Eliminating Deburring Run in Multistage Single Trip Completions Improving Efficiency and Reducing Costs

Operational efficiency is critical to the economic viability of deepwater wells. To accelerate completion timelines, the Multistage Single Trip (MSST) system was introduced in the early 2000s, enabling frac-and-pack stimulation across multiple intervals in a single deployment. While this innovation significantly reduced rig time and operational complexity, it necessitated a dedicated deburring run to mitigate the risk of damage to isolation packers caused by perforation burrs. To further optimize the MSST system, metal expandable technology was integrated, eliminating the need for the deburring trip. This paper presents the planning, testing, qualification, deployment, and field results of incorporating the Well Expandable Inner String Packer (WEA-ISP)—comprising the Metal Expandable Packer (MEP) and Well Expandable Anchor (WEA)—into the MSST system. This integration replaced legacy isolation packers and enabled safe passage through perforated intervals without compromising zonal isolation or system integrity. A multidisciplinary collaboration ensured the successful deployment of WEA-ISP without altering well objectives. Key design parameters—including burr height, perforation length, and clearance—were identified to perform rigorous test on the WEA-ISP. The system underwent comprehensive ISO 14310 qualification, demonstrating its ability to withstand up to 15,000 psi differential pressure and anchoring forces exceeding 480,000 lbf. Field deployments in four deepwater wells, including both water injectors and oil producers in the Gulf of America, validated the system's performance. The integration of WEA-ISP into the MSST system eliminated the deburring run, saving an average of 2.7 days of rig time per ~30,000 ft well—equating to over $3 million in cost savings per well. The system supports both 10,000 psi and 15,000 psi treatment pressures without requiring additional inventory. This paper provides detailed insights into qualification protocols, engineering documentation, operational procedures, and contingency planning. The successful implementation of WEA-ISP within MSST completions demonstrates a robust, cost-effective solution that maintains reliable zonal isolation while significantly enhancing operational efficiency.