Operators for deepwater and extended-reach wells, where daily rig costs can exceed $500k per day, are continuously exploring methods to reduce nonproductive time (NPT) and increase operational efficiency. For example, a common point of focus is liner string deployments in deepwater and highly deviated applications that predominantly employ hydraulic liner hangers. This paper presents a new liner hanger system that uses simple mud flow signals to remotely communicate with a downhole controller on the work string. The controller receives the specific activation signal from the surface and then relays that signal to the liner hanger or running tool via an acoustic signal. The results of the first test trial of the remote liner hanger system controller will be discussed. The traditional method for setting a hydraulic liner hanger includes the use of single or multiple activation balls being dropped from the surface so that pressure can be applied to the work string to function the hydraulic liner hanger and running tool. However, in deepwater and extended-reach applications, many operational issues experienced with running hydraulic liner hangers are related to not landing the ball on seat, which can lead to days of NPT. Developing a liner hanger system that does not rely on dropping activation balls from the surface nor rely on pipe manipulation can reduce the time required to run the liner hanger and minimize issues that lead to higher NPT. This new system does not require dropping activation balls from the surface, reducing the amount of running tools in the work string and the amount of time required to set the liner hanger. The system also allows the use of a solid liner hanger body, eliminating the potential leak paths inherent to hydraulic liner hangers. The results will demonstrate the first deployment of the remote system controller in a well, confirming that it detects various remote commands from the surface. The results will also demonstrate how the system enables operators to choose the activation method depending on the well and rig conditions, for example, varying the flow rate activation signals. This system and method can improve well construction efficiencies and is a step in the direction of a smarter and safer oilfield through more automated operations.

Completion systems are reviewed for gas migration prevention composed of an annular casing packer with remote-set technology activated by either a surface mounted acoustic wave generator or a downhole casing wiper plug (CWP) with a magnetic array. Proven and reliable zero-extrusion gap element technology provides a gastight annular seal while reliability is enhanced by eliminating all communication ports and potential leak paths between the packer's ID and casing annulus. Design and qualification of these systems will be discussed along with successful field installations in 18⅝-in. x 24-in. casing strings in Sakhalin Island offshore wells.

Operators for deepwater and extended-reach wells, where daily rig costs can exceed $500k per day, are continuously exploring methods to reduce nonproductive time (NPT) and increase operational efficiency. One particular area of interest is the deployment of liner strings, which are commonly used as an alternative to long casing strings to minimize well construction costs and increase drilling efficiency. For deepwater and highly deviated applications, hydraulic liner hangers are predominantly used over mechanical tools due to the limitations of pipe manipulation needed to set the hanger. The traditional method for setting a hydraulic liner hanger includes the use of one or more activation balls dropped from surface so that pressure can be applied to the workstring to function the hydraulic liner hanger and running tool. However, in deepwater and extended-reach applications, the time to pump or gravitate the ball on seat can take up to 3 hours. In addition, there are many cases where the ball never properly lands on seat, which can lead to days of more NPT. Developing a liner hanger system that does not rely on dropping activation balls from surface, nor rely on pipe manipulation can reduce the time required to run the liner hanger and minimize issues that lead to increased NPT. This paper presents how a new liner hanger system was developed to use simple mud flow signals to remotely communicate with a downhole controller located on the workstring. The downhole controller receives the specific activation signal from surface and then relays that signal to the liner hanger or running tool via an acoustic signal. The liner hanger and running tool are then actuated with an electronically triggered hydrostatic actuator. This new system does not require dropping activation balls from surface, simplifying system hook-up and reducing the amount of time required to set the liner hanger. The system also allows a solid liner hanger body with no pressure ports, eliminating the potential leak paths inherent to hydraulic liner hangers. The novel approach to design and develop the remote liner hanger system to minimize operational risks and reduce development time will be discussed in detail. This includes the evolution of the remote system from field-proven hydraulic liner hanger technology and the results from testing performed to qualify the remote communication methodology. This liner hanger system improves well construction efficiencies and is a step in the direction of a smarter and safer oilfield through more automated operations.