Field D is a mature offshore field located in East Malaysia. A geologically complex field having multiple-stacked reservoirs with lateral and vertical faulted compartments & uncertainty in reservoir connectivity posed a great challenge to improve recovery from the field. Severe pressure depletion below bubble point and unconstrained production from gas cap had contributed to premature shut-ins of more than 50% of strings. As of Dec 2019, the field has produced at a RF less than 20%. Initial wells design consisted of conventional dual strings & straddle packers with sliding sleeves (SSD). Field development team was challenged for a revamp on completion design to enhance economic life of the depleting field. In 2015, as part of Phase-1 development campaign, nine wells including four water injectors were completed initiating secondary recovery through water flood. An approach of Smart completion comprising of permanent downhole monitoring system (PDHMS) and hydraulic controlled downhole chokes or commonly known as flow control valve (FCV) was adopted in all the wells in order to optimize recovery from the field and step towards intervention-less solutions. Seeing the benefits of intelligent completion in Phase-1, Phase-2, drilled and completed in 2019 – 2020 has been equipped with new technology "All-electric Intelligent Completion System" in 4 out of 8 oil producers. The new design addresses the reservoir complexity, formation pressure and production challenges and substantial cost optimization, phasing out the load of high OPEX to CAPEX. Installation of "All-electric Intelligent Completion System" has proven to be an efficient system compared to hydraulic smart completions system. It requires 50% to 75% less installation time per zone and downhole FCV shifting time is less than five minutes compared to several hours full cycle for hydraulic system. The new system has capability to complete up to 27 zones per well with single cable. It gave more options and flexibility in order to selectively complete more zones compared to hydraulic FCVs which requires individual control line for each zone. Future behind casing opportunities (BCO) have been addressed upfront, saving millions of future investment on rig-less intervention. In addition to that, non-associated gas (NAG) zones have been completed to initiate in-situ gaslift as and when required avoiding the dependency on aging gaslift facility. The scope of the paper is to show case the well design evolution during Field D development and highlight on how smart completion has evolved from original dual completion to hydraulic smart and recently to electric smart system, how it has contributed to cost and production optimization during installation and production life and also support the gradual digitalization of the Field D. In the end it demonstrates the optimized completion design to enhance the overall economic life of the depleting field.

No abstract

No abstract

Mature Field-D has produced at recovery factor (RF) less than 20% due to its geological complexity. As per re-development plan, four wells were drilled from newly built platform in 2020. Each well was completed with combination of oil and gas zones with maximum five zones per well. The gas zone is utilized as an in-situ gas lift, considering gas lift gas shortage and anticipated future requirement for artificial lift upon pressure depletion and water breakthrough. All-electrical inflow control valve (ICV) and permanent downhole gauges (PDG) has been installed across each respective oil & gas zone. The system serves to provide zonal production control to mitigate high producing gas-oil-ratio (GOR) or water breakthrough zones. Single string multi-zone ICV completion enables maximum production from layers with varying reservoir properties and pressure depletion. In addition, gas zones completed with ICV enables cost-effective application of in-situ or well-to-well gaslift, facilitates future non-associated gas production for gas monetization project as well as gascap blowdown opportunities. Application of all-electric smart completion has enhanced proactive surveillance and provided greater production control flexibility resulting in higher production than target. From the downhole data obtained from PDG, wells and network model were updated with good certainty and used to further optimize production at well, platform and field level. Multiple ICV configuration were simulated to maximize oil, minimize gas and water production considering facilities limitation in terms of liquid handling and gas processing to reduce carbon footprint. The gas zones have been utilized for in-situ gas lift using ICV. The smart completion has also enabled efficient unloading facilitated by real-time data acquisition and production control through ICVs leading to additional cost savings. It marks the first installation of an all-electric smart completions offshore Malaysia and Asia Pacific. This paper will explain the functionality of all-electric ICV system and outlines the methodology undertaken to optimize production at well, platform and field level utilizing industry recognized well and network models.