 One open hole packer sliding end facing up-hole
Isolated with one open hole packer above and one open hole packer
Zone A Producing 404
below both with sliding ends facing toward the isolated zone
Isolated with one open hole packer above and one open hole packer
Zone B Producing 444
below both with sliding ends facing toward the isolated zone
SPE 166391 9

Table 3—Packer orientation by zone.

Zone Description Top Bottom Length (ft) Packer configuration
MD/RKB (ft) MD/RKB (ft)
Isolated with one open hole packer above and one open hole packer
Zone C Producing 281
below both with sliding ends facing toward the isolated zone
Water Isolated with one open hole packer above and one open hole packer
Water Shut Off 775
Shut Off below both with sliding ends facing away from the isolated zone
Isolated with one open hole packer above and one open hole packer
Zone D Producing 117
below both with sliding ends facing toward the isolated zone
Water Isolated with one open hole packer above and one open hole packer
Water Shut Off 276
Shut Off below both with sliding ends facing away from the isolated zone
Isolated with one open hole packer above and one open hole packer
Zone E Producing 199
below both with sliding ends facing toward the isolated zone
Water One open hole packer sliding end facing up-hole toward the liner
Water Shut Off 11,166 889
Shut Off hanger

Pressure from the surface pump unit was applied to set the anchors, slip joints, and open hole packers.

Proof of Barrier during Acid Stimulation

With successful completion and setting of the 7 5/8 in. liner, the inner string with ICVs, zonal pressure gauges, and internal
cased hole packers was run. The acid stimulation was carried out in individual zones from the heal (Zone E) to the toe (Zone
A). The zones were stimulated through the surface-controlled ICV flow valves. A 28% HCl solution was used for the main
treatment.
Pump rates achieved for the treatment, ranged from 10 bbl/m to 54 bbl/m as indicated in Table 4 with a Delta P of up to
5,500 psi across the metal expandable packers. During stimulation, the pressure data was recorded in the zone being stimulated
along with the pressure data from adjacent zones. A plot of the recorded data is in Fig. 16.

Fig. 16—Pressure plot showing proof of packers sealing during stimulation.

Table 4—Pump rates by stage and zone.

Stage Zone Pump rate Zone length
1 E 32 bbl/min 199 ft
2 D 10 bbl/min 117 ft
3 C 37 bbl/min 281 ft
4 B 54 bbl/min 444 ft
5 A 46 bbl/min 404 ft

Pressure integrity between zones was initially 100%, holding nearly 2,400 psi differential pressure at times during initial
injection. During stimulation it was found that when the second of two adjacent zones being stimulated underwent acid
injection, communication was established with the initially treated zone. Zones adjacent to untreated intervals maintained
pressure integrity. It is therefore suspected that the wormholes created during the stimulation in adjacent zones may have
intersected and fostered communication between the zones via the carbonate. Diagnostics in future wells will help characterize
this phenomenon and identify remedial opportunities.
10 SPE 166391

With the well on production, further zonal production testing has been completed. The results indicate that some
communication between the lower zones is present. Analysis indicates that the communication occurs within zones that were
acid stimulated from both sides of the metal expandable packer, suggesting that wormholing may be the cause of pressure
communication between the zones. The metal expandable packers isolating zones that were only acid stimulated from one
zone remain pressure tight.
The pressure tight zones and the extreme reservoir contact have yielded excellent production results for the well. The well
remains on a high production rate with less than 2% water cut despite the presence of several water swept intervals.

Further Packer Design Enhancement

To further enhance the efficiency of both the expandable metal packer and the liner deployment, additional work is under
investigation:
 Reduce the running OD to 9 in.; this will reduce the drag during liner deployment and better accommodate mud cake,
hole trajectory, and further reach.
 Reduce the final pressure required for expansion while maintaining the Delta P specification.
 Design and qualification work is being engineered to enhance the ability of the metal expandable packer to carry the
200 klbs loads within a 10.5 in. hole.

Conclusion
For many years, the petroleum industry has sought a reliable and robust solution that enabled well designs to achieve the
desired zonal isolation without being adversely affected by the increasingly higher downhole pressures and temperatures. Until
recently, engineers were limited and required to design around the phase-limits of the available mechanical isolation
assemblies, such as swell-packers or conventional inflatable systems. As this paper demonstrates, this new metal expandable
packer contains innovative design features, so that its pressure allowances conform to the preferred pumping or reservoir
pressures, and it can withstand the more extreme temperature environments being encountered today.
Expandable compounds and metals have been used within the petroleum industry with good results for many years. But as
our industry exploits more challenging environments, the previous well construction or completion methods became
inadequate. This was the case for an operator who wanted to find a way to increase recoverables from a North Sea field they
initiated production in during the 70s. Besides the challenging geological characteristics, one of the most critical needs was to
not only isolate the undesired water encroachment, but to also obtain an effective zonal isolation that would allow high-
pressure acid stimulation and subsequent improved productivity and recoverables. Using this innovative metal expandable
packer enhanced the stimulation design by providing the ability to achieve the desired hydraulic acid stimulation pressures and
rates and under large temperature swings. Furthermore, the data shown substantiates the initial acid wormholing and the
continual sealing of the expanded metal/element mechanism. The highlights of this initial application are:
 Zonal containment (improved stimulation efficiency)
 Extended pumping pressures (higher pressure containment allowed increased hydraulic pressures)
 Zonal isolation (well production monitoring and zonal closure when needed)
 Well construction (robustness of annular barrier during installation and overall operations)
As detailed in this paper, the metal expandable packer uses a unique metal assembly that not only easily expands by
applying readily available well pressure, but also conforms to the most complex formation face to achieve the desired seal and
isolation. This expansion sequence and seal is achieved due to the selected metallurgy and the uniquely designed features, such
as the pressure-activated seals. Ultimately, the expanded face of the packer obtains maximum contact with the formation
without any diminishing thickness of the membrane and thus allows maximum pressure integrity. To further enhance the metal
membrane, another engineered feature is the inclusion of the seal carrier, so that the expanded element extends the overall
pressure rating and sealing of the barrier mechanism to pressures of up to 10,000 psi.
As proven by the North Sea field trial, this all metal expandable packer extends current well construction and completions
designs; overcoming increasingly difficult bottom hole conditions. In addition to achieving the ultimate zonal isolation,
operations such as cement assurance and cementless completions can also be reliably implemented and expected to have a
long-term positive result. Finally, because the metal expandable packer has a much desired full-bore ID, production
considerations are greatly enhanced because larger production tubing can be used.
SPE 166391 11

Nomenclature
DNV = Det Norske Veritas
FAT = Factory Acceptance Test
FEA = Finite Elemental Analysis
HNBR = Hot Nitrile Rubber
ICV = Inflow Control Valves
MD/RKB = Measured Depth below Rotary Kelly Bushing
QCP = Quality Control Plan
RTTS® = Halliburton’s Retrievable Test-Treat-Squeeze (packer)
WAB = Well Annular Barrier

Acknowledgements
The authors wish to thank Welltec management for allowing publication of this paper, the North Sea Operator of the well case,
and the many clients whose use of metal expandable products has also contributed to the development of the technology and
this solution.

References
Furui, K., Burton, R.C., Burkhead, D.W., et al. 2010. A Comprehensive Model of High-Rate Matrix Acid Stimulation for Long Horizontal
Wells in Carbonate Reservoirs. Paper SPE 134265-MS presented at the Annual Technical Conference and Exhibition, Florence, Italy,
19–22 September. http://dox.doi.org/10.2118/134265-MS.
Kent, A.W., Burkhead, D.W., Burton, R.C., et al. 2013. Intelligent Completions and Un-Cemented Liners Combine to Provide a Fully
Completed Solution With Zonal Isolation in Norway. Paper SPE-166209-MS to be presented at the Annual Technical Conference and
Exhibition, New Orleans, Louisiana, 30 September–2 October.
12 SPE 166391

Appendix

Table 5—ISO14310 standard definition of the design specifications.

Min. Opening The minimum borehole size that the particular design can be run in. Part of the overall packer
construction to enable safe deployment into the well.
Max. Opening The maximum borehole size the sleeve can be expanded.
Liner/Casing Size The liner size the packer is mounted in.
Liner/Casing ID The packer designs do not reduce the ID of the casing it is mounted in.
Running OD Maximum OD while running in the hole.
Delta P during injection The maximum differential pressure the packer is qualified for while maintaining the higher
pressure in the sleeve. As the packer sleeve is open to the inner pipe pressure, this number
normally refers to the maximum differential pressure that can be achieved during stimulation. As
the sleeve is supported by the pressure, the design parameter that most affects this figure is the
number and shape of external seals mounted on top of the sleeve. There is no degradation of
pressure capabilities with expansion as the seals are designed to perform at the largest
deformation.
Delta P during production The maximum differential pressure the packer is qualified to with the lowest pressure connected
to the inner sleeve. This number normally refers to the maximum differential pressure that can be
achieved during production. There are several design parameters that affect this figure with the
most important being the sleeve thickness. Increasing the sleeve thickness increases the collapse
resistance of the design. As a trade-off it also increases the pressure required to expand the
packer. There is no degradation of pressure capabilities with expansion, as the seals are
designed to perform at the largest deformation.
Min. Operating Temp. Minimum temperature used during qualification tests cycles.
Max. Operating Temp. Maximum temperature used during qualification tests cycles.
Min. Expansion Pressure The minimum expansion pressure that should be used to expand the packer during deployment.