Successful Deployment of Metal Expandable Technology with Inner String Stage Cementing System Overcomes Well Construction Challenges in Bab Field, UAE
Abstract Inability to effectively isolate depleted aquifer formations due to severe losses during cementation leads to accelerated corrosion of the production casing. Per current practice, a top job is performed from surface to fill the annulus with cement, but with limited success in a severe losses’ scenario. The objective is to improve zonal isolation by applying V0 rated multiple stage cementation technology with inner string thus enhancing well integrity during the life cycle of the well. A metal expandable annular sealing system was selected as a reliable isolation mechanism for effective cementation behind aquifers due to its ability to provide high expansion in potentially washed-out wellbores and the feature of long multi-element sealing systems with built in redundancy. The inner string operated stage cementing system provides a reliable solution to selectively and accurately place cement above the metal expandable packer whilst maintaining V0 casing integrity once closed. Additionally, the unique combination of technologies provides a cost-effective life of well solution compared to current stage cementing methodologies. Following successful execution of three trial jobs, the multi-stage cement using V0 rated tools and an inner string was compared to similar jobs done per current cementing practices. Analysis involved reviewing the cement bond column coverage and quality (CBL) with offset wells. Cement bond log results showed that this technique enhanced the cement column quality behind the 9 5/8" casing across the aquifer zones with moderate to good cement for the most part. Contaminated cement was observed just below the previous casing shoe and this could be addressed by adding another stage tool just above the previous casing shoe. Overall results show improved cement column quality for this section when compared to conventional jobs with similar conditions and is recommended for future use in severe to total losses scenario. In a situation where losses are seen at the previous casing shoe, a three-stage job is recommended. Other benefits include: Security and confidence in gas tight sealing capability and mechanical integrity Precise and conclusive operation for open, close and lock with no risk of accidental lock Ability to squeeze cement below the metal expandable packer No reduction in pressure rating regardless of OH ID and full bore ID of casing No post operation drill out required of the stage tools V0 stage cementing tools with inner string and metal expandable annular sealing system are not available on Oil & Gas market as a single tool. Therefore, this combined technology application of solutions from different technology providers to access a dedicated solution is totally novel and creates an opportunity for future applications across the industry.