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AADE 2023 NTCE 018 A Novel and Sustainable NAIPF

2023, AADE

Abstract

Ensuring well integrity for the life of a well is a crucial challenge faced in the industry. Heat transfer between formation and fluids in the tubing or annulus fluids can result in undesired annular pressure buildup (APB), leading to integrity problems such as collapsed tubing and casing burst. Heat transfer across the wellbore also poses environmental concerns like thawing of surrounding permafrost in arctic environments. Remediation involves costly and unsustainable intervention methods such as killing the well or performing complicated workover operations. Using vacuum-insulated tubing is a conventional practice in the industry to mitigate APB by restricting heat transfer from production flow to casing and surrounding formation, but this mechanical solution used alone has several limitations. Hence, a chemical solution should be included to increase the effectiveness of operations. A chemical solution is placing an insulating packer fluid (IPF) into the wellbore. However, conventional IPF with crosslinking agents does not always provide results that satisfy flow assurance requirements. This leads to the need for developing a more sustainable and robust IPF solution with long-term stability at wide range of temperatures. A novel nonaqueous insulating packer fluid (NAIPF), containing base oil with a newly designed synthetic polymer forms a unique micelle structure chemistry under static conditions. The chemistry provides sufficient viscoelastic properties and yield stress without need of crosslinking agents to minimize convective heat loss in conjunction with low thermal conductivity. The NAIPF exhibits stable rheological properties at high temperatures and provides conductivity superior to water-based IPF systems. With no requirement of any additional solids, it can be recovered back on surface when needed and reused, providing additional sustainability benefit. In this paper, we characterize the micelle structure based NAIPF with different base oils. Validation of chemistry required extensive laboratory study for a period of 2 years prior to being ready for field trials. NAIPF were formulated with different base oils, tested for key properties including thermal conductivity, yield stress, and thermal stability. Extended aging was conducted at temperatures varying from ambient up to 350°F for prolonged periods of time to test fluid stability. Field application required detailed discussion about performance expectations to identify the challenge the fluid intended to address. The NAIPF has been successfully deployed on multiple projects globally including Arctic, South America and West Africa. Performance was further validated during a well reentry to monitor pressures confirming the fluid maintained its properties over extended period. This paper presents the design and implementation of the NAIPF, including methods developed to optimize fluid mixing, transport, and wellbore displacement. The system's ability to limit conductive and convective heat transfer while maintaining stability makes it an economical and sustainable chemical solution to offer maximum protection against well integrity and production complications.