World's First Extension Pack with 7-in. Enhanced Single-Trip Multizone System: Success Case and Learning Points on the Installation and Treatment Design
Authors: Bela Sunanda Magna , B Ahmad Mahdzan Abdil Adzeem , A Rashid Noor Hidayah , A Kadir Zairi , Abu Bakar Azfar Israa , Kamarudzaman Zayful Hasrin , W Hasan W Helmi , B M Nor M Abshar , M Aziss M Yusof , Tham Khai Lun , Arumugam Sivnes Raj , Hashim Saharul , Balasandran Anandhadhasan 
Published: March 2021

Gravel packing in a multilayer reservoir during an infill development project requires treating each zone individually, one after the other, based on reservoir characterization. This paper discusses the installation of an enhanced 7-in. multizone system to achieve both technical and operational efficiency, and the lessons learned that enabled placement of an optimized high-rate water pack (HRWP) in the two lower zones and an extension pack in the uppermost zone. This new approach helps make multizone cased-hole gravel-pack (CHGP) completions a more technically viable and cost-effective solution.

Conventional CHGPs are limited to either stack-pack completions, which can incur high cost because of the considerable rig time required for multizone operations, or alternate-path single-trip multizone completions that treat all the target zones simultaneously, with one pumping operation. However, this method does not allow for individual treatment to suit reservoir characterization. The enhanced 7-in. multizone system can significantly reduce well completion costs and pinpoint the gravel placement technique for each zone, without pump-rate limitations caused by excessive friction in the long interval system, and without any fiuid-loss issues after installation because of the modular sliding side-door (SSD) screen design feature.

A sump packer run on wireline acts as a bottom isolation packer and as a depth reference for subsequent tubing-conveyed perforating (TCP) and wellbore cleanup (WBCU) operations. All three zones were covered by 12-gauge wire-wrapped modular screens furnished with blank pipe, packer extension, and straddled by two multizone isolation packers between the zones, with a retrievable sealbore gravel-pack packer at the top. The entire assembly was run in a single trip, therefore rig time optimization was achieved.

The two lower zones were treated with HRWPs, while the top zone was treated with an extension pack. During circulation testing on the lowermost zone, high pumping pressure was recorded, and after thorough observation of both pumping parameters and tool configuration, it was determined that the reduced inner diameter (ID) in the shifter might have been a causal factor, thereby restricting the flow area. This was later addressed with the implementation of a perforated pup joint placed above the MKP shifting tool. The well was completed within the planned budget and time and successfully put on sand-free production, exceeding the field development planning (FDP) target.

The enhanced 7-in. multizone system enabled the project team to beat the previous worldwide track record, which was an HRWP treatment only. As a result of proper fluid selection and rigorous laboratory testing, linear gel was used to transport 3 ppa of slurry at 10 bbl/min, resulting in a world-first extension pack with a 317-lbm/ft packing factor.