Expandable liner system suits deepwater installations

Overview

In the deepwater Carnarvon Basin offshore Western Australia, a major operator faced repeated failures in drilling and completing a challenging well. Severe borehole instability and fluid losses had compromised previous attempts. To overcome these issues and reach total depth (TD), the operator selected the XtremeGrip® expandable liner hanger (ELH) low equivalent circulation density (LECD) system. This robust solution enabled the successful installation and cementing of a 9 5/8-in. production liner in a depleted formation with complex wellbore conditions.

During the run-in-hole (RIH) operation, the well presented significant challenges,  including the need for aggressive reaming for >1000 m from just outside the casing shoe through the openhole (OH).

The operator required liner system with gas-tight integrity and the ability to maintain LECD throughout cementing to protect the sensitive formation. Halliburton used its global footprint to expedite logistics and deliver the system on short notice. 

Challenge

The well encountered significant fluid losses and borehole stability issues because of the requirement to reduce mud weight to manage the losses. Reaming was required throughout the entire OH section, from 3360 to 4390 m, and extended wash periods were necessary. High torque and revolutions per minute were applied to maintain progress. The depleted formation demanded careful management of equivalent circulating density (ECD) to avoid further losses during liner deployment and cementing.

Solution

To address these challenges, the operator deployed the XtremeGrip® ELH LECD system. This technology provided the flexibility needed for aggressive string manipulation, including reaming, circulating, rotating, and weight-down operations. Its ability to maintain low ECD during cementing was critical for protecting the depleted formation and ensuring high-quality cement placement. The system’s robust design and debris tolerance enabled it to operate effectively in complex borehole geometries and handle suspected cuttings and cave-ins without compromising performance. 

Halliburton’s rapid response and global inventory ensured the timely delivery of the system, allowing the operator to proceed without delay. The XtremeGrip ELH LECD system’s adaptability and strength made it the ideal choice for this high-risk environment.