Abstract:
To address the severe lost circulation issue during technical casing cementing in deep and ultra-deep wells, and to improve wellbore quality, enhance drilling efficiency, and ensure wellbore integrity, our research team has developed a multi-component expansion packer-type stage cementer. This study adopts an approach combining integrated innovation and technological invention. A safety logic controllable technology is designed to integrate the packer with the stage cementer, eliminating various potential risks caused by their separate connection. Additionally, a multi-component expansion packer technology is invented, establishing a three-stage sealing mechanism: "primary setting via fluid injection + secondary permanent isolation via curing + tertiary sealing enhancement upon hydrocarbon contact". Specifically, initial sealing is achieved through hydraulic expansion; permanent structural support is formed by epoxy resin curing; and hydrocarbon-sensitive expandable rubber fills micro-annular gaps to ensure the long-term sealing performance of the packer. Laboratory tests have verified that the packer can withstand a pressure of 45 MPa, exhibiting excellent sealing and pressure-bearing capabilities. This tool has been field-applied in over 300 wells in the Tarim Basin, supporting the construction of 18 key "Category-1" exploration wells. It has effectively overcome the technical bottleneck of lost circulation in ultra-deep well cementing, providing reliable technical support for the development of deep hydrocarbon resources.