As well completions and operating objectives grow more complex, it is reassuring that certain physical parameters can be measured and predicted with extremely high precision. Precision during operational execution using real-time measurements from a customized bottomhole assembly (BHA) is a benefit offered by coiled tubing (CT) fiber-optic technology. Today marks an important milestone and basis for a new era with the development of a real-time hybrid CT service that integrates fiber-optic and electric communication and power. This paper discusses an efficient milling operation using real-time fiber optics with continuous power from the surface, referenced as the first operation performed globally. The following three potential risks are typically associated with milling operations: CT failure attributed to cyclic fatigue loading under extreme conditions and/or exceeding the torque capacity as a consequence of the transmission of the rotational force of the motor.Premature damage to the components of the motor while exceeding the torque capabilities of the motor because of the lack of parameters at surface while milling.Motor stall that can converge into a bit-stuck scenario, or misinterpreting torque output through the motor when pumping fluid commingled with an incompressible gas. The sum of all these conditions generated a challenging scenario. These conditions were also ideal to validate the accuracy and reliability of this technology wherein, because of downhole sensors (torque, load, and differential pressure), it was possible to monitor the milling process in real time, even when there was no detected variation in these operational parameters at the surface. The real-time fiber-optic integrated system enables efficient, reliable execution during CT milling operations. Additional downhole insight is available with the new generation of hybrid technology for CT services, which combines fiber-optic and electric downhole powering communication. This system was designed with an open architecture to accommodate virtually any wireline or mechanical tool in the industry to address operator challenges, such as a milling operations, allowing the operator to monitor the weight on the bit, torque, and differential pressure through the bit. With the ability to constantly monitor bottomhole conditions, it was possible for the engineer to make decisions in real time, even when there was no evidence of any milling constraint at surface. Because the variables did not vary during operation, efficiency increased because of adequate optimization of the motor capabilities. This paper explores one of the many possibilities operators have with hybrid technology for CT services, radically increasing reliability on location. This technology allowed the operator to significantly diminish operational time during milling in a single run without limitations to power or operational duration.
Underbalanced perforating with conventional cable operations involves several risks associated with well tortuosity, cable tension capacity, gun lifting, and the capability of achieving the optimum underbalance for effective tunnel cleanup (Graeme et al. 2008). Because of these risks, an operator in Colombia elected to perform a perforating operation using a coiled tubing (CT) real-time fiber optic (RTFO) integrated system in a newly drilled development well. CT-conveyed perforating is ideal for this type of wellbore. To achieve the proper underbalance and depth correlation to perforate the target interval, an RTFO CT system provides the most accurate and reliable depth correlation process, in addition to real-time pressure and temperature monitoring inside the CT and the outer annulus. Using the RTFO CT system, only two runs were necessary to complete the perforating program, in accordance with the operator design, rather than performing an additional run needed for pickling and to generate underbalanced conditions. The use of the RTFO CT system can help to prevent correlation errors resulting from CT elongation. A CT structure was not necessary to deploy the guns based on the finite model analysis that calculates maximum stress and flange bending, including a safety factor. A hydraulic firing head can be used with an RTFO CT system to activate the guns without affecting the integrity of the fiber optics or the downhole sensor tool after detonation. The RTFO CT system enabled the operator to evaluate the reservoir potential. The evaluation results indicated that one of the zones is a low producer, which avoided the pumping of unnecessary nitrogen to induce the specific zone. The use of a downhole pressure sensor enabled the identification of the time at which the guns were detonated. Improvement to the rigup was evidenced and enabled time optimization without affecting the operation. The casing collar locator (CCL), used for depth correlation, was a crucial factor in reducing operational costs because it helped to optimize placement accuracy and gun detonation and to prevent misfiring (Newman 2003). The guns were successfully activated without nonproductive time (NPT) or health, safety, or environmental (HSE) incidents during operations. A successful perforating operation was completed with 4,000 psi underbalance in a new formation using hydraulic detonation with continuous real-time downhole condition monitoring before and after detonation, enabling the operating company to make decisions in real time. This new approach of using an RTFO CT system combined with the hydraulic firing head can be used to perforate new formations in these crucial scenarios (wells with production greater than 20 MMscf/D and zones with continued sand production).
To measure and analyze reservoir pressure, conductivity, gas/oil ratio (GOR), and skin value, it is necessary to run a pressure buildup (PBU) test to the corresponding zone of interest in the well. This paper describes how the implementation of a coiled tubing (CT) real-time fiber-optic (RTFO) integrated system and a retrievable packer were determining factors to successfully develop both PBU in an upper formation and a pressure evaluation in the lower formation in the same run. To help ensure isolation and evaluation of each high potential zone in the well, conventional methods involve multiple procedures requiring multiple runs. Using the CT RTFO (Vera et al. 2018) integrated system with a retrievable packer, only one run was necessary to complete the PBU program, which involves the isolation and corresponding log of two reservoirs. This new technology helped the operator overcome challenges and deliver improved service quality. Real-time data acquisition during the packer setting helps ensure correct inflation, and continuous monitoring of the isolated zone during the PBU process helps ensure data accuracy and defines the end of data acquisition time once radial flow has been observed in the pressure transient analysis; therefore, the points previously discussed strongly impact production by optimizing operation time. Avoiding the use of materials such as cement to isolate the mentioned zones made this operation environmentally friendly. The greatest value of this technology is that it makes real-time monitoring of both the upper and lower zones possible at the same time. The PBU test was successfully developed by determining reservoir pressure, skin, and flow regime of the near zone formation with precision and confidence, which helps the operator make decisions about future stimulations. High-pressure stimulation was achieved, which resulted in 460 BOPD over the initial production. Finally, a downhole ball-drop tool was effectively used to help ensure that packer setup was accurate and to reduce intervention time.
The oil industry is continuously evolving and the need to be more dynamic and efficient is always present. A new downhole Coiled Tubing (CT) technology is now available, capable of performing intervention with both conventional CT tools, and wireline cased hole tools in the same well, allowing optimization of time and reducing any restriction on logging time, by providing a continuous power supply. Additionally, it is possible to execute diagnostic distributed acoustic and temperature sensing if more details are required for a specific zone. Older techniques used in coiled tubing logging sometimes require several runs to achieve the objective. In the well reviewed in this paper, two runs were performed with conventional techniques without achieving the purpose of the intervention. The high gas production rate of the well and the inability to have real-time monitoring of the Production Logging Tool (PLT) data were significant obstacles to success using these methods. This paper presents an optimized intervention wherein a milling operation, a production log, and pressure buildup test are necessary to understand the production profile of the well, identify the gas-oil ratio per reservoir, understand if additional production is impeded because of cross flow or casing leaks, and identify reservoir pressure of the zone. The real-time hybrid integrated system was designed with an open architecture to accommodate any wireline or mechanical tool available in the industry to address operator challenges, such as milling operations where the operator was able to monitor the weight on the bit, the torque, and the differential pressure through the bit; or a PLT job operation where the operator was able to monitor the weight on the bit, and use Casing Collar Locator (CCL) and/or Gamma Ray (GR) sensors to correlate with wireline logs, all in a single CT rigup without the need to change the hybrid bottomhole assembly (BHA), CT string, nor the CT Connector (CTC). Real-time communication with the wireline tool is achieved with a conductor line installed in the CT, which also provides power to the tools. Communication with the integrated bottomhole sensors and distributed profiling capability utilizes the fiber optic lines to transmit the data in real time. Because the communication of the tools is independent, there is no concern over running combinations of multiple downhole sensors. This case study is the first known instance wherein CT was used in conjunction with downhole tools that were supplied with continuous power to sensors to enable measurement of parameters while milling followed by a PLT job where the same cable not only powered but communicated with the wireline tools. Because of the flexibility illustrated during the operation of the study, a campaign of production and injection logging jobs could be executed in the field without any communication issues or nonproductive time, increasing the efficiency of the intervention.
Efficiency and effectiveness are strong influencing factors when developing rigless interventions within the current market. In the demanding industry of exploration and production (E&P), a synergy was created from strong collaborations between operator and service companies searching for solutions to provide more diagnostic capabilities, reduce overall cost of operations, and maximize well performance. The solution was found in real-time hybrid coiled tubing (CT) services, which drastically increased reliability and reduced assets and wasted time on location. Two onshore CT well interventions in the eastern foothills of Colombia where challenging conditions (i.e., high gas-production rate, high tortuosity, and dogleg severity) were overcome using a real-time hybrid CT system are discussed. To optimize the operational time to run a production logging test (PLT) and obtain downhole visual conditions, it was necessary to, in a single run, combine a flow-through, multisided, high-resolution visualization camera (first in industry) with real-time wireline services and a hybrid bottomhole assembly (BHA). The real-time hybrid integrated system includes a cable to connect any wireline tool and multiple fibers for communicating with additional sensors (i.e., tension and compression) to avoid exceeding the wireline tools’ capabilities, casing collar locator (CCL), and/or gamma ray (GR) sensor. These then correlate as a backup of the logging tool while performing operations as a PLT or injection logging test (ILT) and smarter tools (i.e., downhole multisided camera) that evaluate the perforations and fractures within the desired zones. This occurs in a single CT rig up without the need to modify the hybrid BHA, CT string, or CT connector and reduces the shut-in period of the well because CT and BHA capabilities provide more downhole insight. The hybrid flow-through sensor and camera BHA communication use the fibers installed in the CT; wireline uses the electric path for its telemetry. Because tool communication is independent, data can be evaluated simultaneously without constraints during the same run and pass, helping reduce additional operations because everything is transmitted from downhole, recorded, and displayed at surface the same time the tool senses or sees it. In an industry that demands continuous improvement during each stage of a well, increasing efficiency, reducing operational time, and developing technologies and techniques without compromising safety is no longer a request—it is now mandatory. This technology provides the benefits of fiber-optic and electric cable together and near limitless freedom to deploy multiple technologies independently or simultaneously without interference—a solution only an open architecture system can provide, establishing a step forward within the industry.
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