REPacker System Prevented Annular Flow Paths ... - Baker Hughes

Case HistoryREPacker System Prevented Annular FlowPaths Through CementEnhanced cement job by eliminating micro-annulus fracturesBenefits• Mitigated unwanted migration fluidsto the surface, reducing risks• Avoided the use of future remedialcement job• Eliminated the need for additionalrunning tools to activate the openholeREPacker system• Reduced operational time, savingrig timeBackground and challenges• Cantarell field, offshore Mexico• Operator planned to drill to 10,873 ftbut lost circulation at 10,223 ft• Operator needed a liner hanger thatallowed rotation to reach the linersetting depth with an openhole zonalisolation backup system as support forthe primary cement jobBaker Hughes solution and results• The Baker Hughes TORXS expandableliner hanger assembly with EZReamreamer shoe ran the liner to thesetting depth with rotation andpumped drilling fluids through theentire liner system to reach thebottom hole• The Baker Hughes REPacker systemisolated the zone above the primarycement jobA well located in the Cantarell field in theBay of Campeche offshore Mexico wasplanned to be drilled to 10,873 ft (3315 m)when the customer began to experiencelost circulation problems at 10,223 ft(3117 m) without any drilling progress andwith torque as high as 20,000 ft/lb (2765kg/m). At that point, the customer decidedto pull out of the hole with the drillingbottomhole assembly (BHA).The operator called Baker Hughes for asolution. After discussing the job withthe customer, Baker Hughes developed asolution to use the 7 5 /8-in. x 8.3-in. x 20-ft(6.096 m) oil-swell REPacker reactiveelementpacker with a 7 5 /8-in. x 9 5 /8-in.TORXS expandable liner hanger systemand EZReam casing shoe to run the linerto the setting depth with rotation andpumping drilling fluid.The Baker Hughes REPacker systemwas selected to isolate the zone abovethe primary cement job because thatarea represented partial or completelost circulation zones. Another reasonour packer was selected was to reduceoperational risks during the cementprocess that could jeopardize wellboreintegrity if the cement job was of poorquality. Baker Hughes tailored theREPacker system to the customer’swellbore conditions and job parametersfor optimized performance with no risk tothe primary cement pumping operations.

The REPacker packer is a self-actuating,swelling elastomer that eliminates annularflow in either openhole or cased holeapplications. The packer was manufacturedon a casing joint that matches thespecifications of the liner used in thewell. A special end ring protects the swellrubber, allowing it to be run throughtight holes with rotation or deviated wellconditions, or to support high pumpingrate applications if required.Baker Hughes also recommended usingthe EZReam casing shoe, which allowsreaming longer intervals through the mostchallenging and severely compromisedboreholes. It is the industry’s only casing/liner shoe to offer a secondary bypassport that allows normal circulation orcementing to continue when ports plug.The TORXS system has a high-torsion linerhanger capacity capable of performingliner drilling or heavy working lineroperations through difficult hole sections.The TORXS system has a better bypassarea and has a hydraulically balancedsystem that eliminates presetting whilecirculating in the hole or during cementingplacement. This represented an advantagein the liner installation process in this well.The customer picked up the Baker HughesEZReam casing shoe with the shoe-tracksystem in 7 5 /8-in. casing, made up the7 5 /8-in. x 9 5 /8-in. TORXS liner hanger systemwith the 7 5 /8-in. x 8.3-in. outside diameter(OD) x 20-ft oil-swell REPacker packer, andran the system into the wellbore with 5-in.heavyweight drillpipe at 2 to 3 minutesper stand. The operation was stopped at9,994 ft (3047 m) and parameters werechecked with the following results: pump6 BPM at 700 psi (48.2 bar) and 8 BPMat 1,000 psi (68.9 bar). The operatorattempted to take rotation parameterswith the top drive. At 16,000 lb/ft (2212kg/m) torque, it stalled and increased to20,000 lb/ft (2765 kg/m) torque at 15 RPMwhile it was at 40 RPM picking the stringup. The operators continued going downin the hole, checking weight until reachingthe total depth at 10,878 ft (3315 m)without any problems.The overall results of the operation werethat potential flow paths created bychanneling were sealed, so the integrity ofprimary cement job was enhanced and afuture remedial cement job was avoided.Because no additional running tools wereneeded to activate the openhole packers,operational time and rig time werereduced, saving costs.Afterwards, an element swell test wasthen performed to ensure the compatibilitybetween the REPacker system and the oilwellbore fluid. The test was performed ata Baker Hughes lab in Mexico and also atthe rig during the job.www.bakerhughes.comDisclaimer of Liability: This information is provided for general information purposes only and is believed to be accurate as of the date hereof; however, Baker Hughes Incorporated and its affiliates donot make any warranties or representations of any kind regarding the information and disclaim all express and implied warranties or representations to the fullest extent permissible by law, includingthose of merchantability, fitness for a particular purpose or use, title, non-infringement, accuracy, correctness or completeness of the information provided herein. All information is furnished “as is”and without any license to distribute. The user agrees to assume all liabilities related to the use of or reliance on such information. BAKER HUGHES INCORPORATED AND ITS AFFILIATES SHALL NOT BELIABLE FOR ANY DIRECT, INDIRECT, SPECIAL, PUNITIVE, EXEMPLARY OR CONSEQUENTIAL DAMAGES FROM ANY CAUSE WHATSOEVER INCLUDING BUT NOT LIMITED TO ITS NEGLIGENCE.© 2012 Baker Hughes Incorporated. All rights reserved. 37313 11/2012