A well operator wanted to maximize operational efficiency for extended-reach drilling (ERD) wells of more than 45,000 ft measured depth (MD) by converting from a two-trip to a single-trip completion solution. A safety valve, field-adjustable polished bore assembly (PBA), and production packer were developed for the single-trip completion design used in both the producer and injector well environments. Strong collaboration between the well operator and completion technology supplier resulted in a tailored technology development and validation program that reduced operational risk as much as reasonably practical. The technology developer achieved several significant technical milestones during the process, which are discussed in more detail. A pre-run computational modelling strategy was developed to manage deployment risks and ensure the technology operated as designed. The analysis performed using this strategy, along with details on how this data is used to configure the technology is also discussed. Track record details are provided to demonstrate successful deployment of the new technology in a live well environment. To date, the operator has successfully deployed three systems in wells between 30,000 and 45,700 ft MD. The well operator and technology supplier continue to collaborate on ongoing and future wells, where the developed system adds significant value.
Inflow Control Device (ICD) completions have been used widely in the energy industry to balance the inflow of produced fluids, while delaying water breakthrough. Improving the reservoir drainage results in higher oil recovery. Traditional completions are typically deployed with washpipe to provide washdown and circulation capability. This is especially advantageous for Run In Hole (RIH) through tight spots and extended-reach wells. A tailored ICD design with dissolvable materials was tested and optimized for Middle Eastern fields with the first successful installation in UAE of a washpipe-free ICD completion. The washpipe-free adjustable ICD completion utilizes a combination of permanent and dissolvable temporary ICD plugs. A range of dissolving materials were developed and tested in a variety of representative downhole conditions, including temperature and pressure variables. The dissolvable materials were tailored specifically to suit the fluid program and fluid additives, common to the Middle East. Multiple plug designs were subjected to small-scale and full-scale tests. Computational Fluid Dynamics (CFD) simulations evolved the design of the ICD housing to ensure that the dissolution fluid would reach the ICD plugs. The dissolution rates of the dissolvable materials were empirically established at representative downhole temperatures with field fluid samples. The degradation and pressure integrity of the materials was validated in small- and full-scale testing. Through full-scale testing, the operational sequences during RIH including displacement and filter cake breaker spotting were replicated with representative pressures, fluid rates, bottom hole temperatures (BHT), and fluid compositions used in the Middle East field. The validated ICD plugging rod technology was successfully run in the UAE in an extended-reach horizontal well. The permanent plugs allowed for customization of the completion inflow profile as per the most recent logs, while the dissolvable temporary plugs provided a completion string with pressure integrity while running in hole - capable of washdown, circulation, and filter cake treatment placement. After installation, the temporary plugs dissolved, opening the completion to production through the ICDs for improved reservoir management. The ICD with dissolvable technology allowed deployment of the completion successfully to target depth (TD) with the pressure integrity required for the displacement operations. In not running and retrieving an inner string, and achieving wellbore displacement at a faster rate, time savings for the 6000 ft OH completion were estimated between 35-50 hours, with an estimated cost saving of a half-million dollars.
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