There are wells shut in because of damaged completion components which hinder their production control or integrity, or prevent a remedial intervention from being carried out. Often, the option to pull the completion has inherent risks from an operational, environmental and/or reservoir damage perspective and require extensive resources and time to execute. Rectifying completion component damage through a light but effective in-well intervention solution offers highly valuable options to reinstate production from such wells. This paper will discuss the rapid engineering development of an expander tool run in conjunction with an electric line deployed electrohydraulic mechanical stroker tool. Through a simple but highly-effective design, an expander tool was engineered to harness and magnify the axial force delivered by the stroker to generate a radial expansion with a force magnitude sufficient to prize out a defect in a completion component. Critical to the design was a precise measurement and control of the expansion extent and the radial force exerted, so the component in question and the other components of the completion were not damaged. This toolstring combination, coupled with real-time control and surface readout of key tool parameters, enabled a precise and measured high-magnitude expansion capability to be deployed in two different wells with ease, at pinpoint depth, and applied repeatedly across the length of the defect it was addressing. Furthermore, immediate validation of the repair was available through a drift verification pass. In both cases the in-well repair operation eliminated the need for a high cost, high risk completion retrieval and the repair operation was executed flawlessly in hours, enabling the subsequent intervention operations to be carried out and the wells be brought back on line with positive production results. The tool development was an exemplary case of rapid-response engineering, whose ingenuity stemmed from a direct customer request to solve a challenging completion defect. It resulted in a world first for an electric line deployed in-well expansion solution, the resulting value of which was well acknowledged by the customer.

An operator required straddle related interventions to be carried out on one of their platforms in the North Sea, for both straddle retrieval and straddle deployment purposes. For these they were seeking innovative solutions to deliver more efficient and effective operations providing time and cost savings. The first operation described in the paper was a straddle packer deployment, which, done conventionally using coiled tubing, would have required nine runs to install the 100-meter assembly. This was due to the limited rig up height available. The second operation was to pull a shallow set straddle before setting a plug and punching the tubing as part of a plug and abandon operation. Here, scale had accumulated above the straddle which first needed to be removed to enable the removal of the straddle itself. For both operations, a solution was devised that overcame the challenges and inefficiencies of the more traditional methods, be that using coiled tubing or slickline. In the first (straddle packer deployment), an electric line tractor was used to aid in-well straddle assembly. The tractor's real-time tension/compression readings would provide accurate and controlled deployment and a precise measurement of the over-pull verification once set. The solution provided more rig up height, enabling surface assembly of spacer pipe sections, hence fewer runs for the full straddle system deployment. For the second (straddle packer retrieval), historically such scale removal would be performed by slickline broaching—a time consuming multi-run method. Instead, an electric line powered debris removal tool string was used, removing the scale in hours instead of days. Critical toolstring space-out through the blowout preventer (BOP) stack was managed. Furthermore, an electric line powered stroker was used to retrieve the straddle sections. The application of electric line based intervention technologies provided direct and indirect efficiencies. In the first operation, the electric line deployment of the straddle packer assembly was completed in only six runs compared to the nine runs required if coiled tubing was used, which delivered a time saving of almost two days. Pre-job simulations were carried out to optimise the deployment tool string design. During the second operation, the cleanout mill string, with collection chambers added purely to manage the string space out through the BOP stack, also provided better centralisation for the milling operation. With this operation occurring within the marine riser section, hydraulic oil specification was optimised for 1 °C operation. Advantages brought about through the use of electric line deployed powered mechanical tools were apparent in both operations. The depth resolution, coupled with the real-time surface read-out toolstring command—provided by electric line—enabled fast, precise and controlled operations, including delicate straddle tagging without risk of damage. Both operations were executed successfully.

A plug needed to be set in a well located in the Norwegian Continental Shelf to shut off an existing production interval, followed by the opening of several pre-installed reservoir control sliding sleeves, in order to optimise oil production from the well. It was suggested by the service company that such a two- run operation could be combined into a single run to save time and cost. An electric line deployed solution was designed to ensure high accuracy and control across the combined operation, providing power to both the plug setting and sleeve shifting tools, along with real- time command and toolstring status readout at surface. The combined setting and shifting functionality required the use of a through-wired shifting tool to enable real-time activation of the plug setting tool, which was positioned below. A bi-directional shifting tool was used, which, in conjunction with a bi- directional stroker, would enable sliding sleeve shifting in both directions, if required, during the operation. Furthermore, its dogs were retractable on command to ensure no inadvertent shifting occurred while traversing the multiple sleeve positioned in the well. Pre-job system integration testing was done at the service company location using a mock up completion comprised of two sleeves rigged up with a tubing joint in a horizontal set-up. This tested that there was no incompatibility between the plug setting and sleeve shifting components of the combined tool string, and that no inadvertent tool hang up occurred within the completion. The toolstring was run in hole, depth correlated and the plug set and released. Subsequent correlation was then done for the sleeve section. The real-time control and surface readout of stroker force and position enabled a precise sleeve shifting operation, and all sleeves were shifted successfully as per requirements. The stroker also provided a means of pulling the plug when it got inadvertently stuck whilst running to set depth and the electric line winch was unable to pull the string free. Multiple release subs were also positioned in the toolstring to enable independent recovery of the plug and stroker assembly if required. In addition, a memory pressure/temperature gauge was run, which provided further validation of sleeve shifting upon download and analysis. A tractor was used to convey the toolstring across the highly deviated section of the well. This single-run combined service solution delivered flawless operation with considerable time savings.

Electric line deployed well intervention technologies are continuing to grow in use and relevance, this is due to the value provided by a highly efficient and effective means of intervention. It is light on equipment, personnel and logistics, is controlled and precise in its in-well execution, and is less obtrusive to the wellbore, the reservoir and the environment. These valuable characteristics are making electric line deployed solutions the preferred choice of customers for many interventions, whether that be for addressing new well completion, old well rejuvenation or repair, or eventual plug and abandon (P&A) operational scope. Preference is also increasing with those customers who are keen to push the boundaries of these technologies to leverage their beneficial impact across a broader range of intervention operations. Often, the tasks or workscope assigned to electric line deployed intervention technologies are reserved for what would be considered the lighter end of the spectrum, for example, low volume debris cleanout, small component milling and low force tool manipulation. However, as full system-based intervention technology platforms are developed, incorporating advanced interconnected technology components, the magnitude of what can be achieved has expanded electric line intervention solutions into the realms of work scope previously reserved for heavier methods, like coiled tubing or drill pipe based. That, coupled with the efficient and precise execution and inherently light footprint that electric line deployed intervention brings, is adding to the increased interest in expanding its use. Two recent electric line deployed wellbore cleanout operations carried out on the Norwegian Continental Shelf involving high volumes of debris demonstrate the advantages this advanced intervention technology platform has enabled, the scalability of its performance, and why it is challenging the traditional thinking and perception of what is possible on electric line. In the case operation 1, extensive volumes of produced sand had accumulated in a large mono-bore completion preventing the execution of a required P&A operation. In case operation 2, the well had significant Barium Sulphate (BaSO4) scale deposits over much of its length, which prevented well access for a required gas lift valve (GLV) change out. In both these cases, efficient and effective electric line deployed remediation was possible due to the increased performance, in-well task visibility and real-time task control provided by the advanced electric line intervention technology platform that was utilised. Attempting both these cases was strongly encouraged by the customer, leading a one team approach. For case operation 1, high speed tractor conveyance speeds of over 26 meters/minute were achieved on this multi-run operation. Instrumentation provided real-time indication of collection chambers being full, ensuring minimal time on depth during collection. Consistent high volume recovery rates of 100% were achieved on all but one of the collection runs, with a total of 1400 liters of sand debris being collected, clearing 280 meters of wellbore, at an average of 140 liters per 24 hours. For case operation 2, over 2000 meters of hard scale was milled, at a rate of penetration (ROP) of 44 meters/hour, on average, re-establishing access for required electric line intervention runs and the subsequent change out of the leaking GLV to restore the integrity of the well, enabling it to be put back on line and resume production. Record breaking achievements regarding the volume of debris removed and depth intervals cleaned via the intervention technology platform were made in both cases.