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The client had a leaking gas lift valve (GLV), which needed to be replaced to restore the integrity of the well. The side pocket mandrel (SPM), was located at a high angle part of the well, positioned on the low side and sand debris had accumulated in and around the GLV, impairing its retrieval. Tests carried out on surface to attempt to latch a GLV through the sand proved ineffective, even with jarring. To further optimise production, SPMs are being installed at increasing well depths, enabling deeper gas injection into the tubing. Placing SPMs into the high angle section of deviated wells inherently increases the risk of them retaining debris, as was the case in this well. A novel solution, to remove the accumulated sand debris from the SPM was proposed, utilising an orientation sub, run in conjunction with an electric line deployed tractor-suction tool configuration, incorporating a bespoke side facing inlet nozzle. Tests on the designed solution were conducted in the engineering facility, recreating the deviation, orientation and debris expected and evaluating the nozzle alignment and cleanout capability for the expected debris type. These tests proved to be highly successful, giving the customer the confidence to perform the job. The deviation also necessitated electric line tractor deployment of a modified retrieval device. Following a drift and plug setting run, the well tractor and suction tool assembly was deployed and two litres of sand was collected from within the SPM. The subsequent run to pull the faulty GLV was successful, as was the deployment of a replacement GLV. The operation proved this to be an excellent and highly effective example of a rapidly designed and tested, bespoke, electric line deployed SPM cleanout solution.
The client had a leaking gas lift valve (GLV), which needed to be replaced to restore the integrity of the well. The side pocket mandrel (SPM), was located at a high angle part of the well, positioned on the low side and sand debris had accumulated in and around the GLV, impairing its retrieval. Tests carried out on surface to attempt to latch a GLV through the sand proved ineffective, even with jarring. To further optimise production, SPMs are being installed at increasing well depths, enabling deeper gas injection into the tubing. Placing SPMs into the high angle section of deviated wells inherently increases the risk of them retaining debris, as was the case in this well. A novel solution, to remove the accumulated sand debris from the SPM was proposed, utilising an orientation sub, run in conjunction with an electric line deployed tractor-suction tool configuration, incorporating a bespoke side facing inlet nozzle. Tests on the designed solution were conducted in the engineering facility, recreating the deviation, orientation and debris expected and evaluating the nozzle alignment and cleanout capability for the expected debris type. These tests proved to be highly successful, giving the customer the confidence to perform the job. The deviation also necessitated electric line tractor deployment of a modified retrieval device. Following a drift and plug setting run, the well tractor and suction tool assembly was deployed and two litres of sand was collected from within the SPM. The subsequent run to pull the faulty GLV was successful, as was the deployment of a replacement GLV. The operation proved this to be an excellent and highly effective example of a rapidly designed and tested, bespoke, electric line deployed SPM cleanout solution.
An automated wireline milling solution targeted for removal of wellbore obstructions of a varying type, from scale to metal, with built-in capabilities of autonomous cruise navigation between consecutive obstacles, is presented. This paper highlights design features that made a step change in the efficiency and usability of milling services. Control challenges are still common in downhole milling technology. Changes in milling target composition, cuttings accumulation around the target, drag forces from production flow, and other variations can reduce system efficiency and result in lost time or failed interventions. In the case of wireline milling technology, inclusion of intelligent on-board electronics in the downhole equipment presents an opportunity to actively control the milling process to optimize rate of penetration and implement additional protections to reduce operational risk. We describe a robotic toolstring that automatically and independently controls a wireline tractor using real-time feedback from a milling cartridge and other on-board sensors. Embedded control algorithms implement intuitive workflows derived from the combined experience of multiple experts in well intervention. With this automated wireline milling system, the user can initiate the milling process by defining certain milling parameters and then can monitor progress in real time while the downhole robotic tool regulates weight on bit and the milling motor. This new automated downhole control system significantly improves torque-on-bit and weight-on-bit controls yielding superior performance, such as rate of penetration and usability. Dynamic load conditions are handled in a high-speed distributed control loop downhole to get most of bit torque capacity across the entire speed range defined by the motor power curve. Tractor push force is adjusted quasi-instantaneously with changes in cutting conditions. Control responsiveness along with software solutions for tracking of motor stall preconditions and a torque limiter greatly reduce the occurrence of motor stalls arising due to the bit wedging in highly reactive targets. With stall avoidance and an automatic backing-off feature to reengage the bit in case of a sporadic torque spike, direct involvement of an operator is significantly minimized compared to the previous tool generation. Head-voltage stabilization is another factor positively impacting the overall power stability and performance of electromechanical tools downhole. Safety features are also in place to prevent cable twisting and protect assets from overcurrent and overtemperature conditions. The progressive design of the automated milling tool boosts operational efficiency and autonomy, minimizes human mistakes, and reduces risk of getting stuck during the service. Case histories demonstrate the first field jobs and system integration tests performed with this new tool.
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.
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