Development of a novel packer fluid for high-temperature and high-pressure oil and gas wells with using design of experiments and artificial intelligence

This study introduces a novel phosphate-based packer fluid, designed for use in high-temperature and high-pressure oil and gas wells. The research aims to evaluate the performance of this innovative fluid in comparison with traditional acetate and formate-based fluids. The study highlights the enhanced performance metrics of the phosphate-based fluid, which include a higher density of 114 pcf, moderated pH levels from 13.5 to 10, and a significantly reduced corrosion rate to below 4 mpy, achieved through the addition of diammonium phosphate and potassium vanadate. Moreover, the research presents two machine learning models (an artificial neural network (ANN) and genetic programming (GP)) developed to predict the penetration depth of the phosphate-based fluid. Both models demonstrate high accuracy, with R-square values of 0.9468 and 0.9140, respectively, with the ANN model exhibiting slightly superior performance. The findings of the study indicate that the phosphate-based fluid, free of solubilizers and enhanced with innovative corrosion inhibitors, provides optimal thermal stability, minimal formation damage, and shallow penetration depth, thus representing a significant advancement in well completion technologies. The fluid's distinctive properties and the predictive models' high accuracy highlight its suitability for challenging environments, marking a notable progression in well completion technologies.