Using MPD Techniques for Lower Completion Replacement: Unleashing a Powerful New Solution for Challenging Workover Interventions

Abstract This paper describes how Managed Pressure Drilling (MPD) techniques can be used in some workover and completion operations, such as the lower completion replacement. It also presents the first application of this kind of solution in a subsea well, which has been recently done in Lula field in the Brazilian pre-salt. Highly stimulated wells in the Brazilian pre-salt carbonate reservoirs set significant challenges for well engineers when the lower completion must be replaced in workover operations. Major fluid losses are expected as the formation cannot be isolated from the wellbore. Costly loss control operations must be performed prior to the completion retrieval, introducing LCM in the well, causing formation damage and requiring further well cleaning and stimulation. A new approach was developed, in which MPD techniques such as Mud Cap Drilling (MCD) are used to cope with the fluid losses and avoid loss control operations and its associated impacts while maintaining a safe operation. The use of two of the MPD techniques, Pressurized and Floating Mud Cap Drilling (PMCD and FMCD), in the scenario previously described allow the use of sacrifice fluid, usually treated seawater, to continuously inject underbalance or overbalance fluid into the well and avoid hydrocarbons migration during operations with highly stimulated formations still connected to the well. This also allows monitoring the well for any well control issue, as well as applying well control procedures. Even in the FMCD technique a Rotating Control Device (RCD) is used below the drilling riser slip joint to prevent any possible gas migrated into the riser to reach the rotary table. The use of this kind of solution has turned the lower completion retrieval or replacement an operation with less deviation in terms of duration and budget. Costly loss control operations are avoided and there is no need to introduce loss control materials into the well, which could lead to problems when retrieving or installing the lower completion, such as stuck pipe or equipment failure. The customization of MPD techniques and the development of specific procedures for completion and workover with MPD have led to safe and more efficient operations in challenging subsea interventions with DP rigs. This new approach has set an alternative workover philosophy for some pre-salt wells and also opened new opportunities worldwide by the application of this innovative solution. A significant amount of wells equipped with intelligent completion in pre-salt areas do not have a separated completion that could temporarily isolate the formation during heavy workover interventions. In this scenario the use of MPD techniques like presented in this paper might be a valuable solution.