isolate perforations

IPA20-E-9 – Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production

Published on 17 September 2020

Banyu Urip Upper Perforation Shut-off: A Success Story of Hydroformed Expandable Casing Patch Installation to Reduce GOR and Maximize Oil Production


ExxonMobil Cepu Limited (EMCL), as the operator of the Banyu Urip field in Cepu Block, Indonesia, observed several oil wells with high Gas Oil Ratio (GOR) after several years of production. The client expected curtailment of oil production due to limited surface gas handling capacity. the operator needed to establish additional stand-off against the reservoir gas cap by performing top perforation interval shut-off to reduce GOR and maximize oil production.
Perforation shut-off became more challenging due to high H2S and CO2 concentrations, relatively high reservoir temperature, long perforation interval, and total losses experience.
The remedial solution required a V0 “gas-tight” qualification, live well execution, induced minimum to no formation damage, and provided a minimum reduction of tubular Inner Diameter (ID) post remedial work to avoid significant production impact and allow future wireline tools deployment. Considering the high profile of the Banyu Urip field, which currently produces ~29% of Indonesia’s oil production, EMCL selected the fit-for-purpose remedial method with the highest probability of success. The hydroformed expandable casing patch (patch) with Corrosion Resistance Alloy (CRA) material and its top-down expansion method was evaluated and selected. Re-designing the inflatable element was necessary to improve durability in high temperature and verified by laboratory testing. Patches were installed and overlapped to cover the top perforation interval. Seals on top and bottom of the patch extremities formed V0 “gas-tight” sealing mechanism against the casing. The patches were deployed with a smart coiled tubing unit. The whole patch installation went as per the plan. The wells were brought online with significantly reduced GOR post-patch installation. It was the very first installation of the patch utilizing smart coiled tubing and ~90 feet Coiled Tubing (CT) tower in sour wells within any ExxonMobil affiliates. The detailed technical preparation, strong safety culture, leadership, and relentless learnings application have delivered a successful project to reduce Banyu Urip wells GOR and enable EMCL to maximize oil production.

Read more on IPA (Indonesian Petroleum Association)

Year: 2020 – Authors: Saputra, D., Nugraha, P., K., A., Patel, N., C., Albouy, C.

Basin: East Java

Proceedings Title: Proceedings, Indonesian Petroleum Association, Digital Technical Conference, 14-17 September 2020

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