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Reserves with marginal production potential are often by-passed during the early stages of reservoir
development. Re-evaluations of well logging data has resulted in the discovery of potential reserves located
above the production packer that were not previously considered in the initial completion strategy.
Conventional completion techniques required a workover to re-complete to these potential zones.
However, due to marginal reserves or the presence of production from existing zones below the proposed recompletion (ex: a dual completion where the long string is still producing while short string is shut-in), a
workover is not a good economic option to recover these zones. A new technique of cement packer has
been successfully developed in Offshore North West Java (ONWJ) field to re-complete these zones without
pulling out the existing completion. Pressure isolation of potential zones is accomplished by placing cement
in the tubing-casing annulus above the production packer. This cement then acts as a new production packer
further up the wellbore. Conventional or oriented perforating is then used to complete the well in the new
productive intervals.
The advantages of this technique are it is inexpensive (rigless), there is no need to wait for other tubing
strings in the well to deplete to their economic limit before re-completing up-hole and most importantlyaccess to and production from lower completion is not affected. To date, a total of 14 wells have been
reactivated using this technique to recover productive zones located above the production packer. The
average cost was only 20-60% of conventional workovers and savings of up to US$ 800,000 have been
achieved. These successful results have brought new opportunities for reactivating many more shut-in wells
with by-passed reserves that are economically marginal.
Background
The Offshore North West Java Production Sharing Contract (ONWJ PSC) area is located off of the North
Coast of Java Island in Indonesia (see Fig. 1). The contract area is about 18,000 sq-km. The first
exploration well was drilled in 1967 while the first production occurred in 1971. The ONWJ PSC is divided
into four main areas: Ardjuna, Arimbi, Bima and North West Corner. It consists of about 50 fields, most of
them are oil, distributed in three productive formations, Parigi, Upper and Lower Cibulakan. Throughout its
30 years of production history, 13 flow stations, 150 production platforms, 700 wells with 1013 production
string and more than 1,000 miles of sub-sea pipelines have been built in a
sea depth of up to 40 meters. Gas lift is the primary artificial lift method in this area.
ONWJ reached its peak crude production rate of 180,000 BOPD in 1984 but now it has declined to
around 43,000 BOPD with 200 MMCFD of gas. The continuous decline of crude production is a challenge
to the company goal of being a low cost offshore operator.
In 1999, only 43% of the strings were currently still producing while the rest of them have been shut in
because production has reached economic limit rates or have watered out. Re-evaluations of these shut-in
wells have identified potential reserves above the production packers. Previously, a conventional workover
job was required to recover these zones. However due to marginal reserves a workover is not an option to
develop these zones. In some dual completion cases where one of the strings is still producing, a workover
can not be done without sacrificing the other strings. This condition has challenged the company to find a
better technique to recover those reserves and re-activate shut-in wells without sacrificing production in the
other strings/wells.
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Since early last 4 year, a technique in ONWJ has been developed to recover the zones without pulling
out completion strings. Isolation of potential zones is accomplished by cementing in the tubing-casing
annulus above the production packer. The cement above the zones replaces the production packers and
conventional perforating is then used to complete the well. Current practices require that at least 200 ft of
cement be placed above the top of the target zone to ensure annulus isolation. Casing pressure is monitored
to verify zonal isolation.
A total of 14 wells have been reactivated through this technique to recover by-passed zones above the
first packer. A significant cost savings of up to 80% of conventional workover jobs has been achieved using
this technique. The production results have also been encouraging. These successful results have brought
new opportunities for reactivating many more shut-in wells with by-passed reserves that are economically
marginal.
Workover vs. Cement Packer
Reserves with marginal production potential are often bypassed during the early stages of reservoir
development. Reevaluations of well logging data have resulted in finding potential reserves located above
the shallowest packer that were not previously considered in completion strategies during drilling and
completion of the wells. Therefore, an additional workover or well service job is then required to
access/drain these reserves.
A conventional workover job would require pulling out existing completions, perforating and running a
new completion with a production packer set above the new zones. This would require a rig or light-pulling
unit. Meanwhile, well service jobs only require coiled tubing that can be done by using a boat or jack up
barge, which is in our case (offshore operations) much less expensive than a rig. As a result, the well
service jobs are chosen. Isolation of potential zones is accomplished by cementing in the annulus tubingcasing above the production packer. The cement above the zones replaces or acts as a production packer.
Figure 2 shows the pre-treatment completion diagram and compares the post-treatment completion diagram
of a conventional workover with the cement packer.
In the petroleum industry, a cement packer is a not a new technique. Some operators have used this
technique to recover zones above production packers without pulling out completion strings (5,6,7,8).
However, the applied technique so far that they must abandon the lower completion or they have to drill out
cement in order to re-gain access into lower completion. A novel technique of cement packer has been
successfully developed in OWJ field to place cement in annulus tubing-casing while maintaining access into
lower completion without need to drill out the cement. This novel technique is relatively simple and a cost
efficient compare to previous technique or conventional workover.
The advantages of cement packer technique compare to conventional workover are:
Rigless operation
A cement packer job can be done with coiled tubing or could be done with a pumping unit in a boat only.
Especially on platforms where jack up rigs cannot move in due to obstacles such as: pipelines, spud can
holes, etc, this technique offers an alternative solution to recover zones above the production packer.
Inexpensive
In our experience, the average costs cement packer workovers are only 20%-60% of a conventional
workover costs. This means zones with marginal reserves can be accessed economically.
Minimized Production Deferment.
Simultaneous operation practices in OWJ require shutting in the platform during rig move-in/out. The
impact of deferring production can be significant on platforms that have high production rates. Well
interventions using coiled tubing off of a lift boat or a boat do not necessarily require shutting in the
platform.
Still allows access into the lower completion
For single completions, conventional workovers still might allow well interventions to access lower
completions if the new completions can latch/sting onto lower/old completions properly. But in dual
completion cases, it is almost impossible to gain access into lower completions on both strings anymore
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once it has been worked over because no technique to re-sting/latch the new completions onto both
old/existing completions. The cement packer technique makes wireline/coiled tubing intervention into
lower completion on both strings still possible to perform as no need to change out the completion.
No need to wait the well achieves economic limits for recovering the zones.
Workovers to recover the zones above the first packer are usually done only when the well had achieved
its economic limit rate. In dual completions, where one string is still produced, a workover risk
sacrificing the other string. The cement packer technique allows us to recover new zones without
sacrificing the other string since there is no need to pull out the completion string.
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Cement Design: The cement slurry for this job was a regular class G cement used for coiled tubing
cementing. It was designed to have short thickening time but still be safe enough to pump through coiled
tubing. The short thickening time was designed to reduce the possibility of cement inside tubing-casing
annulus flowing back into the tubing because of the u-tube effect while waiting on cement. A longer
thickening time will give more chance for the cement inside the casing to flow back into the tubing since
fluid (sea water) inside the tubing has less density than the cement inside the casing.
In cases where access into lower completions must be maintained, then tail cement is designed which
has a much longer thickening time or is contaminated in order to still be able to clean out the cement inside
the tubing once the cement in the annulus casing is set. Typically the tail cement and lead cement are mixed
together (so will have same density) and then it separated to put extra retarder. Equivalent weighted mud
could also be used to replace tail cement. In most cases, than weighted mud is preffer than tail cement
eventhough is more difficult to blend onsite. The last cople job we always use mud.
Gun Selection: The gun performance is very crucial for this application since it must be able to penetrate
the tubing-cement-casing-cement-formation. In this case, a deep penetration charge must be used to ensure
the penetration is sufficiently deep enough into the formation. Also, a hollow carrier gun is preferred
instead of a strip gun to prevent the gun from getting stuck and debris from accumulating after the gun is
fired. Typically, a 2 hollow carrier gun with 4 to 6 SPF deep penetration charges is used and so far proved
to have sufficient penetration to formation. Smaller gun, 1-9/16 HC gun, have showed to have very poor
penetration for this type of application.
On dual completion cases, a magnetic oriented device/tool is used to orient the gun and prevent the other
strings from being penetrated by the perforating charges.
Cement Packer Procedure
A guideline procedure for cement packer has been established as a best practice for this technique. The
procedure is as follows:
1. Perform tubing integrity test.
Plug should be installed at the tubing profile below the production packer for tubing integrity test
purposes. For gas lift wells, all GLV valves should be dummied-off.
2. Punch a hole in the tubing close to the production packer.
This can be done using a tubing puncher by slickline unit. Typically two punch holes are sufficient. If
GLM depth close enough then just left it blank and so no need to punch additional hole.
3. Circulate water from tubing to casing to fill up tubing and casing with liquid (uncompressible fluid)
4. Perform packer-casing integrity test.
5. Run coiled tubing to top of plug.
6. Pump lead cement through the coiled tubing while keeping the casing valve open and keeping the CTtubing annulus valve closed.
All cement slurry will automatically go to the casing after filling-up the tubing pass through the punch
hole point.
7. Close casing valve when all cement has gone out of CT. Open CT-tubing annulus valve while continue to
circulate water (displacement fluid).
8. Pump and lay in quivalent weighted mud (or tail cement) from the top of the plug to the punch hole
point. Pull out the CT to the surface (or a safe depth) while keeping water circulating to clean any
unwanted cement in the tubing above the punch hole point.
The cement inside the casing will not flow back into the tubing as long as the casing valve is closed and
the differential pressure achieved between tubing & casing is maintained. The differential pressure
between CHP & WHP is resulted from different on hydrostatic pressure inside tubing and inside casing
due to the different column/height of cement inside them. In this step, equivalent weighted mud could be
replaced with tail cement. (Tail cement is mixed together with lead cement to ensure the same cement
slurry density but then separated and added more retarder just before the tail cement will be pumped).
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9. Close the CT-tubing annulus valves. Wait for the cement and keep monitoring the casing pressure
(CHP) and tubing pressure (WHP).
Pressure trends on the WHP & CHP can identify whether the cement inside the casing has set. Once
there are indications that the cement inside the casing has set, bleed off the casing valve to ensure that
there are no other communications (u-tube) between the casing and tubing.
10. Once the cement inside the casing has set, run CT back in hole to clean out mud (tail cement) to the top
of the plug until there is a clear return. POOH CT.
11. Pull out the plug (if necessary).
While waiting on the cement, the tubing pressure (WHP) and casing pressure (CHP) should be
monitored. These pressures can identify when the cement inside casing has set. Figures 5 show typical
pressure trends during cement setting process. Indications that the cement in the casing has set can be
identified when the differential pressure decreases and goes to minus or the WHP becomes lower than the
CHP. This is caused when there is no communication anymore between the tubing and casing once the
cement inside the casing annulus has already set. They will become two different closed systems. Pressure
tends to decrease when cement starts to set since the cement will release heat during this process and cause
the temperature to drop. Temperature drops cause volumes of fluid inside the casing and tubing to shrink
and the pressure decreases. This trend can be observed in every job where differential pressures were
obtained.
Field History
Two case histories are presented here. The first case history (Well LLB-8) was the first cement packer
application in the OWJ field. The second case history highlights the use of tail cement (retarded cement) in
order to be able to pull out the plug after treatment and still have access into the lower completion.
Case History # 1 (Well LLB-8)
LLB-8 monobore completion was the first well executed to develop by-passed reserves above production
packer. Previously, the well was shut in for 1 year due to being watered-out from the existing zone (L-62).
Another potential zone was located above the production packer. A conventional workover was not a good
option since it would have deferred production of at least 120 MMCFD because of the need to shut down the
platform during rig move-in/out. This was also especially undesirable at that time due to the high gas
demand. The other option was to try to dump the cement on the tubing-casing annulus to isolate the L-40
zone during production. This would only require coiled tubing by jack-up barge and would not require that
the platform be shut down during move-in/out. It was decided to use the cement packer technique to recover
this zone. Figure 3 shows the completion diagram of LLB-8 well before and after the cement packer job.
Prior to the cement job, all GLVs were dummied off. A plug was set on the nipple at 6620 MD and a
tubing integrity test was done to confirm that there were no leaks on the tubing. The gas lift valve in the
deepest GLM @ 6447 MD was pulled out and left blank. Filtered seawater was then circulated from tubing
to casing to clean out any hydrocarbon in casing and fill up casing with incompressible liquid. A total of 49
bbls of cement slurry were laid in from the top of the plug by using coiled tubing to let the cement fill up the
casing and tubing. 420 psi of higher differential pressure was maintained in the tubing compared to the
casing while waiting on the cement in order to keep the cement in the casing from flowing back into the
tubing. The job was successfully performed according to the design, with the top of the cement in the casing
predicted to be around 4685 MD and in tubing at 5959 MD.
The L-40 zone was perforated under balance using a 2 HC gun, 6 SPF 60 deg phasing, and was
continued with the perforation breakdown using 15% HCL acid. The well was flowed 4 MMCFD with
choke and 800 psi FTP. A cost savings of +/- US$ 400,000 (less than 20% of conventional workover costs)
was achieved through this technique. And after 2-year production, casing pressure is remained 0 psi that
indicate cement is still working good as isolation of producing zones.
Additional candidates were selected due to the encouraging results of this well. Continuing
improvements were also made as part of the learning curve through developing this technique.
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Conclusions
1. Cement packer technique has proven successful as an alternative and attractive way to develop the zones
above production packer.
2. There are no differences in production results between cement packers and conventional workovers.
3. A guideline procedure for the cement packer technique has been developed and presented.
References
1) Susilo, Y., Wahju, W., Rich, D.: Cement Packer: An Innovative Technique to Recover Reserves
Above Packer Without Re-completion, paper SPE 78493 presented at 10th ADIPEC in Abu Dhabi,
United Arab Emirate, 13-16 Oct 2002.
2) Nelson, E.B, editors: Well Cementing, Schlumberger Educational Services, 1990.
3) McLeods, B.: Effect on Perforating Condition on Well Performance, paper SPE 10649
4) Kroell, E., Spoerker, H.F.: Brief: Slimhole Completion and Production, JPT, September 1996.
5) Nowak, T.W., et al: Rigless Multi-zone Recompletion Using a Cement Packer Placed with Coiled
Tubing: A Case history, paper SPE 35613 presented at the Gas Technology Conference, Calgary,
Alberta, Canada, 28 Apr 1 May 1996.
6) Loveland, K.R., Bond, A.J.: Recent Applications of Coiled Tubing in Remedial Wellwork at Prudhoe
Bay, paper SPE 35587 presented at the SPE Western Regional Meeting, Anchorage, Alaska, 22-24 May
1996.
7) Hathcock, Larry et al: Innovative Through-tubing Workover Process Utilizing a Cement Packer, paper
SPE 30510 presented at the SPE Annual Technical Conference and Exhibition, Dallas, TX, 22-25 Oct
1995.
8) Soetedja, V., Hunter, D.L.: Production Optimizing With Coiled Tubing and Other Rigless Techniques,
paper SPE 36963 presented at the SPE Asia Pacific Oil & Gas Conference, Adelaide, Australia, 28-31
October 1996.
IATMI
ONWJ
S
U
M
AT
E
KALIMANTA SULAWES
N
I
AV
VA
JJ A
BIMA
ZU
APN
ARDJUNA
B
L
KLX
KLY
E
F
U
CILAMAY
CILAMAYA
JAKAR
JAKART
CIREBON
CIREBON
25
50
Pre-Treatment Completion
2-7/8
Tubing
Post-Treatment Completion
Conventional Workover
Cement Packer
9-5/8
Casing
Cement
New Zone
New Zone
New Zone
Packer
Zone # 1
Packer
Zone # 2
New Zone
New Zone
Cmt Retainer
New Zone
Packer
Zone # 1
Zone # 1
Zone # 3
Zone # 2
Packer
Packer
Zone # 3
Zone # 3
7 Shoe
Packer
Packer
Zone # 2
Packer
Packer
7 Shoe
7 Shoe
Fig 2. Pre & Post-Treatment Completion of Conventional Workover vs. Cement Packer
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LLB-8 Well
Before
3-1/2 Tubing
After
3-1/2 Tubing
1639 MD
2429 MD
3191 MD
3919 MD
GLM
4588 MD
4685
LL-40 Zone
5228 MD
( 5232-5246 )
5868 MD
Cement
5959
6447 MD
Packer @ 6550 MD
Packer @ 6550 MD
7 Casing
7 Casing
X- Nipple @ 6620 MD
LL-62 zone
( 8113-8150 )
X- Nipple @ 6620 MD
X- Nipple @ 6620 MD
LL-62 zone
( 8113-8150 )
3-1/2 Monobore
X- Nipple @ 6620 MD
3-1/2 Monobore
EQD-1 Well
Before
2-7/8
Tubing
1259 MD
After
1286 MD
1830 MD
1856 MD
GLM
GLM
2246 MD
2276 MD
2535 MD
2558 MD
Packer @ 2702
E-23
Cement
E-22 Zone
(2561-2566)
(2587-2602)
Packer @ 2702
E-23
3081
Packer @ 3050
Packer @ 3050
E-26A
E-26
Packer @ 3213
Packer @ 3213
E-27B
E-27B
Packer @ 3490
Packer @ 3490
E-29/30
E-29/30
9-5/8 Casing
9-5/8 Casing
10
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Cost
( US$ )
No.
Well #
LLB-8
Single
50
7"
3-1/2"
URA-4
Dual
50
9-5/8"
2-7/8"
BD-5
Single
49
9-5/8"
3-1/2"
2,500
160,800
BK-1S
Dual
9-5/8"
2-7/8"
453
74,000
BNA-5
Single
50
9-5/8"
2-7/8"
500
244,400
EQD-1S
Dual
9-5/8"
2-7/8"
4,524
157,500
EZA-4S
Dual
52
9-5/8"
2-7/8"
2,957
116,700
LLD-13S
Dual
51
9-5/8"
2-7/8"
1,450
2,200
345,000
FZA-1S
Dual
9-5/8"
2-7/8"
>2,000
160,000
10
PB-2
Single
55
9-5/8"
3-1/2"
Not Perforated
80,200
11
BF-3
Dual
48
9-5/8"
3-1/2"
273
380
82,300
12
BL-3
Dual
50
9-5/8"
2-7/8"
72
129,800
13
LLB-8
Single
50
7"
3-1/2"
318
445
186,800
14
LLB-1
Dual
58
9-5/8"
2-7/8"
413
79,200
549
4,084
-
82,000
232,400
500
PRESSURE, PSIG
400
300
200
100
Cement set in
consistometer
0
0
-100
-200
100
200
CT-TBG PRESS
CASING PRESS
300
400
500
Cement set
in water bath
DIFF PRESS
600