due to high pressure, temperature, or corrosive

1. Introduction environments. According to SPE (Society of

Workover and completion operations represent Petroleum Engineers) data, equipment failure
critical phases in the life cycle of oil and gas wells accounts for approximately 15-20% of
that directly impact productivity, safety, and workover complications (SPE 196347, 2020).
economic viability. Workover operations involve These failures often occur in hostile downhole
re-entering an existing well to perform environments where temperatures can exceed
maintenance, repairs, or stimulation to restore or 150°C and pressures can reach 15,000 psi.
enhance production. Completion operations
transform a drilled well into a producing asset by
installing the necessary equipment to bring
hydrocarbons to the surface safely and efficiently.
Despite technological advancements, these
operations frequently encounter various problems
that can lead to increased costs, production delays,
safety hazards, and environmental issues.
According to industry reports, workover and
completion problems account for approximately
25-30% of non-productive time in well operations
worldwide, resulting in billions of dollars in lost
revenue annually (Schlumberger, 2022).
This article explores the common problems
encountered during workover and completion
operations and discusses potential mitigation Figure 1 : Fishing operation to retrieve stuck
strategies based on industry best practices and pipe during workover (You Tube: Fais Akbar
recent research. (Abang Fais))
❖ Equipment Failures: Downhole tools and
2. Problems Encountered During
surface equipment may fail during operations
Workover Operations due to high pressure, temperature, or corrosive
Workover operations face numerous challenges environments. According to SPE (Society of
that can disrupt operations, damage equipment, Petroleum Engineers) data, equipment failure
reduce well productivity, and pose safety risks. accounts for approximately 15-20% of
workover complications (SPE 196347, 2020).
2.1 Mechanical Problems These failures often occur in hostile downhole
Mechanical issues represent some of the most environments where temperatures can exceed
common problems encountered during workover 150°C and pressures can reach 15,000 psi.
operations: ❖ Improper BOP (Blowout Preventer)
Function: BOP failures during workover
❖ Stuck Pipe/Tools: Tools or tubing can become operations can lead to well control incidents. A
stuck due to mechanical factors (key seating, report by BSEE (Bureau of Safety and
differential sticking) or formation collapse. Environmental Enforcement) documented that
According to a study by Schlumberger, stuck BOP-related issues contributed to 12% of
pipe incidents account for approximately 25% serious workover incidents between 2018-2022
of non-productive time during workover (BSEE, 2023). These failures can range from
operations (Schlumberger, 2022). These minor seal leaks to complete malfunction of
incidents typically require complex fishing ram preventers.
operations that significantly extend project
timelines and costs. 2.2 Formation Damage
❖ Equipment Failures: Downhole tools and Formation damage during workover operations
surface equipment may fail during operations can significantly impair well productivity:
❖ Fluid Invasion: Workover fluids can invade ❖ Corrosion: Tubular corrosion can lead to leaks
the formation, causing clay swelling, or complete failures during workover
emulsions, or chemical incompatibilities. operations. According to NACE International
Research published in the Journal of Petroleum (National Association of Corrosion Engineers),
Technology suggests that invasion-related corrosion-related failures account for
formation damage can reduce permeability by approximately 25% of tubular failures during
30-80% depending on fluid compatibility (JPT, workover operations (NACE, 2023).
2023). ❖ Mechanical Wear: Wear from previous
❖ Solids Invasion: Solids from workover fluids operations or current workover activities can
can plug pore throats and reduce permeability. weaken tubulars. Research published by SPE
Studies indicate that improper solids control indicates that mechanical wear is responsible
can reduce post-workover production by up to for 18% of tubular integrity issues during
40% (SPE 189301, 2021). This is particularly workover operations (SPE 193426, 2021).
problematic in formations with small pore
throats or naturally low permeability. 2.5 Cementing Issues
Cement-related problems during workover
operations include:
❖ Poor Cement Bond: Existing poor cement
bonds can worsen during workover operations,
leading to fluid communication issues.
According to Schlumberger studies,
approximately 30% of mature wells have some
degree of cement bond deterioration that can be
exacerbated during workover (Schlumberger,
2023).
Figure 2:Cross-sectional view of formation damage
mechanisms during workover operations (Halim,
M. C., Hamidi, H., & Akisanya, A. R. (2022))
3. Problems Encountered During
Completion Operations
2.3 Well Control Issues
Completion operations face their own unique set of
Well control problems during workover represent challenges that can impact well performance and
serious safety and environmental hazards: longevity.
❖ Kicks and Blowouts: Unexpected formation
pressure can cause kicks (formation fluid
3.1 Formation Damage During
entering the wellbore) which, if not properly Completion
controlled, can escalate to blowouts. Data from Formation damage during completion can
the International Association of Drilling significantly reduce well productivity:
Contractors shows that kick incidents during
❖ Drilling and Completion Fluid Invasion:
workover operations increased by 8% between
Fluids used during drilling and completion can
2020-2023 (IADC, 2024).
invade the formation and reduce permeability.
❖ Lost Circulation: Loss of workover fluid to
Studies by Baker Hughes indicate that fluid
the formation can lead to well control issues. A
invasion can reduce initial production by 20-
comprehensive study by Weatherford reported
50% if not properly managed (Baker Hughes,
that lost circulation events occur in
2023)
approximately 20% of workover operations and
❖ Perforation Damage: The perforation process
increase costs by an average of $150,000 per
creates a damaged zone around each
incident (Weatherford, 2023).
perforation, reducing productivity. Research
2.4 Tubular Failures published in SPE Production & Operations
journal shows that perforation damage can
Problems with tubulars during workover can lead
extend 1-4 inches into the formation, reducing
to costly repairs and safety issues:
 local permeability by 40-90% (SPE 197204, 3.5 Completion Fluid Problems
2022).
Issues with completion fluids can impair well
3.2 Sand Production performance:
Sand control issues are common during and after ❖ Filter Cake Removal Issues: Incomplete
completion operations: removal of filter cake can restrict production.
Research published in SPE Production &
❖ Screen Failures: Sand control screens can fail
Operations indicates that incomplete filter cake
due to erosion, plugging, or collapse. Data from
removal reduces initial productivity by 15-40%
ExxonMobil indicates that screen failures occur
(SPE 197213, 2023).
in approximately 12% of completions within
❖ Fluid Loss: Uncontrolled loss of completion
the first three years of production (SPE 191283,
fluid to the formation can damage the reservoir.
2022).
According to Baker Hughes, fluid loss during
❖ Gravel Pack Issues: Incomplete packing,
completion operations occurs in approximately
voids, or gravel pack settlement can lead to
30% of wells and leads to an average 25%
sand control problems. Research by
reduction in initial productivity (Baker Hughes,
Schlumberger shows that roughly 25% of
2022).
gravel pack completions experience some form
of performance deterioration within the first 4. Mitigation Strategies
five years (Schlumberger, 2023).
Several strategies can be employed to mitigate
3.3 Tubing and Casing Failures problems encountered during workover and
Tubular problems during completion operations completion operations:
include: ❖ Proper Planning and Risk Assessment:
❖ Installation Damage: Casing or tubing can be Comprehensive pre-job planning and risk
damaged during installation. Data from the SPE assessment can identify potential problems
indicates that installation-related damage before they occur. According to research by
occurs in approximately 5% of completions and Shell, companies that implement rigorous pre-
often isn't detected until production begins job planning experience approximately 40%
(SPE 188526, 2022). fewer operational problems during workover
❖ Connection Leaks: Poor makeup or damage and completion operations (Shell Technical
during handling can lead to leaking Report, 2023).
connections. Research by NOV shows that ❖ Fluid Selection and Compatibility Testing:
connection leaks account for approximately 9% Proper fluid selection and laboratory testing
of early completion failures (NOV, 2023). before operations can prevent formation
damage. Studies by Halliburton show that
3.4 Perforation Issues comprehensive fluid compatibility testing
Perforating operations can encounter various reduces formation damage incidents by
problems: approximately 60% (Halliburton, 2022).
❖ Advanced Monitoring and Real-Time Data
❖ Misalignment: Perforations may not align with Analysis: Using real-time monitoring to detect
the target formation zones. According to and address problems early. According to
research by Halliburton, perforation Schlumberger, operations utilizing real-time
misalignment occurs in approximately 8% of monitoring and data analysis experience 28%
completions and can reduce productivity by fewer serious complications during workover
15-30% (Halliburton, 2021). and completion operations (Schlumberger,
❖ Inadequate Penetration: Perforations may not 2024).
penetrate deeply enough beyond the damaged ❖ Training and Competency Management:
zone. Studies by Schlumberger indicate that Ensuring personnel are properly trained for
inadequate penetration reduces production by workover and completion operations. Data
an average of 20% compared to optimally from the International Association of Drilling
perforated wells (Schlumberger, 2023). Contractors shows that crews with
 comprehensive competency programs
experience 45% fewer operational failures
(IADC, 2023).

5. Conclusion
Workover and completion operations are critical
activities in the oil and gas industry that frequently
encounter various technical challenges.
Understanding these challenges and implementing
proper mitigation strategies is essential for
successful operations. The oil and gas industry
continues to develop new technologies and
methodologies to address these challenges, but
comprehensive planning, training, and adherence
to best practices remain the cornerstone of
successful workover and completion operations.
As reservoir conditions become more challenging
and environmental and safety standards more
stringent, the importance of addressing these
operational problems effectively will only increase.
Continued research, technology development, and
knowledge sharing within the industry are vital to
improving the success rate of these critical
operations.