This paper summarizes the completion designs and operational challenges of successful well completions in more than 400 wells in the Rajasthan onshore block of Northwest India. The Rajasthan onshore block has three core fields, with a total 37 oil and gas discoveries. These wells were completed in over three and a half years without compromising aspects of health, safety, or the environment. During the campaign, a commendable feat of zero HSE incidents was observed. These wells are broadly categorized as development and exploration wells and include a variety of both open- and cased-hole well completions. The completion systems are wide-ranging, varying from monobore conventional completions to open-hole, sand-control applications. The scope of work and challenging parameters include highly deviated open-hole and cased-hole sections, along with complex workovers. A wide range of products and services were designed to maximize well production. The completion design included a variety of packers, flow-control devices, intervention solutions, and other relevant completion tools. There were various operational, health, safety, environmental, logistical, and manufacturing-related challenges that were overcome to drill and complete the wells. The purpose of this paper is to provide insight into the well types, completion designs, and to discuss the associated challenges. The technology and practices established from these successful operations have become the standard operating procedures for completion jobs. This paper will take the reader through the evolution of well-completions technology, from the early days, when perceived risk was both hindered and was the spark for innovation, to the present time, when this technology is routinely used to meet production and reservoir development goals.

Bhagyam field is a shallow onshore field in Northwest India. The field development includes 150 production wells with 40 plus injection wells. The crude is sweet & light oil (27 Deg API) with 30 % wax content and a varied viscosity from range 50-450 cP. The Wax appearance temperature is ~ 2° C lower than the reservoir temperature of 53° C which impacts the completion design and affects the flow assurance of the field. In recent times, the field production has been impacted by frequent work-overs in the field. The run life of the PCP systems, which was impacted by tubing punctures that arose from substantial rod-tubing contact loads, had reduced drastically from ~ 500 days to 259 days. The objective of this paper is first to analyze the drastic reduction in the run life of the Bhagyam PCP systems and then provide design changes which when implemented increased the run life of the PCP system. The paper describes the measures taken and the design changes made to limit the system failure due to failed tubing and increase the run life of the system back to 500 days and will allow the readers to understand, in detail, the various types of problems that were encountered in operating PCP wells, the methods that were used to analyse the PCP failures, and new completion design that help to alleviate the problems to significantly improve the Bhagyam PCP run-life.

The subject well is a recently drilled and completed in Cambay field offshore in West coast of India. After landing the completion, two mechanical plugs were installed to nipple down BOP and nipple up X-mas tree. The plugs were installed in a 3.875" tubing hanger profile and in a 3.813" SC-TRSSSV selective profile. The problem arose while retrieving the 3.813" selective plug with 4" GS tool after installation of X-mas tree. The slickline wire snapped while doing the jarring operations resulting in fish in the well with BHA and plug slipping down below the selective profile. The plug fell inside the well and got stuck at the 4.5" × 3.5" tubing crossover joint ~20m below the SC-TRSSSV depth. The fished slickline wire along with the slickline tool-string BHA was successfully retrieved from the well, however, the plug remained stuck at the 4.5" × 3.5" tubing cross-over and could not be fished out even after several conventional approaches with slickline. Solutions involving rig based retrieval and rig less coil tubing intervention and e-line robotic technology for retrieval of the plug were evaluated. Upon completion of a detailed feasibility study of available options, it was decided to conduct fishing of the plug with e-line based advanced robotic well intervention techniques such as eline miller, tractor and stroker. Unique milling bits were designed and customized for this operation. The milling operation involved multiple runs to target the removal of various parts of the struck lock mandrel. Upon successful milling operation, it was planned to retrieve the plug with slickline. Initial attempts to retrieve the plug by straight pull using 33k pulling capacity Eline Stroker were unsuccessful. Subsequently, milling was attempted with a combination of E-line tractor and Miller to drill thru the plug. The milling initially started as per the plan but after 3 inches of milling the bit got stalled and was eventually stuck inside the plug. The E-line BHA had to be released from the mechanical disconnect sub above the bit. A modified 2" UPT tool with E-line tractor-stroker was run to fish out the bit and plug which resulted in the plug getting released from the stuck position and moving upwards about 10-meter from the stuck depth. Once this was accomplished, plug and bit were successfully retrieved with slickline. The paper details the background of the stuck incident, selection methodology of fishing technique, fishing work plan and its successful execution. The paper also describes the operational difficulties encountered and the mitigation chosen while milling a plug with an electric line in the offshore environment.