An operator in the Middle East wanted to install 11,878 ft of production liner, with the bottom at 27,904 ft. The extended openhole length combined with a low fracture gradient made it challenging to manage formation surges without risking loss of wellbore fluid to the formation. Earlier operations in the field had highlighted these issues, and the operator was seeking a system with superior bypass capacity, minimized ECD, and high hanging capacity to derisk installing the longest liner in the field.
SLB introduced its Xcelis high-performance liner hanger system, which provided >160% increase in hanging capacity and >13% increase in bypass area compared with conventional systems. Torque and drag simulations were conducted using ERA (Extended Reach Architecture) Wellpath Builder and the advanced liner installation planning analysis technology option within DrillPlan™ coherent well planning and engineering solutions.
These simulations confirmed the Xcelis system's ability to support the liner's weight and reach the desired setting depth. The system's enhanced bypass area effectively minimized ECD and the risk of lost circulation due to surge pressure, facilitating lower circulation pressures, higher flow rates, and faster speeds while running in hole (RIH). Unique design features reduced the risk of presetting and loosening or loss of slips while the high operational torque capacity enabled using rotation to reach target depth.
The proprietary system saved 8 hours during the RIH phase compared with offset wells without inducing any fluid losses. Initiating circulation at the setting depth required 350-psi-lower pressure but still enabled faster cleanout, saving an additional 2 hours. The liner top packer was set at 16,025 ft, where the well inclination was 71°, and annular pressure testing confirmed an effective seal. This successful deployment demonstrated the benefits of the Xcelis system and provided valuable insights for future projects.
