First Ever Offshore Deployment of an Inflatable Packer Anchoring System for Rigless Installation of an Insertable Progressive Cavity Pump: A Case Study

An offshore well located in Indonesia required rigless installation of an insertable progressive cavity pump (I-PCP) as a cost-effective solution to restore production while eliminating the need to retrieve the upper completion for extensive maintenance. The well had been previously completed with a conventional progressive cavity pump (PCP) as an integral part of the completion and was placed offline for approximately one year due to mechanical failure of downhole components. Typical I-PCP anchoring methods were not feasible alternatives for this application. A pump-seating nipple (PSN) insertable seal stack could not be used due to the lack of a PSN at the required I-PCP setting depth, and a mechanical J-slot anchoring device could not be deployed because rod conveyance from an offshore barge is subject to constant heave, which results in fluctuating axial loads and rod position, which would pose the risk of prematurely activating a mechanical J-slot anchor during deployment. An inflatable packer anchoring system was selected as a solution to the operational challenges encountered in this application. The system comprises inflatable packer technology, a hydraulically-actuated anchoring slip mechanism, seal cups, and a shearable intake sub. Conveyed on sucker rods, the system provides the required pressure competence to confirm tubing integrity and enable a complete hydraulic setting sequence. The first ever offshore installation of this system proved its optimal functionality by successfully anchoring an I-PCP inside 3-1/2" production tubing riglessly from an offshore barge. The system was set by applying pressure via the tubing-rod annulus, and the well was immediately placed into production. After being shut-in for more than one year, this unique solution provided the well operator with a safe and low-cost alternative to reestablish production while eliminating the need for a workover rig. The objective of this paper is to provide a case study analysis of the first offshore deployment of this technology, discuss its potential for optimizing PCP/I-PCP completion designs, and explain the economic and operational benefits of associated rigless well intervention operations in comparison to current alternative methods.