Well completion and commissioning operations offshore present a variety of technical and operational challenges in the quest to maximize well productivity and optimize the economic value together with focus on safety. This is very relevant to the perforation operations performed in hostile and high-pressure reservoir conditions encountered in a complex development project in the Caspian basin. We provide description of the project and the innovative solution applied, including challenges faced, experience gained, and lessons learned.

To overcome challenges, we selected electric-line-enabled (e-line-enabled) coiled tubing (CT) for precise depth control, and the latest advanced gun deployment system for conveyance of long gun strings under pressure. Innovative solutions implemented throughout the project included the perforation-shock-resistant bottomhole assembly (BHA), two independent emergency disconnects, and tuned software to predict and evaluate shock load and dynamic underbalance. Some of the unique technical solutions were designed specifically for this project: high-pressure and H2S-rated connectors; specialized tool deployment stack; 15,000-psi working pressure 5.12-in. ID H2S-rated rounded scallop guns; shock-resistant electrical disconnect; and high-tensile CT logging head disconnect weak points.

To date, more than 10 well commissioning operations were successfully completed with this innovative method—e-line-enabled CT perforation under high pressure. This perforation technique proved to effectively minimize operational time, associated risks, improper equipment use, and footprint on location. Such approach allowed safe and efficient perforation in a controlled well environment that resulted in accurate depth control and managed detonation shock load and overbalanced conditions, which avoided any well fluid influx or H2S release. The developed solution required seamless integration of innovative techniques and hardware, including e-line enabled CT, the CT logging head, the gun deployment system for pressurized well conditions, wireline tools and specialized perforation equipment. The design was optimized to perforate the well in three or four runs at overbalanced condition (squeeze mode) in a single rig-up job instead of more than 20 wireline runs. Additionally, the use of CT granted flexibility and increased operational safety to perform pumping operations for well displacement and well control, injection of H2S scavenger, and stimulation, as per Operator's plan, without or with only partial rig-down.

This is the first time that the described CT perforation operation using such techniques has been performed in the Caspian region. The experience demonstrates a method to safely and efficiently facilitate perforation jobs under challenging conditions in the future.