Custom solution allows operator to perform offshore HWO intervention

Overview

An offshore operator sought to reinstate an electric submersible pump (ESP) on a compact platform but wanted to avoid a full production shutdown associated with a conventional hydraulic workover (HWO). The limited deck footprint, restricted fluid storage capacity, and technical constraints around crane proximity made traditional intervention methods impractical.

Halliburton collaborated with the operator, vessel teams, and multiple third‑party vendors to design a modular HWO approach that restored the well safely and efficiently while keeping the platform online. This solution demonstrated that a modular HWO system can execute heavy workover operations in space‑constrainedoffshore environments.

Challenge

The operator required ESP workover and acid stimulation on a compact platform. Using a jack-up rig would have substantially increased cost and required shutting in production due to overlapping rig and platform activities.

To further complicate operations, the proximity between the HWO unit and the modular crane restricted standard guying methods and prevented slickline intervention with the existing crane configuration. The wellhead itself presented additional complexity due to a nonstandard split design with an offset tubing hanger. Managing equipment, fluid storage, and multi-vendor logistics across both the platform and the support vessel required a highly coordinated and customized approach.

Solution

Halliburton worked across multiple product service lines (PSLs) and collaborated closely with vessel teams and third‑party vendors to develop a comprehensive logistics and equipment plan. This included coordinated tank management, streamlined material movement, and staged operations to optimize the compact platform layout.

To maximize deck space, the team designed and manufactured a modular mini extension deck. An outrigger system was engineered to support safe guying and enable efficient inter‑well movement. With this configuration, the HWO package could be rigged up using a modular crane positioned away from the well slot and then skid‑moved into its operating position.

Additional efficiencies were built into the design. The tubing hanger running tool (THRT) was preinstalled using saver subs to minimize time spent latching it to the hanger profile during pullout of hole (POOH). The landing‑joint configuration and stack‑up height were redesigned to fit within the limited clearance above the HWO workbasket. A heavy‑duty winch mounted on the HWO mast supported the slickline stack rig‑up within the confined space envelope. These engineered modifications allowed for a safe and efficient intervention on a platform where traditional rig‑up methods were not feasible.

Result

The modular HWO solution allowed the operator to complete its first offshore ESP restoration with acid stimulation without shutting down the platform. The tailored design eliminated the need for a jack-up rig, avoiding associated production deferment and reducing overall operational costs. The intervention was executed without any service quality (SQ) or health, safety, or environmental (HSE) issues, demonstrating that modular HWO units can effectively deliver heavy workover operations in compact offshore environments.

The success of this work was recognized and highlighted in the SPE/ICoTA Well Intervention Conference and Exhibition (SPE-209020 MS), reinforcing the applicability of modular HWO systems in complex platform settings.