Designing, Making, and Testing Syntactic Foam of Precisely Controlled Hydrostatic Strength
This paper describes a recently developed syntactic foam material designed to collapse under precisely defined conditions of temperature and pressure to protect ultra-deep high pressure offshore oil and gas wells. Each grade of syntactic foam is engineered to have a specific set of characteristics, tailored for the region of the well it occupies. In the startup phase, the materials remain intact, with no significant volume change. As pressure and temperature in the well rise during operations, the materials begin to compress and relieve pressure in the narrow, confined space of the annulus. Finally, when conditions reach preset limits, the syntactic foam undergoes a sudden and dramatic collapse, preventing excessive overpressure, and protecting the steel casing. An important advantage of this material is that it is passive, requiring no controls or active intervention. It responds automatically to protect the well casing from overpressures and temperature spikes. The properties of the material can be adjusted to suit a wide range of conditions inside a given well, or from one well to another.