High Expansion Zonal Abandonment Solution for Extended-Reach Horizontal Well in the Middle East

Region: Middle East
Well Type: Offshore Oil Producer

Key Facts:

  • Field Proven Globally
  • Available for setting in Cased/ Open hole application
  • Available in different sizes and configurations (to set in holes as large as 30”)
  • Successfully deployed offshore and onshore
  • Provides axial and radial seal and anchor
  • Available for HPHT applications
  • Bi-directional seal with DuraGRIP technology

Challenge

A leading offshore operator in the Middle East required a tailored solution to shut-off an open-hole formation taking excessive fluid losses in an extended-reach horizontal well. Zonal abandonment was required to properly finalize drilling operations and commence completion activities in a safe and timely manner. The main challenges associated with this application were as follows:

  • The target zone borehole inside diameter (ID) was expected to be washed out to a range as high as 16 to 20 inches.
  • There were no caliper logs available for review.
  • The well had an 8.6” ID restriction above the open hole section.
  • Well control procedures required pump-through circulation during deployment.
  • Excessive drag forces through the horizontal section prevented effective axial manipulation at setting depth.
  • Conveyance through the extended-reach open hole section required the bottom hole assembly (BHA) to be rotated during deployment.

Solution

IPI’s tailored solution for this challenge was an 8” OD Permanent Inflatable Bridge Plug configured as a Cement Retainer (PIBP-CR). The BHA was configured with the following custom-made components in order to increase reliability:

  • An 8” OD inflation element was designed and tested for the job in order to increase elastomer cross-sectional thickness and reduce the risk of potential element damage caused by frictional forces through the horizontal.
  • A dual-shear sleeve sub to enable circulation, allow compatibility with a pressureactivated swivel, and obtain pressure competence for bridge plug inflation as well as hydraulic-release disconnection.
  • An emergency locking valve was also included in the design as a contingency to regain pressure competence, which was required for the activation of other components across the BHA.

The PIBP-CR was deployed to setting depth and it was inflated by applied pressure. The setting sequence was finalized by the activation of a shut-in valve mechanism which permanently locked in the inflation pressure within the bridge plug. Zonal isolation across the bridge plug was obtained by activating a bi-directional dual flapper sub which was functioned by pulling an inner-stinger at the time of disconnection. IPI’s DuraGRIP™ inflation element technology was used to provide leak-free bidirectional anchoring and the integrity of the shut-in valve was thoroughly tested against flow erosion based on the maximum expected flow rates and volumes prior to the job.

Created Value

The PIBP-CR was set in the horizontal section of the well and zonal losses were successfully shut-off in a single run, allowing the operator to carry on with programmed completion activities. The job was successfully executed in a safe and timely manner without operational issues, which generated substantial savings in operational costs and rig time.

 

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Stuart Brown

Director

Stuart recently joined IPI as the Director of Oil and Gas, bringing with him 15 years of diverse experience in the industry, with a strong focus on inflatable packers. His extensive background encompasses a variety of roles, including field engineering, operations management, sales, and business development. This breadth of expertise, coupled with his international experience in markets across North America, Europe, Australia, and the Middle East, positions Stuart to effectively lead and expand IPI’s oil and gas operations on a global scale. Stuart holds a Master’s degree in Mechanical Engineering from the University of Aberdeen and a Master’s degree in Finance from City University of London. His robust technical foundation and financial acumen uniquely empower him to drive strategic initiatives and foster growth within the company.

Masoud Jangani

Director

Masoud joined IPI Packers in 2022 as the Oil & Gas Region Manager for the Asia Pacific, bringing over 20 years of experience across operations management, technical sales, and business development in the resources sector. His diverse career spans both the mining and oil & gas industries, where he has held key leadership roles at global companies. In 2024, Masoud was appointed Director of the Mining, Water, and Geotech product lines (MWG), driving strategic growth and expansion across these sectors. Masoud holds a bachelor’s degree in engineering and graduate certificates in finance and business law.

Garry Taylor

Dave Knell

Director

David (Dave) Knell has been involved with the manufacture and application of inflatable packers for over 35 years. He started his career as an apprentice aged 15, and within a year, was running packers offshore, in Western Australia. Dave was the first employee of IPI and has been instrumental in the development of IPI’s manufacturing facility and capabilities. His knowledge of building packers is backed by extensive experience in the field, an innate understanding of real-world applications, and a fierce attention to detail. Dave is currently focused on expanding IPI’s ISO9001 certified manufacturing operations on a global scale, to better serve customers and to foster the continued growth of the company.

Francis Ford

Director

Francis joined IPI in 2005, based in Perth, Western Australia, as an apprentice. He developed his skills in manufacturing, tool and packer design and field operations across multiple industries – mining, water, civil/construction and oil & gas. His level of expertise and understanding enabled him to progress into leading IPI’s R&D efforts as manager. This included leading key custom / OEM designs and their practical developments, for multiple clients as well as continuing to progress the design and development of IPI’s unique systems. Now as engineering director, he is developing IPI’s engineering team to better support clients by improving our predictive packer modelling and fostering the continuous improvement of our packer tools and technology. A member of the Society of Petroleum Engineers and author of several technical papers, he is credited in several industry patents.

Joel Adams

Director

Joel Adams is a hydrogeologist, turned packer expert who has spent 30 years applying inflatable packer technology to complex downhole problems. His experience includes well testing for nuclear waste site characterization, water resources, water rights, rock stress testing, water well rehabilitation, and plug and abandonment (P&A). Joel has been leading the team as Director – North America since 2007 and has been associated with IPI, either as a key customer, agent or employee, since its founding in 1999. He led the introduction of IPI packer technology to P&A work, offshore in the Gulf of Mexico, and the establishment of DuraFRAC® packers as the market leader in the water well hydrofrac market. With numerous publications and presentations, Joel is a recognized expert in well testing and custom packer system design.

Howard Kenworthy

Director

Howard joined IPI in 2005 as commercial manager when IPI had 5 staff and was making customized product to order. His prior career was with UK public companies in retailing and financial services, leading operating companies. He holds an MBA which he took a few years after his degree from Oxford (Philosophy, Politics and Economics). He has led IPI’s distribution development with standard products and established most of IPI’s international operations as part of his role in business planning, finance and strategy. This included joint ventures in the USA, Chile and Indonesia. He was based in South East Asia 2015 to 2022, prior to relocating to Sharjah in the UAE, from where, as Commercial Director, he continues to develop and co-ordinate planning and strategy, the group’s global distribution and financial operations.

Clem Rowe

Founder and Executive Chair

Born and bred in Western Australia, Clem is a Curtin University graduate with a degree in mechanical engineering. Early in his career, Clem worked on offshore engineering projects in Western Australia and France. While working offshore, Clem was first exposed to inflatable packers, manufactured by a small Australian company that he subsequently joined in 1988 as Engineering Director. Clem established IPI in 1999 and has grown it from a small Western Australian manufacturing operation, to the world-wide manufacturing and distribution organization that it is today, by carefully selecting a competent team, that shares his values of quality, innovation and customer service. Clem is a member of the Society of Petroleum Engineers, the Institute of Hydrogeologists and the Institution of Engineers, Australia. He is the author of multiple articles and papers on inflatable packers and their application and has several international patents to his credit.

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