Inflow Control Devices (ICD) (Fig. 1) is a part of the well completion to help optimizing the production by equalizing the reservoir inflow. Multiple ICD can be installed in the completion at a long section, as each ICD going to partially choke the flow. Completing wells with ICD is one of the most common techniques that is used to maintain uniform production across multi-layer reservoirs. One of the challenges in such completions is to achieve a uniform matrix acid stimulation across these screens due to well deviation and length of the screens. In most cases an effective diversion method is required during acid treatment to ensure all the screens are treated uniformly for maintaining homogeneous production across the reservoir. Over the time, wells with ICD screens show decline in production due to plugged screens which necessitates immediate action. In most cases remedy is to acid treat all ICD screens on individual basis using straddle packer System and real-time telemetry coil system due to requirements of diversion method, criticality of the packer setting depth and downhole pressure monitoring. Multistage acid stimulation for ICD screens is achieved using straddle packer's system with real-time telemetry coiled tubing (CT). The real-time telemetry coil system ensures depth accuracy – as each ICD port length is not more than couple of inches – and monitoring of pressures and straddle packer system's integrity during multistage acid stimulation across the horizontal screens. This operation involves challenges of properly setting the packer to selectively treat each ICD screen by mechanically diverting the acid treatment while maintaining seal integrity in each stage and re-using it multiple times. After drifting and wellbore conditioning run, the multi-set straddle packer system is deployed on real-time telemetry coil (fiber-optic enabled) for multistage acid treatment. Starting from total depth, the real-time CCL readings are utilized successfully to identify the first screens joint allowing the packer system to be stationed across the required screen. The packer elements are then energized to divert the acid treatment fluid into the targeted screen Thru the coil and exiting from per adjusted nozzles between the Packers; this diversion is confirmed by monitoring bottom hole pressure inside and outside the coil tubing string. Upon completion of the acid treatment of the ICD screens the tension-compression sub of telemetry coil system confirmed the elements is de-energized to make safe to move the packer without damaging the elements. The treatment is then successfully repeated across the remaining ICD screens with positive indication of diversion across each ICD screen. This study illustrates how the combination of the straddle packer System and downhole real-time telemetry system was utilized to successfully acid stimulate up to 38 stages and monitor the behavior of straddle packer continuously during diversion of multistage acid treatment of screens while maintaining packers seal integrity and downhole pressures. In addition, the study also provides lessons learned from implementation of multi-stages packers with real-time telemetry for successful diversion of acid treatment uniformly across the screens in horizontal well.
One of the highest profile extended reach drilling (ERD) oil projects in the world is presently operated by Saudi Aramco. It is being developed with a large number of horizontal ERD wells targeting a carbonate reservoir; classified according to the well objectives as producers or injectors. The wells are being drilled from land locations, artificial islands and offshore platforms which increase the complexity and challenges of the project. The production and well delivery requirements for the development phase were planned with very ambitious targets. Therefore, multiple drilling and completions technologies have continuously been pursued to achieve the planned schedule.During the past years, the drilling team planned to take this project to the next level by drilling and completing the longest horizontal ERD well in Saudi Arabia (M-1) to a total depth (TD) of 37,042 ft MD with an open hole completion of 10,002 ft. To achieve this and to push the drilling envelope to that extent, many drilling challenges were expected and new approaches, procedures and technologies were deployed to overcome them.The main challenges were related to torque and drag limitations for drillpipe and casing runs, losses and wellbore stability considerations, hole cleaning and equivalent circulating density (ECD) management for stuck pipe prevention, drilling dynamics in harsh drilling environment, logging data transmission at deep intervals of the well and pushing the limit of drilling performance and equipment reliability. To overcome them, considerable well design changes were introduced, along with customized procedures and new technologies to ensure the safe and efficient delivery of this well. First, the well design was optimized and changed from a standard design to a deepened casing design, to cover unstable formations. Second, the drill string design loads were simulated through comprehensive torque and drag modeling to determine the components specifications and to develop safe running procedures. Third, well specific ERD hole cleaning procedures, ECD management guidelines and tripping roadmaps were implemented to deliver optimum hole condition and minimize stuck pipe risks. Finally, multiple drilling technologies, including rotary steerable systems, telemetry tools, sidetracking equipment and mud additives, were introduced to realiably deliver the well objectives.The optimization changes in the well design, procedures, practices and drilling technologies have resulted in delivering a number of records which include: drilling the longest well in Saudi Arabia safely and efficiently, installing the world's deepest 7-in. solid liner, achieving the world record for the deepest 6 1/8-in. lateral section and the longest 6 1/8-in. section for the project; and successfully running and setting the world's deepest 7-in. cased hole whipstock. These records are considered a step change for Saudi Aramco drilling operations and a new milestone for the ERD drilling industry.
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