Milling out retrievable safety valve on e-line

Close-up of an E-Line milling tool designed for precision milling, used to remove a retrievable safety valve during well intervention operations.

Well type

Gas

Max. temperature

304°F (151°C)

Max. pressure

3,812 psi

Max. deviation

54.4° @ 9,567 ft (2,916m)

Min. restriction

4.437” 28 ft (8.5m)

Background

An operator was having problems with a wireline retrievable safety valve assembly impeding production in a vertical, cased hole oil well in Nigeria. The valve failed to seat properly in the tubing and flowed up hole with production to get stuck somewhere near the tubing hanger; precise position unknown.

The operator had made several slickline attempts to jar the fish free. The first of these involved more than 200 strokes in each direction using 2 1/2” heavy sinker bars, accelerator and a spring loaded jar with a pulling tool latched into the lock mandrel fish neck. When this was unsuccessful, another slickline attempt was made using a blind box on top of the inner packing mandrel sleeve to attempt to land the blows below the keys. In total, more than 1,000 strokes were made.

During the last phase, indicators showed that the lock mandrel fish neck was partially open, suggesting that its keys were jammed in a slightly inclined position, below the lower ID (4.795”) of the tubing hanger profile. The operator then turned to the contingency of using CT to perform a cut using sand erosion. But with little progress and lack of precision control they decided to engage Welltec® to mill out the obstruction and save the completion string.

Operation

Based on the unique problem description, Welltec engineered a custom solution consisting of a Well Tractor®, Well Stroker®, Well Miller® and a variety of bits.

The plan, as designed, was to mill through the safety valve in stages to remove the inner mandrel sleeves. This in turn would release the springs that were holding the dogs and subsequently dislodge the valve.

A System Integration Test (SIT) was conducted beforehand to confirm the solution for this project’s objective. Using the Well Tractor and Well Miller plus custom nipple milling bit in combination with the Well Stroker the team succeeded in milling out the safety valve as planned during the SIT.

The safety valve fell to the bottom of the well as desired, restoring access and production.

Achievements

This successful milling operation enabled the operator to avoid having to pull the entire completion string and saved more than USD 2 million compared to the alternatives.

The operator was very pleased to be able to regain the well in a shorter time frame and estimated that the milling solution was twice as efficient as the other options.

Products applied

Well Miller for Hardware Milling tool with a metallic body, gold-colored ring, and precision cutting edges for efficient downhole milling.

Well Miller®

for Hardware Milling

Side view of a Welltec tool featuring a metallic body with a gold-colored end piece, designed for precision downhole operations.

Well Stroker®

For actuation

Close-up view of a Welltec tool with metallic body, gold-colored ring, and precise engineering for downhole operations.

WRD®

Welltec® Release Device

Welltec Tractor tool with a metallic body, gold-colored ring, and internal mechanisms for efficient downhole operations.

Well Tractor®

The original tractor with 30 years of experience

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