(47) EXPANDABLE STEEL TECHNOLOGY: THE GROUNDBREAKING SOLUTION FOR DOWNHOLE ISOLATION
There are 3 ways that was used to make packers: inflatables, Hydro-mechanical, and swellables. Using Expandable Steel as the reinforcement of a sealing system is an innovation that allows unseen features to the market. A long history of using Expandable Steel in Casing Patch operations allowed Saltel Industries to develop unique ways to create isolation systems with expanded metals.
The Saltel Expandable Steel Annular Zonal Isolation Packer (SES Packer) is designed in a unique way. It is slid onto the casing, before both of its extremities are fixed by welding or crimping. High pressure inside the casing (or a straddle tool) is then transmitted inside the packer through an expansion port. This triggers the plastic expansion of a steel barrier which will mold inside the borehole, sealing-off the annulus for the life of the well. This simple philosophy enables Saltel Industries to provide reliable and cost effective annular isolation packers for a variety of applications.
Its simple design increases the reliability and the success ratio of the operations, as well as its cost efficiency. With no moving part, and reduced length and OD, it is sturdy to go to reach TD safely. The packer molds the formation or casing even of oval or out-of-gauge boreholes. By controlling very accurately the expansion of the metal sleeve, the operation allows to predict the stresses that will be applied to the formation. It can sustain a significant axial load before, during and after treatment. It seals even with severe temperature variations. It is sealing for the life of the well.
The sealing profile and pressure compensation systems are tailored to fit the application needs. The innovation brings:
• An increased reliability and lifespan to ECP (External Casing Packers) used in cement stage operations, with a gas tight efficiency and a 10,000 psi internal pressure rating to sustain frac pressures.
• A slim profile for existing well isolation to mitigate the ID loss for Refrac or Remedial application with the Slimline Packer
• A 10 to 15k differential rating even with temperature drops with the FracPacker used in Open-hole completions (with ball-drop sleeves of CTAS)
• A preserved Well Integrity after the setting of the Well-Integrity Annular Zonal Isolation (WI-AZIP)
This paper will describe in details the advantages of Expandable Steel technology applied in Casing Patches and in Packers for those applications, and will go through the necessary qualification process used for demanding environments.