How industry demand has led to the development of solutions designed for ‘the next frontier’ of offshore drilling
At the end of July 2025, US well specialist, Expro, launched the most advanced version of its Brute Packer system for deepwater wells, the Brute Armor Packer
One aspect of this launch that Jeremy Angelle, vice president of Well Construction, is particularly proud of, is the system’s ability to help users overcome longstanding and tough challenges. “The Brute Armor Packer suite wasn’t just another incremental upgrade,” he emphasises. “It was a direct response to industry demand for high-spec solutions in extreme deepwater environments, particularly for 20k psi-rated wells and large outside diameter (OD) casing strings.”
Putting this technical evolution into context, Angelle explains: “During well suspension operations, Gulf of America operators follow government regulations that require temporary well barriers to be placed very close to the mudline in subsea wells. This setting depth requirement limits deploying standard equipment deeper in wellbores to counteract increased pressures from reservoirs below. The Brute Armor concept began with a project directly commissioned to address this exact issue for a major operator’s Gulf of America, 20ksi development. Expro was tasked with delivering a retrievable packer system that could be used as a suspension barrier to satisfy regulations and withstand unprecedented downhole pressures that could be encountered in this next frontier of offshore drilling.”
Since that initial project, Angelle reports a powerful ripple effect that nicely illustrates the user demand for such a solution. “Following the successful initial runs, we are continuing to work with the same major operator, but we are also in conversations with other operators that are in the process of planning for their 20ksi projects around the globe. Additionally, we have received other positive feedback that has pushed us to commission projects that push this concept across the other Brute Packer sizes.”
SCALABLE SOLUTIONS
Size is a subject Angelle is often focused on, and he highlights another recent innovation from Expro that demonstrates exactly why size matters. The company has launched a new 20in/22in packer system, which addresses the historical challenges associated with these size retrievable mechanical packer systems. Detailing this development, Angelle says: “Once we started to see successful testing results with Brute Armor, a new question was asked: ‘if Armor can perform in high differentials environments, could this technology handle relatively lower differential pressure, and push the historical limits on seal expansion and retraction?’” The answer was a decisive ‘yes’, as Angelle confirms: “That discussion led to us scaling the technology to the 20in/22in Brute packer design to specifically address large casing string well suspension applications.”
Expanding on this concept, Angelle explains: “Subsea wellheads and blow out preventors (BOPs) have internal clearance restrictions when compared with 22in casing strings that have become very common in subsea well designs. In the past, these clearance issues have been a problem for mechanical packers. Historically, the industry solved the issue using ‘inflatable’ retrievable packer systems. Although these systems have served the industry well, they have technical and operational limitations that a mechanical packer system does not have. That being the case, creating a mechanical packer that could expand enough to meet operator requirements, while not having limitations of the current tool of choice, would give the industry a ‘best of both worlds’ solution.”
STRESS TESTING
When asked to comment on applications of Expro’s new innovations, Angelle says that, “The one thing all these applications – i.e. high pressure, high expansion – have in common is the increased amount of stress put on the elastomer seals.” Because of this, he reveals that Expro is now evaluating, “any – and all – of the industry’s current applications where standard elastomer seal designs are being pushed to the limits.”
And though he can’t confirm specific details on future announcements, Angelle hints: “I can tell you to be on the lookout for two more Brute Armor projects. We are currently wrapping up a development project, for the same major operator, that will result in the release of two new Brute Armor sizes. These sizes will be functional in 14in and 11-1/4in casings with pressure differential ratings above 15ksi and should be released by the end of 2025.”
Looking further ahead, Angelle adds: “Once those packers are released, another area we will focus is the industry’s need for ‘gas-tight’ retrievable barriers. Gas containment is another environment that highly stresses elastomer seals, and we believe our Brute Armor system can provide a solution in that space.”
PURPOSE BUILT
When asked what is unique about Expro’s technical approach, Angelle says that, “It is driven by innovation with a purpose. It starts with a deep understanding of key trends – spanning geographies, basins, formation targets, and rig designs. What sets us apart is a proven formula that allows us to identify and interpret these trends years in advance, enabling us to anticipate the evolving challenges operators will face in safely and efficiently extracting hydrocarbons.”
He continues: “Leveraging this foresight, we continuously adapt and refine our innovation strategy to maintain a sustainable competitive advantage. This positions us as a trusted advisor to our customers – focused not only on technology, but also on solving their most complex operational problems. From this foundation, we build technology roadmaps that align with real-world needs and deliver advanced solutions with measurable results.”
