Design and Installation of an On-Demand Activated Electronic Liner Shoe Mitigates Risk of Differential Sticking and Eliminates Intervention Cost

Abstract This paper presents a case study of the first installation of an on-demand activated Remote Actuated Shoe (RAS) in offshore extended-reach wells. The Middle East operator faced challenges related to potential differential sticking while running lower completions in high overbalance conditions. To mitigate this risk, the liners were equipped with isolation-valve Inflow Control Devices (IVICD) and a system at the toe of the liner to allow circulation from the shoe. However, conventional ball drop-activated shoe valves proved unreliable and time-consuming, often leading to expensive interventions to close the liner shoe. In collaboration with the operator, the original equipment manufacturer (OEM) designed a fit-for-purpose RAS tailored to offshore applications. The RAS was programmed to close after measuring 400 psi above hydrostatic pressure for 45 minutes, providing an on-demand solution for immediate closing of the liner shoe after reaching total depth (TD). A ported bullnose with choke functionality was also designed to create the pressure increase during circulation to signal the RAS to close once at depth. Upon reaching TD with the lower completions, the wells were circulated for the prescribed 45 minutes before seeing the indication that the shoe had shut, and the completion was successfully set as per plans. The successful installation of the on-demand RAS resulted in significant cost savings, with $1 million saved in potential intervention costs and a reduction of 120 metric tonnes of CO2 emissions per well. Two offshore wells have been completed successfully so far using the on-demand RAS, leading to its adoption as the standard liner shoe for the operator's offshore extended-reach wells in these fields. This case study demonstrates the effectiveness of the on-demand RAS in mitigating risks associated with high overbalance conditions, differential sticking, and operational challenges during the installation of lower completions in offshore extended-reach wells. The findings highlight the potential for significant cost savings and environmental benefits through the adoption of innovative intervention less technology in oil and gas operations.