Open Hole Toe Isolation in Deepwater High Pressure High Temperature Well with an Innovative Metal Expandable Packer Saves Multiple Days of Rig Time

Abstract Openhole (OH) toe isolation in deepwater high‑pressure, high‑temperature (HPHT) wells remain 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, uncertain, and risk additional remediation at ultra‑deep measured depths. This paper documents the testing, integration, and field deployment of a metal expandable packer (MEP) used as an open hole toe isolation plug in a deepwater well at ~30,000 ft true vertical depth (TVD) under HPHT conditions (to ~21,000 psi and ~350°F). The MEP concept leveraged existing inventory, a modified liner‑hanger running tool (RT), and a structured engineering and risk‑management process to enable rapid mobilization and execution. The design review covered metallurgy (Inconel 718 base pipe with Sanicro 28 sleeve and SAF 2507 components), elastomer selection [FFKM (Perfluoroelastomer) / TFE-P (Tetrafluoroethylene-Propylene)], and anchoring/sealing requirements (ISO 14310 V3 seal qualification; axial load capacity up to ~1,000,000 lbf). Laboratory and surface integration tests confirmed the RT could actuate and release at required pressures (MEP expansion ~5,000 psi, hydraulic release ~6,000 psi). Field development for the operator involved drilling and completing three wells. A planned contingency was executed on the second well when an undesired zone was intersected at the base of the well. The MEP OH plug was deployed and set per procedure, enabling immediate progression to the OH gravel‑pack completion. Compared with a balanced cement plug (BCP), the MEP approach reduced operational time from ~80 h to ~52.5 h for toe isolation, translating to a total cost reduction from ~$3.7 MM to ~$2.7 MM for an assumed $1 MM/day rig spread, while avoiding cement contamination risks. Results, best practices, and an economic comparison are presented to support broader adoption of MEPs for open hole toe isolation in deepwater HPHT applications.