Record-breaking VersaFlex® ELH deployment in the Gulf of America

Overview

A major operator in the Gulf of America faced significant challenges in the deployment of heavy liners in deepwater wells. The operator sought a solution that could support extreme loads, maintain well integrity, and provide flexibility during installation. Halliburton collaborated with the operator to deliver a record-breaking solution using the VersaFlex® expandable liner hanger (ELH) system.

Challenge

Various challenges faced during these four installations included the support of heavy liner weight, tripping to TD with long string (e.g., with supplemental adapters, if the string does not reach TD, its hanger will not reach the profile necessary to support the liner load), and the capability to set down weight, rotate, and reciprocate the string to trip through tight spots.

Solution

Halliburton deployed the 16×22-in. VersaFlex ELH system, which can be set at any point in the parent casing without a fixed landing profile. This flexibility helped eliminate the use of supplemental adapter hangers and preserved the full internal diameter through the 22-in. casing. The system enabled rotation and reciprocation during cementing, which improved cement placement and zonal isolation. Halliburton’s proactive planning, detailed engineering, and collaboration with the operator helped facilitate seamless execution during four installations.

Result

The campaign delivered notable results. All four installations were completed without failure or reruns, which demonstrates the reliability of the VersaFlex ELH system. The operator gained greater operational flexibility, improved cementing efficiency, and achieved stronger well integrity.

Removal of supplemental adapters preserved future access and reduced complexity. Most notably, the system supported the heaviest liner ever deployed with VersaFlex ELH technology and established a new benchmark for load-bearing capability in deepwater environments.