The scope of this paper is to highlight the difficulties faced together with the respective solutions proposed and executed during the de-completion of a deviated well having complex horizontal internally plastic coated (IPC) completion during its work over phase, for a sour gas field. This was the first instance an abrasive jetting technology was used to punch a completion during a workover operation in Saudi Arabia.

In an unrelenting pursuit to reduce rig time per well, operators have to explore new innovative technologies that can reduce their reliance on multiple intervention techniques, subsequently saving rig stand by and operating hours by cutting unnecessary trips in and out of the wellbore.

In this candidate onshore well, the operator wanted to identify, isolate, and eliminate downhole tubing casing annulus (TCA) communication by changing the existing IPC completion. The production region was a deep horizontal openhole section with the reservoir having high gas oil ratio (GOR), based on previous experience the well was expected to produce sour gas any time even when it is killed. Initial operation on the rig was to nipple down (N/D) the wellhead (WH) and nipple up (N/U) the rig's blow out preventer (BOP) by loading up the well with kill fluid and setting secondary mechanical isolation barriers for well control. It was unfeasible to cure kill fluid losses using loss circulation material (LCM) because of the large openhole section, the highly deviated completion further limited slickline or wireline reach for barrier placement.

This paper explains the innovative solution devised and executed on this well, further covering the execution part of the operation, elaborating the combination of coiled tubing (CT) with slickline tools for intervention, tubing punch by abrasive sand blend jetted by means of specifically designed carbide nozzles, and the implementation of best practices to deliver a successful TCA isolation and well de-completion in record time.

The operation consisted of multiple CT runs, from cleaning out the completion of any residue plastic junk to lock mandrel enabled leak isolation, and mechanical plug barrier placement before abrasive jetting for tubing punch just above the packer with depth correlation by memory casing collar locator (CCL). Based on similar work performed on a nearby well, this innovative abrasive punch technology enabled the rig to save more than 40 hours of operating time on Well X.

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