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Performance Report: Critical Deepwater

Frac-Pack Recovery and Successful


Workover Attributed to DIPRO System
Challenge: The highly faulted and compartmentalized field consists of geopressured,
unconsolidated silt/very fine sand Pleistoceneage reservoirs. Casedhole, fracpack
completions are used on all wells in this field to maximize well productivity with minimum
solids production. Shunt tubes have been installed with the gravelpack screens to help
ensure proppant placement in the casing/screen annulus over the entire reservoir interval.
The third well in a series of completions was fracpacked and completed in the same
manner as the first two successful completionsa premium laminated screen on 3.5in.
(89mm) outside diameter, 9.2 lb/ft base pipe with two shunt tubes placed across the
perforated interval. The gravelpack screen failed at the beginning of production due to
excessive production rate and drawdown. The well was shut in. Coiledtubing operations to
remove the gravel and screen from the well proved unsuccessful.
Solution: After conferring with the operator and field participants, MI SWACO engineers
specified the fluid requirements to carry solids and debris to the surface at low pump rates
and to control whole fluid loss to the formation with an overall objective to recover the
gravelpack screen, reperforate and recomplete the well. A 12.8lb/gal (1534kg/m3)
DIPRO fluid was recommended to control losses to the formation through open
perforations, as well as washover the screen and remove the fracpack proppant.
Result: Total losses of DIPRO fluid to the formation were 41 bbl after 25 days of exposure
to the formation. The brinebase drillin fluid was used to wash over 225 ft (69 m) of blank
sand screen in 13 hr (two trips) with minimal fluid loss and no sweeps required. A short
period of lost circulation (35 bbl to regain full circulation) was experienced while washing
over the screens near the suspected screen failure depth. After washing over the screens
down to the sump packer, the screens and shunt tubes were retrieved fully intact. One shunt
tube was packed with formation sand. The outer layer of screen was packed with filter cake
and a greater than 2in. (51mm) diameter hole was observed in the premium screen
adjacent to an end ring. The well was successfully reperforated and recompleted.
Well Information
Location

Garden Banks, Gulf of Mexico

Well deviation

36.44 degrees

Perforated
intervals

Total of 130 ft (40 m) from 15,354 to


15,494 ft (4680 to 4722 m) measured
depth

Perforated
intervals

106 ft (32 m) from 14,996 to 15,102 ft


(4571 to 4603 m) total vertical depth

Density required

12.8 lb/gal

Bottomhole
temperature

146F (63C)

Completion type

Casedhole, fracpack

Product

lb/bbl

12.5lb/gal CaC12/CaBr2
DITROL

8.00

DIBALANCE

0.50

SAFECARB 2

4.00

SAFECARB 20

15.00

SAFECARB 40

9.00

After the well was killed with 12.8lb/gal (1534kg/m3) calcium chloride/calcium bromide
blend and tubing and control lines were recovered, the blend was displaced with 12.8lb/gal
(1534kg/m3) DIPRO fluid. With the approach of the first hurricane, the rig was evacuated
for six days. The fluid system maintained its prestorm properties and was used to wash
over and recover the gravelpack assembly.
To retrieve the screen a 3bbl/min wash rate was required. On the workover well, this
equated to 300 ft/min (91 m/min) annular velocity for the screenbywashpipe annulus and
950 ft/min (289 m/min) annular velocity for the washpipebycasing annulus. A high torque
rate was experienced during washover operations and the washpipe was rotated at 40 to 50
rpm during the entire wash as any added torque would have increased the risk of damaging
the screens or leaving washpipe in the hole.
With the approach of a second hurricane, the rig was evacuated for four days. The DIPRO
system again maintained its prestorm properties. The well was displaced to the 12.8lb/gal
(1534kg/m3) brine before reperforating and completing the well.