SPE 109791

Wellbore Isolation Intervention Devices Utilizing a Metal-to-Metal Rather Than an

Elastomeric Sealing Methodology
Gordon Mackenzie and Garry Garfield, Baker Oil Tools

Copyright 2007, Society of Petroleum Engineers

This paper was prepared for presentation at the 2007 SPE Annual Technical Conference and
Exhibition held in Anaheim, California, U.S.A., 1114 November 2007.
This paper was selected for presentation by an SPE Program Committee following review of
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presented, have not been reviewed by the Society of Petroleum Engineers and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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Box 833836, Richardson, Texas 75083-3836 U.S.A., fax 01-972-952-9435.

Abstract
Metal-to-metal sealing technology is a medium-tohigh expansion, innovative type of seal that utilizes
expanding metal to achieve a fully formed pressure
barrier on a tubular wall. The presented material will
highlight the evolution of common oil and gas industry
wellbore isolation/intervention devices that take
advantage of a sealing system with an expandable
metal-to-metal approach rather than a more
traditional/conventional elastomeric packing element
style.
The applications for the technology within our
industry are wide ranging even reaching through areas
such as completions, liner hangers, sand control, and
flow control. Initially the development was centered
around proving the technology from a predominantly live
well intervention philosopy focusing on bridge plugs and
straddles. The replacement of an elastomeric sealing
element applies in many environments; however, the
metal-to-metal seal is designed with an extraordinary
seal performance envelope that cannot be achieved by
conventional elastomeric seals and is perceived to be
particularily desirable within the realms of hostile, high
pressure, high temperature and geothermal markets.
Many common failures in these type of environments
leading to NPT issues will be shown to be mitigated with
a technology step change in seal design.
The results of the learning curve knowledge gained
from both the design and implementation phase of the
project will be compiled and introduced. Case histories
to highlight the effectiveness and uniqueness of the
technology will be disseminated in order to show the
differentaiting technology between the use of a metal

sealing methodology when compared with that of an

elastomeric approach.
Evaluation of the metal-to-metal sealing technology
will offer a guide in order to help in the construction of a
set of criteria to fully interpret the benefits and selection
of a metal sealing technology over an elastomeric seal.
The contributions to our industry will be shown through
the features and benefits of the metal-to-metal sealing
technology over an elastomeric sealing system.
Description
The first evolutionary step for bridging devices was
launched in Prudhoe Bay, Alaska, in the mid 1980s with
the introduction of the inflatable-type isolation device.
The inflatable-type packers and bridge plugs had never
before seen expansion characteristics dictated by the
necessity of deploying through production tubing and
setting in the casing below the completion while
maintaining pressure holding capability. The inflatable
tool was born and would forever change the high
expansion world for pressure isolation devices.
As operations in bottleneck type completions were
becoming more common practice in the workover arena,
the applications for the through-tubing inflatable also
began to evolve, including:
1. Selective and zonal chemical treatments;
2. Temporary and permanent plug back
operations;
3. Intermediate zone blank off;
4. Production and injection flow profile
modifications; and
5. Formation fracturing.
As applications began to increase, the development
of high expansion tools followed closely with the
evolution of permanent and temporary bridge plugs,
permanent cement retainers, permanent and retrievable
straddle systems, and reliable coiled tubing conveyed
multi-set straddle systems for accurate placement of
wellbore treatments such as acids, scale treatments and
water shutoff polymer gels.
It was clear that the requirement for high expansion
sealing devices was considerable in bottleneck type
completions given the increasing neccessity for medium

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SPE 109791

to high expansion alternatives occurring wherever a

restriction (either planned or unplanned) exists above
the depth at which the intervention is required. In
response to the industry continuing to push the limits of
elastomer technology in regards to pressure,
temperature, and expansion ratios, the development of
the high expansion, metal-to-metal sealing system was
initiated in 2000.
Application
Initiated in 2000, the original scope of the metal-tometal sealing system project was to develop a bridge
plug capable of achieving 10,000 psi differential at 350
degrees F. The design concept of the sealing system
relied upon the controlled application of load to expand
the seal and create a fully formed pressure barrier. The
compliant metal of the seal forms this pressure barrier
with the inner diameter of the tubular wall into which the
tool is being set.
Traditional rubber, polymer, and plastic based
sealing systems all have their limitations in terms of
maximum differential pressure, temperature, chemical,
and/or gas resistance. The complete replacement of
elastomeric seals with metal-to-metal sealing technology
fundamentally revolutionizes downhole equipment
performance by eliminating commonplace elastomer
failure modes, including:
1.
2.
3.
4.
5.
6.

Gasification/Explosive decompression;
Temperature degradation;
Shearing across extrusion gap;
Dynamic fatigue under pressure cycles; and,
Compression load catastrophic failures;
Chemical degradation

The metal-to-metal sealing system has evolved since

2000 to a point where expansion ratios of up to 160% of
the original run-in diameter are possible while at the
same time being able to preserve the systems pressure
and temperature requirements. The expansion
characteristic from the non-elastomeric seal is a
desirable feature to have for applications that would
have previously only been serviceable by inflatable type
elastomeric devices.
Although still in its relative infancy, the development
has resulted in a metal-to-metal sealing system
employed primarily on well service type tools such as
permanent and temporary wellbore plugging devices,
straddle systems, and flow control devices.
When examining the traditional failure modes more
commonly associated with elastomeric type sealing
systems on well servicing tools, such as bridge plugs,
the metal-to-metal seal is designed to overcome what
can become a catastrophic failure for not only the
service tool itself but in most cases the entire workover
operation.
Gasification and explosive decompression are
phenomenon generally applicable within an environment
containing gas under pressure.
Gasification is a
particular threat to elastomers because of their relatively

lower elastic strength and potentially becomes significant

for service applications exceeding pressures as low as
510 psi. Gasification is most common at elevated
temperatures when the elastic strength of elastomers
has been significantly reduced or at sub-zero
temperatures when the elastomers are brittle.
In
conditions where pressure differential is high, serious
damage can occur to elastomeric seals after just a single
decompression cycle. The description of explosive can
be misleading, since decompression damage can occur
even when pressure is let down gradually over many
hours similar to the run time associated with tripping out
of the hole with downhole equipment. Elastomeric seals
contain voids and rigid inclusions that are produced
during manufacture. In downhole environments, fluids
that are in contact with elastomeric surfaces are
absorbed into the material and the absorbed gas
diffuses into the bulk of the elastomer until fully
saturated. At higher pressure, the absorbed gas is in a
compressed state; however, when external pressure is
suddenly reduced, the compressed gas nucleates at the
voids, expands within the elastomers, and the voids
inflate leading to high tensile stresses or strains in the
void walls. If the tensile void wall stress or strain is
higher than the strength of the elastomer, then cracks
can form and propagate leading to the explosion of the
elastomer. Since the metal-to-metal seal is a nonelastomeric sealing system, it is immune to the effects of
gasification and explosive decompression since gas will
not penetrate to metal components of the seal itself
Temperature degradation is a common failure mode
in elastomeric sealing systems that can occur when
operating in high temperature environments that are
becoming increasingly more common in the industry as
wells are drilled deeper and in more remote locations.
Elastomeric seals are highly temperature sensitive and
start to mechanically break down at temperatures as low
as 150-200 degrees F. Sealing with an elastomer in
temperatures beyond 250-300 degrees F can be
extremely difficult. However, the metal-to-metal sealing
system is constructed entirely of metal and is not
sensitive to temperature failure modes normally
encountered in oil and gas operations. Feasibility
studies of the metal-to-metal seal have shown the
potential of the seal to operate successfully in
temperatures up to 700 degrees F.
At
downhole
pressures
and
temperatures,
elastomeric sealing systems can begin to act in a fluidic
manner that leads a phenomenon where failure can
occur due to shearing of the element across the
extrusion gap. Not only will extrusion gap failure cause
a pressure loss in the elastomeric sealing system, it can
also make the service tool difficult to retrieve especially
when retrieving through restrictions in the ID above
setting depth. High pressure differential across a rubber
based seal may cause the rubber to break down and
extrude. Anti-extrusion rings help support the rubber
over the extrusion gap; however, the inherent lack of
strength of the elastomer causes failure at high loads.
The failure becomes even more problematic as the seal

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SPE 109791

expansion is increased. The metal-to-metal seal is

constructed entirely of metal and can withstand and
support high pressure forces giving it the integrity to
withstand extrusion gap failure.
Chemical degradation of elastomer seals can occur
in harsh environments that utilize traditional elastomeric
sealing systems. Elastomers are highly sensitive to
chemical attack and correct material selection is vital.
Elastomers may break down rapidly if exposed to
aggressive chemicals.
The metal-to-metal sealing
system is constructed from advanced CRAs normally
utilizing a nickel based alloy favoured in oil and gas
applications as that most resistant to chemical attack.
The corrosion resistant properties of the materials used
for the metal-to-metal seal typically exceed the qualities
of the tubular materials.
The advantage of the metal-to-metal sealing system
over conventional, traditional elastomeric seals can be
seen when compared in the above mentioned failure
modes. The analysis shows that generally speaking the
metal-to-metal seal is not susceptible to the same failure
modes as the elastomeric sealing systems giving. The
technically advanced design of the metal-to-metal seal
gives it superior qualifications in the more harsh
environments the industry is continuing to work in as
wells get deeper, hotter, and more remote.
The first application identified and chosen specifically
to prove the metal-to-metal sealing concept (in a worstcase scenario) was a high expansion, fully retrievable,
bridge plug. A bridge plug is run into an oil or gas well
and can be set at any depth to act as a barrier to flow or
pressure and is vital in the construction and
maintenance of a well. The bridge plug has to be
retrievable and may also be required to pass into and
out of a restricted wellbore. The metal-to-metal seal was
required to form a pressure barrier inside poor condition
and uncontrolled diameters of completion tubing.
Since the first application of the metal-to-metal seal
being run on a bridge plug was identified, it quickly
became the most common type of application for the
sealing system used for zone isolations similar to
traditional bridge plugs. A bridge plug with metal-tometal sealing technology can perform operations that
require pressure integrity for zone fracing, water or gas
shut-off, or abandonments.
The expansion ratio
characteristics allow the bridge plug to be run through an
upper restriction in the wellbore and be set in a lower
portion of the completion for remedial work. These types
of applications that are required in a bottleneck type
completion or workover are ideal for the metal-to-metal
sealing system especially in cases where higher than
normal temperatures are encountered and increased
operating pressures are required.
The second most common application of the metalto-metal seal systems was to be run as part of a straddle
system. A straddle system combines two bridge plug
type devices with a tubular mid section that joins the
plugs in tandem. Straddles are used to isolate or patch
a section of a well where a leak exists or unwanted flow
occurs while providing a flow path to a point below the

straddle.
These systems are essential in the
management of mature fields where isolation of nonproductive zones or water producing zones can lead to
massively improved oil recovery. The higher expansion
ratio and low profile nature of the metal-to-metal seal
allowed it to be used for straddle systems that could be
deployed through wellbore restrictions and still provide a
large production through bore. This cost effective,
remedial, through-tubing, zonal control system can
provide operators with an alternative to the more
expensive completion workover, which would previously
have been required.
Since the metal-to-metal sealing system was initially
designed to be run in a restricted wellbore or throughtubing environment, the conveyance methods for tools
equipped with the sealing technology had to comply with
the same outer diameter limitations as the isolation
devices. Therefore, a contingent of running tools had to
be designed to be compatible with conveyance methods
common to the through-tubing environment. Bridge
plugs and straddle systems loaded with the metal-tometal sealing system can be run and retrieved in a
restricted wellbore on coiled tubing, electric wireline, or
slickline.
Results, Observations and Conclusions
The first case history involved an operator that
required a proppant frac operation on a set of upper
zone perforations to a maximum potential differential
pressure of 7500 psi. It was of critical importance to the
operator to have the lower four perforated zones in the
well permanently isolated. The well was completed with
5.50-inch, 20.00 lb/ft, N-80 tubing crossed over to a
4.50-inch, 12.60lb/ft, tubing string above a 6.625-inch,
65.80 lb/ft Q-125 material production liner. The minimum
restriction within the production tubing above the liner
was a 3.833 inch ID gauge carrier. With the ID of the
heavy weight production liners being 4.375 inches, the
geometry of the wellbore eliminated the use of a more
conventional type, full gauge, bridge plug with which to
provide isolation of the lower producing zones. It was
also identified by the operator that there was the
potential for the production liner at the proposed bridge
plug setting depth to be in a non-round or oval condition.
The well parameters were such that the top of upper
most lower four perforated zones to be isolated were at
a measured depth of 11,723 feet and the open
perforations to be treated with the proppant frac were to
be placed at 11,697 feet to 11,707 feet. The maximum
deviation of this well at the plug setting depth was 67.
After the plug was to be set, the operational plan was to
perforate the new upper zone, perform a proppant frac,
and then clean out prior to returning the well to
production.
The first stage of the development and testing
program was identified to be an engineering feasibility
study into the potential of setting a metal-to-metal
sealing device for a zonal isolation plug with a maximum
running OD of 3.60 inches, while utilizing coiled tubing
as a deployment method. The designed OD was

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SPE 109791

required in order to pass all potential wellbore

restrictions and still have the capability of sealing and
anchoring within the 4.375 inches ID of setting depth
within the liner. For this program it was dictated that the
worst case minimum restriction would be a 3.725-inch ID
XN profile as the operator had identified the potential
for similar operations to be conducted on multiple wells.
This feasibility study also necessitated that the plug be
able to function at a temperature of 350 F. The
minimum required differential pressure rating was 6000
psi although it was noted that a 7500 psi rating may be
beneficial for future operations.
Once it was identified by the feasibility study that the
required parameters could in fact be met, the project
was accelerated to the next stage. The operator supplied
a joint of casing for the test which had an approximate ID
of 4.448 inches. The test joint was considerably out of
round in places and had one large flat area protruding
into the ID along the full length of the test joint as a
representation of the potential IDs that could be seen in
these wells.
A 3.60 inch OD, 17/4 PH stainless steel bridge plug
dressed with a 316 SS metal sealing system was made
up to the hydraulic setting tool and shear stud and
positioned within the ID of the test joint. The application
of applied pressure to the setting tool up to 4400 psi
initiated and completed the setting sequence including
the release of the bridge plug. Prior to pressure testing,
the position of the plug within the joint was measured
and recorded in order to identify any potential plug
movement under pressure testing conditions. A number
of pressure tests were then conducted in order to firstly
satisfy the minimum pressure requirement followed by
efforts to achieve the higher pressure criteria. Initially a
hydraulic pressure test of 6000 psi from the top side of
the plug was successfully conducted with a hold time of
thirty minutes. A similar test with equal results was
conducted from the lower end of the bridge plug. With
the successful conclusion of testing to the acceptable
criteria, a similar set of tests were conducted, but this
time meeting the upper 7500 psi specification. After
removal of the test caps the position of the set plug
relative to the casing was again measured. No linear
movement of the bridge plug in relation to the test casing
had occurred, proving that not only had the metal-tometal sealing system functioned under load but also that
the anchoring system had maintained the plugs position
under a loading condition greater than 110,000 lbs. of
equivalent force.
The metal-to-metal seal plugging system was then
released and removed from the test casing by means of
utilizing a GS spear along with a mechanical spang jar.
Once released the plug was visually inspected. The
metal-to-metal seal had deformed appropriately to the
casing ID and had a good symmetrical profile. The slip
condition was good with no visible wear indication of the
wickers. All other component parts of the plugging
system were in good condition.
Although initially the operator had a preference for
deployment of the plug on wireline, the low bottom hole

pressure at setting depth exhibited by the well led to the

use of coiled tubing as the deployment method. The
metal-to-metal sealing system, when deployed on either
slickline or electric wireline, utilizes bottom hole or
hydrostatic pressure to function a multi-stage setting
tool. In this particular well, the low BHP would have
resulted in the setting tool having a length greater than
would be practical for live well operations. For this
reason coiled tubing would be used whereby applied
surface pressure was more than sufficient to achieve the
balance between force requirements and lubricated BHA
length. The operator selected to utilize a 2.375-inch OD
coiled tubing spread. Although the application called for
a permanent isolation of the lower four perforated zones,
this high expansion metal-to-metal sealing system did
have the flexibility engineered within to allow for release
of the set plug should for any reason it be required.
In order to position the plug at the required setting
depth, a memory logging tool along with a caliper tool
was run on coiled tubing in order to position a flag
reference point on the coiled tubing. The plug was run in
hole in July 2005 on the coiled tubing utilizing a standard
coiled tubing bottom hole assembly along with a
circulating valve and a multi-stage hydraulic setting tool.
Once the bridge plug had been correlated to the required
setting depth of 11,713 feet MD the setting ball was
released in order to shut-off the circulation from the
coiled tubing and allow for the application of applied
pressure. The application of applied pressure was
staged in order to maximize the efficiency of both the
anchor deployment and the uniform expansion of the
metal-to-metal seal within the profile of the heavyweight
production liner. With the final application of 4500 psi,
evidence was seen at surface of the parting of the shear
ring. The coiled tubing was slowly raised from the plug in
order to identify that the setting tool was in fact released.
At this point a pressure test of 5000 psi was conducted
on the plug to confirm the reliability of this isolation in
terms of both anchoring ability and metal-to-metal seal
integrity. With the confirmation of the successful
pressure test the BHA was run back in the hole to
conduct a weight test on the plug to 5,000 lbs. in order to
confirm that the plug had not moved.
Once the BHA was retrieved, the 3.125-inch, 0 180, 5 shots per foot (SPF) TCP gun was deployed in
order to perforate the new zone. On completion of this
perforating, the proppant fracture operation was
conducted which consisted of a 4305 lbs 100 mesh slug,
followed by 7010 lbs 12/18 RC proppant slug through
the perfs at 30 barrels per minute (bpm). Then 346,000
lbs of a 12/18 resin coated proppant was pumped. A
total of 10,995 lbs of proppant was left in the wellbore.
Maximum wellhead pressure during the frac was 3813
psi. On conclusion of the proppant frac, prior to returning
the well to a stable production rate of 2,000 BOPD, a
coiled tubing clean out operation was conducted.
The next case history involved a water injector well
that required the isolation of an upper zone in order to
allow the continued injection profiles into the lower
zones. The mixed tubing string of 5-1/2-inch, 17 lb/ft

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SPE 109791

and 20lb/ft had a minimum restriction of 3.650-inch ID

because of a partially closed fluid control valve. The
straddle system that was to be installed to isolate the
upper zone required the top pack off to be set in the 17
lb/ft tubing and the lower pack off to be set in the 20 lb/ft
tubing. The objectives were to first mill out the partially
closed fluid control valve with coiled tubing deployed
mills and motors to 3.91-inch ID. Also, the clients
required the straddle system design to allow up to
20,000 B/D of injection fluid, to be compatible with either
slickline or coiled tubing conveyance methods, and had
to be retrievable. The solution for the application was to
develop, test, and install a straddle system that had an
OD of 3.85 inches, an ID of 1.81 inches, capable of high
expansion while maintaining a 5000 psi pressure
differential. The lower straddle packer was run on coiled
tubing and set in the 5-1/2-inch, 17 lb/ft pipe. A single
coiled tubing run was made to set the upper straddle
packer in the 5-1/2-inch, 20 lb/ft tubing with the spacer
tubing and centralized latch stinger in place. The
straddle system was approximately 875 feet long and
was recorded as the longest straddle deployed from a
semi-submersible. Operations were completed safely
and successfully despite bad weather conditions and
significant heave.
The next case history utilizing metal-to-metal sealing
technology was for custom built bridge plug application
to isolate holes in the tubing string of an injector well.
Due to the well integrity problem resulting in tubing-toannulus communication, the objective was to install an
injection valve in the tubing below the hole and allow the
continued use of the injector well. The custom designed
bridge plug/packer incorporated the metal-to-metal seal
and was built to set inside the 5-1/2-inch, 20 lb/ft tubing
while maintaining a run-in OD small enough to pass
through the 4.675-inch minimum restriction. To allow for
the continued used of the injector well without replacing
the tubing string, the injection valve was designed and
developed to be run in conjunction with the bridge plug.
Both the bridge plug and injection valve were engineered
to withstand the platform injection rates of 25,000 to
30,000 B/D. The objectives required the bridge plug and
injection valve combination to allow the well to be
injected into but also required to act as a deep-set safety
valve. On completion of fishing the previously installed
slick plug, the bridge plug/injection valve system with
metal-to-metal sealing technology was run in the well on
slickline utilizing a hydrostatic setting tool to a setting
depth of 17,413 feet. After the bridge plug was set, a
leak-off test was performed on the well to confirm the
metal-to-metal seal was indeed holding pressure. The
injection valve on the bridge plug had allowed the
required injection rates and the plug was retrieved after
180 days of successful isolation.

the application of new technology within their operations.

The advantage of having a reliable high expansion
metal-to-metal seal is that it offers the industry the
opportunity to solve many of the predicaments
associated, particularly with elastomeric seals, in HP /
HT environments. It is also a conclusion that with new
technology evolution the operator / service company cooperative approach towards acceptance is very much in
the interests of both parties. Here the approach taken
was to task the new technology owner with the feasibility
study based on sample well requirements, followed up
with committed resources funding relevant lab testing
and ultimately field mobilization and installation. The
metal-to-metal high expansion seal as the enabler for
this intervention allowed the well to be delivered within
objectives, within the AFE and with a good production
profile.
Significant New Contributions
To date, development focus has been restricted to
the incorporation of the metal-to-metal seal onto bridge
plugs and straddle systems in the well-servicing market.
However, due to the outstanding potential of the metalto-metal seal, a vast array of additional well-servicing
products still awaits the incorporation of technology. In
addition and more significantly, the technology can be
used for completions products such as packers, liner
hangers, and flow control devices to name a few. The
metal-to-metal seal demonstrates the ability to retrofit to
existing packer technology thus removing the need to
redesign a complete packer system to incorporate the
benefits of metal sealing technology.

Conclusions
These particular operators, as evidenced by the
above illustrated case histories, have clearly
demonstrated their willingness to embrace and prove out

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