Liner hanger operations and well integrity across the liner overlap have been always a challenge in the gas well. Conventional liner hanger relies on elastomeric devices as the primary sealing mechanism to isolate the liner lap strings, with two trips required to deploy the liner hanger, top packer and tie-back seal. This paper will introduce an expandable liner hanger/packer and tie-back system to isolate high pressure reservoir and problematic shale in Offshore Abu Dhabi.

The selected single-trip expandable XPak liner hanger/packer and tie-back system offers a metal-to-metal seal throughout the complete liner stack, with 17 to 24 inches of an expandable section on the hanger/packer body that generate sufficient metal-to-metal contact area between the liner and the host casing achieving a robust sealing device that is to be considered as a primary isolating barrier. Feasibility review of technology was then conducted, covering review of running procedure, risk assessment and success criteria (covering HSE, performance, integrity, and efficiency). Business case was issued to install the 13-3/8″ × 9-5/8″ system. The system was deployed in a gas well drilled in 2021. Cementing job of 9 5/8″ liner was conducted smoothly with liner string rotated at 10 rpm while pumping & displace cement. Liner hanger/packer was set with 4,400 psi, hanger setting was then confirmed with 70 klbs overpull and the setting tool was released by slacking off the drill string with 120 klbs.

The operation was conducted safely and with zero NPT. The system was successfully demonstrated by the effectiveness of the offered features and its running procedure. Liner and tie-back casing integrity was achieved and confirmed through successful pressure tests. Based on the trial result, the selected single-trip expandable liner hanger/packer and tie-back system achieved the defined success criteria. The actual time saving from deployment of single-trip expandable liner hanger/packer and tie-back system compared to conventional liner hanger in this application is 2.54 rig days. The detailed analysis and operation feedback will be beneficial to assess the suitability of this technology to overcome future drilling and integrity challenges.

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