The methods used for high-pressure/high-temperature (HP/HT) tool development are evolving, and development cycles are lengthening, particularly for ultra-HP/HT applications (those involving pressures greater than 15,000 psi or temperatures greater than 350°F) in which materials screening and stability assessments are required. What can the industry anticipate for future HP/HT wells in terms of architecture, product development, and regulatory challenges? This paper identifies current development paradigms and discusses the future challenges in well planning, product development, and regulation.
HP/HT Completion Technology Challenges
The technological challenges associated with the completion of wells at and above HP/HT conditions are diverse and continue to increase. Previous investigations into HP/HT projects identified technology gaps related to packers, bridge plugs, liner hangers, subsurface safety valves (SSSVs), tubing-to-packer seals, and related products. (Please see the complete paper for a comprehensive list of challenges faced in HP/HT environments, as well as a discussion of the historical perspective in HP/HT well development.)
In addition to the general challenge of materials design and testing for HP/HT environments, several specific component-based challenges also exist.
Packers. Packers and bridge plugs have been developed for service conditions as challenging as 500°F and 25,000 psi, but the primary difficulty in the development process today is the availability of materials, both metallic and nonmetallic, which are suitable for very high levels of stress and strain and which possess the desired corrosion resistance to achieve longevity requirements.
SSSVs. SSSVs contain many dynamic seals which must maintain their integrity and operating characteristics over the life of the completion.
