Improving Well Completion Operations on the First Five Zone Smart Completion on Multi-Lateral Well in Offshore Abu Dhabi
Authors: Mesra Jodi , Abu Libdi Ziad Talat , Toki Takahiro , Wood James , Tajudin Tajrul Shaheer 
Published: October 2022

Reducing the number of wells along with the associated capital expenditure, while increasing the production capabilities, has been the target for most of the major oil operators operating in the mature field environment. Wells completed in multi-layered reservoirs with multi-lateral compartments using Extended Reach Drilling techniques has become common practice within offshore Abu Dhabi. Combining smart completion and multi-lateral technology has been proven to be one of the optimum solutions to achieve the well objectives. However, this increases the well complexity and subsequent risk. This paper outlines the recent success story of the first five-zone smart completion, performed in offshore Abu Dhabi. This paper will also highlight the challenges faced, and subsequent lessons learned throughout the installation and operational phases.

Achieving a successful well completion installation of a five-zone smart completion in a highly deviated well, with multiple hydraulic and Tubing Encapsulated Cable (TEC) lines in a multi-lateral well involves detailed planning in order to reduce the potential risks and challenges. In order to mitigate these completion challenges, detailed optimizations and improvements were harnessed to increase the success rate and minimize the risk. These optimizations included all aspects of completion design, equipment selection, equipment preparation and completion execution. Simplifying the well design, optimizing the job sequence, and well-planned completion installation procedures assisted with the efficiency of the operation and the overall outcome.

Well completion was safely executed ahead of the planned time and achieved the required well integrity requirements. Zonal isolation between flow control valves (FCV), completion tubing, and multiple gas lift mandrels (GLM) were all tested and confirmed as integral. All eight control lines in the completion were tested and confirmed as integral based on the function testing the flow control valves. The permanent down hole gauges (PDHG) were also fully tested before installation and readings taken pre/post installation to confirm their functionality.

The successful installation of this well has shown that an optimized well design along with preparation is the key factor to achieving success for a complex smart completion. A well-planned job execution similarly played a crucial factor in this installation. Utilizing proper running equipment, rig space management, and managing the multiple control lines, was also a key factor. This was further complemented by having well-trained service personnel, who were supported onsite during the execution phase which impacted the overall success of the installation. There were, however, some aspects to the operations that require improvements, and this has been captured for any future operations.

This paper presents the practices used throughout the well design, and equipment preparation /installation that were adopted over the entire well completion to achieve the key objectives. It also highlights some challenges that were seen during the installation, and operations that allowed for the delivery of a quality completion. All the key learnings from this install, were captured as lessons learned and will be considered for improvements for any future well designs and operations for the future.