New Electro-mechanical Perforating Technology Reduces Cost and Increases Safety in Workover Operations

Abstract

Saudi Arabia wells, onshore and offshore, often require workovers as a result of the corrosive environment to which the downhole equipment is subjected. When the workover jobs required a single hole to be punched in "soft" tubing using traditional methods, high failure rates and inherent delays in mobilizing explosives often severely compromised job economics. This paper presents several case histories in which a new slickline-deployed electro-mechanical tubing punch was used for the first time worldwide. Although the workover requirements in each well were different, and the jobs were conducted in both onshore and offshore environments, all required a single hole to be drilled. The case histories will discuss the advantages provided to the operator through use of the new electro-mechanical tubing punch. These included:100% perforating reliabilityReduced rig time by eliminating mobilization of explosives and other equipment, if failures occurred.Reduced costs, since electro-mechanical perforating is more cost effective than electric-line "soft-shot" methodsApplicability to deployment on slickline, E-line, or coiled tubingSimplicity in use of the electro-mechanical perforatorEnhanced personnel and environmental safety from:Elimination of explosivesUse of alkaline or lithium batteriesUse of mono-conductor lineUse of CTU pressure-switch adapter The new method was 100% successful and resolved the problems experienced with all previously used conventional mechanical perforating methods. Although run in highly corrosive downhole conditions, the perforating tool had 100% success in perforating the "soft" tubing. A thorough follow-up inspection of the tool showed that it had sustained no damage of any kind. An in-depth discussion concerning the electro-mechanical perforator design, its application in Saudi Aramco wells, its operational advantages, and its significant impact on safety and economics will be presented. Introduction Improved well completion methods in Saudi Aramco have enabled safe, efficient, and economical production from oil and gas wells. However, as the fields matured, the wells often required workovers due to several factors, which included:CorrosionReduced productionNeed for conversion to water injector wellsSidetracksIntegrity of the well headIncreased safety concerns. Once a well completion had been designated as a candidate for a workover, the first step for Aramco was to determine a safe, economical procedure to successfully perform the workover.

Re-Engineering The Business Process of Slickline and Electric Line Operation

“…From academic perspective, there are limited number of articles about how to reduce the cost related to the slickline and electric line operation. From the limited number, several articles about this issue are presented by Bargawi, Dean, Clemens, andWhitmire (2008), Foster, Clemens, andMoore (2001), Larimore and Fehrmann (1998), Larimore, Fehrmann, and White (1997), Larimore, Goiffon, and Bayh (1996), Loov and Billingham (2014). These articles discuss about the cost reduction issue in the operating slickline or electric line however from this limited number, the articles about cost reduction in this area using Lean and Business Process Re-Engineering perspective has not been found yet.…”

Case History: Extended-Stroke Downhole Power Unit Successfully Pulls Subsea Wellhead Plugs

“…Hundreds of DPUs have been operating successfully throughout the world since the mid-1990s, and it is the preferred servicing tools in some regions due to its reliability and special operating characteristics. 1,2,3,4,5,6,7 The extended stroke DPU used in this application provides 36 inches of stroke at the power rod.…”