Professional Documents
Culture Documents
Carbonate Reservoirs
F. Marketz, SPE, and R.W.F. Welling, SPE, Petroleum Development Oman; and R.H.J. van Noort and
M.N. Baaijens, Shell
an OHC cannot be retrieved. If set in the wrong place, the OHC stalled is not possible. The running OD of the OHC is larger than
would need to be perforated and a cement squeeze carried out. the drift diameter of an expanded OHC. Clad-through-clad capa-
Scenario 2 can occur in highly fractured or permeable reservoirs bility would require more advanced expandable tubular solutions.
where a shallow water shutoff treatment cannot work. This risk can be
mitigated by reservoir characterization and inflow modeling. Zonal Isolation Design. Zonal isolation design is based on caliper
Scenario 3 would lead to channeling of water behind the OHC, data. The design parameters are the thickness of the seal and the
similar to the problem of poor zonal isolation with cement and placement of expandable casing joints with seals at a specific well
leaking scab liners. This risk can be mitigated by gauge-hole drill- depth. In the example shown in Fig. 5, a 758-in.958-in. expand-
ing and proper zonal isolation design. Holes need to be near the able liner with seven joints of expandable casing coated with
gauge to achieve a seal. Expandable tubular solutions do not seal 7-mm thick elastomer seals was installed. By expanding the cas-
if the borehole diameter exceeds the sealing envelope. In a 618-in. ing, an instantaneous seal can be created in wellbores with a maxi-
hole, a 5-in. OHC with swelling elastomers can provide a seal up mum borehole diameter of 8.94 in. The minimum required radial
to a 6.9-in. hole size. In the case of a leaking OHC, the OHC would compression of the seal is 5%. If the wellbore diameter is larger
need to be perforated and a squeeze cement job would be required. than 8.94 in., a seal can still be created up to a maximum hole size
To overcome this limitation, another casing expansion method of 9.45 in. by swelling of the seals in produced water. The time to
without a fixed cone must be used. Alternatively, a 3-in. liner create a seal by swelling of the elastomer can vary from several
with expandable zonal inflow profiler (EZIP) tools can be used in days up to several months, depending on hole size, produced water
a 618-in. hole (Ogoke et al. 2006). An annular seal is created salinity, and downhole temperature.
entirely by swelling of the seals. Because of the smaller outside
diameter (OD) of the liner compared to the clad (3 in. instead of Technology Implementation. The operator has managed the
5 in.), the thickness of the elastomer seal is larger. As the can implementation of expandable tubular technology as a new tech-
seal typically swells to twice its original thickness, the sealing nology project with dedicated resources. As soon as expandable
envelope is larger than it is for the OHC. tubular solutions were offered as a commercial service, the opera-
tor screened its entire well construction and workover portfolio for
Technical Limitations. applications. In the operators onshore, mainly low-cost well en-
1. Access to the well for surveillance purposes is required. To vironment, water shutoff and zonal isolation were identified as the
locate the water influx in existing wells, production logging ac- highest value drivers. As a result, expandable tubulars were intro-
cessibility is required throughout the completion. This is only pos- duced for water shutoff rather than drilling applications.
sible if the well has been completed with gas lift or electrical A producing well with high water cut was selected as the best
submersible pumps (ESPs) with Y-tools. first candidate to perform a trial of OHC technology. The operator
2. With currently available expandable tubular technology, it is decided to shut off two water-producing fractures in a barefoot
not possible to do through-tubing shutoffs. In the case of a work- horizontal oil producer. This application has been documented in
over, the well needs to be killed and the tubing pulled. For ex- detail in earlier papers (Van Noort et al. 2002; Braas et al. 2003).
ample, for a shutoff in 7-in. casing through 4-in. tubing with After the water shutoff, oil production from the well more than
3-in. expandable casing, an expansion ratio of approximately doubled. Two years after the workover, the well is still producing
80% is required. Maximum diameter expansion ratios of currently as much as before the fracture shutoff. After this successful proof
available products are approximately 15%. of concept, further applications were identified, mainly in new
3. A second shutoff with an OHC below a previously installed wells, for fracture shutoff in the drilling phase and zonal isolation
OHC is not possible. Running an OHC through one already in- with cement.
b. If OHL, expand OHL into previous casing and pressure using a tier system. A successful installation can occur with or
test OHL overlap. without operational problems.
7. Mill out shoe. Tier 1: Achieved installation objective. Successful comple-
The main installation risks and their mitigation approaches are tion of expansion operations and pressure testing of OHL.
outlined in Table 1. Tier 2: Achieved installation objective. Successful comple-
To manage the operational risks, generic installation proce- tion of expansion operations and pressure testing of OHL. Con-
dures have been developed in close collaboration between operator tingency operations, remedial actions, or fishing operations required.
and contractor personnel. These procedures have been updated Tier 3: Did not achieve installation objective. Unsuccessful
periodically to include improvements and additions based on ac- completion of expansion operations and pressure testing of OHL.
tual installation experience. For each installation, the contractor Thirty installations were executed with one service provider. 25
prepares an installation procedure based on well data and applica- of these were Tier 1, two were Tier 2, and three were Tier 3
tion objectives provided by the operator. Toolbox talks are held on installations. One fracture shutoff trial on Well A#4 was unsuccessful.
the rig site when the installation operation begins. An alternative product from another service provider was tried.
A summary of the installations discussed in this study is pre- Operational difficulties encountered during three Tier 2 in-
sented in Table 2. Trials of the technology were carried out in five stallations stemmed from a quality assurance failure, borehole-
carbonate reservoirs. OHLs were installed in horizontal oil pro- quality-related difficulties, and the need for milling the shoe track.
ducer wells (HOP), vertical oil producer wells (VOP), deviated oil Better borehole quality and hole preparation are essential to reduce
producer wells (DOP), horizontal water injector wells (HWI), and nonproductive time (NPT) associated with installation operations
sidetracked wells (ST). Multiple OHCs were installed in four for expandable tubulars. It is important to provide the drilling
wells. Multiple fracture shutoffs were required in Wells F#5 and engineer with an incentive to deliver good borehole quality. This
F#6. In Wells Y#4 and Y#5, a 1000-m-length wellbore section was includes the application of good drilling practices and bottomhole
lined. This was not possible in a single pass because of small assemblies to deliver a gauge hole and to minimize doglegs and
running clearances.
Installation time normalized with respect to the length of OHC
installed for all wells has been reduced by 75% over time. Instal-
lation time excludes the time for milling the shoe track. To im-
prove and sustain installation reliability, the main focus areas have
been improved quality assurance and control and the drilling of a
gauge hole. It is desirable to make milling of the shoe track re-
dundant, which would save one trip plus additional time. Alterna-
tive products with retrievable shoes are under development.
Of 31 installation operations, 27 (87%) were successful, as
shown in Table 3. From the operators point of view, an installa-
tion operation is either a success or a failure and is evaluated
Fig. 6Design of an openhole seal with expandable tubulars and swelling elastomer seals, based on caliper log data.
Fig. 8Water cut of wells after 1 month of production vs. losses encountered while drilling the reservoir section. Comparison of
wells completed barefoot (green), with scab liners (blue), and with openhole clads (red).