Lessons Learned from Casing-Casing Annulus Repair Utilizing Rigless Operation Approach in Offshore Oil Field
- Abdullah Al-Dhafeeri (Saudi Aramco) | Sultan Al-Aklubi (Al-Khafji Joint Operations) | Shebl Abo Zkery (Al-Khafji Joint Operations)
- Document ID
- Society of Petroleum Engineers
- SPE Annual Technical Conference and Exhibition, 30 September - 2 October, Calgary, Alberta, Canada
- Publication Date
- Document Type
- Conference Paper
- 2019. Society of Petroleum Engineers
- bleed down pressure, Offshore oil field, Casing Casing Annuls (CCA), Well Integrity, Sustained Casing Pressure
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- 123 since 2007
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Several aged oil wells in offshore oil field are drilled in a conventional method. These wells are subjected to Casing-Casing Annulus (CCA) problems that might appear during the production operation and/or the shutdown phases. A continuous monitoring is performed to avoid issues related to well integrity and safety. The expected source of Casing-Casing Annulus (CCA) problem is mainly due to poor primarily cementing placement into the outer-casing strings especially across shallow aquifers formations. Due to long shutdown period on subject wells, these wells are encountered with high rate of CCA phenomena among other wells. An immediate mitigation action is required to resolve the issues by applying rig workover operation which is considered highly cost approach with low success rate. The rig workover operation results might lead to suspension or abandonment of these wells. The impact will affect the production target and the oil recovery around the area.
A new methodology approach was selected using chemical sealant recipes as a rigless operation to repair CCA problem with cost-effective and safe manner for first time in offshore filed. Based on the wellhead and annuli survey, the bleed down and build up tests were conducted and followed by close monitoring on suspected wells, which revealed sustained casing pressures and fluid return at the surface. Several fluid samples were collected and analyzed in the lab. Based on the findings, the procedures and the proper design were conducted to inject the chemical sealant into connected cement channels behind casing strings. Curing time and injection rate with required volumes of chemicals were considered based on the pressure responses and chemical performance.
The results from the rigless operation job utilizing the new approach showed wide-ranging success rates based on well by well cases and conditions such as 1) Age of the well, 2) Sustained pressure observed at the surface, 3) Injectivity rates, 4) Chemical additives volume and 5) Downhole conditions (pressure / temperature).
The new technique added a great value on restoring the well integrity and saving the rig operation cost. In addition, the approach contributed to achieve maximum sustainable production target through ensuring the well operability and reducing the production down time. Challenges, methodology, work schedule, risk assessment, lessons learned and findings have been covered in this paper.
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