Downhole Completion Challenges and Solution using Critical Nonmetallic Sealing Technologies

Abstract

Many of the new completion technologies were introduced to address the challenges related to the increasing well complexity and the advancement in the downhole high-pressure high-temperature (HPHT) realm. This paper focuses on the evolution of Nonmetallic sealing technologies used in downhole completion tools, from the simple O-ring based chevron stacks to the energized hybrid composite seals. Furthermore, future advances in seal development are discussed to tackle the new corrosive challenging environments. A literature review and subject matter expert input were gathered to study the nonmetallic seal design technologies and tool applications. The topics covered include material selection; chemical and environmental resistance; mechanical design and characteristics; durability and abrasion resistance; rigors of verification and life validation testing; challenging corrosive downhole scenarios for seals; and harnessing the environment to create application-specific seals. Various categories of sealing functions are discussed, including tubing/annulus barriers, static/dynamic sealing configurations, and temporary/permanent applications. Sealing technology selection for every downhole tool in the completion string is crucial to ensure safety, reliability, and profitability of a well completion for its planned life. This paper provides a reference with guidelines and best practices for reservoir and production engineers. Often, collaboration projects between operators and service providers can help in developing tailored and advanced Nonmetallic solutions. An understanding of sealing technology will assist in efficient project execution and curated design assurance.