W e l l c o m p l e t i o n a n d i n t e r v e n t i o n

Workover Operation
Course
 Eng. Elsayed Amer
Petroleum Engineer

BSC Of petroleum & NG engineering Phone : 01065860658

Senior Process & Production Engineer Email: Eng20072007@gmail.com

Now petroleum Eng. At SUCO & RWE DEA https://www.facebook.com/elsayedameer

Worked for weatherford drilling international Married with twins Mai & Nada.
 Page 4

About Workover

Welcome Introductions

“…any work performed after the initial completion that alters the well performance or
mechanical structure”
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01 Introduction

Workover
All jobs performed in a completed well any time during its productive
live to enhance well integrity and production rate.

Types of Operations
• Measurements
• Maintenances
• Workover

01
 6

Workover Operation

Workover: The process of performing major maintenance or remedial treatments

on an oil or gas well.

• Increase or restore hydrocarbon production

• Decrease water production

• Repair mechanical failures

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Introduction

Well Intervention Workover

 8

Workover Operations

01 Measurements
✓ May involve the status of equipment
✓ Quality of pay zones-borehole connections
✓ Status of reservoir and well equipments etc.

02 Maintenances
✓ Simple operations that can be done on a well during
production operations

03 Workover

✓ Heavier operations that might require the well to be

02 killed
✓ Sometimes carried out with the well under pressure
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01 Reasons for work over

Installing New Equipment

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01 Reasons for work over

Casing window cutting for side track

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01 Reasons for work over

Well Plugging and abandonment

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01 Measurement Operations
At the Wellhead
➢ Pressure and temperatures, variation would mean modification in production conditions.
➢ Pressures or loss in pressures in the annulus to check integrity of packers, casing and
production strings.
➢ In artificial lift operations to monitor stress on rods, pumps or gas lift valves.
➢ Safety valve testing etc.
At the Tubing
➢ Calibrations and checks
➢ Corrosion or deposit problems etc.
At the Bottom hole
➢ Checking top of sediments
➢ Production logs –density, flow rate or temperature.
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02 Maintenance Operations
At the Wellhead
➢ Routine operations such as adjusting flow rates
➢ Opening and shutting in well.
➢ Replacing faulty parts downstream
➢ Periodic verification of safety valves etc.
At the Tubing
➢ Operations connected with problems of deposits, corrosions etc.
➢ Injection of inhibitors, chemicals, de-emulsifiers, anti foaming agents etc.
➢ Operations for exchange of equipments downhole etc.
At the Bottom hole
➢ Sand control, further perforations etc.
➢ Pumping chemicals etc.
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03 Workover Operations
At the Wellhead
➢ Leaks in lower master valves, tubing hanger.
➢ Problems with SSSV control lines etc.
➢ Damaged back pressure valves and other wellhead components.
At the Tubing
➢ Casing or tubing problems/leaks.
➢ Collapsed, burst or broken pipe.
➢ Tubing partially or totally plugged.
At the Bottom hole
➢ Leaks in equipments that has seals such as packers, locators, slip joints etc.
➢ Gas lift valves, fish, broken rod, pumping problems
➢ Miscellaneous faulty downhole equipment such as sensors, control lines etc.
Modification in production conditions
Restoration pay zone –bore hole conditions
Change well purpose
Fishing
MINOR WORKOVERS
Workover operation techniques include
Wireline
• Tubing gage cutter
• Scale or paraffin removal
• Sand bailer
• Plugs installation
• SSSV repairs
• Gas Lift installation
• SSD shifting
• Perforation
• Through tubing activities
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Pumping operations Coil tube & Snubbing
• Well Killing • Chemical injection
• Chemical Injection • Acidizing
• Acidizing • Sand Clean out
• Hydraulic fracturing • Cement plug
• pressure testing • Remedial through tubing
gravel pack
• Fishing
• Scale clean out
• Non routing well kill
• Kick off
 WORKOVER TECHNIQUES AND EQUIPMENT

These will be discussed with reference to two different categories namely:-

(1) Internal through tubing operations
(2) Tubing retrieval operations

(1) Internal Through Tubing Operations

A number of techniques are available to access and intervene inside the production tubing
including:-
• Conventional slick wireline operations
• Through Flow Line techniques for application in subsea wells
• Concentric tubing
(2) Tubing Retrieval Equipment
Equipment available to conduct such operations could be either:-
• A full drilling rig with the necessary BOP equipment and the capacity to pull tubing.
• A concentric unit which can be installed over the producing well.
Data Required for
Successful Workover
DATA REQUIRED FOR WORKOVER

A Fluid Levels In Tubing

B Wellhead Pressure Rating

C Formation Pressure

D Casing & Tubing Sizes

E Formation Fracture Pressure

F Casing & Tubing Strengths

G Infectivity Pressure

H Maximum Allowable Surface Pressure (MASP)

PRODUCTION HISTORY 19

500

400

300
BOPD
BOPD

200

100

0
1991 1992 1993 1994 1995 1996 1997 1998
Year
WATER PRODUCTION HISTORY 20

500 1000

400 800
FTP

Flowing pressure
BOPD, BWPD

300 600

BOPD
200 400

100 200
BWPD

0 0
1991 1992 1993 1994 1995 1996 1997 1998
Year
Job preparation
Economic phases of field development
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23

SUCCESSFUL WORKOVER INVOLVE

A Step 1 - Diagnose the problem

B Step 2 - Determine solutions

C Step 3 - Prepare Workover procedures

D Step 4 – Perform economic analysis

unlimited
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A Selecting Workover Rig

Workover Rig

wheel mounted, propelled unit

containing a fabricated derrick and
a pulling system that operates a
multisheave traveling block with a
"tubing line “drum.
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A Selecting Workover Rig

A number of factors will influence the selection of a Workover rig

including:-

1. The nature of the operation to be conducted.

2. Tubing size.
3. The suspended weight of the tubing string, pressure control requirements for
well re-entry etc.
4. location of well, proximity to operating company base, space on rig/platform,
crane lift capacity.
5. Economics - cost, availability and its impact on deferred production.
6. The reservoir characteristics for example:-
7. Type of fluid
8. Fluid contaminants e.g. H2 S content
9. Pressure, temperature, fluid rate etc.
10. Depth of well
01
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B Killing the well

Killing the well is the process of replacing the contents of production tubing
with a fluid with sufficient density called kill fluid to overbalance the
pressure in the producing formation

01
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B Killing the well

Pumping

Pumping is the simplest way to

pump killing fluid through well
bore

01
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B Killing the well

Circulating killing fluids

01
Reasons for Workover
and remedial actions
COMMON REASONS FOR A WORKOVER

Formation Problems
• high water cut (water shut off)
• Sand production (gravel pack )
• high gas oil ratio (gas shut off)
• viscous oil (chemical treatment)
• lower productivity (re - perf.+vacuum)
• formation damage (frac + acid)
COMMON REASONS FOR A WORKOVER

Some of the more common reasons for a workover are:

• Repair mechanical damage
• Stimulate an existing completion
• Complete into a new reservoir
• Complete multiple reservoirs
• Reduce/eliminate water/gas production
• Reduce/eliminate water coning
• Repair faulty cement jobs
Potential Well Problems
1. Control of Water Production:

• Excessive water production can lead to a number of production problems

including
✓ loss of production and eventual well death
✓ expensive treatment and disposal costs,
✓ corrosion and scaling.
• Recovery from water drive reservoirs
• Significant increase in water production
• Rise in water/oil contact as a result of reservoir depletion.
❑ Fingering
• Water migrating along a high permeability streak.
❑ Water Conning
• water is drawn up from the aquifer either across bedding planes leading to
coning.

32
Potential Well Problems
1. Control of Water Production:

• Water Drive in Oil Reservoirs Oil producing well

Bottom-Water Drive

Oil Zone

Water

Cross Section
33
Potential Well Problems
1. Control of Water Production:

• Water Drive in Oil Reservoirs

Edge-Water Drive
Oil producing well

Oil Zone

Water Water

Cross Section
34
Water Coning

Oil zone
Cone

Water
Water Breakthrough

Low
permeability

High
permeability

Intermediate
permeability
Low
permeability
Water Communication

High pressure
water
sand
Casing leak

Water channel along

bad cement job

Low pressure
oil reservoir
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Potential Well Problems
1. Control of Water Production:

Oil Rate

Water Rate

39
Solution Gas Drive in Oil Reservoirs
Typical Production Characteristics

Oil production rate, STB/D 800 400

600 Pressure, psia 300

400 200 Reservoir

pressure

Oil production rate

200 100

0 0
Time, years
40
Water Drive in Oil Reservoirs
Effect of Production Rate on Pressure
Production data - lower oil production rate

Pressure, psia
2000
Reservoir pressure
1900
1800
1700

Water Cut, %
60
Water
40
Oil production,

20 20
MSTB/D

15 0
Oil
10
5
0
Time, years

41
Gas Cap Drive
Typical Production Characteristics

Pressure, psia
Production data
1300
Reservoir pressure
1200
1100
1000
900
Oil production rate,

2
MSTB/D

Oil
1

0
Time, years
42
Potential Well Problems
1. Control of Water Production:

• Remedial Actions

• Squeeze cementing
• plugging back and re-completion
• Straddle system

43
Potential Well Problems
1. Control of Water Production:

• Remedial Actions

• Straddle system
Perforation Shut Off

44
Potential Well Problems
1. Control of Water Production:

• Remedial Actions

• Squeeze cementing

45
Potential Well Problems
1. Control of Water Production:

• Remedial Actions

• plugging back and re-completion

46
Potential Well Problems
1. Control of Water Production:

• Remedial Actions

• P&A

47
Potential Well Problems
2. Low Reservoir Pressure

• The reduction in reservoir pressure and hence flow rate is particularly acute
in dissolved gas drive reservoirs.
• In gas cap and water drive reservoirs, pressure maintenance techniques can
often offset the reduction in pressure due to depletion.

48
Potential Well Problems
2. Low Reservoir Pressure

• Remedial Actions

• Recomplete the well with either smaller tubing or some form of artificial lift.
• Injection

49
50
Potential Well Problems
2. Low Reservoir Pressure

• Remedial Actions

• Injection

51
Potential Well Problems
3. Poor permeability

• Fields with low reservoir permeability suffer a rapid decline once the fluids
near the wellbore are produced

• Remedial Actions

• Reservoir stimulation
1. Acidizing
2. Hydraulic frac

52
Potential Well Problems
3. Poor permeability
• Remedial Actions
• Matrix Acidizing
usually accomplished by
introducing a mild acid through the
perfs and into an existing
producing reservoir for the
purpose of dissolving acid soluble
solids and regaining or restoring
production. This can be done by a
coiled tubing unit, snubbing unit, or
small tubing unit.

53
Potential Well Problems
3. Poor permeability
• Remedial Actions
• Matrix Acidizing
usually accomplished by
introducing a mild acid through the
perfs and into an existing
producing reservoir for the
purpose of dissolving acid soluble
solids and regaining or restoring
production. This can be done by a
coiled tubing unit, snubbing unit, or
small tubing unit.

54
Potential Well Problems
3. Poor permeability
• Remedial Actions
• Hydraulic frac

55
Potential Well Problems
4. Wellbore Restrictions

• Typical causes of restrictions include scale, sand, paraffin and asphalt etc.
• Many of these problems may not be apparent during early field life but can
become a significant problem as the field matures.
• Remedial Actions

• Mechanical remove of restriction.

• Chemical remove of restriction.

57
Potential Well Problems
4. Wellbore Restrictions

• Remedial Actions

• Mechanical remove of restriction.

1. Scale and Sand milling out

58
Potential Well Problems
4. Wellbore Restrictions

• Remedial Actions

• Mechanical remove of restriction.

1. Scale and Sand under reaming

59
Potential Well Problems
4. Wellbore Restrictions

• Remedial Actions

• Chemical remove of restriction.

1. Jet Pump Sand Cleanout

60
Potential Well Problems
4. Wellbore Restrictions

• Remedial Actions

• Chemical remove of restriction.

2. Acid washing

61
Potential Well Problems
5. Mechanical failure

• Mechanical failures of tubing, casing and downhole equipment often require a

workover to rectify the problem.
• Typical problems would include
✓ casing leaks, either as a result of corrosion or collapse,
✓ tubing failures, packer failures and
✓ Downhole safety valve failures.

• Remedial Actions

• Replacement of downhole components by work over units

• Expandable tubular

62
Potential Well Problems
5. Mechanical failure

✓ casing leaks, either as a result

of corrosion or collapse,

63
Potential Well Problems
5. Mechanical failure

✓ casing leaks

64
Potential Well Problems
5. Mechanical failure

✓ tubing thread failures

Scab Liners INFLATABLE PACKERS

65
Potential Well Problems
5. Mechanical failure

✓ tubing thread failures

Scab Liners

66
Potential Well Problems
5. Mechanical failure

✓ Downhole safety valve failures.

67
Potential Well Problems
6. Primary Cement Failures:

✓ A poor primary cement job which

leaves channels behind the casing
can lead to the influx of unwanted
fluids and in certain instances
casing collapse.

• Remedial Actions
• Squeeze cementing
• Scab liners
• Expandables

68
Potential Well Problems
6. Primary Cement Failures: packer

• Remedial Actions tubing

• Squeeze cementing FORMATION

casing
Forces cement slurry, under pressure, through DEHYDRATED
CEMENT
perforations or holes in the casing or liner….. cement
slurry

cement PRIMARY
nodes CEMENT

CHANNEL BEHIND
CASING

69
Potential Well Problems
7. Sand Production:

• Failure of reservoir formations and subsequent sand production from

wellbore can cause
✓ Erosion of tubular and components
✓ Productivity impairment
✓ Clogging of separators

• Remedial Actions
• Mechanical sand control
✓ Screens
✓ Gravel pack
✓ Frac pack
✓ Expandables
• Sand Management-
✓ reservoir pressure maintenance

70
Potential Well Problems
7. Sand Production:

71
Potential Well Problems
7. Sand Production:
UNDERREAMED UNDERREAMED
INSIDE CASING CASING SCREEN LINER OPEN HOLE OPEN HOLE
GRAVEL PACK GRAVEL PACK IN OPEN HOLE GRAVEL PACK GRAVEL PACK

72
Potential Well Problems
7. Sand Production:

73