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Specific Challenge

Repair surface casing failure and return well to production

Region - South America

South America

Region - South America

Challenge

  • Repair 20 in. surface casing failure with installation of a support frame and restore well to production

Solution

  • Multidisciplinary engineering and operational approach to repair 20-in. casing and install landing base

Result

  • Achieved objectives in three months
  • Performed operation safely with zero incidents in a cost-effective manner 
  • Avoided heavy workover operation to change wellhead 
  • Reconnected well to former production rates 

Overview

An onshore operator removed a highly productive well from service after a 20-in. casing failure at the surface. After considering heavy workover remedial options, with potentially high costs and long delays, the operator sought alternative solutions to return the well to production with the shortest delay.

Challenge

During cellar cleaning, the operator observed that a 20-in. casing was damaged and corroded at the cellar level below the casing head. It had been buried in sediment for an unknown period, and the operator suspected prolonged exposure to water and sediment accumulation. The operator noticed wellhead movement due to thermal expansion. The wellhead was not appropriately supported, causing stress on the casing during production and shutdowns. Fatigue on the casing, combined with infrequent inspections and cleaning, led to surface failure.

Solution

Halliburton Boots & Coots®  developed an engineering and execution plan. The team treated this operation as a workover and secured the well with a blowout preventer. The primary stages were as follows: 

  • Install downhole plugs, monitor annular pressure, and perform bleed-off operations
  • Remove surface installations: cellar floor and wall (trench excavation)
  • Cut the corroded section in 20 in. casing 50 cm below cellar excavation 
  • Built concrete foundations and rigged up stand-jack lifting equipment. Installed and closed a BOP to secure the well. Install the tensioning spool, the system, and all casing and tubing strings
  • Replace the 20 in. corroded section with two new, half-moon 20 in. casing sections (welded)
  • Installed support frame
  • Released tension on the custom-designed support frame 

Result

All objectives were achieved through this innovative and multidisciplinary engineering and operational approach. In total, preparation and engineering required three months. The operation was performed safely with zero incidents and cost-effectively, and the repair helped the operator avoid a heavy workover to change the wellhead. Halliburton Boots & Coots reconnected the well and restored it to its former production.

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