In 2022, Shell Exploration and Production Company discovered a leak in the upper completion of a deepwater injector well in the Gulf of Mexico, located in a high-pressure, high-temperature field with a significant presence of sour gas (H2S) in depths up to 7,400 ft. The wellbore temperature exceeded 340 degF and a pressure of 14,000 psi challenged the operating limits of intervention tools.
To fix the leak, Shell recompleted the well. During this phase the well was killed with a heavy drilling fluid (16-ppi density). After recompletion was finished, a 500-ft column of heavy mud remained above the isolation valve. This heavy fluid had to be removed before the operator could open the well for injectivity as it would clog the screens and damage the well’s ability to receive injected fluids.
Shell tried to clear the debris using CT, but the ocean currents kept it from relatching the wellhead after a CT lift frame was damaged. As a result, the best way forward was to continue ongoing debris collection operations using slickline and wireline. The bailing runs started with pumpdown slickline bailers, but the efficiency of this process was limited because of the limited volume of the bailers and leaky flapper valves.
After 43 runs using the ReSOLVE iX active debris removal tool, the entire column of debris and heavy fluid was cleared out, and the upper completion was filled with light brine, eliminating the risk of compromising future production. In all, more than 300 galUS of drilling fluid and 80 lbm of solids were collected.
After multiple runs at 340 degF during 10 days of continuous operation, this extraordinary operation highlighted the robustness and reliability of the ReSOLVE iX active debris removal tool, which helped Shell avoid the cost of a CT mobilization and enabled the rig to resume its normal activities.
