Restoring Production Via Non-Rig Deployed Wireline Technology

Objectives/Scope: This paper details the challenges faced and the solutions deployed to restore production following failure of a formation isolation valve (FIV). Methods, Procedures, Process: The FIV was installed to isolate the reservoir during the deployment of the Upper Completion. Once the wellhead, tree, and flowlines were hooked up, several attempts were made to open the valve to initiate production. Despite the planned pressure cycles being applied, the FIV did not open. It was suspected that there was fill/debris on top of the valve preventing its hydraulic activation. The failure of the FIV, and associated lost production, drove the team to develop a remedial intervention plan. The Operator and Business Partner team evaluated multiple alternatives before selecting a combined slickline and electric line tractor-deployed solution. The plan included a drift run to determine the wellbore condition above the FIV, followed by a cleanout run and the milling of the FIV Inconel ball-valve. Due to the high hole angle, a tractor was required to apply weight on the mill bit. Results, Observations, Conclusions: After the removal of the wellbore debris using a slickline bailer and a suction tool deployed with electric line (EL), a tractor milling assembly was deployed that successfully milled through the FIV ball-valve. The successful milling operation saved approximately $30MM in Major Rig Work Over cost by bringing the well back to production levels in accordance with the pre-drill estimates. Novel/Additive Information: This paper describes the process followed to design an optimal intervention plan, and the detailed planning and operational steps. The optimal engineered solution coupled with operational discipline during execution successfully brought the well back to production, minimizing the lost production cost while avoiding a costly rig-based intervention. This paper also highlights the novel technologies utilized, the milling BHA configuration, specific lessons learned, and best practices recorded during the execution.