A deviated newly drilled gas well in Western Caspian Sea in Azerbaijan, with a flowing water reservoir pressure of 17,500-psi and a flowing gas reservoir pressure of 12,200-psi was unable to regain flow after an unsuccessful attempt to bullhead produced water back into the well. During the bullheading operation, there was a peak registered pumping pressure of 12,933-psi without admission of fluid into formation. Producing interval was 5880mTVD with a MASP of 9,700-psi for gas reservoir. Coiled Tubing was the most viable option to identify the problem, to solve it and to regain access to the lower completion and then proceed with interval abandonment program.
This being an unconventional well in multiple aspects, presented serious challenges accentuated in Safety, Well Integrity Control, Obstruction Removal, and Well Conditioning Plan Forward. Integrity of completion was believed to be compromised by the high pumping pressures applied during bullheading and a confirmed communication between production tubing and "A annulus". After performing 2 rig site visits, an action plan was issued to adjust the platform for a Coiled Tubing intervention for the first time. Points to be developed in the plan were HSE, Structural Analysis and modifications required for proper equipment accommodation.
For well integrity control, it was imperative to evaluate the potential scenarios which could have led to the problematic well status. Completion history and specifications were reviewed to assure each of the potential operating scenarios could be controlled without compromising well integrity.
On obstruction removal, simulation software was used to design procedure with optimum string, chemicals, rates and fluids to be used for the operation and which contingency fluids considered to be available offshore. It is challenging to perform effective cleanouts in completions with 2 different sizes of tubings (IDs 3.74" & 2.2") combined with restrictions (1.92" nipple), the success is a function of overcoming limited fluid pumping rates, slow annular velocities, particle sizes, cleaning speeds, among others.
Well conditioning for future completion operations was planned depending on successful achievements of the coiled tubing intervention.
A total of 14 runs with coiled tubing using different BHA configurations were performed to complete the scope. Well was safely and successfully cleaned from a starting depth of 2,512mMD to a target depth of 5,864mMD (5,610mTVD) by removing mud deposits, consolidated sand bridges and completion restrictions. Throughout the cleanout operation, best practices discussed on planning stage were applied to remove multiple obstructions encountered and dealing with potential corkscrewed casing. By accomplishing the well delivery, it is evident that the methodology followed during the planning stage and execution, was crucial to save the well from being lost or abandoned.
There was an uncertainty whether the completion integrity was compromised by the high pressures used during the bullheading operation. Novelty in this intervention was the methodology for the risk assessment for an unconventional live well intervention with a 17,500-psi BHP, unseen pressure in the region. Thorough structural analysis was performed to assure the coiled tubing equipment could be placed safely on the platform to condition the well to regain production