SPE 113805

New Electro-Mechanical Perforating Technology Reduces Cost and

Increases Safety in Workover Operations
Riyadh A. Bargawi, Saudi Aramco, and Doyle Dean, Jack Clemens, and Clem Whitmire, Halliburton Company

Copyright 2008, Society of Petroleum Engineers

This paper was prepared for presentation at the 2008 SPE/ICoTA Coiled Tubing and Well Intervention Conference and Exhibition held in The Woodlands, Texas, USA, 1–2 April 2008.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written consent of the Society of Petroleum Engineers is prohibited. Permission to
reproduce in print is restricted to an abstract of not more than 300 words; illustrations may not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
Saudi Arabia wells, onshore and offshore, often require workovers as a result of the corrosive environment to which the
downhole equipment is subjected. When the workover jobs required a single hole to be punched in “soft” tubing using
traditional methods, high failure rates and inherent delays in mobilizing explosives often severely compromised job
economics.
This paper presents several case histories in which a new slickline-deployed electro-mechanical tubing punch was used
for the first time worldwide. Although the workover requirements in each well were different, and the jobs were conducted in
both onshore and offshore environments, all required a single hole to be drilled.
The case histories will discuss the advantages provided to the operator through use of the new electro-mechanical tubing
punch. These included:
• 100% perforating reliability
• Reduced rig time by eliminating mobilization of explosives and other equipment, if failures occurred.
• Reduced costs, since electro-mechanical perforating is more cost effective than electric-line “soft-shot” methods
• Applicability to deployment on slickline, E-line, or coiled tubing
• Simplicity in use of the electro-mechanical perforator
• Enhanced personnel and environmental safety from:
a. Elimination of explosives
b. Use of alkaline or lithium batteries
c. Use of mono-conductor line
d. Use of CTU pressure-switch adapter
The new method was 100% successful and resolved the problems experienced with all previously used conventional
mechanical perforating methods. Although run in highly corrosive downhole conditions, the perforating tool had 100%
success in perforating the “soft” tubing. A thorough follow-up inspection of the tool showed that it had sustained no damage
of any kind.
An in-depth discussion concerning the electro-mechanical perforator design, its application in Saudi Aramco wells, its
operational advantages, and its significant impact on safety and economics will be presented.

Introduction
Improved well completion methods in Saudi Aramco have enabled safe, efficient, and economical production from oil and
gas wells. However, as the fields matured, the wells often required workovers due to several factors, which included:
• Corrosion
• Reduced production
• Need for conversion to water injector wells
• Sidetracks
• Integrity of the well head
• Increased safety concerns.
Once a well completion had been designated as a candidate for a workover, the first step for Aramco was to determine a
safe, economical procedure to successfully perform the workover.
2 SPE 113805

Using traditional methods, however, the workover jobs that required a single hole to be punched often were economically
compromised for several reasons:
1) Delays in mobilizing explosives
2) The failure rates in punching a hole in soft tubing using mechanical perforator methods.
Traditional mechanical perforators are designed to be run in C-75 and harder-grade tubing, as softer-grade tubing will
swedge or bow out under the action of the punch. Also, the traditional slickline tubing perforator requires the tool string to be
jarred to create the perforated hole. In Saudi Aramco wells, J-55 or K-55 tubing had been used, and failure rates had been
high due to the soft grade of this type of tubing. In J-55 and other soft-type tubing, the jarring action often caused the punch
to deform the tubing rather than punch the required hole. This usually would result in a failure of the mechanical punch or
perforator body.
To avoid costly delays as well as the use of “soft shot” explosives, a new tubing punch was needed. This initiated
development of an electro-mechanical tubing punch.
The new electro-mechanical tubing punch can be run on slickline, electric line, and coiled tubing depending on
operational requirements, and with any of these options, activation can be performed without the use of explosives. With all
of these options, an electro mechanical downhole power unit (DPU®) produces the activation method.
The slickline version of the downhole power unit generator uses batteries to provide the energy to the motor and timing
circuits.
The E-line version of the DPU generator is activated on surface through the mono-conductor line, which eliminates the
timer, circuits, and batteries.
The coiled-tubing version of the DPU generator is activated by a pressure switch adapter, which is attached to the DPU
by replacing the fishing neck with a circulating flow-control valve. The rotary motion from the motor is converted to a non-
rotating linear motion. As discussed in the following sections, eliminating the use of explosives has several positive affects
for the operator. The safety of personnel and the environment is enhanced, and because the delays experienced when
mobilizing explosives in Saudi are eliminated, job time is reduced significantly.

History and of the New Perforating Technology

The first requirement for the new electro-mechanical tubing punch technology was the need to identify a safe, economical
solution for a method to mechanically perforate 4½-in. 12.6# and 11.6# J-55 tubing.
A primary requirement was that the size of the tool had to be compatible with another suite of downhole tools currently in
use ― those compatible with a 3.66-in. downhole electro-mechanical setting tool (Fig. 1). The electro-mechanical setting
tool provides a practical alternative for explosive and hydrostatic setting tools to set and retrieve packers, bridge plugs, and
other downhole devices. The tool, which is known as the downhole power unit (DPU) is a battery-operated device that can
produce a setting or retrieving force without the use of explosives or atmospheric chambers.1,2,3,4,5 The downhole electrical
power generator is an electro-mechanical device that is designed to produce a linear force. The linear force may be produced
in either a push or pull direction. Initially, the linear force was developed for setting (or pulling) wellbore tools such as
monolocks, bridge plugs, or packers. Because of the advantages noted with the earlier applications, additional applications
for the DPU have been developed to perform similar tasks, and one of these applications has been the focus of this paper ― a
tubing punch that would perform in soft tubing. The DPU was a logical choice since it has a long successful history of
actuation throughout the world and has been used successfully on thousands of downhole jobs.
In operation, a gear motor operates a linear drive to generate a gradual, controlled, axial compressive or tensile force to
optimize setting procedures. It has capability to provide a linear push / pull force of up to 60,000 lbf. The electro-mechanical
tubing punch was formulated to work with the DPU to provide a hole-punch operation that would eliminate the problems
encountered with the other methods typically used.

Introduction of the New Tubing Punch

The electro-mechanical tubing punch transmits the required force to the tubing punch in a cam-type action using a hardened
blade on a pivot point that slices or cuts a hole in the tubing wall. The DPU linear actuation is extremely slow, and actuation
is approximately ½-in. per minute. Thus, in the initial movement of the blade, it pushes the tool over and anchors the tool
against the tubing wall. As linear travel continues, the blade continues to swing, pushing against the opposite side of the
tubing. This creates the fluid communication hole. As the DPU linear travel continues, the blade swings down until it is
completely retracted inside the housing of the tool. At this time, the process is complete, and the tool is ready to travel to the
surface. Fig. 2 shows the tubing punch in the ready-to-run position. Fig. 3 shows the tool with the blade fully extended in
the maximum position. This is the position in which the blade is extended through the tubing wall to create a hole in the
tubing. Fig. 4 is a view of the tool with the blade fully retracted after the hole has been punched, and the tool is in the
position to travel up the hole. Fig. 5 is a photo showing the actual hole that has been punched into the tubing.
When deploying the electro-mechanical tubing punch on slickline, it is conveyed into the well using a standard slickline
tool string and wire. The DPU has an onboard timer that is preset on surface prior to running into the well. Once the
slickline deployed electro-mechanical tubing punch is at the target depth where the tubing is to be punched, the tools are held
static, and the preset time is allowed to lapse. As soon as the preset time has lapsed, the DPU will activate. This action
SPE 113805 3

punches the hole with no manipulation of the wire required. When the tool has completed the punching cycle, the tools are
recovered from the well with no jarring required.
When deploying the electro-mechanical tubing punch on E-line, it is conveyed into the well using a standared service tool
string, which is built as well specific to the operation. Once the electro-mechanical tubing punch is at the target depth, the
DPU is activated on surface by an electronic signal delivered through the mono-conductor line. The motor is rated for
maximum performance at 200 VDC and 0.75 amps. This action punches the hole with no manipulation of the mono-
conductor line. When the tool has completed the punching cycle, the tools are recovered from the well.
When deploying the electro-mechanical tubing punch on coiled tubing, a pressure switch adapter is attached to the DPU
by replacing the fishing neck with a circulating flow control valve. The pressure-switch adapter isolates external pressure
from the atmospheric pressure within the DPU pressure-sensing actuator. It is pinned in the closed position. By changing the
shear-pin material and number of shear pins, the activation pressure is configured. The pressure-switch adapter is activated by
increasing the pressure within the tubing above the annulus pressure. Once the tubing pressure exceeds the annulus pressure
by an amount equal to the shear value, the valve opens and allows external well (hydrostatic) pressure to enter into the DPU,
which turns on the timer. Upon expiration of the selected time delay, the DPU motor starts. This action punches the hole with
no manipulation of the coiled tubing. When the tool has completed the punching cycle, the tools are recovered from the well.
Generally, standard slickline equipment is on site during workover jobs. Therefore, since the slickline equipment is
already on location, it can be used to perform the electro-mechanical tubing punch operation. This reduces the cost to the
operator by eliminating mobilization and rig-up costs for a traditional “soft shot” perforation along with all the standby costs
of the rig, equipment, and services required when waiting for explosive to be mobilized. This also increases the safety to the
personnel involved in the tubing punch operation by eliminating the explosives.
The electro-mechanical tubing punch uses alkaline batteries with no explosives, and the alkaline batteries require no
special handling. The alkaline batteries are environmentally friendly with regards to disposal. Also, since the electro-
mechanical perforator does not use explosives, safety is enhanced as no explosives are transported to and from location,
handled on surface or made up on the rig floor.
Throughout many regions of the world, the transportation of explosives requires special permits and a police escort.
Obtaining these permits and arranging escorts can be very time consuming, and the delays typically involved can
significantly compromise the rig operations. Because the electro mechanical tubing punch does not use explosives, the jobs
are never compromised by delays in receiving explosives.

Initial Design Concepts and Testing

When it first became apparent that an alternative method for punching a hole in soft tubing was needed, several concepts
were initially considered. When reviewed by the slickline team, a blade-type design was determined to be the best solution
for the DPU. Due to the complex loading to which the blade would be subjected during the punching process, several blade
materials and configurations were manufactured and tested before a final blade design was chosen. The initial blade design
successfully punched holes in the J-55 tubing, but a new blade design with more robust shape and more ductile material
enhanced the blade life. The new blade material was more compatible with the high stress application and with downhole
fluids. FEA modeling aided in creating the new robust shape, which reduced high stresses at peak stress points.

Case Histories
Case History 1
Date: August 25, 2006
Well: Workover #1
Workover Objective: The well had originally been completed in 1984 as a water injection well. The well was known to
have had severe corrosion and scale build up in the tubing. Due to cross flow and communication between zones, the
decision was made to perform a workover and sidetrack the well.

Summary of Rig Operation:

• Rigged up wireline
• Ran tubing drift
• Installed 4½-in. mono-lock plug at 7,090 ft
• Tested tubing to 1,500 psi. Test results were good
• Ran slickline-deployed electro-mechanical tubing punch to 7,060-ft and punched hole in 4½-in., 12.6# J-55 tubing
successfully

Workover #1 Conclusion
The slickline-deployed electro-mechanical tubing punch performed successfully in the heavy scaled well.
4 SPE 113805

Case History 2
Date: October 6, 2006
Well: Workover #2
Workover Objective:
1. Cut and re-stub severely corroded surface casing
2. Install new landing base
3. Check casing integrity
4. Extend 7-in. liner/casing to surface
5. Clean out fill to PBTD if any
6. Complete well with 7-in. packer and 3½-in. tubing

Summary of Slickline Operations:

• Rigged up slickline
• Set plug-in nipple (3 runs)
• Ran check set tool
• Ran prong
• Pressure tested plug to 1,000 psi
• Pressure tested casing to 1,500 psi
• Ran 4½-in. mechanical perforator three times, but could not punch hole in 4½-in. 12.6# K-55 tubing.
• Rig company man called out slickline-deployed electro-mechanical tubing punch.

Summary of Slickline Operations:

• Ran 3.833 drift to 4½-in. x 3½-in. X-over
• Ran slickline-deployed electro-mechanical tubing punch to 5,740-ft
• Punched hole in 4½-in. 12.6# K-55 tubing.

Workover #2 Conclusion
The mechanical “A” perforator could not perforate the soft tubing; however, the hole was successfully punched with the
slickline-deployed electro-mechanical tubing punch.

Case History 3
Date: October 24, 2006
Well: Workover # 3
Workover Objective:
Drill to 15281-ft MD and complete well as a horizontal power water injector.

Summary of Rig Operation:

• Made up 4½-in. liner hanger and ran 4½-in. 11.6# J-55 casing to 9447-ft
• Dropped setting ball and made up cement head
• Attempted to lower liner with no success; unable to wash down liner
• Made various attempts to set liner hanger with no success
• Pulled DP to surface and found that the liner hanger setting tool was damaged
• Modified setting tool and engaged liner. Attempted to pull out of the hole without success
• Attempted to circulate down DP; pressure increased to 800 psi. with no returns
• Attempted to pull out of hole with liner, but hole was swabbing badly
• Attempted to pump down annulus without success
• Ran in hole to 9447-ft and released from liner
• Ran 3-7/8-in. clean-out assembly to 6066-ft
• Drilled out wiper plug and washed down to 6145-ft
• Pumped slug and pulled out of hole
A decision was made to perforate the 4½-in. 11.6# J-55 new liner. The electro-mechanical tubing punch was available on
another offshore platform and on standby at the time. The electro-mechanical tubing punch, the DPU, crew, and equipment
were transferred by helicopter from one platform to the other.

Summary of Slickline Operations:

• Rigged up slickline
• Ran slickline-deployed electro-mechanical tubing punch to 6115-ft
• Punched hole in liner. Pulled out of hole
SPE 113805 5

• Re-dressed slickline-deployed electro-mechanical tubing punch and ran to 6106-ft.

• Punched a hole in the liner. Pulled out of hole
• Rigged down
• Transferred equipment back to original platform

Workover #3 Conclusion
After rigging down slickline, the liner hanger setting tool was run to the top of the liner hanger at 6053-ft. The rig could not
engage the liner hanger with the liner hanger setting tool. Pumping down the annulus through the holes punched by the
slickline-deployed electro mechanical punch was tried. The pressure increased to 800 psi, and it was decided to pull out of
the hole with the liner setting tools. The rig recovered 21.5-ft of fish, which included the packer and liner hanger assembly.
The rig went on to recover all of the fish. A successful hole was punched with the slickline-deployed electro mechanical
tubing punch.

Case History #4
Date: September 16, 2006
Well: Workover #4
Workover Objective:
1. Mill 93-ft of 4 ½-in. liner down to whipstock setting depth
2. Cut window in 7-in. liner
3. Sidetrack well and drill 2,045-ft of 6-1/8-in. short radius hole.
4. Complete well with 7-in. packer, 4½-in. tubing with permanent downhole monitoring sensors (PDHMS)

Summary of Wireline Operation:

• Rigged up wireline
• Ran 3.813 gauge cutter to 6,302-ft
• Ran 4½-in. monolock to 6,295-ft, and tested to 2,000 psi. Test results were good
• Ran slickline-deployed electro-mechanical tubing punch to 6,290-ft and punched hole in 4½-in. 12.6# K-55 tubing

Workover #4 Conclusion
The slickline-deployed electro mechanical tubing punch successfully performed the desired operation.

Future Enhancements Planned

Due to the success in the application of the initial slickline-deployed electro mechanical tubing punch, additional designs of
the electro-mechanical punches are being considered for use in additional sizes and grades of tubing.

Conclusions
1. The new electro-mechanical tubing punch enhanced personnel and environmental safety as well as job economics by:
a) Eliminating explosives by using alkaline batteries on routine jobs and lithium batteies for high-temperature jobs.
This reduced environmental waste and eliminated special disposal needs
2. Provided 100% perforating reliability when compared to other mechanical alternative methods for punching soft tubing
3. Reduced rig time by eliminating time to mobilize explosives and other equipment, if failures occurred using alternative
methods
4. Since explosives are not required, security issues that could have impacted job for mobilization of explosives time were
eliminated.
5. Reduced costs since the electro-mechanical tubing punch is more cost effective than E-line soft-shot methods.
6. The electro-mechanical tubing punch is simple to use.
7. The tool can be run on slickline, electric-line or coiled tubing, which reduces operational time since one of these methods
is usually available on site.
This tool, which was developed by a service/engineering company to resolve operator problems, is an example of a
solution attained by close cooperation between the service and operating companies. This tool not only solved a major
problem but also was capable of providing operational and economical efficiency as well as enhanced safety, providing a
win/win situation for all parties involved.

Acknowledgments
The authors wish to thank the management of Saudi Aramco and Halliburton for their help and permission to write this
paper. Special thanks are also extended to Roy Jordan, Fred Key, Jerry Foster, Bill Vidrine, Glen Hall, John Waddington,
Scott Gordon, and Tom Chandler for their help in designing the new slickline-deployed electro-mechanical punch as well as
to Saudi Aramco for giving Halliburton the opportunity to resolve this problem.
6 SPE 113805

References
1. Goiffon, J.: “Setting Tool Increases Safety and Decreases Setting Time for Packers and Bridge Plugs,” published in the January edition
of WORLD EXPRO 96.
2. Larimore, D.R., Goiffon, J.J., Bayh, III, R.I.: “Low Cost Solutions for Well Interventions Through Advanced Slickline Services,” Paper
SPE 35236 presented at the SPE Permian Basin Oil & Gas Recovery Conference, 27-29 March 1996.
3. Larimore, D. R., Fehrmann, G. Z.: “Field Cases of Cost Efficient Well Interventions Performed with Advanced Slickline Technology,”
Paper SPE 38097 presented at the 1997 SPE Rocky Mountain Regional Meeting held in Casper, Wyoming, 18-21 May 1997.
4. Foster, J., Clemens, J., Moore, D.: “Slickline-Deployed Electro-Mechanical Intervention System, a Cost-Effective Alternative to
Traditional Cased-Hole Services,” SPE paper 67201 presented at the SPE Production and Operations Symposium held in Oklahoma
City, Oklahoma, 24–27 March 2001.
5. Bargawi, R. A., Dean, D., Clemens, J. and Dove, J.: “Case Histories: New Perforating Technology Enhances Workover Operations in
Difficult Scenarios,” paper No. SPE 11098 presented at the 2007 SPE Saudi Arabia Technical Symposium held in Dhahran, Saudi
Arabia, 7–8 May 2007.

SI Metric Conversion Factors

ft x 3.048* E - 01 = m
in x 2.54* E + 00 = cm
psi x 6.894 757 E + 00 = kPa
lbf x 4.448 222 E+00 = N
°F (°F - 32)/1.8 =°C
*Conversion factor is exact

DPU® is a registered trademark of Halliburton

Slickline Fishing Neck

Pressure Actuator

Controls and Power Source

Drive Section

Adapter Kit

Fig. 1 ― Electro-mechanical Downhole Power Unit.

SPE 113805 7

Fig. 2 ― Electro-mechanical tubing punch in the “ready-to-run position.

8 SPE 113805

Fig. 3 ― Electro-mechanical tubing punch in the “blade-extended” position. This shows the maximum position extended,
which cuts through the tubing wall and creates a hole in the tubing.

Fig. 4 ― The electro-mechanical tubing punch in the “fully-retracted” position after the hole has been cut. The
tool is ready to travel back up the hole.
SPE 113805 9

Fig. 5 ― The hole punched into the tubing.