Archer Oiltools has been awarded a plug and abandonment (P&A) campaign by Wintershall Noordzee B.V across 2021 and 2022. The scope awarded to Archer is to perforate, wash, and provide cement and formation integrity testing tools, services, downhole tools on tubing conveyed, and plugs-cutters for 22 wells with an option of another 20 wells.
Hugo Idsøe, Vice President of Archer Oiltools, commented, “Over the last decade Archer has delivered a high number of P&A and Slot recovery operations to our customers in the North Sea with great success. This contract is a milestone for the southern part of the North Sea and a testimonial of all the good work that we have done for Wintershall Noordzee B.V. over the last three years.”
“Our team have delivered excellent performance and we continue to prove that Archer’s Oiltools is an industry leader for smart and robust solutions in markets where well integrity, reliability and time savings are of upmost importance.”
“With a broad portfolio of products and services within P&A and Slot Recovery, Archer is in a unique position to deliver lower carbon solutions to our clients. Through our development of new technologies and solutions, we are rapidly adapting to and embracing the sustainability focus on lower emissions,” Idsøe added.
Archer has been carving a formidable presence for itself in the North Sea in recent months with this announcement coming soon after its acquisition of DeepWell, a leading Norwegian well intervention company focused on high-tech based wireline service. DeepWell commands one of the most modern wireline unit fleets on the Northern Continental Shelf and holds a strategic long-term contract in the light well intervention market, making a fine addition to Archer’s portfolio. It is therefore no surprise that the company was awarded another contract by Wintershall Noordzee B.V. and it is highly likely more work will be coming its way in the future.
At the Offshore Well Intervention Conference, Middle East and North Africa 2021 host Tural Yusuboc, Senior Engineer of Well Integrity at ADNOC, was joined by an experienced panel to discuss the pressures shaping the well integrity market and the factors that will drive change for the discipline in the future.
Briefly outlining its history, Fayez Issa, Group Well Integrity Advisor for ADNOC, commented, “Well integrity has gone through different stages. If you go back 30-40 years it did not exist, there was minimum knowledge. But then after many incidents and major catastrophes the knowledge of oil integrity has become a vital aspect of oil and gas. It changed a lot ten years ago after the events on the Macondo field in the Gulf of Mexico. Before, people could happily ask things like do we really need to log cement? Is it important to see variations? Do we need special requirements for a gas lift? Additionally, a lot of things were done at minimum costs. Now if a well is planned to last for thirty years it has to be designed to last that long, a change partially due to the environmental challenges and more stringent regulations.”
Nowadays well integrity is a much larger concern for the industry, emphasised by Neil Ferguson, Business and Sales Development Manager of Well Intervention and Integrity at Expro Group, who noted that Expro now has 50% of its portfolio dedicated to this discipline whereas 20 years ago it was just 20%.
Exemplifying why well integrity and surveillance is such an important topic in today’s world, Mustafa Adel Amer, Well Integrity Focal Point at BAPETCO, said, “Ten years ago BAPETCO started doing well integrity management systems which accelerated the building up of knowledge. But unfortunately after the crash in 2014 the company took the decision to save costs and stop things such as corrosion logs etc. Now after six years the company is going to pay more to fix the unknown causes of corrosion and will have to probe the wells.”
While the discipline has grown significantly over the last few decades, the panellists noted that there was still room for improvement. Ferguson, suggested that there was perhaps a bit of a disconnect from integrity as it was so often bound up as part of drilling and production. The participants suggested that if well integrity is kept within these departments it might not perform its role as effectively, but having well integrity as a separate entity within companies would empower it to do so.
Abandonment
Switching the conversation slightly, Ferguson turned the focus on well integrity related to abandonment. He said, “One of my concerns is how do we help customers safely abandon their wells when they need to stay abandoned. There is now an expectation that once abandoned, these wells stay that way forever. The next challenge is figuring out how to do best possible job to ensure integrity in not just in a well’s operating life but once it is abandoned also. I don’t think we will be able to just forget these wells once they are abandoned and there will be elements of risk that will continue to challenge the industry. We have a huge responsibility as we move forward as to what we categorise as well integrity.”
Abandonment remains a difficult topic for the industry as, at the bottom line, it does not return any profit. As the panellists noted, drilling wells is exciting as you then get the reward, but this is not the case with abandonment and so often it can be neglected. This is exemplified by Bloomberg projecting that more than 32 millions wells worldwide are no longer producing and awaiting proper abandonment.
To ensure these operations are carried out and, importantly, are done so in a proper way to ensure the integrity is not compromised, the panellists suggested that cost must be projected forward, so that operators can plan for these financial hit in advance rather than bear the brunt unexpectedly at the end of a well’s life. Additionally, more stringent regulations would ensure that abandonment would be a requirement, but of course the implementation of regulations varies from region to region. Ultimately, the panellists agreed, if there is an event relating to an abandoned well’s integrity, it could easily be a catastrophic event that will affect everybody, not just the local region. Therefore it is also the responsibility of the oil and gas industry, not just the regulators, to ensure the integrity and abandonments of wells is taken seriously and performed in an environmentally responsible manner.
The role of technology
The participants noted that technology has played, and will continue to play, a huge role in the well integrity sector and, in recent years, perhaps the most significant advancements have been made with AI and big data.
Ferguson said, “AI is used in just about everything else we do in day to day life, so why shouldn’t we use it to our advantage in our industry to give us a predictive view on well integrity issues. We are in the era of big data and digitalisation, and there is so much data to look at that is very easy to miss some key information. The capacity for AI to interpret data and predict well integrity issues in the future is a huge cause for optimism and I think it is going to be hugely important moving forward.”
Adel Amer commented, “One of the challenges of performing corrective actions was the unavailability of material. We had one well, for example, that had three failures and we couldn’t acquire the material to replace the faults for one and a half years. But just replying on a simple data model, we can plan ahead for such instances by seeing how many faults occurred in previous years to predict what material we will need in the future. I think more solutions like this are going to come up if we make data available to these smart minds.”
Although enormous strides have been made with digitalisation and AI the panellists noted that there were still areas for improvement which would greatly enhance well integrity capacity. For instance, Issa noted that while there is a lot of data being collected from various sources such as corrosion logs, cement logs etc, there was still not enough surveillance data being conducted. Improving this would only enhance the ability to predict issues and rapidly remediate them.
Another area of improvement is centred around data sharing. As noted, the more data available the easier it is to predict potential issues in the future and, while perhaps there is scope for acquiring more, collectively oil and gas operators hold a plethora of data from locations across the world. If companies were more visible with their data, it would enhance opportunities to rapidly remediate wells and ultimately capture value for operators.
“But this is something the industry is not keen on, sharing products and data. This hinders a lot of the opportunities that could be unlocked without really spending any money,” noted Adel Amer. “If we want to move forward in the digital era we need to exchange data and make data sets available.”
The Covid-19 effect
The panellists also turned to how Covid-19 had affected the well integrity discipline, noting that perhaps the most significant change, which will most likely last into the future, was the withdrawal on reliance from externals. For instance, Adel Amer noted that in Egypt typically the company orders a lot of materials from abroad but this was, of course, dramatically hindered by travel restrictions and so, instead, local companies began manufacturing more advanced equipment. There was also an emphasis on training to ensure that the expertise was available within companies rather than seeking it from exterior sources. Issa noted that in ADNOC the company has recently issued a well integrity e-learning which was mandatory not only for those related to the discipline but also drilling and operation etc to ensure all employees know what they should be looking for.
It was clear from the discussion that while the discipline of well integrity had taken great strides over the last few decades, things such as lack of surveillance and a reluctance to share data was holding it back. Addressing these obstacles would only enhance the field, which would ultimately lead to healthier wells with extended production lives capable of providing more value to operators and the industry.
Serica Energy plc, a British independent upstream oil and gas company with operations centred on the UK North Sea and gas accounting for over 80% of its production, has encountered difficulties in the drilling of the Columbus development well, located in the North Sea, 35km north-east of the Shearwater production facilities.
The Columbus development well was spudded in mid-March and drilled, as planned, to a total measured depth of 17,600ft by the Maersk Resilient heavy duty jack up rig. A 5,900ft horizontal section was drilled through the reservoir formations of the upper forties and encountered a sequence of sands and shales, in line with pre-drill expectations. The well required sand screens to be installed to prevent fine particles being produced and difficulties were encountered while running the screens so that it was ultimately not possible to install them.
As a result, the reservoir section of the well will be side-tracked and re-drilled, using data collected during initial drilling to optimise its trajectory and avoid the difficulties encountered running the screens in the original well. The additional operations are expected to take around 3-4 weeks at a net cost to Serica of around UK£3mn.
While this has raised the expense of the operation, these recent developments are not expected to affect the timing of production start-up, which is still projected during Q4 2021. Serica stated that further updates will be provided on each project when flow test data is available.
Mitch Flegg, Chief Executive of Serica Energy, commented, “Whilst frustrating, the additional operations on Columbus are not expected to affect the timing of first production, and the economic returns of the project remain very attractive for the company.”
A recent Competent Person’s Report estimates the Columbus gross undeveloped 2P reserves to be in excess of 14 million boe and, once production begins, the average gross production forecast is projected to be around 7,000 boe per day, of which over 70% is gas.
Rhum 3 update
Serica also provided an update on the R3 Intervention Project, situated on the Rhum field, which commenced in October. The company stated that the R3 well has now been cleared of all equipment installed when it was originally completed in 2005. Reservoir access has been regained, thus allowing new completion equipment to be run in preparation for production.
The new completion is currently being installed prior to performing a flow test on the well, which is expected to be carried out in June. A diving support vessel has been contracted to install the subsea control equipment required so the well can start producing in Q3 2021.
The Australian oil and gas industry is, unfortunately, making all the wrong headlines at the moment as a serious row over a decommissioning levy proposed by the Australian Government continues to rage.
The tinder for this firestorm is the Northern Endeavour floating production storage and offtake (FPSO) vessel, moored between the Lamarinaria-Corallina oil fields, which was shut down by the National Offshore petroleum Safety and Environmental Management Authority (NOPSEMA) after an immediate threat to health and safety caused by structural corrosion was found at the facility. Since the former owners Northern Oil & Gas Australia (NOGA) went into liquidation in late 2019, the national government has been maintaining the vessel until, at the end of 2020, it decided to decommission the facility and all related infrastructure once and for all.
To help cover the US$200mn expected cost of doing so, in its 2021-22 budget, the Australian Government announced it would be enforcing a levy to the Australian oil and gas industry, a decision which has so far come under heavy criticism from the sector.
Last week, Australian Petroleum Production and Exploration Association (APPEA) Chief Executive, Andre McConville, led the criticism against the Australian Government calling it an outrage that many companies who were never involved with the project will have to help pay. He also noted that such a decision could potentially hold back the Australian economy as well as the 80,000 jobs that it supports.
Now ExxonMobil and Chevron have expressed their disapproval towards the Australian Government’s decision as well.
As reported by Reuters, a spokesperson for Chevron commented, "Chevron Australia is committed to working with the government on a decommissioning policy framework that would effectively preclude the need for this type of ad hoc, arbitrary action.”
Similarly, ExxonMobil noted that it had established a track record of executing successful decommissioning operations around the world and so shouldn’t have to shoulder the burden of covering costs for other companies as well. The company, therefore, was disappointed in the decision by the federal government, as detailed by Reuters.
While the debate will no doubt carry on for some time, the problem remains that at some point the Northern Endeavour and associated infrastructure will have to be decommissioned and dismantled. At this stage, however, who will pay for it is anyone’s guess.
PTT Exploration and Production Public Company Limited (PTTEP) has announced yet another gas discovery from its first exploration well, Kulintang-1, in Block SK438, located off the coast of Sarawak, offshore Malaysia.
Phongsthorn Thavisin, CEO of PTTEP, disclosed that PTTEP, through its subsidiary PTTEP HK Offshore Limited (PTTEP HKO), commenced the drilling of Kulintang-1 wildcat well in Block SK438 in March 2021 and successfully drilled to a total depth of 2,238 metres in April 2021.
Block SK438 is located in the shallow waters, approximately 108 kilometres off the coast of Bintulu in Sarawak. PTTEP HKO is the operator with 80% participating interest while PETRONAS Carigali Sdn. Bhd. (PETRONAS Carigali) holds the remaining 20%. PTTEP expects to drill another exploration well in this block in the second quarter of 2021.
Block SK438 is adjacent to Blocks SK405, SK309 and SK311, SK314A, all of which are operated by PTTEP, with existing facilities nearby. The location, therefore, provides an advantage for future development including the potential for cluster development.
PTTEP’s Malaysian success story
This discovery is the latest of PTTEP’s continued success in Malaysia. Already this year the company discovered a significant oil and gas column of more than 100 metres from exploration well, Sirung-1, in Block SK405B; revealed a high quality gas reservoir from the Dokong-1 well in Block SK417; registered a new record for its largest ever gas discovery from the Lang Lebah-2 appraisal well in the Sarawak SK 410B Project; and announced the start-up of natural gas production from Rotan and Buluh deepwater fields of Block H which targets production capacity at 270 million standard cubic feet per day.
“The Kulintang-1 well adds to the consecutive discoveries PTTEP has made this year which demonstrate our significant exploration progress in Malaysia. The discovery highlights our strong partnership with PETRONAS and continuous efforts in applying new techniques and interpretation to identify opportunities in mature areas. We are determined to explore further and make more oil & gas discoveries in Malaysia to serve future energy demand,” said Thavisin.
Magma Global has delivered the world’s first high-pressure composite riser pipe to HWCG’s storage location on the U.S. Gulf Coast, completing its rapidly deployable Offset Flexible Riser (OFR) system.
HWCG, to enhance its rapid deployment emergency well containment system, commissioned Magma Global to qualify and manufacture a high pressure, high temperature m-pipe to be used as a flexible riser connection. The lightweight, flexible m-pipe section will provide additional flow and capture emergency response options for HWCG’s members in the U.S. Gulf of Mexico.
The m-pipe is designed for rapid installation and is suitable for responses where vertical access is restricted and an offset is required such as water depths where the presence of combustible and volatile compounds affect personnel safety or where access under a floating production facility is needed. The system may also be used in deeper waters where more flexibility is desired in managing the marine systems during a response.
The 800 ft long section of m-pipe will provide a flexible riser connection between the capping stack placed on the incident well and a rigid riser suspended from a MODU. The m-pipe will form a horizontally oriented “S” shape between the capping stack and the rigid pipe riser, thus decoupling motion and decreasing surface station-keeping requirements for the temporary production facility. Once in operation, hydrocarbons released from the well flow through the complete riser flow path and are processed on board the temporary production facility to be collected in shuttle tankers for transportation.
Martin Jones, CEO at Magma Global, said, “This is a bittersweet success for Magma. We are proud to supply the first composite flexible riser for high pressure, high temperature hydrocarbons, for use in the Gulf of Mexico, yet we hope it will never have to be used. Nevertheless, m-pipe doesn’t corrode or degrade over time and hence will always be ready to enable HWCG to install at speed and with confidence.”
Bolstering HWCG’s well containment capabilities
HWCG’s response provides for the installation of a capping stack within 7-14 days and the ability to commence contingent flow and capture operations within 18 days, assuming no weather or other uncontrollable delays. Once installed the m-pipe is qualified to operate for at least six months, which is enough time to drill a relief well to provide final well kill and containment.
Mitch Guinn, Technical Director for HWCG, commented, “HWCG was one of the first organisations to accept the responsibility for providing equipment and personnel to respond rapidly and safely to a deepwater well incident. The addition of a flexible riser component to our suite of response equipment further enhances our ability to respond even more efficiently by allowing more flexibility in selecting a temporary production facility and enabling the selected facility to increase its operating window regarding weather conditions. The addition of Magma’s composite m-pipes is a huge benefit for our Members and is seen as one of their critical response components. We hope this work will open the doors to future applications of this breakthrough technology.”
Andy Jefferies, Deep Sea Development Services, and OFR Project Manager for HWCG, added, “The initial concept, and subsequent evolution, of the Offset Flexible Riser builds on the industry’s use of riser technology to manage unique operating conditions and environments requiring incident well flowback as part of a well containment strategy. The engineering and design aspects of this breakthrough technology have been led by DSDS for HWCG. The application of the Magma m-pipe design represents a step change in that technology and brings a time effective solution to well containment for flow and capture operations for all scenarios, but is particularly well suited to shallow water, high-rate gas wells, and wells requiring an offset flow and capture operation.”
SEAJET Systems has launched to the subsea intervention market to provide the ability for companies to own and operate the most advanced controlled flow excavation (CFE) technology without third party interference, providing a more flexible, cost-effective and efficient solution.
Established by industry leaders Hector Susman, a pioneer of industry-leading excavation equipment, and Faisel Chaudry, who has more than 15 years’ experience in the sector with Rotech Subsea, Reef Subsea and James Fisher, SEAJET offers one of the most versatile CFE systems on the market. Developed by optimising existing CFE equipment, the company’s build-to-order technology introduces advanced hydrodynamic properties suitable for a wide range of applications and variable seabed conditions. SEAJET offers a tailored aftermarket support package to inspire client confidence to own, operate and maintain their own-in-house CFE equipment.
Chaudry commented, “We’ve launched SEAJET to meet the significant demand for cable trenching and de-burial in the rapidly growing offshore wind market. In addition, the use of CFE equipment continues to escalate in the inspection, maintenance and repair, decommissioning and salvage applications across oil and gas and marine sectors. Our unique mix of expertise in this specific area of subsea intervention provides customers with a solution they can trust.”
Susman added, “Having designed 95% of the CFE tools available on the market today, with the new SEAJET excavator, I have taken all lessons learned over that 25-year period and introduced the most advanced CFE system to date. Our technology has been optimised to work in the widest range of applications and soil conditions. We have honed the real sweet spot between flow and velocity, resulting in something others cannot offer – a flexible solution with enhanced performance and a business model that has efficiency built-in at every turn.”
Headquartered in Dubai, with operations in Europe and South East Asia, the company currently employs a team of seven people. Together, the senior management team has delivered more than 30 builds of MFE/CFE systems and execution of over 600 trenching/excavation projects globally.
The Australian government has come under fire after it announced, in its 2021-22 budget, a levy to cover the cost of decommissioning facilities around the Lamarinaria-Corallina oil fields in the Timor Sea.
In 2019, the 170,000 bpd Northern Endeavour floating production storage and offtake (FPSO) was shut down by the National Offshore petroleum Safety and Environmental Management Authority (NOPSEMA) after an immediate threat to health and safety was found at the facility, caused by structural corrosion.
The task of decommissioning the infrastructure fell to owners Northern Oil & Gas Australia (NOGA) but, in late 2019 the company went into liquidation and so the facility has been abandoned, with the national government forced to maintain the facility. At the end of 2020, the government decided it was finally time to push the facility into retirement, announcing it would take on responsibility to decommission the FPSO and all related infrastructure.
The estimated cost of such an undertaking is an eye watering US$200mn and, to help cover this, the Australian government has now issued a levy to the oil and gas industry to help foot the bill.
The announcement has gone down poorly and the Australian Petroleum Production and Exploration Association (APPEA) Chief Executive, Andrew McConville, has led the criticism against the government. McConville was outraged that many companies that have never been involved with or benefited from the project will have to help pay, and noted such a decision had the potential to hold back Australia’s economy and the 80,000 jobs the industry supports.
McConville said, “Tonight’s announcement of a new levy on the entire (offshore) oil and gas industry is a terrible precedent and could have serious repercussions to Australia’s economy and to jobs. Everyone agrees that the Northern Endeavour needs to be decommissioned and the costs managed, but there are a number of ways that the government can do so without risking undermining investment confidence in the oil and gas industry.”
The Chief Executive added that there were other options still available, such as making the government’s current management of the operations more efficient, reducing the cost of decommissioning through collaboration, and looking at alternative funding such as selling the asset or accessing PRRT credits.
While leading the charge, McConville did note that he was glad there will be extra consultation where APPEA will be able to put forward alternatives that the government should consider to meet the costs of decommissioning. He said, “We stand ready to work with the government to look at how best to manage the decommissioning of the Northern Endeavour.”
Following an offer letter signed in April 2021, Archer has announced that it has signed a sales and purchase agreement (SPA) to acquire DeepWell for NOK177mn on a debt and cash free basis which will be financed using existing cash and liquidity reserves.
DeepWell is a leading Norwegian well intervention company which provides wireline and downhole services to oil companies on the Norwegian Continental Shelf (NCS). The company currently employs approximately 200 people and, across 2020, had a revenue of around NOK360mn.
The acquisition of DeepWell, which commands one of the most modern wireline unit fleets on the NCS and holds a strategic long-term contract in the light well intervention market, will greatly enhance Archer’s well intervention service offerings in the North Sea.
Lage Nordby, Vice-President of Wireline at Archer, commented, "We are pleased to welcome DeepWell’s team of employees to Archer. By strengthening our wireline equipment fleet and organisation, increasing our low emission solutions, and continuing our track record for service quality, Archer is well positioned on the Norwegian Continental Shelf. The acquisition of DeepWell gives us access to equipment and employees needed in order to fulfill our obligations under our recently awarded wireline contracts with Equinor and ConocoPhillips."
Jan Erik Rugland, COO of Moreld AS and CoB of Deepwell, said, "We are pleased to have reached an agreement with Archer securing continued operations on existing contracts and the continued development of DeepWell’s state of the art wireline technology. I want to thank all the employees, both on- and offshore, for their dedication and perfection. This transaction is in line with our strategy to divest capital intensive businesses in order to focus our energy on transition and growth plans."
The closing of the transaction is expected to be finalised during Q2 2021 and is subject to customary closing conditions and regulatory approvals.
The rate of technological advancements is advancing, and it is pulling the oil and gas industry into new realms of digitalisation, automation, AI and more. The field has become more competitive and yet, despite this, the latest innovation from Blue Spark Energy, the wireline applied stimulation pulsing technology (the BlueSpark tool) which has the potential to radically increase the efficiency of well intervention operations, stands apart.
In a virtual webinar, Blue Spark Energy representatives Todd Parker, CEO, and Chris Grahame, VP of Sales and Marketing, presented the technology, describing it as the future of environmentally responsible wellbore interventions.
As Parker explained, the engineers at Blue Spark Energy have utilised electrical energy in a third format outside of AC or DC, high pulsed power, for application within the well intervention sector. High pulsed power is the idea of taking electricity and compressing it to be released in a very short period of time. Returning to school physics, power equals energy over time, so by reducing the time taken, the power is much higher. By example, Parker demonstrated a test in the Blue Spark Energy laboratory which used the energy equivalent to two cell phone batteries and releasing it in microseconds to generate power in the hundreds of megawatts range. The company has taken this and built a device to take electrical energy, compress it and then produce a high power output for use in the well intervention sector.
Production enhancement
So what can this technology actually do? Well, as Parker continued, “The primary application of this technology is to return oil wells to optimal production by removing blockages that could cause disruptions. The BlueSpark tool, through repeated high power pulses, can effectively remove organic and inorganic debris in production zones and reopen perforations which have been plugged either immediately after perforation or as the well has matured.”
Already Blue Spark Energy has deployed this technology in hundreds of wells across the globe and returned with some incredibly promising results. Listing some of these examples, Parker stated that in one example in the Middle East, a customer used the BlueSpark technology for two remote wells and found that the high power pulses were just as effective as coiled tubing acidisation methods and was able to more easily target specific zones. Additionally, the small footprint and ability to rapidly mobilise to the remote location (due to the small amount of equipment and personnel required) meant the BlueSpark tool produced the same result in just 10% of the time and led to an aggregate increase of 60% in oil production across the two wells.
Parker noted that the technology can be used to clear blockages across the wellbore – be that in the productive zone or the completion equipment further up – any part that has the capacity to create somewhere for debris to start building up the BlueSpark tool is effective at treating the disruption. It is also not restricted by the kind of debris that is obstructing the well, and anything from waxes, calcium carbonate or even iron sulphides can be treated. With other intervention methods you often need deeper diagnostics to ascertain what chemicals are required, for example, but all Blue Spark Energy operators need to confirm is if there is debris and where – they are not concerned with what it looks like or what it is.
To emphasise this, Parker added, “In the North Sea at an unmanned installation the operator encountered a barium sulphate scale build up in the tubing and across the surface controlled subsurface safety valve (SCSSV). Operators were unable to use conventional methods due to scale build up restrictions above the SCSSV and were therefore required to shut-in the well and set up a plug as a barrier below the SCSSV. We were able to take out a small wireline mast and within 24 hours place the technology across the SCSSV, remove the debris and put the well back into production. This was a 3500bpd producer in danger of being shut which we were able to rapidly treat without causing any damage.”
Multiple applications
In addition to cleaning screens and gravel packs in oil production, the BlueSpark tool has also been deployed for usage in other applications such as water source wells or improving geothermal efficiency, proving its versatility across the energy sector. In another case in the North Sea, Parker showed how the technology was used to improve the efficacy of decommissioning wells by removing debris to allow for a rigless type of decommissioning as opposed to section mill or something more complicated.
This technology, as Parker continued, is particularly suited when deployed by wireline tractor, and is compatible with all wireline industry equipment – if a perforating gun can be run off the wireline unit so can the BlueSpark tool. It is very transportable, able to be transferred in a helicopter for example, and is deployed in pairs to de-risk operating time. It also has an incredibly small environmental footprint, without using chemical fluids, explosives and requiring only a small amount of energy. Although the pulses are released at high power, due to the low energy used, there is no risk of damaging any equipment.
Saving money as well as the environment
After the webinar, Parker spoke to Offshore Network to shed more light on this innovative new technology and which markets the company is targeting in the future.
Parker said, “The process people are talking about a lot at the moment is the electrification of a lot of carbon intensive processes. The BlueSpark tool can become that intervention device that leads in the electrification of conventional well intervention techniques. There is no risk of creating a situation worse than you had before, no safety hazards, and finally you are reducing the carbon footprint of your intervention operations.”
Aside from the environmental and safety benefits, the BlueSpark technology also offers significant financial incentives as well. Parker added, “The costs savings mainly come from operators not having to move a rig or heavy equipment, and the ability to intervene quickly. It costs less to transport, there are less people required to move it, and it’s very fast to set up (there is no wellbore preparation). Looking from a fiscal perspective you are probably looking at being able to save more than 50% over using a conventional technique to accomplish the same result. We have case studies where we have saved customers days of operating time and millions of dollars.”
The story so far
Parker took some time to reflect on Blue Spark Energy’s journey so far which, at times, has been quite frustrating. He said, “The physics is basically high school physics, the engineering was not, so it took some time to build the tool robust, durable and slimmer to access more wellbores, but we finally had a commercial model in 2013 which we started to take around the world.”
“Unfortunately this is where you run up against the inherent conservativeness of the industry itself. From 2013 to 2018 we really faced that from a lot of operators who, broadly speaking were interested in new technology but really struggled to introduce it as it is radically changing their intervention, not changing a small part of it such as introducing a type of chemical. It took us a few years to get some customers to where they were comfortable making that change.”
Currently Blue Spark Energy has quite a large capacity, after deploying to more projects and manufacturing more assets to meet demand. It has ongoing projects in Nigeria, Denmark, Norway, the UK, Malaysia and the Middle East and, to date, has completed over 600 projects across the world working with a variety of clients such as Exxonmobil, Chevron, Shell, Equinor and more. Across the thousands of well descents attempted by the technology, it boasts a 99.6% operating efficiency and rarely creates downtime for customers. As there is a small amount of equipment and capex required to perform an operation, it is a relatively easy fleet to maintain. Additionally, as there are no complicated moving parts and the supply chain is quite simple, it is an extremely scalable business.
Looking ahead
Turning to the future, Parker commented, “Covid had an impact on business, 2020 was not our best year but it was our second best year. Now there is a tremendous backlog of wells that require maintenance and people want to do it rapidly and effectively, so we are envisioning a big uptake in activity in the short term. We think it is an opportunity for a lot of customers to see the benefit of this technology.”
Parker continued, “We want to continue to operate in logistically challenged regions, that is the easy argument. In some regions such as Africa, the Middle East, and Far East it is hard to get equipment to these locations, so why not try something radically different that is easy to get there.”
“The second dimension is we are still discovering additional applications. People are coming to us and asking, can we do it for this or use it for this purpose and we are continually refining the technology. So while there is a geographic spread there is also some technical growth we are seeing as well. Being able to help the decommissioning process, for example, to more effectively cut off any methane leaks in the future is exciting, as it is a big topic which at the moment has tremendous costs for operators. We are starting to get some real interesting air time in that space.”
Petrofac has secured a contract with BP to develop operational procedures for the Greater Tortue Ahmeyim (GTA) Project in Mauritania and Senegal.
Centred on minimising risk and harm to personnel, plant and the environment, the procedures will encompass all offshore operations, including subsea, floating production storage and offloading (FPSO) and hub.
The Tortue Ahmeyim gas field, with estimated resources of 15 trillion cu ft of gas, is located offshore the border between Mauritania and Senegal in water depths of more than 2,000 metres. Spanning five blocks (three in Mauritania and two in Senegal) in addition to the GTA unit, the LNG project will have BP as operator and is being jointly developed by BP, Kosmos Energy, Societe des Petroles du Senegal (Petrosen) and Société Mauritanienne des Hydrocarbures.
The final investment decision (FID) for phase 1 of the project was taken in December 2018 with the FID for phase 2 expected in 2022. Initial production was projected in 2022 before Covid delays caused this to be pushed back to 2023. Once completed, the GTA LNG project is expected to produce up to 10mn tonnes of LNG a year.
The integrated gas value chain and near-shore liquefied natural gas (LNG) development will export LNG to global markets as well as supplying gas to Senegal and Mauritania.
On the opportunity to take part in this exciting project, Steve Webber, Senior Vice-President of Operations at Petrofac, commented, “BP is an important longstanding client and we look forward to supporting them in operating safely and responsibly, in their delivery of the GTA Phase 1 Project, which is creating a new LNG hub in Africa.”
Aker BP was the first operator worldwide to use bismuth alloy to plug the top section of old oil wells. Since then, the technology is now used on 30 wells on the Valhall field, resulting in safer, permanent well plugging.
The Valhall field
The Valhall field in the southern part of the North Sea has produced over a billion barrels of oil equivalent since it began production. To ensure consistent performance, old oil wells must be plugged to make room for new wells in the hopes that over the next 40 years another one billion barrels of oil will be drawn up.
Martin Knut Straume, Aker BP’s Chief Engineer for Plugging and Abandonment, commented, “We’ll continue to work on Valhall for many decades to come. That means we have to make sure that we shut down and abandon old wells safely, so that it is safe for us to be there when we continue to produce and drill new wells at the same time. We use the best available technology, and in this case, in the top part of the old wells, that means bismuth.”
Aker BP has already started removing the old field centre on Valhall with the living quarters platform removed in 2019. Another two installations will disappear over the next five years and all wells connected to the old drilling platform will be permanently plugged over the course of 2021.
Egil Thorstensen, Senior Engineer for Plugging and Abandonment at Aker BP, said, “We’re currently installing bismuth plugs in the top section of all the wells; in other words, in the 30-inch casing. That’s the last thing we do before we cut and pull the pipes from the seabed to the platform, and the well is permanently abandoned.”
Diverse solutions provided by new technology
Plugging wells on Valhall may pose an additional challenge both due to gas migration to the surface, and due to subsidence and compaction. The seabed around the Valhall field has sunk seven metres since the early 1980s, and the top of the reservoir has dropped about 15 metres.
This means that cement, which is commonly used as a barrier material to plug wells, is an inadequate solution as it can fail when subjected to wellbore or casing stresses resulting from subsidence and compaction events. In the worst case, hydrocarbons in old wells could migrate upwards and potentially leak into the sea.
“Aker BP installed a trial plug over two years ago, and was the first operator worldwide to use bismuth alloy in the top section of the well. When we use this technology, we make sure that the plug is 100% impermeable. Gas cannot leak to the surface,” said Thorstensen.
Bismuth is a metal with unique properties that make it particularly well-suited for applications in P&A operations. As a solid metal, it is completely impermeable and is heavy as lead, making it less prone to contamination during its placement into the well. When melted, liquid bismuth flows like water, giving it the ability to flow into the smallest interstices in the well. When bismuth solidifies, it expands, which helps provide permanent sealing capability inside a wellbore.
Additionally, unlike cement plugs which need to be several dozens of metres in length in order to qualify as barrier, a 2.5 metre-long bismuth plug suffices to provide long term isolation in the well.
Reducing environmental impact
Bismuth alloy is typically a more expensive option than cement but total costs of plugging the top well sections are less due to decreased rig time for these operations.
“Even so, we have chosen to use it on Valhall because of the unique field conditions. For us, this is a matter of making sure that we minimise the carbon footprint from our operations, while ensuring that the wells are plugged and abandoned to the highest standard. Bismuth has what cement lacks: it changes almost instantaneously from liquid to solid when the heating source is removed, it is completely impermeable, and it is not affected by contamination issues,” commented lead technical engineer at Aker BP, Laurent Delabroy.
During the autumn of 2020 and winter this year, bismuth plugs were installed continuously from the Maersk Invincible rig on the Valhall field centre. The plugs are up to 2.5 metres long and weigh 9 tonnes. The work has been performed through the jack-up rig alliance between Aker BP, Maersk Drilling and Halliburton. Time spent per well was cut in half to a record-low 30 hours this winter which has resulted in significant cost savings and freed up several months of rig time that can now be used for new operations.
Delabroy concluded, “We succeeded through strong teamwork and close collaboration with our solid technology partner, BiSN. And last but not least, because we are part of a company that dares to use new technology. Aker BP is not only the first in the world to develop and perform this type of operation, we are now the world’s largest users of this technology, and many other oil and gas operators are following suit. That says something about our company.”
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