Achieving effective zonal isolation within long reach horizontal wells via conventional means, such as cement or swell packers, is becoming increasingly challenging to the industry. The longer step outs limit the Equivalent Circulation Density (ECD) due to frac/pore pressure limitations. Subsequent complex stimulation operations impose higher differential pressure (dP) across the packers.

To address these challenges, a novel design was introduced, effectively creating an expandable metal, sleeve-type annular barrier that allows cementless completions and effective zonal isolation. The design of the new annular barriers, assembled on a full bore liner, minimizes the running outside diameter (OD) whilst delivering a high differential pressure seal even within a washed out hole.

The qualification process was designed to meet the International Organization for Standardization ISO14310 V3 standard and to simulate the lifecycle of the packer during acid stimulation and later-life water management.

The benefits to operators include increased reliability and certainty for success, both in the short-term and over the life of the wells.

This paper reports recent implementation of the new annular barrier to meet the unique challenges of annular high pressure containment. Findings are supported by specific case examples, and the paper includes a discussion on design, application and performance.

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