Challenging Horizontal Well Abandoned with Innovative Plug Setting Technique and Tailored Slurry Design

Abstract

Setting multiple plugs across a horizontal well can be a challenge. One way to do this is using the "pump and pull" methodology to achieve the objectives set out by the project team. Tailoring of the cement slurries and the execution of cementing operations for the successful deployment of multiple cement plugs using this method to achieve a dependable barrier across a horizontal reservoir section will be reviewed and discussed. A development well in Malaysia lost a bottom hole assembly (BHA) in their 8.5" hole section. This resulted in the requirement to abandon a long horizontal section along with the requirement to spot a 2,100 ft continuous cement plug on top of the BHA to abandon the well. The main challenge for setting a cement plug across a horizontal section, is cement slumping and stuck pipe, which might result in repeating cement plug jobs or non-productive time having a negative impact on well economics. To achieve isolation objectives in the first attempt, this long continual plug was broken up amongst four smaller individual plugs "stacked" on top of each other. The first 3 plugs were designed to each be 600 ft in length followed by a 340 ft plug. To avoid cement slumping, a cement support tool was deployed above the BHA before the first plug in the horizontal section. The first three plugs were placed in the horizontal open hole section and the fourth plug was placed at an inclination of 75 degrees, all using the "pump and pull" method. The pump and pull method is a common practice for worker operations with coil tubing and this similar technique can be applied in ERD drilling operations to aid in the homogeneous and accurate placement of cement plugs. However, for this job, the pump and pull placement method was preferred to aid in the homogenous and accurate placement of cement slurry through the horizontal open hole section. Detailed job calculations, the slurry design which was tailored for this application along with detailed operational procedures which resulted in the successful placement of all plugs on the first attempt under challenging well conditions will all be discussed. The approach utilized here resulted in the successful placement of a 2,100 ft continuous plug which isolated the BHA and saved the project valuable rig time. Similar approaches can be used in other areas to achieve successful results in first attempts to help well economics.