Successful Application of Fiber-Optic-Enabled Coiled Tubing and Inflatable
Packer Used for Testing the Formation’s Upper Zone Carolina Gonzalez, and Johana Muñoz, Schlumberger; Natalia Orozco, SPE, and Josue Higuera, SPE, Equion; Dubrasky Nava, SPE, Schlumberger
Copyright 2014, Society of Petroleum Engineers
This paper was prepared for presentation at the SPE/ICoTA Coiled Tubing & Well Intervention Conference & Exhibition held in The Woodlands, Texas, USA, 25-26 March 2014.
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Abstract
Floreña field, located north of the Cusiana and Cupiagua fields, has been producing since 2001. Floreña field is part of the series of thrust sheets developed as result of the Eastern Cordillera uplifting.
In order to determine pressure depletion, establish connectivity between wells, reduce the risks of geological uncertainty along the field, and meet Ministry of Mines data acquisition commitments, we performed a pressure buildup test using inflatable packers as the isolation method.
In the past, when a pressure buildup test was required in the well’s upper formation, operators had to set up a bridge plug in the lowest part of the tested formation, set up a sand plug, and finally, pump a cement plug. These extra steps increased HSE risks and project costs.
A synergistic approach using real-time down hole measurements from fiber optic coiled tubing were combined with the cased hole inflatable packer to improve operation reliability while reducing risk of failure and time.
The availability of real-time logging casing collar locator (CCL), annular, coiled tubing (CT) bottom hole pressure, and bottom hole temperature data allowed the inflatable packer to be set properly. The measurements helped ensure adequate packer inflation, monitor the maximum draw down without exceeding the packer integrity, and perform a well test to a specific formation in just one run. In addition, the BHA configuration allows a memory tool down the packer to record the lowest formation static pressure.
After the pressure buildup test was performed, the results showed well connectivity with Florena Field. The test also confirmed reservoir pressure and permeability, which helped in future job and field planning.
Introduction
Eastern Colombia (foothills region) producing zone can be divided in; fields Cusiana, Floreña, Pauto Complex and Recetor. General characteristics: wells have an average depth of approximately 19,000 ft, slightly deviated, above 200 degF, three producing zones, permeability contrast between formations, cross flow & high gas and water cut.
Field Floreña has been active and producing continuously since 2001. After thirteen years, it was necessary to develop a strategy that complies with government requirements about well data, and also, could help with the geologic uncertainties by the establishment of formations connectivity and reservoir pressure depletion. 2 SPE 168262
Wells included in the study had two formations open to production, Barco and Mirador. Performing a pressure build up test (PBU) to study each individual formation was an operational challenge; an open zone had to be temporarily isolated to enable the test.
Initially, the method used to perform the operation was:
1. Set a packer between the two zones; in some wells, mechanical packers have to withstand elevated differential pressures as well, important cross flow rates and mechanical restrictions. 2. Place sand plug on top of packer; a Wireline unit often was the preferred method to place the plugs. The objective behind the operation was to protect the fish neck of the packer. 3. Place cement plug on top of the sand; often this was done in the same run the sand plug was placed. The cement provided full isolation. 4. N2 lift if neccesary, which imply a CT interevention. 5. Perform PBU test real time or in memory mode with wireline unit. 6. Mill and clean cement & sand plug 7. Fish mechanical packer 8. N2 lift if neccesary, which imply a CT interevention.
A complete intervention took around 17 days and included numerous runs. Several challenges and risks existed, associated with milling and cleaning after the test was performed, as well as fishing the packer. Also, 20000-bbls of deferred production due to 7 days of shut in had to be considered.
As an alternative method, it was proposed to perform the operation with a Coiled Tubing Unit, fiber optics deployed on CT string (enables real time down hole measurement), and an inflatable packer to isolate zones. All operations were planned to be performed in one run.
Statement of Theory and Definitions
Inflatable packer Inflatable packer systems are specifically designed for reliable thru tubing zonal isolation. The system includes a hydraulic set packer, tension and pressure operated running tools and it is compatible with real time and memory pressure and temperature gauges. (Figure 1).
The system is designed to perform single-trip, single set zonal isolations. It can be run in deep, deviated and horizontal wells. No rotation or ball drop is required, and all operations can be achieved through application of pressure and/or load. A software for design analysis (maximum & minimum pressures and forces) is also included. The key factor with inflatables is the expansion ratio, as it increases; the differential pressure the packer is able to withstand decreases. A high expansion/pressure ratio was required to perfom the tests; PBU test stated that well has to be full or partial opened generating an important differential pressure down hole on the packer. The inflatable packer is capable of expansion ratios of over 3:1 at differential pressures up to 2000 psi. Differential pressures across the element of up to 10,000 psi can be achieved at lower expansion ratios. Figure 2 shows the maximum differential pressure vs. casing ID for 3 in and 2-1/8 in packer.
The packer is deployed with CT as part of the BHA. Depth control is crucial if there is small window to set packer. Once at depth, the inflation process begins. Packer may be inflated with water, brines, or diesel among others. The process may vary depending on method, but as a basic concept, fluid is pumped through CT increasing rate and/or pressure until packer is set. To confirm packer is anchored to casing/tubing, slackoff CT weight, and it should remain stable. After packer is set and anchored, depending on the purpose of the operation, it can be disconnected from the CT to leave as a temporary or permanent barrier, or it can be used as a treating packer in which treatment can be pumped above and/or below the packer (fluid can also be pumped through the annular space).
Figure 3 shows a schematic of the packer, the seal is provided by the rubber (in black) at the middle of the packer and the anchoring is provided by the body (in gray). Once treatment is done, over pull must be applied to deflate packer and retrieve it to surface.
Fiber-Optic-Enabled Coiled Tubing
Fiber-Optic-Enabled Coiled Tubing is non obtrusive, real time surface readout system of downhole measurements through fiber optics deployed on CT. SPE 168262 3
The tool is 2 1/8 in OD with an inner flow path of 11/16 in. It is composed by an electronic section that processes the readings of the two pressure gauges for inside and outside pressure of the CT, and the reading of the temperature of the chassis of the tool. At the bottom end it can be found the casing collar locator, CCL, module which serves as reference for depth correlation. The fiber optics fiber serves as telemetry device for optical data transmission. The carrier containing the fibers is compatible with acid, solvents and H2S. The size of the carrier is negligible in the CT inner diameter maintaining the pumping capabilities of the CT string. A complete description of the downhole measurement system was 1 presented by Rangel et al in 2007.
Coiled Tubing Intervention
Well is a gas & oil well, with a deviation of 28-deg, 4300-psi of bottom hole pressure (BHP), 7-in liner up to 14546- ft, 5-in liner up to 16337-ft and a 2-7/8 in pre drilled liner up to bottom of the well. Job objective was to RIH CT with 3-in OD inflatable packer, and Fiber Optics deployed with Coiled Tubing. Set packer at 14,100-ft to isolate Mirador and Barco formation. Once set, perform an above drawdown and finally shut in the well to perform a Pressure Build Up Test (collecting live downhole data). After the PBU is completed, unset packer and POOH. (Figure 4).
Main challenges for this job:
§ Reduce operating times and footprint.
§ Packer to withstand high differential pressures; above drawdown to perform well test. § Dynamic downhole conditions; high gas cut (which tends to impregnate packer rubber). § Cross Flow between formations
The whole system used in this intervention was composed by the following elements
Fiber-Optic-Enabled Coiled Tubing string: This system allows data transfer from downhole tool to surface data acquisition system and vice versa.
Coiled Tubing Connector: Used to connect the bottom hole assembly to the CT.
Fiber-Optic-Enabled Coiled Tubing Tool: Downhole electronic package with pressure sensors for Bottomhole Pressure outside the CT, i_AnnBHP, and Bottomhole pressure inside the CT i_CTBHP, and temperature of the BHA, which is directly related with wellbore temperature i_BHT. A secondary module, 2 1/8” CCL, is attached for accurate depth correlation.
Double Flapper Check Valves: It is one-way flow valve that is used to prevent flow back up through the tool string or CT. This is included in BHA’s for well control should the CT be parted or used during low well head pressure deployment.
Hydraulic Disconnect: This BHA component allows the CT to be disconnected from the BHA should it become stuck and contingency measures are required, or as part of the planned operation. It is activated by dropping a ball and pressuring up to shear a set of shear screws. Following disconnection this component leaves a fishing neck profile to simplify retrieval.
Circulation Sub: It directs fluid flow axially through the tool until activated. Once a ball lands on the seat and activates the piston, this component then directs all fluid flow to the tool string annulus. If a dual circulation sub is used then this tool has an additional feature of an overpressure device (e.g. burst disk) to also achieve fluid flow to the tool string annulus if activated.
Centralizers: This component allows protection to the inflatable packer while running in hole avoiding direct contact of the rubber and slats with the tubing.
3” Inflatable packer: Through tubing inflatable packer is used for temporary isolation of sections of well bore.
Inflation Valve: The Inflation valve was designed to control flow within coiled tubing strings. Primarily it is meant to provide a means to control setting of inflatable packers. 4 SPE 168262
Surface data acquisition: This system combines the regular parameters recorded in a regular CT job with the downhole readings, providing a broad picture of the intervention.
Execution Stage 1
For the first stage of the intervention the well was shut in with 3470-psi well head pressure. Then the tool was run and set the inflatable packer in a 7-in tubing at 14,100-ft. RIH procedure was performed while the differential pressure between CT and annular was monitored closely to avoid an increment pressure that could set the packer prematurely, this was done thanks to the sensors downhole which allow pressure behavior monitoring. Depth correlation was made through CCL tool installed in the BHA for 7” casing 13% Cr-. (Figure 6). With the packer at setting depth a 30 minutes wait was done for temperature and pressure equalization inside and outside the packer.
Execution Stage 2
Inflating packer procedure started pumping at 0.2-bpm and recording the circulating pressure, bottom hole annular pressure and bottom hole coiled tubing pressure reading. Increments on the pumping rate where made in 0.1- bpm stages during 5-min between each step until pressure readings showed packer was inflated at the pressure designed (Table 1). As an indicator packer was set, circulating pressure at surface and coiled tubing bottom hole pressure decrease abruptly when inflation pins shear. (Figure 7).
In this point the packer´s pressure was 6669-psi, the difference between the packer pressure and the above pressure was 4252-psi, and the difference between the packer pressure and the below pressure was 1252-psi. To confirm packer set, 2000-lbf slacks off weight was applied.
Execution Stage 3
Well was opened until the lowest stable rate possible was achieved with a choke of 10/64” to take PVT samples from opened interval in Barco. The downhole pressure data gave an accurate indication of the appropriate drawdown to avoid losing packer integrity. (Figure 8-)
With a WHFP: 3,070-psi, Qg: ~11 MMSCFD, BHFP: 5,120-psi, CT pipe was displaced out with N2 at 500-scfm meanwhile internal sensor was monitored to have an estimated Mirador shut in pressure. Once all N2 and diesel flowed to surface 4 hours stable flow period was performed with following conditions:
Choke: 10/64”, WHFP: 3,130-psi, WHFT: 122 deg F, Qo: 1,357 bopd, Qgas: 11.856 MMSCFD, Qw : 0 bwpd, BS&W: 0 %, GOR: 8,737 scf/stb, API: 45.0 deg, SG: 0.7, and 2 PVT sets of samples were taken at 10/64” choke, each PVT set contained: 2 cylinders of 20 lt of gas and 1 PDS of 750 cc with liquid from the separator.
After taking PVT samples, the well was shut in while pressure and temperature parameters where recorded and monitored from surface. After 1 hour shut in time the following parameters were recorded WHSIP: 3,375 psi, WHSIT: 103 F, BHSIP: 5,375 psi, BHSIT: 225 F.
After 12 hours shut in time, information was downloaded and sent to interpretation, after analyzing the data Reservoir Group decided to end the PBU after 12 hours instead of 24 hours planned.
Final Data acquired: WHSIP: 3,389 psi, WHSIT: 82 F, BHSIP: 5,373.1 psi, BHSIT: 225 F.
After completion of job objective, 14000 lbf over pull in steps was applied to CT, when 42000 lbf was achieved, the weight changed abruptly to 28000 lbf, showing evidence of packer unsetting. After waiting 1 hour to let packer rubber relax, CT pipe and tool were pulled out of the hole successfully. SPE 168262 5
Results
Data was analyzed by reservoir group with the following results:
Kh: approximately 8500 md.ft.
Skin: 40 Reservoir pressure: Approximately 5000 psi, this value was expected and is according with the numeric model from Florena field. Possible faults: the red line slope was interpreted as two faults near to the well, which is in accordance with the geological interpretation where florena fault is at east of this well. (Figure 9, Figure 10 and Figure 11)
Conclusions
• Integration of Fiber-Optic-Enabled Coiled Tubing and Inflatable Packer enabled client to perform drawdown to take PVT samples and PBU test in a single run without need of any other services but CT. • CT depth correlation eliminates the need of an extra run to ensure inflatable packer is set at desired depth. • Fiber-Optic-Enabled Coiled Tubing and sensor down hole enabled the monitoring of inflatable packer performance and behavior. Pressure differential between CT and Annular monitored to avoid premature inflation of the packer and correct inflation process. • Effective PBU test performed to Mirador formation thanks to inflatable packer seal between formations and real time data from Fiber-Optic-Enabled Coiled Tubing. • As there was no need to kill the well during intervention, no fluids were lost to the formation. • Impact in production was reduced 60 %
PBU test can be done to both formation simultaneously (above and below packer); by deploying a memory gauge below packer as part of the BHA, or modifying the tool assembly and allowing i_CTBHP measurement to be interpreted as bottom formation shut in pressure
References
1. P.D Rangel, SPE, and I. Sorman SPE, Schlumberger, C.G Lount, SPE, and N. Woods, SPE, CoconoPhilips. Fiber-Optic-Enabled Coiled-Tubing Operations on Alaska´s North Slope. SPE 106567
2. D.A Fernandez Castano, SPE, Schlumberger, N. Ruiz, R Zabala, SPE, and E. Mora, SPE, Ecopetrol SA, and D.J Nava, SPE, Schlumberger. Real-Time Evaluation of a Velocity String: Case History of a Suitable Solution for Well Recovery. SPE 163920
Nomenclature
HSE: Health, Safety, Enviromental
CCL: Casing Collar Locator CT: Coiled Tubing BHA: Bottom Hole Aseembly PBU: Pressure Build Up Test OD: Outside Diameter RIH: Run In Hole ID: Inside Diameter WHFP: Wellhead flowing pressure Qg: Gas Production rate BHFP: Bottomhole flowing pressure, WHFT: Wellhead flowing temperature Qo: Oil production rate, Qw: Water production rate 6 SPE 168262
BS&W: Base Sediment and Water
GOR: Gas Oil Rate SG: Specific Gravity PVT: pressure, volume, temperature WHSIP:Wellhead shut in pressure WHSIT: Wellhead shut in temperature BHSIP: Bottomhole shut in pressure BHSIT: Bottomhole shut in temperature
Figures
Figure 1- Common Bottom hole assembly schematic
Figure 2- Common Bottom hole assembly schematic
SPE 168262 7
Figure 3- Common Bottom hole assembly schematic
Figure 4- Well Configuration
TOP BOTTOM TOTAL GUN PHASING
DATE CODE DEPLOYMENT RUN No STATUS FORMATION TYPE SPF (FT) (FT) FEETS SIZE (IN) (DEG) 31-Oct-2011 PER E-LINE 2 13967 13987 20 ACTIVE BARCO 2.875 2906 PJ NOVA 6.00 60 31-Oct-2011 PER E-LINE 3 13990 13999 9 ACTIVE BARCO 2.875 2906 PJ NOVA 6.00 60 30-Oct-2011 PER E-LINE 1 13999 14010 11 ACTIVE BARCO 2.875 2906 PJ OMEGA 6.00 60 30-Oct-2011 PER E-LINE 2 14019 14039 20 ACTIVE BARCO 2.875 2906 PJ OMEGA 6.00 60 31-Aug-2011 PER E-LINE 16340 16404 64 ACTIVE MIRADOR/JARAMA 2.875 PREDILLED 12.00 135
