The Amenam/Kpono field is located eastern offshore of Nigeria in a water depth of 43m and about 35km away from the coast. The field development has been challenging in so many ways:Deep reservoir targets (3600m to 4300m TVD/SL)High temperatures (130 -150 degree Celsius)High pressures (370 to 500 bar)High-reach departures up to 3km in certain wellbores, giving rise to highly deviated and deep wells (up to 6600m MD/RT)Reservoir fluid containing 3% by weight paraffinReservoir fluid containing 3% carbon dioxide contentCritical reservoir fluids (bubble point pressure is very close to the reservoir pressure in the main reservoir). This necessitates the requirement for the early and efficient pressure support for the reservoir In order to deliver wells under the above challenging environment and circumstances such as to ensure field life production, a lot of emphasis is placed on completions optimization. Hence, completion technology was taken beyond the conventional limit and an innovative, reliable and cost effective approach applied through complete integration of the service companies. The main interest was to reduce the operational risks with diverse and enhanced completion equipment in order to reach the plateau as quickly as possible. Hence, a Monobore completion design with Interventionless technology was embraced in this offshore field development. The total budget for the first phase of the development is $1.5 billion (U.S.) and it covers drilling, completion, construction and production installations. This paper will discuss the well completion designs, material selection, manufacturing, preparation, execution and evaluation of the Amenam/Kpono well completion. The paper will focus more on how new technologies (Reservoir drilling fluid, fluid spring-operated valve, gravel-pack packer, tubing- tester flapper valve, production packer, permanent gauge, etc) are integrated in all the wells, and especially, in the challenging horizontal gas injectors. By using these technologies, completion efficiency was increased, safety performance was improved, and rig cost was reduced by 50 hours per well. Introduction The Amenam/Kpono oil field straddles the boundaries of OML 99 and OML 70 of the Nigerian Continental Shelf in the eastern part of the offshore Niger delta, in an average water depth of 43m. The field is located at about 35km to the south of the nearest coast line and 33 km from the Odudu field (see Fig. 1). Elf Petroleum Nigeria Limited (E.P.N.L.), a subsidiary of Total Exploration and Production, is in the process of developing the field. The first phase concerns the development of levels R4; R9, R10 and R11 in the Western and Central parts of the field. Two drilling platforms AMD1 and AMD2 is installed 90m apart and bridge connected to a production platform (AMP1). This field development involves the drilling and completion of 34 wells, of which 18 are oil producers, 5 are gas injectors and 11 are water injectors. At the R4 reservoir level, gas injectors are required for total pressure maintenance from the start of the production since the bubble point pressure is close to the reservoir pressure. Thus, gas injection is as important as oil production at this reservoir level in this field development. All the producers and injectors are being developed with the interventionless technology, which allows running and pressure testing of the completion string to be done as often as needed without deployment of slick line. It also allows the setting of the production packer without slick line. As a double confirmation of no-restriction in the entire completion string, only one slick line gauge cutter run was required at the beginning of the project. The first horizontal gas injector was constructed with deviations of less than 60 degrees in the upper completion to meet this operational need.
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