Devastating oil spills in Bayelsa’s Nembe community from a leaking wellhead that was affecting local residents for more than a month was eventually stopped by a team of engineers from Kenyon International West Africa Company Limited, an international oil and gas servicing company owned by a Nigerian.
The OML 29 Well 1, which is operated by Nigeria’s largest indigenous oil firm, Aiteo Eastern Exploration and Production Company Limited, had been spilling unabated into the Santa Barbara River, impacting marine lives and polluting the environment until Kenyon International West Africa intervened and brought the spill to a halt.
Efforts to contain the flow from the shattered wells were futile at first. The spill was of a special type – a gas blowout, which involved 80 percent gas and 20 percent oil.
The Wellhead owner Aiteo Eastern E&P, the petroleum minister, and Nigeria’s president all promised that specialist workers would stop the spill. And contrary to widespread claims that the spill was brought under control by foreign experts, it was the expertise of Kenyon International West Africa that effectively contained the leak.
“A key feature of our response model is transparency across all stages of response to the incident” said Victor Ekpenyong, founder & CEO at Kenyon International West Africa. “ We ensured that we factored in crucial pointers such as the size and type of spill and the environmental/ economic sensitivities of the resources at risk to avoid lasting damage on the waterways as the affected aquaculture is a major source of livelihood for the people of the community” he added
According to Ekpenyong, because the organisation is highly specialised in well intervention, well remediation and idle well management, solving the Nembe spillage came naturally to them as they had done the same for other companies. “Our client base is comprised of International Oil and Gas Companies (IOCs) and Nigerian Oil and Gas Companies (NOCs).” he explained.
Kenyon International West Africa is now rapidly becoming a recognized force in providing cost-effective well control services, well intervention services, well remediation services and idle well management services. In addition, the company has successfully completed several high-level projects for customers in the African continent.
We bid for a brownfield project on well remediation and won. We set out and planned for the job, acquiring all necessary equipment that would be needed for the job. Due to the intensity of degradation that had happened to the well, the project was categorised into three phases: well securement, well integrity and well perforations. The entire project encompassed well head team, slickline team, e-line team, pumping team, structural team, marine team, security team and catering crew.
First milestone: Well Securement
After we had conducted a thorough survey to know the amount of work that needed to be done, we mobilised a wellhead team, slickline team, etc., to the field. At the field, we liaised with the client’s production team and had the well shut in and the pressure bled off. The wellhead team ascertained the XMT integrity while the slickline team rigged up their unit and carried out drift with GC (gauge cutter) to confirm that the wellbore was free.
they ran in hole and retrieved the WRSCSSV to the surface, rigged up yet again and retrieved PXN plug, and installed a new PXN plug on the well which was pressure-tested okay. Afterwards, a new WRSCSSV was installed, and pressure tested okay. Finally, at the surface, we ran in hole and installed BPV to have a triple barrier to finish up the short string.
We proceeded to the long string which had not been producing for a long time and was shut in. BPV was installed again. We broke out the tree cap, rigged up lubricator and attempted to retrieve the existing NRV but could not. We subsequently rigged down our lubricator and ran in Lead Impression Block (LIB) to take impression of what had impeded the operation since we could not make up our NRV running tool. Using the LIB, we ascertained the internal diameter (ID) of the existing NRV and saw that it was quite smaller than the original ID of the NRV. Through our ingenuity, we designed a special tool that enabled us to retrieve the NRV from the long string. We then made up a TWCV and ran in the hole and conducted the Xmas Tree Valve checks to ensure the integrity of the valves. The NRV was retrieved and the slickline crew retrieved the WRSCSSV, retrieved the PXN and installed a new PXN plug and, afterwards, ran in a new WRSCSSV (wireline retrievable subsurface safety valve).
The three barriers were successfully established to ensure that the well was secured, and no hydrocarbon was leaking to the surface. We proceeded to the annulus valves, checked them, installed a VR plug to make sure there was no pressure or gas coming out from the annulus valve. We secured the annulus valve, nippled down the 3” XMT and installed 3” abandonment flange with a 3-1/2″ MGV + 1/2″ KTV + Pressure Gauge stop to monitor pressure. We rigged down the flowline.
Second milestone: Well integrity remediation
For the well integrity remediation, we mobilised structural team, well integrity team, piling team and casing integrity team. Once we got to the field, we signed a permit for hot work. We commenced a massive hot work on the platform to decommission the platform. Afterwards, we commenced installation of a new platform prefabricated at our base in town. We positioned the piling machine and drove in 4 platform pillars with it to the point of refusal. We filled the four pillars with cement mixtures to prevent corrosion. The structural team were able to install the new platform.
After installing it, we chipped out the cement that was between the 26’ conductor pipe and the collapsed 13’3-8 casing. We cold-cut a section of the 26” conductor pipe, beveled it to enable the installation of Gussets, hydro-blasted it and installed composite wrap on the collapsed 13’ 3/8 casing to restore the integrity of the casing. The composite wrap was left for some time to dry. Then, we installed 26” split pipe on the existing 26” conductor pipe and installed a gusset that was fabricated at our base. and welded them together.
The weight of the wellhead was transferred to the gusset situated atop the 26” casing. *This gave the new platform triple support to prevent it from bending. * A mud engineer finally mixed the G-class cement, ascertained the mud balance and dumped the cement inside the section of 26’ casing/gusset filled to the brim. After correcting the bend on the collapsed 13’ 3/8 casing, the well’s integrity was restored, and the structural and piling teams were demobilised.
3rd Milestone: Perforation
After refurbishing the XMT at Kenyon base, it was sent to the field. The abandonment flange that was installed on the well was nippled down for the refurbished XMT to be re-installed.
The wellhead team retrieved the NRV that was set on the long string, and then the slickline crew went ahead to retrieve the WRSCSSV, and eventually retrieve the PXN. The e-line team rigged up their unit and caried out a drift on the long string to ensure the wellbore was clear, and a subsequent C/O log was carried out to analyse the reservoir for crude content. Once that was done, we ran in and set a magna range plug, then dumped few feet of cement on top of the magna range plug, let it cure before we eventually made up the perforation gun and perforated the tubing.
As we observed crude on the surface, we then shut in the well and installed CCU. We went ahead to retrieve the NRV on the short string, shut in the well and installed antitheft to secure the XMT and the valves. Once this was completed, we handed the well over to our customer and demobilised from site.
Going through a process or undertaking an unfamiliar task, most times, may seem too difficult and uninteresting. It often requires lots of patience and discipline to go the extra mile or see them to the end. The truth is, the end is usually rewarding if only you can push and persist till then. At Kenyon, we do not back out of difficult situations confronting our clients. We love to see our projects to the end and giving them the best shot. We are Kenyon!
The choke valve being one of the valves that make up the Christmas tree plays a sensitive role during production. In upstream oil and gas industry, choke valves are used wherever there is a requirement for wellhead flow and pressure control. That is, it is used to regulate the flow of fluid to keep pressure under control. Operators are constantly monitoring the production system, and hardly do they ever open the choke valve fully because the level to which the valve is opened will determine the life of the well. This highlights the need for careful control of the flow of the well fluids to avoid any production well formation damage. A client contacted us when their wellhead adjustable choke became faulty and was affecting their production. We removed the old choke and successfully installed a new one. After the replacement of the choke valve, our client was able to optimize production.At Kenyon, our desire is to see our clients achieve their set goals within the speculated time and maximize production.We are Kenyon!
One of the vital parts of a well is the CCU. This equipment enables emergency shut down of a well to prevent it from explosion and other well challenges such as leaks and oil and gas assets vandalism that could endanger the environment. A CCU is set hydraulically to shut down on any eventuality, keeping the well safe from harm. In one of our operations, we had to install CCUs on a well to enable emergency shut down. Prior to installation, we function tested the CCUs okay and successfully installed them on the designated well, ensuring that the environment is kept safe from leaks, explosion and oil, and gas assets vandalism. At Kenyon, we are committed to giving you the best service with such uncommon excellence and deliver right on time.We are performance-driven, we are Kenyon.
In brownfield development, one of the important activities carried out in well/Xmas tree repair is the installation of a back pressure valve (BPV). To allow a well that has been in use for a long time to realize its full production potential, some works need to be done on the well, some of which entails creating a pressure barrier to enable personnel work safely in restoring the integrity of a well. Some of these works—such as removal of Christmas tree and repair or replacement of master valve—make necessary the installation of a BPV. In recent times, we were contacted by a client who was interested in its brownfield development; and among the activities to be done, well remediation was of utmost importance. To restore the well integrity, BPV needed to be installed to serve as barrier to allow personnel to work safely on revitalizing the well. We were able to successfully install the BPV and the well was safely worked on. At Kenyon, we derive joy in deploying our expertise in developing brownfields and enabling compromised wells regain their integrity for optimum production and profitability. Our customers can count on us for result-oriented well repair.We are Kenyon!
Solving wellhead vandalized cases by Kenyon International
Wellhead vandalism is one of the major problems Niger Delta region faces due to the volatility of the area. Rising cases of wellhead vandalism has significantly affected Nigeria’s and oil companies’ sources of revenue in the region.
The Alakiri and Olubiri wells suffered severe vandalism. They were both wrecked by miscreants who stole the Bonnet and gate valves from these wells, leaving the wells’ integrities compromised and rendering the sites highly unsafe as hydrocarbon keeps gushing uncontrollably at high pressure. These attacks on wellheads by vandals have huge devastating environmental effects.
We received a distress call from our client to arrest the situation at the two locations (Alakiri ad Olubiri), swiftly, we swung into action. We fixed the damaged wellheads, installed the Bonnet and Gate Valves locked with anti-theft nuts, and the wellheads were restored to normal.
We at Kenyon have pledged to remain at the forefront in the oil and gas servicing industry, providing unprecedented services to our clients, and solving all well-intervention-related problems.
Solving wellhead vandalized cases by Kenyon International
Wellhead vandalism is one of the major problems Niger Delta region faces due to the volatility of the area. Rising cases of wellhead vandalism has significantly affected Nigeria’s and oil companies’ sources of revenue in the region.
The Alakiri and Olubiri wells suffered severe vandalism. They were both wrecked by miscreants who stole the Bonnet and gate valves from these wells, leaving the wells’ integrities compromised and rendering the sites highly unsafe as hydrocarbon keeps gushing uncontrollably at high pressure. These attacks on wellheads by vandals have huge devastating environmental effects.
We received a distress call from our client to arrest the situation at the two locations (Alakiri ad Olubiri), swiftly, we swung into action. We fixed the damaged wellheads, installed the Bonnet and Gate Valves locked with anti-theft nuts, and the wellheads were restored to normal.
We at Kenyon have pledged to remain at the forefront in the oil and gas servicing industry, providing unprecedented services to our clients, and solving all well-intervention-related problems.
Our client had a challenge of fitting elbows into an impossible position on the wellhead, and there they did not have to alter the design of the valve, thus, a technical solution was sought. Kenyon was called upon to provide a solution. The solution we provided was to designed and manufactured a 45 degree and 90 degree elbows to fit into the required position without altering the design of the wellhead. Thus we delivered the job satisfactorily.
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45 Degree elbow manufactured
90 Degree elbow manufactured
Elbows installed on wellhead
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Piping elbows are vital pipe fittings used to change the direction of flow in a piping system. Finding a suitable piping elbow to fit into wellhead could sometimes be quite challenging.
Our client once had a challenge of fitting piping elbows into an impossible position on the wellhead, and they were not keen on remodelling the valve to fit in; thus, a technical solution was sought.
Kenyon was called upon to provide a solution. We designed and manufactured a 45 degree and 90 degree elbows to fit into the required position without altering the design of the wellhead. At the end, our clients were satisfied.
We have conducted numerous Conductor Pipe Inspections and Re-threading for our reputable clients, using best practice. We have earned the trust of our clients to render such services without the fear of any mediocre from us.
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Conductor pipe inspection is a vital process that must be carried out to ensure that conductor pipes are still performing optimally. Conductor pipes protect shallow sand from being contaminated by drilling fluids and prevent washouts as well.
We have conducted numerous conductor pipe inspections and re-threading for our reputable clients using best industry practices. Such industry practices are what enabled us to earn the trust of our clients. We have rendered these services efficiently without our clients fearing quality compromise from our ends.
