Well engineers are often presented with a number of potential solutions to drilling challenges as they develop a plan to safely and efficiently execute the drilling program to meet the overall well objectives. The solutions will be evaluated and the option that presents the lowest risk while providing the maximum benefit is normally selected as the preferred solution.The scope of this paper is to review the challenges faced by a North Sea Operator after identifying the likely presence of high pressure gas stringers in a carbonate formation on a recent brown-field datagathering well, and the subsequent deployment of solid expandable technology to provide a safe and effective solution. Solid expandable tubulars have demonstrated value as a reliable alternative solution to conventional liners in providing zonal isolation of troublesome formations while maximising drill-through inside diameter (ID). The improved technology and increased reliability in the systems has provided greater confidence that the systems can be deployed successfully with an acceptable level of risk.The Operator required the isolation of a high pressure gas-bearing zone located below the 9-5/8Љ casing shoe to enable the safe drilling and logging of the reservoir section. The use of conventional liners was evaluated but discounted due to the reduction in internal diameter that would prevent subsequent logging and running of the planned liner in the reservoir section. Deepening the 9-5/8Љ shoe to cover the high pressure stringers presented higher risks associated with drilling into the anticipated depleted reservoir. After evaluation of the various options, solid expandable technology was selected as the best option to meet the well objectives.A 7-5/8Љ 29.7 lb/ft solid expandable liner system was successfully installed to isolate the high pressure gas stringers located below the 9-5/8Љ shoe. The system included an expandable liner hanger set in open hole to provide zonal isolation in place of cement. In addition, the liner lap was extended back into the 9-5/8Љ casing to isolate a leaking stage tool. The application of both repairing a casing leak and isolating a high pressure open hole zone using an uncemented liner was a first for the Operator. This allowed the Operator to drill the reservoir section with a lower mud weight while minimizing the risk of differential sticking and losses, the logging program to be conducted as desired and the 5-1/2Љ fibreglass liner to be installed as planned. The safe and successful drilling of the well, coupled with the capture of desired information met the Operator's well objectives, adding value to future field development.While this was the first solid expandable installation in this size for the Operator in the area, their confidence in the technology from previous installations allowed them to adapt the system to provide the required open hole zonal isolation whilst also reinstating integrity to the 9-5/8Љ casing.
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