Openhole Toe Isolation in HP/HT Well With Expandable Packer Saves Days of Rig Time
Chris Carpenter_
This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper OTC 36363, “Openhole Toe Isolation in Deepwater High-Pressure High-Temperature Well With an Innovative Metal Expandable Packer Saves Multiple Days of Rig Time,” by Yosafat Esquitin, SPE, and Nolan Sperle, SPE, Welltec, and Kai Sun, Chevron, et al. The paper has not been peer-reviewed. Copyright 2026 Offshore Technology Conference.
_
Openhole (OH) toe isolation in deepwater high-pressure, high-temperature (HP/HT) wells remains operationally complex when deeper drilling is required to confirm reservoir boundaries, oil/water contact (OWC), or proximity to salt. Conventional balanced cement plugs can be time‑consuming and uncertain, and risk additional remediation at ultradeep measured depths. The complete paper documents the testing, integration, and field deployment of a metal expandable packer (MEP) used as an OH toe-isolation plug in a deepwater well at approximately 30,000 ft true vertical depth under HP/HT conditions (to approximately 21,000 psi and 350°F).
Background
On a newly explored area in the deepwater Gulf of Mexico, a single‑zone OH gravel pack (OHGP) was selected as the most‑effective method to complete the wells. Batch drilling was performed for the three producer wells to the top of the reservoir, where the 10⅛‑in. production casing was run and cemented. The reservoir sections of the three wells were to be batch‑completed by drilling an OH to the bottom of the reservoir formation, running the OHGP system, and tying the OHGP system to the wellhead.
Uncertainty of the reservoir bottom and potential encroachment of the underlying salt formation or the OWC was always considered.
Two alternatives were considered during the evaluation, a balanced cement plug (BCP) and an OH mechanical barrier (OHMB). The latter option was analyzed, with multiple technologies assessed, including OH inflatable packers, swellable packers, and MEP. The evaluation concluded that the best option for the OHMB was the MEP, owing to the following characteristics:
- Significant differential pressure capabilities in OH and washed‑out holes vs. inflatable and swellable packers
- Rated to HP/HT conditions, with differential pressures of greater than 15,000 psi and temperatures greater than 400°F
- Offers high load‑carrying capabilities to withstand extreme pushing forces
- The seal against the rock creates a V3‑ or V0‑rated seal to prevent liquids and even gas from passing through the sealing surface
OH Plug Requirements
The evaluation of MEP OH plug‑system requirements began with a comprehensive statement of requirements, capturing all critical downhole conditions and life‑of‑well expectations. The selected MEP OH plug and running‑tool configurations were tailored to meet the specific demands of the GOM deepwater environment. Following extensive technical reviews and stakeholder engagement, the requirements for the OH contingency plug were defined (the full requirements are provided in Table 1 of the complete paper).