The actual case described here is about successful implementation of the freezing plug technology utilized as a well mechanical barrier for the first time in the company's history. The use of the ice plug resolved a complicated integrity issue and the high H2S gas producer well was brought back on to production.
Reduced space for the ice plug placement made this case unique. Despite the challenging conditions of limited accessibility, injectivity, and zero asset experience with this application, the job was performed successfully.
One of the challenges was a corroded surface casing, which is a common problem in Gulf onshore fields. The casing was previously repaired by welding a mechanical sleeve around the corroded area, which limited the plug length. Several additional problems occurred inside the Christmas tree. The wireline retrievable Surface Controlled Subsurface Safety Valve (SCSSSV) became dislocated out of the landing nipple profile and hit the Swab Valve. The Swab Valve was damaged and became stuck in the closed position, and was not holding pressure. The SCSSSV became stuck across the Lower Master Valve (LMV) and the Upper Master Valve (UMV), and left the well with no operable barriers. Well killing operations using high viscous pills ended up with lost injectivity. Different scenarios of curing this problem have been analyzed involving multi-disciplinary teams and contractors.
During further well service operations and the ice plug installation more challenges were encountered; however, all challenges were handled safely. The ice plug, once installed and tested, provided a mechanical barrier that allowed the team to perform the required services and to reactivate the well riglessly, and avoid drilling a relief well. The case was presented internally and the process was initiated to improve availability of this technology on a regular basis due to growing demand in the field.
The lessons learned during the execution of this job and the methods used will be interesting for all companies who operate naturally flowing wells, helping in curing well integrity issues in a safe and cost efficient way.