First Five-Zone Smart Completion Technology Deployment in ERC Well

Abstract

Abstract The global demand for energy is on the rise daily, this puts a heavy burden on Oil and Gas companies as the drilling and production challenges are increasing. Efficient and cost-effective solutions are always sought. Drilling multilateral horizontal wells is considered as one of the optimum solutions to maximize recovery with minimal cost in terms of wells drilled. The production from multilateral wells imposes it is own challenges, such as flow distribution and contribution from laterals. Installing smart completions in multilateral wells was a huge breakthrough and revolutionized the industry. The idea behind smart completions is to continuously monitor and control the production from each lateral individually. With the current configuration of downhole packers, the number of interval control valves (ICV) installed per well is four at most, which limits the number of effective laterals in a well. Considering the primary objective of minimizing drawdown and hence maximizing sweep efficiency from each well, it was studied and simulated that some reservoir compartments have an optimum number of five laterals, which makes it complicated to control and optimize the production. This paper exhibits the deployment of the first "5-Zone Smart Completion" technology in a five lateral well, to control the flow contribution from each lateral. Each completion section installed is comprised of a gauge carrier, a hydraulic flow control valve, a packer with feed-through ports and a sub to accommodate and secure control line splices. The technology enabled the control of the flow rate from five different zones and the measurement of pressure and temperature from each compartment. The completion design included another two pressure and temperature sensors downstream of the flow, only a few hundred feet above the gauge of the upper zone, utilizing a single electric cable to power up and communicate with the surface panels. All hydraulic valves were successfully tested and fully cycled in place and the packers installed at the programmed depths upon installation. The technology enhancement that supported five zones completions ranges from material technology, which permitted enough metal to be removed from the packers, where seven, quarter-inch bores, have to be drilled for control lines to be run to accommodate electronics and telecommunications. This development enabled up to 16 sensors to be connected by one single electrical conduit. The paper presents the production string concept, the technology used to achieve seven bores in the packer, while maintaining the packer's integrity, the complete sequence of pre-job preparation, and the installation outcomes, with its impact on the downhole flow controls.