Successful Rig-Less Intervention Solutions to Unlock Wells Potential Due to Inflow Control Device System Failure

Abstract This abstract presents three different distinctive solutions for three wells suffering from failures in Hydro-Mechanical Inflow Control Devices (HM-ICDs). The ICDs of those wells were deployed during rig operation while remaining stuck in close position with multiple unsuccessful attempts using the ICD shifting tools. The main goal was to overcome these equipment failures efficiently, aiming to restore well's productivity without the need for extensive and costly workover operations. Each case required a unique approach to address its specific challenge. One solution underwent a precision punching operation based on open-hole log data utilizing E-line tractor and Puncher tool. Puncher tools offer a non-explosive, e-line transmitted, and effective way to punch tubing. Without the need for explosives, its design instantly produces a regulated diameter hole in the tube at the desired depth. By employing a rapid drilling method, the Puncher creates multiple accurate and consistent holes in a single run. Another process and solution involved coiled tubing runs for wellbore cleanout and abrasive jet perforation for creating targeted perforations, with real-time monitoring to maintain well integrity. The challenge in this case was the minimum restriction of the XN Nipple preventing the solution of puncher tool. During the operation, a coiled tubing was used with abrasive jet perforation BHA pumping a mixture of water along with sand at a specific pumping rate leading to a successful restoration of the well productivity. The third solution faced a distinct condition in which a leak in the horizontal section exist and was addressed by setting a plug below the leak then employing a specialized nano-silica mixture to chemically seal the leak before punching the tubing. HEX plug was deployed using coiled tubing and set below leak point. At first stage, inhibited treated water was injected to free the area from any debris followed by nano-silica in which it was pumped and squeezed at the targeted zone leading to a successful isolation of leak point. Followed to that, E-line tractor and Puncher tool were deployed successfully resulting to a series of punches based on open hole logs to enhance the well's production capacity. The collaborative and timely well intervention in these 3 wells has led to a significant restoration of production. This success not only represents a major boost in production, but also a substantial optimization in reducing the cost by 64% compared to workover rig cost. In addition, the rig-less operation expedited in establishing the production of the well with 50% less time than workover rig which in turn facilitate for an efficient workover rig allocation for more critical jobs. This paper demonstrates the effectiveness of innovative mechanical and chemical interventions in addressing specific challenges of HM-ICD failures in which it highlights the importance of custom-tailored solutions based on thorough diagnostic evaluations and the strategic use of technology to enhance well's productivity. These insights are valuable for the oil and gas industry, particularly in managing similar challenges in well operations.