Curing SAP a Riglessly Using Annular Cement Plug
Authors: Yugay A. , Prasetio A. , Al Breiki N. , Tawfik F. G. , AlKarbi M. A. , Berdiyev Y. , Bazuhair M. K. , Vorozhikhin S. , Zhukin A. 
Published: November 2024

Wells with positive pressure at surface have to comply with double barrier policy. Any failure of the primary barrier envelope creates policy non-compliance, leaving it with single barrier only. Standard practice is to perform a rig intervention to replace the completion. This paper describes the outcome of the cost optimization proposal to cure the failure riglessly.

The actual WAG (water-alternate-gas) injector had a packer leak and tubing leak just above the packer. New rigless curing method assumes filling the annulus above the packer with cement that would get set and create a new seal. Cement should be placed through the tubing-annulus circulation device or punched hole. Coiled tubing should be used for better control and accurate cement placement. Once the cement is set and isolation is verified through the pressure testing, the cement should be drilled out by coiled tubing. This cost optimization proposal was evaluated by involved stakeholders including field, development, drilling rigless team and well integrity. The project was executed successfully, restoring well integrity riglessly using in-house resources. Project deployment program was agreed considering data verification, future rig interventions, zonal isolation.

Curing packer leaks without using a conventional rig (often referred to as "rigless" operations) offers several benefits compared to traditional rig-based methods. Here's a comparison highlighting these benefits:

Benefits of rigless methods:

Cost Savings:

Reduced Costs: Rigless operations typically cost less than conventional rig-based methods. This is due to the reduced need for a full drilling rig, which involves higher day rates and associated operational costs. Lower Mobilization Costs: Transporting and setting up a rig is expensive and time-consuming. Rigless operations generally require less equipment and logistics, resulting in lower mobilization costs.

Operational Efficiency:

Faster Execution: Rigless methods often allow for quicker intervention since they involve less setup time and fewer complex procedures. This can significantly reduce downtime and improve overall well productivity. Flexibility: Rigless operations can be more adaptable to various well conditions and are often employed for specific tasks, which might not require a full rig.

Reduced Surface Footprint:

Less Equipment: Rigless operations usually involve smaller, more portable equipment, leading to a reduced surface footprint. This can be particularly advantageous in environmentally sensitive areas or where space is limited. Minimized Environmental Impact: With less heavy equipment and reduced surface disturbance, rigless methods can have a lower environmental impact compared to traditional rigs.

Operators who deal with packer or tubing leaks above the packer in their wells might find this paper useful. A detailed procedure complete with verification and validation will facilitate the entire process, ensuring that the program is devised in the most efficient and effective manner. The well was successfully returned to production, fully compliant and accessible. The positive impact of this approach includes not just the direct cost savings from avoiding a rig intervention (which on average amounts to around USD 3.3 million, along with additional indirect costs related to preparing the well and site for rig access), but also the opportunity to reallocate that rig slot to expedite other projects. Furthermore, by dodging months of delayed production, this technology proves to be exceptionally beneficial.