Banyu Urip Upper Perforation Shut-off: A Success Story of Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production

Saputra, Dian; Nugraha, Putu K. A.; Patel, Naynesh; Albouy, Charles

doi:10.29118/ipa20-e-9

Proc. Indon. Petrol. Assoc., Digital Technical Conference, 2020 2020

DOI: 10.29118/ipa20-e-9

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Banyu Urip Upper Perforation Shut-off: A Success Story of Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production

Dian Saputra¹,

Putu K. A. Nugraha²,

Naynesh Patel³

et al.

Abstract: ExxonMobil Cepu Limited (EMCL), as the operator of Banyu Urip field in Cepu Block, Indonesia, observed several oil wells with high Gas Oil Ratio (GOR) after several years of production. Oil production curtailment was expected due to limited surface gas handling capacity. Additional stand-off against reservoir gas cap shall be established by performing top perforation interval shut-off to reduce GOR and maximize oil production. Perforation shut-off became more challenging due to high concentrations of H2S and C… Show more

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Intelligent Coiled Tubing Operation Practices to Install Expandable Casing Patch

Rahimov

Arstianti

Cahyono

2022

SPE/ICoTA Well Intervention Conference and Exhibition

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A customer in Asia Pacific had challenges with high gas oil ratios on several wells that limited production as not to exceed a gas handling facilities capacity. One of the most effective and challenging options proposed to isolate the intervals of high gas production was the installation of expandable metal patches. While historically the preferred deployment method of a patch has been wireline, due to the accuracy required to set the patch, with coiled tubing enhanced in providing real-time data transfer, the advantages of utilizing it for installing mechanical isolation become superior. The Intelligent coiled tubing system consists of a customized bottom hole assembly that transmits differential pressure, temperature, casing collar locator and tension-compression-torque data instantaneously to the surface via a nonintrusive wire installed inside the coiled tubing string. All of these parameters are crucial for an appropriate deployment of a patch, the information is required to accurately understand the scenario of what is happening downhole at each given moment and what effect a control input could possibly have on the work scope The right solution to a problematic well is only as good as the accuracy it can be applied with. The Intelligent Coiled Tubing System was a defining factor for the success of the production solutions. The setting process of the patch is composed of several duplicated cycles; these cycles must be performed simultaneously and be harmoniously integrated with a very small margin for error. On an intervention where 99% accuracy is not enough, the proper performance of each patch installed, is also attributed to the precision of the data received from the sensors in the BHA, this made possible for the patch to be set at the right depth and in the due diligence required for the scope. The efficient system performance confirmed the advantage of using intelligent coiled tubing for patch installation, providing immediate production benefits to the operator and direct positive financial impact. This paper will detail the process followed, to successfully set the multiple patches in the several wells. It will also highlight the accuracy from the coiled tubing performance simulation vs the execution.

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Intelligent Coiled Tubing Operation Practices to Install Expandable Casing Patch

Rahimov

Arstianti

Cahyono

2022

SPE/ICoTA Well Intervention Conference and Exhibition

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How Expandable Casing Patches Can Restore Casing Integrity and Enable the Sidetracking of an Old Well

Shahreyar

Kelly

Albouy³

et al. 2023

Day 2 Thu, March 02, 2023

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This paper describes how an operator restored the casing integrity of a nonproducing well to resume offshore drilling operations by installing four 10¾-in. overlapping expandable steel patches. From 2020 to 2022, the operator scheduled a sidetrack drilling program, Māui A Crestal Infill (MACI), from the Māui A offshore platform, located in the Taranaki Basin of New Zealand. The operations included eight wells targeting the remaining unswept zones within the Māui A structure. During a reentry in a plugged and abandoned well, MA-03, a multifinger caliper log and a failed pressure test indicated a casing leak in the 10¾-in. intermediate casing. The log identified severe longitudinal casing wear with some fully penetrating holes. This lack of integrity prevented the scheduled operations from being performed. Several lost circulation material (LCM) and cement squeeze jobs attempted to seal off the leak but were unsuccessful. A service company proposed a mechanical repair solution to cover the long interval with four 13-m- (42.7-ft)-long customized, overlapping patches. Later, a second caliper was run to check if the cement squeeze jobs had reinforced the area for better patch support. Surprisingly, the zone appeared significantly more damaged, with a complete circumferential casing breach. Thus, the planned solution looked very challenging to implement. A video camera run, additional thinking, modeling, and cooperative engineering led to a complete redesign of the solution. The lengths and positions of the patches were changed, and one of the patches was assigned to serve as an inner reinforcement. The team assembled, deployed, and installed the patches in an accelerated mode. In 10 days, the casing integrity was fully restored, enabling the 8½-in. sidetrack hole to be drilled to total depth. This case is a typical example of how industry practices should evolve regarding the management of casing integrity issues. Remedial cement squeezes are often prioritized over mechanical options, even though mechanical options are now adjustable, much quicker to implement, and likely offer greater success rates.

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Banyu Urip Upper Perforation Shut-off: A Success Story of Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production

Cited by 2 publications

References 0 publications

Intelligent Coiled Tubing Operation Practices to Install Expandable Casing Patch

Intelligent Coiled Tubing Operation Practices to Install Expandable Casing Patch

How Expandable Casing Patches Can Restore Casing Integrity and Enable the Sidetracking of an Old Well

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