SPE 97668
Disposable Wells: A Monobore One Trip Case Study
W. Chapman, Baker Oil Tools
Copyright 2005, Society of Petroleum Engineers
This paper was prepared for presentation at the SPE International Improved Oil Recovery
Conference in Asia Pacific held in Kuala Lumpur, Malaysia, 5–6 December 2005.
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Abstract
This paper will discuss a Monobore one trip cement through
completion system. The system was designed to add artificial
lift capabilities and improve safety to short life monobore
wells. The disposable well bore concept is gaining popularity
in regions worldwide. This paper will also discuss case
histories including operation issues and problems and how
they were solved.
Operational procedures will be outlined to effectively
demonstrate, and discuss the decision making process when
determining the most cost effective candidates for this
technology.
Introduction
Throughout the oil and gas industry focus is turning to
economical methods of completing wells that in some case
due to high completion cost would not be feasible. Over the
years several methods have been utilized in an attempt
develop adequate means to safetly and productivily complete
these wells. These methods have ranged from merely
cementing the tubing in place to completing in several stages
so as to utilize necessary safety and gas lift equipment. A
more fit for purpose completion system for disposable
wellbores would include all the equipment necessary to safely
and economically complete these wells. This system would
also need to be a true Mono-Bore one trip completion which
would allow cement to be pumped offline freeing up the rig to
move to another location on the platform. Since the inception
of this completion techno;ogy an average of 40 hours of rig
time has been eliminated from each completion (see figure
two). This reduction has represented a considerable cost
saving when utilized on the entire platform . Components of
this one trip mono-bore system would also need to function
properly following the cementing operation. These
capabilities currently exist in the Mono-Bore CemenThru
completion system. This system relies on specifically
designed cement tolerant components. This system is
currently being used in the Gulf of Thailand.
Mono-Trip CemenThru Completion System
Completion Design. The Mono-Trip system is based on a
true mono bore design with one trip capabilities. More
importantly the system will operate as intended after cement
has been pumped through each of the components. Pressure
cycles are utilized throughout the completion to operate the
various components.
As depicted in the graphic(Completion Designs fig 1)
several completion designs have been utilized for this
particular type of completion philosophy. Conventional
methods (fig 1) show the typical mulitizone completion
technique. Although effective the cost associated with the
components and the time required to complete can reduce the
economics to an undesirable level.
The second method Monobore (fig 1) is obviously the
most economical since it consists of tubing string and a
SCSSV. The drawback to this design is the absence of any
ability to gas lift as he well starts to deplete. Also since a
packer was not used it would not be possible to cut above the
cement and run completion strig with gas lift components as
there would be no positive seal to allow safe operation of gas
lift.
Prior to the design and implementation of the Mono-Trip
system a two trip method was utilized which was time
consuming adding cost to the completion of the well. The
two-trip method required up to twice the amount of time to
complete than the current one-trip method.
A major factor in the design of this system envolved fluids
dynamics research. This research allowed a better
understanding of how various fluids reacted under these
conditions. To ensure that residual cement would be
eliminated turbulent flow would need to be simulated. This
simulation was preformed utilizing current component design,
and the conceptual design of the new Gas Lift Mandrel. The
introduction of turbulent flow creating areas would in fact
enhance the washing characteristics during the cement
pumping operation. Another important factor of this
simulation was the research as to how production fluids would
act during normal production environment. In other words
would the introduction of these turbulent flow areas reduce the
efficiency of the system during normal production?
The same Computational Fluid Dynamics methods were
used to determine actual production characteristics. This
simulation clearly shows that mixing patterns are improved by
2 SPE 97668
the new design. Flow velocities are also higher within the
new design. The combined effects will stir the misture of
fluids, and gas within the new mandrel design with more force
and improved efficiency.
Component Descriptions. The completion consisit of the
following components . Liner top element only packer. Slips
are not required on this packer as it used for sealing only and
will bear no load once the cementing is complete. The
element utilized on this packer is a zero extrusion element.
Directly above the packer will be the Hydrostactic Closed
Circulating Valve, approx four CemenThru Gas Lift Mandrels
and SCSSV designed specifically for cement through
operation. The SCSSV, Hydrostacticaly Closed Circulating
Valve, and Cement through gas lift mandrel were specifically
designed and patented for this application.
The SCSSV design is such that while during the cementing
operation the flapper area and dynamic seals are protected
from cement. The flow tube portion of the SCSSV provides a
positive seal at the bottom of the valve while the valve is open.
This greatly reduces the chance of fluids entering the flapper
or sealing areas.
The Gas Lift Mandrels required more expensive research
and development to determine the flow characteristic of
cement being pumped through this component.
Computational fluid dynamics were utilized to develop a
component with self cleaning capabilities while allowing
unhindered passage of the wiper plug. It was determined that
by adding turbulaent inducing vanes inside the gas lift mandrel
any residual cement would be removed during the cleanout
portionof the completion. This was designed for the purpose
of circulatin out excess cement through the annulus once the
packer is set. This will assure that the gas lift will function as
intended. Acuation pressure of the Circulating valve, and the
packer can be modified depending on the characteristics of the
well, and the available system pressure. Based on the
configuration of a gas lift mandrel an extended wiper plug was
also designed to insure passage through the gas lift mandrels .
The Hydrostatic Closed Circulating Valve (HCCV) is key
to the success of the completion. The purpose of this
component is to clean excess cement from the annulus
allowing the Gas Lift portion of the completion to be utilized.
The opening and ultimately closed of this component is again
achieved through pressure cycles. The first pressure cycle will
open the rupture disc, and the second will close the outer
sleeve. There is also an internal sleeve that acts as a redundant
seal from tubing to annulus.
Operational Procedures.
Unlike previous methods of completions the one trip system
requires detailed procedures to assure a positive outcome.
Pressure cycles are required to assure that the tools function
properly.
In an effort to overcome these obstacles training of
personell was carried out prior to the first completion.
Working closely with the provider of the cement pumping
service will also assure that each detail is covered.
Every effort should be made to make sure the open hole
section is properly prepared. Fluid weights, circulation
pressure, and shear pressure sequence were discussed for each
well during pre-job planning. Reviewing well characteristics
on each individual well assured that the appropriate pressure
settings of the Mono-Trip completion equipment was
maintained.
Not unlike any completion prior to being deployed
extensive shop preparation was completed prior to the
equipment being deployed.
Installation sequence, and operation of this completion
begins once the equipment is deployed and the tubing hanger
is landed. Once the tubing hanger is landed and secured the
rig can then be skidded to another location as the remander of
events will happen offline freeing up the rig to begin
subsequent drilling activities on another well. The cement is
pumped offline to a predetermined volume wthat will place
approx 300 feet of cement in the annulus above the packer.
Once this is complete wiper plug will be launched and
pumped to bottom until landed and sealed in landing collar.
Tubing pressure will be increased to approximately 3000psi,
differential and held for ten minutes to set the Hydraulic
Packer. Once this cycle is complete the tubing pressure will
be increased to approximately 4000psi differential to open the
rupture disc in the Hydrostatic Closed Circulating Valve
(HCCV). This will establish tubing to annulus
communication, and allow circulation of excess cement from
the annulus side. Continue to observe annulus returns until
appropriate volume of cement has been circulated through the
annulus. Once this is complete close the annulus side and
increase tubing pressure to approx 5,500psi which will shear
the outer sleeve of the HCCV and place it in the closed
position regaining tubing to annulus integrity. From this point
tubing and annulus pressure test can be performed to insure
the integrity of the completion. It is also appropriate at this
time to utilize and Up-Shift shifting tool to close the inner
sleeve which wil provide redundant seal, and internally close
the HCCV. It is advisable at this time utilize wireline
equipment to pull, inspect, redress and reinstall dummy valves
in the gas lift mandrels, or the appropriate gas lift valves
depending on the timing of the gas lift operations.
Case Histories
The one-trip cement through completion system has been
installed in over 70 wells since the initial design and
implementation. Operational and procedural issues continue
to be evaluated and improved to assure success.
Of the seventy (70) (See fig. 1) wells that have been
completed sixteen (60) or 86% can be classified as flawless
execution.
As summary of these completions is as follows; Completion
string including all components RIH to bottom and tubing
hanger successfully landed. Rig skidded to complete
subsequent drilling operations and offline cementing carried
out to correct volume. Extended wiper plug launched and
pumped to bottom landing in latch collar and forming seal for
pressure cycles. Packer set utilizing up to 3 pressure cycles.
Mulitple pressure cycles are utilized to assure that excessive
pressure is not placed on the circulating valve causing early
rupture of the disc. Appropriate pressure applied rupturing the
SPE 97668
disc in the circulating valve allowing excess cement to be
removed from the annulus. Once annulus returns are
acceptable the appropriate pressure is applied closing the
external sleeve on the circulating valve. As a redundant seal
the internal sleeve of the circulating valve is then shifted up to
clase assuring tubing to annulus integrity.
Operational and Procedural Issues
As in any new technology there is a learning curve for
operational and procedural issues. Of the wells classified
as less than flawless the following will outline the
problems encountered and the measures taken to
overcome, and eliminate.
Since late 2003 70 wells have been completed in the Gulf
of Thailand utilizing the CemenThru Mono-Trip System.
Of these 70 wells 60 have been flawless in execution (see
figure three). Operational errors, component issues were
responsible for 10 of these completions being less than
perfect. The majority of these were functional following
the cement set.
• Plug failed to launch stuck in cementing head. Set
pkr with slick line plug did not actuate HP Defender.
– Adapted cement head to accommodate
extended wiper plug.
• Wrong Bonnet installed, SSV closed thermal
expansion actuated Pkr, and ruptured disc to HP
Defender.
– Reviewed procedures.
• Pkr, or HP defender not set dur to inadequate tubing
pressure.
– Worked with operations to assure adequate
tubing pressure.
• Well circulation problem could not set Pkr left as non
gas lift well.
– Reviewed procedure lost circulation
identified as root cause.
• Pkr set on first attempt could not close HP Defender.
– Additional training
• Unable to close HP defender due to inadequate
annulus pressure .
– Pressure loss in annulus identified as root
cause.
• Unable to close HP defender due to inadequate
annulus pressure .
– Same as above.
• Pkr not set as disc partially ruptured utilized slickline
to close inner sleeve.
– Excessive pressure cycles caused rupture
disc to partially open.
• Problem with leaking SCSSV shut in well to monitor
tubing and annulus pressure.
– Unidentified problem with SCSSV .
• Pkr not set leave as std Mono-bore completion.
– Issued first alert root cause identified as
excessive movement during packer setting.
Decision made to add hold down slips to
midstring packer.
3
Risk and Cost Reduction.
The successful application of a true monobore, cement
tolerant system as described has the added benefit of reducing
cost, providing safety, and eliminating the additional trips in
the well. By reducing the number of trips required to
complete the well the economics of completing the well can
be enhanced. Addiitonal rig time is a major factor when
completing wells that have a short life expectancy.
A major facter of any well completion operation is Health,
Safety, and Environment. The reduction in time to complete
each well will translate to a significant reduction of
opportunities for accidents. By reducing the number of trips
to complete from 2 to 1 is an obvious advantage.
The fact that fewer service personel will be required will in
effect improve the safety issues as well. Since the system is
completed without the normal amount of accessory tools the
chance of probles that will require fishing operations will be
reduced as well.
Conclusions
1. Cemented monobore wells offer operators an
economically viable method of completing wells
with life expectancies of 3-5 years.
2. Field trials have shown that using this method
can reduce rig time, and Non-Productive Time
(NPT)
3. Adapting this technology can provide completion
solutions for enhanced productivity and safety
benefits to other regions of the world.
4. Life of the well can be extended with the use of
a proven gas lift system.
5. Detailed run history database to assure that
issues are resolved in a timely manner.
6. Fewer tools reduce the risk of fishing operations
which can be costly and time consuming.
7. Reduced man hours on the rig floor.
The author wishes to thank Baker Oil Tools for
permission to publish this paper.
4 SPE 97668

•Financial Impact

Conventional Monobore 2 - Trip GL 1 - Trip GL

• 180K savings over 2

trip system.

•Improved HS&E by
reducing to one trip

•Improved Oil and Gas

recovery with efficient
gas lift system

$2.5MM $1.60MM $1.85MM $1.67MM

Step
Change

27

Figure one
SPE 97668 5

Time Reduction (hours)

60

50

40 Std Monobore

30 Mono-Trip
Current
20 Mono-Trip Goal
10

26

Figure Two
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Mono-Trip Run History

• Flawless accounts for largest 60
percentage
• Operational errors in early 50
Flawless
stages of project. 40
• Two wells of the 70 total Op
30 Errors
experienced tool failure that
Tool
caused the well to be std non 20 Failed
gas lift Mono-bore. Cement
• Functional following cement 10 Set

set. 0

Figure Three