Restoration of High-Temperature Well Integrity via Real-Time Coiled Tubing Patch Application

Abstract

A prolific gas producer in Sarawak waters was shut-in and idle due to a tubing leak resulting in a significant decline in the total hub production. The well remained idle and required immediate remedial action to meet the contractual sales target. Hence, an expandable tubing patch was proposed to isolate the leak and reactivate the well faster. This paper presents data gathered to identify leak location, tubing patch design, and installation using real-time coil tubing. Several logging surveys were performed to detect leak depth including caliper log, leak detection log (LDL), and downhole camera run; since no pressure build-up was observed post bleed-off tubing and casing, while SCSSV was in closed-state. Running caliper log could not indicate severe metal loss of 7-inch tubing, hypothesizing that the leak could be of a smaller dimension. Therefore, LDL was conducted, indicating temperature gradient and acoustic energy changes at a single depth location of 247 ft.THF, above SCSSV. Utilizing the leak depth marker from acoustic log, a downhole camera was staged to verify geometry of tubing leak. Root cause failure analysis (RCFA) was carried out for this tubing anomaly using diagnostics data to determine the possibility of UHP-17Cr-110 tubing failure. The likelihood of tubing failure is attributed to two main causes namely oxygen corrosion cracking and stress corrosion cracking. Based on RCFA outcome, Hastelloy C276, a nickel-molybdenum-chromium superalloy with the addition of tungsten was selected for the patch material, which is V0 rated, internal gas-tight qualification for temperatures up to 150 degrees Celsius and 5,000 psi. Moreover, this patch material satisfies the well conditions at approximately 20% CO2, 200 ppm H2S, 1000 mg/L salinity, and varying Hg concentrations from 800-2,000 ug/Nm3. The design of patch has been improved by adding AFLAS elastomer for the whole exterior of patch to eliminate contacts between the two metals: reducing the risk of galvanic corrosion. Real-time coiled tubing application was selected for setting the patch to ensure accurate depth-sensing control. Additionally, patch is a rig less intervention technique that will not disrupt the production from the existing wells sharing the same drilling platform. Generally, for high-rate gas wells, economic indicators seem lucrative with tubing patch application, where the payout can be achieved within a month of continuous production. The first step in ensuring the success of tubing patch is by running right diagnostics tools such as leak detection logging and downhole camera run, since multi-finger caliper analysis alone would not locate the leak depth and the leak geometry precisely. Valid design inputs are quintessential for the fitting recommendation of tubing patch design which includes accurate reservoir and fluid properties to ensure sustainability of the expandable tubing patch application.