First Heavy Workover on Intelligent Completion in Santos Basin Pre-Salt

Abstract The intelligent well completion in Brazilian Pre-salt wells poses challenges for workover operations. This paper describes the main challenges faced and the new methods employed for workover in this scenario. Since acid stimulation caused severe fluid losses in these wells, which are equipped with integral intelligent completion 1 – SPE-195935, the removal of the production string brings several complications. Through tubing operations, such as the use of nippleless plug set, feedthrough packer release, and mechanical cutting of the production string, were conducted. The removal of the completion string was done in a single trip, with fluid losses sustained and well safety concerns considered. The use of Managed Pressure Drilling (MPD) techniques was employed and required modifications to existing tools. A thorough planning for the new completions was developed to safely return the well to production. The successful application of these techniques in a workover operation in 2023 demonstrated its suitability for high complexity and high productivity wells, such as those found in the Brazilian Pre-salt, potentially benefiting the entire industry.