Xpandable Steel Packer technology

The development of expandable steel packers has opened new horizons. The basic concept of attaching an expandable steel sheath to the outside of the casing by welding (cost effective) or crimping (high anchoring and pressure ratings without impacting the base casing characteristics) opens up a wide range of products and applications.…

The Xpandable Steel Packer is slid onto the casing, and sealed by welding or crimping. Hydraulic pressure is applied in the completion casing to expand the metallic sleeves through an inflation port, up to the contact with the formation or casing it is set in. The stainless steel sleeves plastic deformation creates a solid and permanent annulus seal. Robust to run, set quickly, with a high pressure life of well seal, this is the ideal solution for annular zonal isolation.

The sealing is achieved with a layer of bonded elastomer on the outside of the metallic sleeve which molds the borehole geometry. It enhances the sealing efficiency and reliability, while minimizing formation stress at the packer/borehole interface. Dynamic seals can be mounted between steel rings to enhance the sealing capacity and increase the temperature range. The end fittings protect the expandable sleeve while running in the well.

Pressure compensation systems incorporated in certain steel packer versions, provide very high differential pressure ratings, well above anything else available in the industry.
As more and more successful operations are recorded, and the notion of a steel barrier between casing and borehole is shown to be the most effective possible, we can expect to find expandable steel packers becoming the industry standard for annulus integrity. Cement has been used for annulus isolation for over 100 years, replacing it by a steel barrier may well be the next revolution in the oil industry!

Annulus Zonal Isolation Packers (AZIP) are slid onto the completion casing and sealed by welding or crimping. Hydraulic pressure is applied in the completion casing. The hydraulic pressure expands the metallic sleeves through an inflation port, and the sleeves plastically deform until contact with the borehole or the casing. The deformation creates a robust and permanent seal in the annulus. Saltel Xpandable AZIP is an open hole packer specially designed for zonal isolation requirements.

Saltel Expandable Steel Annulus Zonal Isolation Packers are robust to run, set quickly, and ensure high-pressure life of the well seal. These packers are the ideal solution for annulus zonal isolation. The expandable steel zonal isolation packer seals effectively, including in oval, out-of-gauge, and irregular boreholes. It provides a cost-effective solution for the life of the well. The packer seals reliably through thermal cycling and temperature fluctuations. It minimizes cost with no special well fluid requirements for the expansion and saves time with on-demand deformation and immediate sealing.

Saltel Zonal Isolation Packer uses proprietary expandable stainless steel technology and a patented thin layer of bonded elastomer to achieve zonal isolation during injection, production, and cementing operations. Each Zonal Isolation Packer displays specific features and performances depending on the application and the well configuration.

Saltel Zonal Isolation Packer is made up of a casing string, which is run into an open or cased hole. The lower end of the string is sealed with a plug, and the internal pressure is increased by pumping from the surface. This pressure is transmitted to the packers’ integral stainless steel sleeve through the expansion port. The sleeve expands out into the annulus between the casing and borehole or outer casing string, conforming to the shape of the wellbore or casing and isolating the annulus below the Zonal Isolation Packer from the annulus above. Alternatively, one or more packers can be used for:

  • selective multizonal production
  • preventing zonal crossflow
  • conducting multizonal acidizing
  • sealing off a water zone
  • performing other remedial operations.