Finding simple solutions to complex problems
Do low-cost solutions work when solving complex problems or does the search for quick, easy and simple options excessively complicate the issue? writes Alan Quirke, Chief Commercial Officer, HydraWell.
HydraWell has always focused on addressing the problems faced by well owners during well integrity, slot recovery and well abandonment operations and has remained committed to delivering simple, cost-effective solutions starting with a greater understanding of the challenge – which historically has been presumed to be too complex to warrant the implementation of straightforward solutions.
Installing barriers in wellbores to permanently isolate zones of flow potential or remediate incomplete barriers installed during well construction is a significant problem for the wellbore management industry. Keeping vent flows and emissions permanently contained without incurring excessive time or cost is aspirational. Traditional methods were often deployed believing that a complex problem required a complex solution, preventing the consideration of a simple solution to aid progression.
HydraWell’s perf-wash-cement (PWC®) barrier remediation and installation methodology was introduced to change the perception of how to solve the well barrier placement challenge. The methodology has revolutionised the process and, by understanding the challenge, employing a scientific approach to barrier design and demonstrating confidence in outcome before operations commence, HydraWell has changed the paradigm and drastically reduced the cost, support requirements and carbon footprint of well barrier placement operations.
Soon after its inception, the company introduced the HydraWash™ cup based, low pressure cement remediation system, designed to mitigate high risk, replace material cost and time-consuming alternative methods for getting access to isolate zones of flow potential. Successfully deployed in wells with poor or no cement across the annulus, HydraWash™ was adopted by clients who recognised the time, cost and efficiency benefits offered.
The legacy of HydraWash™ remains woven throughout the company’s offering today and provided a foundation from which the company created the second generation PWC® system, HydraHemera™, a more versatile jet-based PWC® system. It was deployed across a wider range of applications targeting multiple annuli in more challenging, higher inclination wellbore environments. The high pressure, technically superior jet-washing tool, soon became the solution of choice in single and multiple casing applications, recognised as an easier more predictable system. Delivering a 98% plugging success rate, it overcomes risk associated with exerting excess pressure on the formation without relying on “limited entry” to force fluid through all perforations.
Innovation also included a method for reliably testing in-situ barriers, squeezing shales, squeezing salts (commonly known as GeoSeals) and subsequently isolating the wellbore internally resulting in the introduction of the annulus integrity test (AIT) tool. Post perforating, the integrity of the AIT is verified in blank casing before the cups are positioned across the lower perforated interval. Pressure is applied between the cups to test the integrity of a suspected surrounding formation. Testing can be repeated to confirm the initial test or moved in the wellbore to test a secondary area. Post testing, an internal cement plug can be set, or the tool can be retrieved.
A subsequent drive to increase the operational envelope of jet-based PWC™ and address more and greater challenges from a growing global customer base gave rise to the HydraTyphon™ PWC™ tool which was developed to address more challenging barrier placement applications with a specific focus on larger casing sizes (11 3/4” and larger) set in a heavy or high viscosity fluid environment.
Simultaneously, and against a backdrop of HydraWell’s 500th plug installation in 2023, a further advancement in the portfolio saw the introduction of HydraCT™ which enables PWC® operations to be conveyed by coiled tubing or small jointed pipe, opening up a new set of opportunities for well owners to install wellbore barriers thru-tubing whilst remaining true to the already established PWC™ barrier installation principles and methodology. Specifically designed for low footprint rigless applications, HydraCT™ has the potential to cut CO₂ emissions, during barrier placement activities, by almost 80% and reduce installation costs by up to 60%.
As an industry first PWC® system for rigless abandonment using conventional barrier materials, HydraCT™ uses the fluid energy to not only penetrate and remove debris in the annulus space but also as a propellant, creating a rotational force downhole which replaces the requirement to rotate the entire workstring from surface. During the cleaning of the casing and annulus, wash fluid is circulated through the coiled tubing to the tool which incorporates a hydraulic brake. As fluid exits the tool, flow introduces rotation facilitating the formation of turbulent vortex flow which cleans the annulus with multi-directional nozzles focusing the high energy jetting force and displacing annulus content with the fresh wash fluid.
Most recently, the benefits of the HydraCT™ PWC™ system successfully achieved the annular isolation and P&A of eleven wellbores in Alaska. The project needed a cost-effective method in a remote area where rig availability is extremely limited. In a single run per well, HydraCT™ eliminated the need to mobilise a rig to site and cut the requirement to run drill pipe for remediating the annuli without compromising barrier quality or barrier verification – and all in less than 24 hours per well.
Using learning to develop the portfolio has enabled it to grow and evolve in new and exciting ways over the years and this will continue driven by a desire to prevent vent flows and unintended hydrocarbon releases from abandoned wellbores.
About HydraWell
HydraWell is a global well Integrity specialist, providing engineered solutions that replace traditional Plug & Abandonment techniques. HydraWell’s proprietary PWC, Perf-Wash-Cement ® technology enables the energy transition by delivering reliable and sustainable zonal isolation services for plugging and abandoning Oi & Gas wells. Established in 2008 and headquartered in Stavanger, Norway with strategically located facilities in Aberdeen (UK) with a presence in Australia, Brazil and Malaysia, the experienced team of 35 employees is committed to developing the most advanced downhole solutions to increase efficiency, reduce operational costs and minimise environmental footprint.
To find out more, visit www.hydrawell.com
