Korchagina and Filanovskoe oil fields in the north Caspian Sea have many extended- and mega-reach wells that uses inflow control device (ICD) screen completions with sliding sleeves. This completion technique empowers the operator with the ability to shut off unwanted water/gas breakthrough and allows for more control of injection or inflow with unlimited number of stages or zones. This paper describes a new verified workflow to successfully intervene these wells and manipulate (open/close) these sliding sleeves using coiled tubing (CT). It has proven challenging to shift these sliding sleeves using conventional methods with CT owing to the limitation of available weight on bit (WOB) at the toe end of those extended-reach wells, even when using large-size CT strings. The new proposed workflow uses a well tractor operated in tandem with a hydraulic shifting tool to generate the required shifting force downhole. The bottomhole assembly (BHA) also includes a novel flow control sub, assembled between the shifting tool and the tractor, with the ability to control the flow to selectively activate the tractor, the shifting tool, or both, based on surface commands by manipulating pump rate. To verify the methodology, a realistic well scenario was simulated at a test site by installing two ICD screens with sliding sleeves at the end of a 1,000-ft-long horizontal flow loop. The sleeves on each ICD screen required approximately 4,000 lbf set-down force to open. The available WOB at the end of horizontal loop with 2-in. CT was only 1,000 lbf; applying more than 1,000 lbf set-down load could have detrimental effects, including CT buckling. The 3⅞-in. OD well tractor used for the job was able to generate 6,000 lbf of pulling force downhole, which was more than enough to shift the sleeves open. Both sleeves were successfully opened by tractoring down while maintaining both the tractor and the shifting tool in the on position, which was achieved by manipulating the flow control sub using pump rate cycles. Both sleeves were then successfully closed, one after the other, by pulling with the CT with the tractor turned off while maintaining the shifting tool in the on position, again achieved by manipulating the flow control sub. Live downhole pressure and force measurements were key in confirming proper functionality of the tractor and identifying different tool modes. Having real-time data is also crucial for proper depth correlation using casing collar locators (CCL) or gamma ray measurements to ensure activating the correct sleeves. This marks the first time that a workflow was verified on the use of pull force generated by a well tractor to manipulate completion accessories in extended-reach well interventions using CT. The technology, preparation, results, and prospects of implementation are discussed in this paper.
The paper describes the results of the first multistage hydraulic fracturing operations in Russia on the Caspian Sea shelf in the gas condensate and oil deposits of the Aptian formation of V. Filanovsky field. In addition to the small productive formation depth, long horizontal sections with a complex trajectory and high collapse gradients due to large zenith angles when passing the Albian and Aptian deposits of poorly consolidated sandstones are an additional challenge for choosing a multistage hydraulic fracturing assembly. The above features require the use of modern sand control screens with enhanced frac sleeves. A design was developed which includes frac sleeves and sand control screens that can withstand multiple cycles of hydraulic impact during hydraulic fracturing, as well as many opening/closing cycles. A seawater-based frac fluid system was applied. The frac fleet was located on a pontoon, the coiled tubing – on a platform. For the first time in Russia, a 2-5/8 inch coiled tubing with a complex-type friction reducing system was used to switch coupling/sleeves in conditions of very long horizontal sections, complex trajectories, and high friction coefficients. The minimum distances between the screen's sliding sleeves and frac sleeves did not prevent from performing manipulations in complex environment. For well cleaning, the frac assemblies of reverse rotary-pulse and rotary-directional types were used. At the first stage of the project, the development of an optimal method of well completion was successfully implemented. Due to the close interaction of the operating company, service company, and science & engineering team of the operator, for the first time in Russia the design of downhole equipment with the use of advanced technologies of sand control screens, frac sleeves was presented. This solution has proved its effectiveness – the downhole equipment has retained its operational properties after a long period of well operation and further in the process of hydraulic fracturing. At the second stage of the project, 32 MSHF operations were performed at four wells. To reduce nonproductive time and operational risks, a satellite communication complex was additionally deployed on the pontoon to join the engineering centers of Astrakhan, Moscow, and Houston. After finishing the well development, the design indicators for formation fluid rates were achieved, which proved the effectiveness of the stimulation of the field's target objects – this opens great prospects for further development of low-permeability reservoirs at offshore sites in the Caspian Sea. The successful project implementation and the achievement of the design values of oil flow rates has expanded the possibilities of commercial operation of the low-permeable Aptian formation, complicated by the presence of a gas cap and underlying water. A solution was presented for working in extended horizontal well sections with 2-5/8 inch coiled tubing together with a complex-type mechanical friction reducing system. The economic effect was achieved when solving tasks of manipulating mechanical screen couplings and frac port sleeves without the involvement of downhole tractors. The use of new solutions in the completion assembly made it possible to eliminate additional sand ingress problems.
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