Successful Implementation of Barrier Device Glass Plug Technology for Enhancement of Well Barriers Assurance Process

Abstract This technical paper presents valuable insights and recommendations related to Barrier Devices, commonly known as Glass Plugs, which have been extensively utilized by the largest UAE Oil and Gas Operator to enhance well integrity assurance. In 2019, the Operator revised its internal Company procedures for verifying completion barriers during well construction. These revisions aligned the practices with international industry standards. As part of this enhancement, the use of Barrier Devices (specifically Glass Plugs) became mandatory during the installation of upper completions in wells capable of establishing natural flow. The decision to adopt Barrier Devices was driven by the need to address challenges associated with conventional slickline operations, including stuck plugs and limitations in depth accessibility due to high inclination angles. From the beginning of 2023 Operator successfully completed over 400 wells, utilizing Barrier Devices for setting production packers and conducting inflow tests on downhole safety valves. Notably, the Operator emerged as a major global consumer of Barrier Devices, not just within the Middle East. Access to Barrier Device technologies from various vendors allowed the Operator to accumulate extensive experience with different types of Barrier Devices—ranging from mechanically removed to remotely activated options, each with varying metallurgies and sizes. These Barrier Devices were effectively integrated into Upper (Cased Hole) Completions, serving as an alternative to traditional slickline plugs. The extensive use of Barrier Devices led the Operator to compile a comprehensive database of lessons learned and practical recommendations. This knowledge is invaluable for future deployments of this novel technology. Additionally, close collaboration with Barrier Device vendors facilitated operational efficiency improvements, enhanced equipment reliability, and ensured alignment with the Operator's Drilling Plan, meeting HSE and well integrity requirements. Despite a long term existence of glass plug technology on the market, comprehensive details on the selection and efficient usage of these completion tools remain scarce. By sharing insights into technology principles and best practices based on end-user experiences, this paper should benefit other industry professionals.