Session: 13-03-03: General: Mechanics of Solids, Structures and Fluids III

Paper Number: 164759

Finite-Element Analysis for the Design and Optimization of High-Pressure Liner Top Packers 

Liner top packers (LTPs) serve as critical pressure barriers in well completions, preventing hydrocarbon migration by sealing the annular space between a liner and the previously installed casing string. These packers rely on elastomeric sealing elements, which expand radially upon deployment to form a pressure-tight seal. The failure or suboptimal performance of an LTP sealing element can result in hydrocarbon leakage, posing environmental and operational risks. This study focuses on the design and analysis of a high-pressure LTP sealing element composed of an annealed AISI 8620 steel frame bonded with an AFLAS elastomer. Activation occurs through a downward compressive force applied to a cone, inducing deformation of the metal frame and elastomer to establish an effective seal.

 

This paper presents a comprehensive finite-element analysis (FEA) methodology for optimizing LTP sealing element performance. The developed numerical model incorporates key physical phenomena, including plastic deformation of the metal frame, hyperelastic behavior of the elastomer, thermal expansion effects, interfacial friction between the sealing element and both the cone and wellbore casing, and pressure penetration. The simulations were conducted using ABAQUS, capturing interactions between the sealing element and associated components such as the cone, slips, and seal stacks. Model setup, material properties, boundary conditions, and solution processes are detailed, demonstrating the robustness of this approach in predicting LTP performance under downhole conditions.

 

Case studies are presented to assess critical performance parameters, including slip engagement, expandable element sealability, the impact of external loads, and sealing performance under extreme conditions of 15,000 psi differential pressure at 350°F. Model validation was achieved by comparing numerical results with full-scale physical qualification tests performed at SLB in accordance with API (American Petroleum Institute) standard 19LH. The FEA methodology played a crucial role in troubleshooting and refining key packer components, leading to enhancements in slip design, expandable sealing elements, and seal stacks. Despite inherent modeling simplifications, the simulation results exhibited a strong correlation with experimental data, reinforcing the accuracy and predictive capability of the approach.

 

The developed FEA methodology contributed to the successful design and qualification of 15,000-psi-rated LTPs, which have been deployed in the field since 2023. These packers have been installed in multiple wells in the Kingdom of Saudi Arabia without reported operational failures, further confirming the reliability of the modeling approach. The findings highlight the effectiveness of advanced FEA techniques in developing LTPs that comply with API 19LH standards, ensuring robust performance in high-pressure downhole environments. The insights gained from this study underscore the value of numerical modeling as a powerful tool for optimizing packer designs and enhancing the reliability of wellbore sealing technologies.

Presenting Author: Jose Hurtado SLB

Presenting Author Biography: Jose Francisco Hurtado is a Principal Mechanical Engineer at SLB (formerly Schlumberger), based at the Completions Center in Rosharon, Texas. With over 21 years of experience in oilfield equipment development, he has specialized in designing and optimizing coiled tubing tools and completion systems. He currently works in the Liner Hangers and Multilateral Rapid Response Group, focusing on advanced wellbore solutions.

Jose earned his bachelor's degree in Mechanical Engineering from Universidad Tecnologica del Centro in Venezuela and went on to obtain both his Master of Science and Ph.D. in Mechanical Engineering from the Georgia Institute of Technology in Atlanta, USA. He is a licensed Professional Engineer in the State of Texas.

Authors:

Jose F. Hurtado SLB
Richard Windslow SLB
Juan Macin SLB