Pushing the Boundary of Ultra-HPHT Completion Technology: The First 20,000 psi, 470°F Permanent Production Packer for As-Rolled Casing

n technologies. However, well completion of ultra-HPHT fields poses great technological challenges to the operator and service companies. Existing completions technology is reaching its design limits around 15,000 psi and 450°F. As operators continue to drill in deeper and more extreme formations, the technology demand to suit these environments has steadily increased. Great efforts have been made across the industry to develop safe and reliable completion tools qualified for conditions in excess of 15,000 psi and 450°F. A new technological boundary was set recently in permanent production packer development―the first 20,000 psi, 470°F permanent production packer for as-rolled casing. A modified ISO 14310 V3 validation test was conducted on this permanent packer in as-rolled casing ID. The packer passed the test with no visible seal element extrusion, slip damage, or leaks detected at any of the load points in the test (including the bubble test). This paper presents how the packer utilizes a novel seal system design that evolved from several field-proven HPHT seal systems and the ways technological challenges are addressed using state-of-the-art materials and design processes. The paper comprises conceptual design, design optimization using finite-element analysis, and material characterization for metallurgical and seal materials. The qualification testing processes for the permanent production packer are also described in detail.