Wireline packer remediation using novel bismuth technology
Isaac Hochberg A * , Andrew Fowlie A and Konstandinos Dalianas AA Woodside Energy Limited, Perth, WA, Australia.
The APPEA Journal 62 S122-S126 https://doi.org/10.1071/AJ21150
Accepted: 7 April 2022 Published: 13 May 2022
© 2022 The Author(s) (or their employer(s)). Published by CSIRO Publishing on behalf of APPEA.
Abstract
Prior to the execution of this project, there were limited options for repairing a failed production packer. Conventional oilfield practice would default to a well workover to replace the failed component. In an offshore environment, this approach not only carries significant capital cost, but also material risk and health, safety and environment exposure associated with the large operational footprint and time requirement of the operation. An innovative solution was developed to remediate the failed packer without a workover while simultaneously significantly reducing cost and risk. A new packer was formed by melting a bismuth alloy plug into the annulus using wireline equipment, eliminating the requirement for a workover rig. Bismuth alloy pellets were deposited onto the packer via precisely drilled holes in the tubing before being melted into an annular plug, forming a gas-tight metal-to-metal seal. As this was an industry first, prototype testing of the annular bismuth plug was undertaken to demonstrate concept feasibility. After a series of iterative testing a viable concept was achieved, and the prototype was taken forward to qualification. The annular plug was qualified to industry standard ISO 14310 V0 for the well’s operating conditions which included both pressure differential and axial loads. After the bismuth annular plug was qualified, the deployment method for the bismuth pellets was optimised to ensure they reached targeted location without compromising well integrity. After 2 years of design, the industry-first wireline intervention was successfully executed in 2021 and the well was returned to production.
Keywords: bismuth, completions, engineering, gas, intervention, offshore, packer, platform, remediation, repair, rigless, thermite, wireline, workover.
Isaac Hochberg is a Completion Engineer at Woodside. Some of his major accomplishments include, the return to service of several high-rate gas wells in the North West Shelf Project and the development of well completions on Woodside’s Sangomar project. Isaac has a range of project experience, starting from concept definition and establishment of contracts, through to offshore well site supervision. He is recognised for his skill in quality management and advises on projects company wide. Isaac holds a degree with honours in Petroleum Engineering and a degree with honours in Physics and Mathematics from the University of Western Australia. |
Andrew Fowlie is a Completion Engineer at Woodside Energy and was responsible for origination and conceptualisation of the bismuth packer repair strategy. During his time in the Platform Well Intervention team, he worked through the full project lifecycle from prototype feasibility testing to execution planning. He held both onshore and offshore roles in this team. He is now working as a Completion Engineer on Woodside’s Sangomar project. Andrew graduated from the University of Western Australia with a Masters of Mechanical Engineering and Undergraduate in Engineering and Finance. Prior to commencing his engineering career, he worked in corporate advisory. |
Konstandinos Dalianas is a Completion Engineer in the Platform Well Maintenance and Interventions team at Woodside. He was part of the team executing the return to service of the well in the North West Shelf Project with the bismuth technology offshore. Konstandinos is a recent graduate of the University of New South Wales with a dual degree in Petroleum Engineering (Hons) and Commerce. Konstandinos has previously authored papers on the numerical modelling of chloride-dominated brines and ganglion flow dynamics. |
References
Carragher P, Fulks J (2018) ‘Well Abandonment Solutions Utilizing Bismuth and Thermite.’ (Society of Petroleum Engineers)| Crossref |
Carragher P, Fulks J (2020) ‘Alternative Abandoment Material: Bismuth.’ (Society of Petroleum Engineers)
| Crossref |
International Organization for Standardization (2008) ISO 14310:2008 Petroleum and Natural Gas Industries – Downhole Equipment – Packers and Bridge Plugs. (ISO)
