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Prolonging Production and
Increasing Recovery through
Regular Well Interventions
Author: Brian K Sidle, Vice President -
C...
PAGE 2Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Introduction
Innovation...
PAGE 3Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Quick example, your car...
PAGE 4Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
In some industries, thi...
PAGE 5Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Conversely, however, if...
PAGE 6Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Another important facto...
PAGE 7Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Examples
Does this appr...
PAGE 8Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
A few examples to highl...
PAGE 9Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
PRODUCTION RESTORED, $2...
PAGE 10Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
On the first run the W...
PAGE 11Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032
Innovative, Efficient,...
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Welltec: Prolonging Production and Increasing Recovery through Regular Well Interventions

Innovation, efficiency and reliability: no one can argue that these are the keys to lower cost and higher
profitability in today’s oil and gas industry. The economics of every field, especially mature fields, have
to be considered closely. And in many cases, more than 50% of the hydrocarbons remain in place. It’s a
real challenge for operating companies to harvest those resources and manage their reservoirs in this
environment. Fortunately, there are places where the required innovation, efficiency and reliability can
be found to lower cost and increase profitability for the operating companies. But before we get to that
answer there are two main points to be addressed.

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Welltec: Prolonging Production and Increasing Recovery through Regular Well Interventions

  1. 1. Prolonging Production and Increasing Recovery through Regular Well Interventions Author: Brian K Sidle, Vice President - Corporate Marketing, Welltec Disclaimer: Whilst every effort has been made to ensure the accuracy of the information contained in this publication, neither Offshore Network Ltd nor any of its affiliates past, present or future warrants its accuracy or will, regardless of its or their negligence, assume liability for any foreseeable or unforeseeable use made thereof, which liability is hereby excluded. Consequently, such use is at the recipient’s own risk on the basis that any use by the recipient constitutes agreement to the terms of this disclaimer. The recipient is obliged to inform any subsequent recipient of such terms. Any reproduction, distribution or public use of this report requires prior written permission from Offshore Network Ltd.
  2. 2. PAGE 2Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Introduction Innovation, efficiency and reliability: no one can argue that these are the keys to lower cost and higher profitability in today’s oil and gas industry. The economics of every field, especially mature fields, have to be considered closely. And in many cases, more than 50% of the hydrocarbons remain in place. It’s a real challenge for operating companies to harvest those resources and manage their reservoirs in this environment. Fortunately, there are places where the required innovation, efficiency and reliability can be found to lower cost and increase profitability for the operating companies. But before we get to that answer there are two main points to be addressed. Background Producing wells have problems, no secret. And the older the well, the more likely it is to have problems or to have more severe problems. Failed valves, stuck sliding sleeve doors, produced sand, fill, scale, restrictions, and so on. Some wells have a combination of these elements or additional ones not mentioned. All of them, however, contribute to an ever decreasing performance and subsequently cash flow position. Unfortunately, the conventional solutions for addressing these problems likely won’t address the challenges posed today or else companies’ cost basis would be much better. Is your current approach innovative, efficient and reliable? If only one or none of these attributes is characteristic of your remediation plan, likely there is room to increase your profitability through improvements. Overview As wells are being designed, a universal design criteria is the capability to keep production flowing as long as possible without having to intervene in the well. This is why, typically, interventions are only done when something ‘breaks;’ ie production becomes restricted, or stops or an unwanted production type begins. But this conventional strategy often forces operators into a position where they must cope with unnecessary levels of uncertainty, leading to inefficient responses.
  3. 3. PAGE 3Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Quick example, your car won’t start. There can be many reasons or causes, as partially illustrated in the fishbone diagram above, under a few main categories. Perhaps you’ve been driving it somewhere it was never meant to go (Environment cause). Or maybe you’re doing something wrong as you try to start it, like not applying the clutch (Method cause). Or perhaps something is actually broken (Machine cause). Regardless, it requires repair and therefore cost. As Figure 2 indicates, there is a minimum fixed cost associated with the repair. Even if it’s a lightbulb that can be replaced without a trip to the repair shop, there is still a cost. And the cost of the repair increases with activity; the longer the asset has been operated without maintenance, the higher the associated cost to remediate. Figure 1 Machines Methods People Vehicle won’t start Environment Materials Fuel Gauge is Broken Battery is Dead Spark Plugs Broken Starter is Broken The Gear is in the wrong position Lack of Training Cold Climate Turning Belt is Broken Out of Fuel Potential causes of vehicle failure Engine has Overheated Lack of Car Maintenance Figure 2 Total cost ($) Activity Minimum fixed element Repair cost optimization Variable element
  4. 4. PAGE 4Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 In some industries, this ‘fix it when it breaks’ approach is completely unacceptable. Who would fly on an airline that didn’t adhere to a service maintenance schedule for instance? And yet in the oil and gas industry billions of dollars are invested into putting wells in the ground only to squander the potential performance of the well and reservoir development through gross inefficiencies. An expensive, highly complex system of parts idle for days, weeks, rather than operating at optimum performance. Similar to a vehicle or other expensive asset, regularly performed maintenance will increase the current performance and extend the overall life of the asset. Operators can prolong production and achieve the highest ROI possible while simultaneously increasing recovery factor and reservoir drainage. This is point number one, illustrated by Figure 3. Back to the car example, it’s sitting idle, unable to do its job. You want it back in operation, with the best solution at the lowest possible cost. What to do? If it’s a sports car and it’s been driven off road, through high water several times a week to take a shortcut to work, perhaps this insight could reduce the uncertainty regarding the possible failure mechanisms. Likewise, if the car has been in to the shop several times to fix a re-occurring problem, perhaps it’s obvious what the challenge is again this time. Figure 3 Natural Decline Curve Oil Production Volume Extended Decline Curve Regular interventions enable higher recovery rates, increased ROI versus a conventional ‘fix it when it breaks’ approach E-line Interventions Time
  5. 5. PAGE 5Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Conversely, however, if the car has been operating for several years and has never had any maintenance on it, then what? Call a friend? Take it to the local shop? Or does it immediately go off to the dealership on the back of a tow truck? Similarly for your ‘broken’ well, what next? Where do you begin with addressing the solution? Let’s take a look at a somewhat subjective measurement system, Figure 4, which compares some of the potential options using a scoring system of 1-10 with the higher scores being the best. Defining efficiency as the ability to quickly mobilize, rig-up, run in and out of the well, rig-down and demobilize off location, it’s clear that a WO rig is the lowest while slickline and e-line score the highest. Reliability is defined as the ability to solve the problem once on location. Here the WO rig scores the highest as it can generally overcome even the most severe of challenges. On the definition of innovation, this is the ability to understand what the problem is, adapt to the challenge and bring the appropriate technology to bear quickly, minimizing downtime and restoring production as quickly as possible. With real time, surface controllable features enabled by e-line versus the mechanical solutions offered by the others, it scores the highest in this category, offering a 40% advantage over the WO rig. Extra Benefits While a workover rig has the highest chance of success to rectify the problem, what about the trade- off on efficiency and innovation? Slickline may be efficient as per our definition, but what is the confidence level on its reliability and innovation to overcome and fix the unknown challenge? Overall, e-line stands out as the overall winner for these key elements of success. Figure 4 Efficiency Reliability Innovation 18Slickline Coiled Tubing WO Rig E-line 18 17 24 8 5 3 8 8 8 10 4 9 4 6 4
  6. 6. PAGE 6Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Another important factor which has not been addressed or scored, but should be considered as part of the innovation content is the ability to accomplish the work in the safest, most sustainable and cost effective way possible. A quick comparison of a CT unit to an e-line crew with regards to some simple metrics: total footprint, size, number of people, number and weight of lifts, sustainability, complexity of operations and carbon footprint, demonstrates that there is significant additional value to be gained from deploying e-line. If a WO rig were to be compared the contrasts become even greater. When you consider these additional benefits it becomes even more clear that an e-line solution offers significant advantages, especially if you’ve got the right portfolio of tools. That’s point number two.   Figure 5
  7. 7. PAGE 7Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Examples Does this approach work? Irrefutably. Since the 1990’s Welltec’s technology has been put to work redefining the boundaries of what e-line workovers could accomplish. Not only does this methodology provide efficient operations, e-line is a proven, reliable method of accessing and addressing wellbore challenges. And it is also a proven platform for the development and successful introduction of new, innovative technology. Trying to future proof wells by installing current technology in them can be a risky proposition since it remains in the ground indefinitely, unable to be updated. Rather the application of new, appropriate technology as it develops is the real solution for maximum value. A problem occurs and modern technology is applied quickly and efficiently, capitalizing on what’s available now and relying on what was ‘new’ five, ten or twenty years prior. Perhaps our industry will never get to the stage where point number one of implementing regular interventions is realized universally, but certainly point number two about applying modern e-line technology is relevant and applicable immediately. Innovation, efficiency and reliability at your fingertips to optimize production at a lower cost. 0% 0% 0% 0% 9% 24% 31% 49% 55% 63% 68% 79% 87% 87%86% 88% 90% 92% 92% 93% 97% Figure 6 #ofinterventions 92 93 94 95 96 97 98 99 00 01 02 03 04 05 06 07 08 09 10 11 12 Snubbing/ Ras Coiled Tubing Wireline Tractor Wireline Tractor e-line share of total interventions
  8. 8. PAGE 8Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 A few examples to highlight that approach are provided below. 94% TIME SAVINGS, INCREASED SAFETY AND CASH FLOW Offshore Mexico, subsurface safety valves (SSSV) require periodic function testing to ensure reliable operation when needed. Typically, they are tested and if they fail, a workover rig is scheduled to shut in the well and replace them. A new technique has successfully been implemented which precludes the requirement to shut in the production or even to mobilize a workover rig. Using the Well Cleaner® Wishbone Honer (WBH), the operator has been able to repair the valve in-situ with the well flowing. Analysis determined that often the SSSV failed to close completely due to debris which limited its ability to hold pressure during the testing. After careful planning, a Well Tractor® and Well Cleaner® WBH were mobilized and run on e-line to the desired depth. There the WBH was activated and cleaning of the SSSV and surrounding tubing was performed. Following the cleaning the SSSV was successfully tested. The entire operation was completed in only 18 hours compared to ~ one week for the rig operation to pull the SSSV. And the well remained on production throughout, demonstrating the benefits that e-line interventions can provide.
  9. 9. PAGE 9Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 PRODUCTION RESTORED, $2MM SAVED Onshore Nigeria, a retrievable safety valve assembly failed to seat properly in the tubing and flowed up hole with the production to get stuck somewhere near the tubing hanger; precise position unknown. More than 1,000 slickline jar attempts were made to free the fish. Indicators showed that the lock mandrel fishing neck was partially open, suggesting that its keys were jammed in a slightly inclined position, below the lower ID of the tubing hanger profile. Based on this problem description, Welltec® engineered a solution. Using the Well Tractor® and Well Miller® plus a custom nipple milling bit in combination with the Well Stroker® the team succeeded in milling out the safety valve which fell to the bottom of the well as desired, restoring access and production. This successful milling operation enabled the operator to avoid having to pull the entire completion string and saved more than $2MM compared to the alternatives. The operator was very pleased to be able to regain the well in a shorter time frame and estimated that the milling solution was twice as efficient as the other options. WELL STROKER® XXS SAVES FIVE DAYS OF RIG TIME AND RECOVERS STUCK TOOL Baku, Azerbaijan, time and costs were mounting during an operation when a 7” retrievable packer and the setting tool got stuck at 6,486 ft (1,977 m) preventing the operator from putting this oil producer on production. Determined to return the well to production as quickly as possible, the operator called out Welltec’s new double stroker. Capable of accurately exerting force up to 60,000 lbs, the Well Stroker® XXS latches the assembly, locks into place and exerts the force directly onto the fish (or sliding sleeve or plug) with no strain on the e-line or other parts of the toolstring. Surface read-out allows direct measurement and control of the force downhole.
  10. 10. PAGE 10Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 On the first run the Well Tractor® deployed the Well Stroker® XXS to the fish where it latched and applied 55,000 lbs to release the stuck setting tool from the plug. Then the entire assembly was pulled from the well and operations resumed to put the well on production. Use of Welltec’s e-line solutions enabled the operator to prevent mobilization of a heavy duty coiled tubing unit, providing a fast, effective solution and saving a minimum of five days rig time as well as the environmental and cost differences. 90% COST REDUCTION WHILE RESTORING INJECTION ON A LIMITED SPACE PLATFORM Offshore India, limited crane height, space and daylight operations posed challenges on a small platform to an operator trying to restore injection on a converted producer. A thorough risk assessment was conducted and equipment mobilized offshore to rectify the problem. The first run revealed that the GS profile couldn’t latch onto the lock mandrel completely. A Well Cleaner® Power Suction Tool (PST) was then run to remove debris which had settled on top of the lock mandrel. The Well Cleaner® PST uses a venturi system to create a powerful vacuum which agitates and mobilizes the debris, trapping it inside bailers and removing it from the wellbore. Once the Well Cleaner® PST was recovered, the Well Stroker® with GS pulling tool was run. It latched the lock mandrel and with one stroke pulled the reluctant lock mandrel (and attached TTSS) free. The entire assembly was removed from the well and injection established at 22,000 bwpd. The operation was carried out in only three days and provided significant savings, approximately 90%, versus a barge-based, coiled tubing operation.
  11. 11. PAGE 11Offshore Network Limited, Registered in England and Wales, Company Registered Number 8702032 Innovative, Efficient, Reliable Solutions Innovation, efficiency and reliability: no one can argue that these are the keys to lower cost and higher returns in today’s challenging environment. At Welltec, we have the vision and technology to help improve returns, reduce risks and increase sustainability without increasing your exposure. Our success is based upon our ability to continuously create truly disruptive innovations, making the industry safer and more sustainable while achieving higher recovery. Through a unique combination of patented technology and pioneering approaches, we deliver game-changing value. Welltec’s customers benefit from increased production and overall recovery rates using a fraction of the time and energy of conventional methods. Their cash flows have been improved by higher, extended revenue streams and significantly lower costs. And they can exploit the full value of their reservoirs. Now is the time. Explore your options. At Welltec we believe it’s possible to improve the way the industry operates by offering a change in mindset, a change in technology. We have pioneered and developed robotic tools which safely and reliably carry out their operations to repair wells through e-line interventions. Restored production, optimized assets with a safer, more sustainable approach than conventional methods. Yes, it sounds too good to be true….but it is. www.welltec.com OFFSHORE NETWORK WOULD LOVE TO HEAR FROM YOU… Offshore Network Ltd. is an independent business intelligence & conference provider catering specifically to the offshore oil & gas industry. We exist to facilitate a safe and efficient future for the exploration and production of oil & gas around the globe. We do this by uniting the most in-fluential figures in the industry to challenge the status quo and share cutting edge innovations. This all happens at our industry leading conferences and through our original content. If you would like to contribute to this discussion or are interested in taking part in a future Q&A or article, please contact Offshore Network (www.offsnet.com) today: info@offsnet.com UK Telephone: (0)203 411 9937 US Telephone: 713-5706-576 Join the Offshore Engineering Group on LinkedIn Follow Offshore Network on Twitter

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