Adapting to Requirements: Custom HPHT Bridge Plug Solution for HPHT Field Development

A major North Sea operator required a contingency barrier solution in the event of a failed pressure test of their 5.5” – 26.0# liner shoe. The solution needed to pass through a 4.125” restriction while withstanding a differential pressure of 10,700psi and a temperature of 196°C in heavy-weight Oil Based Mud (OBM). Additionally, it had to be ISO 14310 validation grade V0 qualified, ensuring the highest level of sealing integrity under demanding conditions.
 

To add flexibility, the operator requested a solution that could also accommodate a potential 5.0” – 18.0# liner, in case they were unable to run the 5.5” – 26.0# liner. This meant the barrier needed to be adaptable to different liner sizes while maintaining full reliability. Furthermore, the operator required a contingency solution for setting a hydraulic production packer and pressure testing the upper completion to 15,000psi. These factors called for a well-engineered, versatile solution capable of meeting a broad range of technical requirements without compromising performance.

Interwell did not have an existing High Pressure High Temperature (HPHT) Retrievable Bridge Plug (RBP) that met the operator’s specific requirements, so the team embarked on a Design & Development (D&D) project to create the 397-550 (3.97” OD for 5.5” tubing) HPHT Retrievable Bridge Plug (RBP). This solution was ISO 14310 validation grade V0 qualified to withstand 10,700psi differential pressure in a temperature range of 200-120°C in 5.5” – 26.0# tubing, ensuring its reliability under challenging well conditions. Post ISO testing, the RBP was pulled through a 4.125” restriction ID to confirm that it could be deployed and reliably retrieved through this narrow restriction.

In response to the operator’s request for greater flexibility, Interwell developed a conversion kit to accommodate deployment in a 5.0” – 18.0# liner. By adapting the 397-550 HPHT RBP into the 397-500 HPHT RBP, we ensured the solution could be utilized in either liner size without sacrificing 
performance or reliability. The RBP’s adaptability was confirmed by successfully achieving ISO 14310 V0 qualification for both liner sizes.
 

Additionally, Interwell addressed the operator’s requirement for a contingency solution capable of setting the hydraulic production packer and pressure testing the upper completion to 15,000psi from above. We carried out an ISO 14310 validation grade V6 test, achieving V0 acceptance criteria for pressure testing at 15,000psi from above in 5.5” – 26.0# tubing, ensuring the RBP could handle the full range of operational pressures.
 

One of these RBPs was recently installed and pressure tested successfully in the first of four wells planned for the operator. Initially designed as a contingency barrier for a failed pressure test in the 5.5” – 26.0# liner, it was decided during the drilling phase that the RBP would become the primary barrier solution in the shoe track for all wells.
 

Throughout the project, Interwell maintained continuous dialogue with the operator, providing regular updates and ensuring the development process stayed aligned with the client’s evolving requirements. This collaborative approach resulted in the successful delivery of RBPs and conversion kits, offering the operator a reliable and flexible solution for their well operations.

Interwell delivered a flexible and reliable HPHT RBP barrier solution that met the operator’s complex requirements, ensuring seamless adaptability for both the 5.5” and 5.0” liners. The development of a conversion kit allowed the operator to avoid costly delays while maintaining operational efficiency. By successfully qualifying the RBP to ISO 14310 V0 standards and conducting a 15,000psi pressure test from above, Interwell ensured the operator had a robust solution for both primary and contingency operations. The successful installation of the RBP in the first well demonstrated its reliability, while continuous communication and alignment with the operator’s needs ensured smooth project delivery, adding significant value to their well operations.