With Prostar’s advanced equipment, we have completed some of the industry’s most challenging workovers in NE Alberta. Many of these workovers include stuck pipe in deep horizontal wells, casing failures, experimental designs, running slim hole liners, massive sand cleanouts and drilling operations.
Case Study #1: Workovers
Prostar Rig #17 recently completed horizontal tubing rotations with the use of the top drive in the Cold Lake Imperial field. With this new proven method, Imperial is realizing an estimated $2 million/year in savings. Previously, when using a conventional service rig with a power swivel to complete this work, it was deemed too unsafe a task to perform. Previous methods also included running the well until failure mechanical and having to replace the rod or tubing string. By rotating the tubing, the friction spot (wear point) changes and provides a significant increase in production. With Prostar Rig #17, completing a rotation is typically achieved in one day. This quick turnaround benefits Imperial by increasing production, minimizing costly downtime and minimizing the frequency of expensive workovers.
Case Study #2: Workovers
Suncor has also been a beneficiary of ProStar’s innovations. By using inverted slips in the tool carrier, Prostar is able to push tubing into the lateral section of selected well bores at Suncor’s Firebag SAGD field. Previously, Suncor was using third party casing jacks and/or a snubbing unit along with friction reducing chemicals to help push tubulars into the horizontal section of SAGD wells. This process added extra time, cost and more importantly risk to completions and workover operations in the field. By using Prostar’s SRR-150 rigs, Suncor no longer requires casing jacks or snubbing units to place the tubing strings into the toe of the wells. In some cases friction reducing chemicals are required , but rarely. This change has drastically reduced completion times to three days from five days. The overall costs are much lower because of the increased safety, efficiency and reduced schedule.
Case Study #3: Workovers
With the integration of engineered davit arms, Prostar was able to set ESP pull and run records in the Suncor Firebag field. These davit arms were designed to hold cable sheaves, allowing smooth third party tie-ins for spooling. Automation removes workers from the line of fire and other hazards associated with handling of tubulars, giving us a better prep time and quality focus on installing cables and clamps. With conventional rig designs, the average time of completion for ESP change was three to four days. With Prostar, the change has taken only two days, allowing Suncor to repair more ESPs within a year than previously with conventional rigs. Programmable carriage speed and precise operation has prolonged the ESP run life initially from 400 to 600 days but most recently 800 to 1,000 days, increasing Suncor’s production as a result.
Case Study #4: Workovers
Mud pump automation has allowed Suncor to keep steam on the injector wells, while working on adjacent producers. With the touchscreen ability to control trickle fluid flow down the wellbore, ensuring hydrostatic control of pressure, Suncor has saved time and money by leaving the conventional steam flow and mitigating risks.
An extra crew member is no longer required to monitor the pump operations, rates and tank levels as they can be controlled/monitored from the operator’s cab. In the past, with traditional procedures, this has caused issues with communication and efficiency.
Case Study #5: Workovers
Hilcorp Alaska purchased an SRR-150 for work in the North Slope. The rig was able to perform in Arctic conditions, minimizing exposure of workers to the elements due to its automation. The SSR-150 has reduced previous AFEs by 40%, allowing Hilcorp to work on more wells and go after production volumes that were once uneconomical.
Case Study #6: Workovers
Snubbing/Stripping Operation Design – With the well kill complexities in McKay River, Suncor approached Prostar Energy’s team to aid with designing a system to snub/strip components in and out of the well that provided the option to work under pressure. Our Operations and Engineering team devised a plan and design to reach this goal, and with the rig’s push capability, we can now offer the snubbing/stripping operation feature.
With the introduction of automation to the service rig design, ESP’s that once lasted 400 to 600 days now last 600 to 800 days. Better quality control and programmable speeds have lessened the use of cable and decreased instrumentation damage caused by the old method of “turning and burning” pipe into the well. Prostar has specially designed the SRR-150 with no tubing board, allowing the installation of sheave arms that carefully spoon the ESP cables into the well, avoiding overhead equipment damage.