The paper is focused on emerging plasma-based milling technology enabling wider use of Light Intervention while restoring Well Integrity. The tool should be able to RIH through tubing minimizing footprint of the equipment using coiled tubing system. The presented milling technology uses electrical plasma for material disintegration. A significant advantage is based on the size of disintegrated material when compared to conventional milling producing massive swarf / debris. Analysis of cuttings produced during casing / tubing milling with plasma-based tool shows that their size distribution is based on the major fraction in the range of 1-5 mm. This feature reduces possibilities of intervention failures related to swarf / debris in the well in order to maintain Well Integrity. The technology is currently under development with expected field testing in 2016. Currently, the technology´s application is focused on Plug & Abandonment (P&A) service while being developed within Joint Industry Project (JIP) with O&G operators and oilfield service provider. Parallel to JIP, the team is capable to customize the technology and the tool itself for applications like slot recovery, side-tracking and pipe recovery. The unique features of the plasma-based technology can be beneficial for several Well Intervention applications in the Middle East region.
The main objective of the paper is to present the possibility of non-contact approach based on electrical plasma in downhole milling or cutting operations. The features of this approach can be beneficial for a variety of Well Intervention applications characteristic for Middle East region. These applications include slot recovery, side-tracking, pipe recovery and several others. The presented approach utilizes thermal electrical plasma capable to disintegrate a variety of materials (steel, cement, rock) with the same tool. Milling or cutting using this approach is based on a hybridized plasmachemical and thermochemical processes resulting fast metal degradation and removal in water steam environment. The main processes responsible for the rate and effectivity of steel/cement removal are oxidative processes as well as melting and evaporation. This non-contact approach utilizing coiled tubing (CT) technology brings also improved reliability by minimization of wear and tear of the tool itself. Based on its features, the technology can bring the following benefits into Slot recovery application area: Multicasing milling in fewer trips100% rigless operation – Light Well Intervention Vessel offering flexible use and satisfying immediate needsGeneration of small swarf (no mechanical stuck, less viscous and cheaper fluids)Reduction of HSE-related risks due to reduced tripping and automated CT systemReduction of issues with fluid management due to simplified handling with milled materialShortening of the whole process due to its structural simplification Similarly, the mentioned features can be used also for other potential applications including: Multi-lateral side-trackingPipe recovery of stuck BHARepair/replacement of damaged casingWellhead retrieval Moreover, after development and modifications of the tool geometry, it can provide an efficient substitution of conventional junk/fish milling tools.
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