Deepwater crown plug retrieval with Wellgrab

Crown plug retrieval via e-line often requires preparatory runs with clean-out tools to address debris accumulation around the fishing neck. 

In deepwater operations, this debris accumulation is typically greater due to factors such as extended suspension periods, heavier solids settlement, and limited natural circulation, often leading to an increased number of runs to recover debris, and to latch the crown plug. Furthermore, the increased distances elevate risk of wireline fatigue and operational delays, even when utilizing industry-leading tools and best practices. 

Operating offshore Indonesia, Eni was seeking an assured and efficient solution to these challenges, with the aim of reducing operational time compared to previous experiences.

This led to the first in-country application of Wellgrab™ HIROS, chosen specifically for its ability to displace debris while engaging with its target, allowing operators to leverage surface-controlled and fully repeatable actions with latch confirmation.  

In preparation for the operation, Welltec designed and manufactured a custom grapple to align with the specific crown plug design – this was fully validated through pre-operation testing against a plug starting in a set position. 

While running in hole in the field, real-time monitoring and control of the Wellgrab HIROS tool enabled the crew to carry out precision, damage-free crown plug retrievals. 

The grapple displaced and redirected debris around the crown plugs without requiring a separate clean-out run, applying consistent force to eliminate the need for speed variation and successfully latching both the upper and lower crown plugs on the first attempt. 

The target measurement capability of HIROS served as a means of confirmation for proper engagement and latching, with the crew observing a match in surface readout data to the inner diameter of the fishing neck before pulling out of hole.

The operation demonstrated the advantages of Wellgrab™ HIROS in deepwater crown plug retrieval, delivering clear operational, safety, and efficiency gains.  

Time savings: Reduced retrieval time from ~5 hours in the past to 1 hour, significantly cutting rig time.

First-time success: Both crown plugs were latched and retrieved on the first attempt despite the presence of debris, eliminating the need for clean-out runs.

Reduced wireline risk: Surface-controlled latching at consistent force eliminated cable fatigue and shear pin risks seen with varying speeds during GS operations.

Real-time confirmation: Measurement capability provided live surface verification of proper engagement before retrieval.

Debris handling: Grapple design allowed debris bypass, overcoming limitations of conventional 360° contact tools.

Higher retrieval force: Applied consistent 70,000 lbs pulling force, more than double GS tool capacity. 

The first in-country deployment has successfully set a new benchmark for safe, efficient, and predictable crown plug retrieval in Indonesia’s deepwater environment.