A multizone cased hole completion with a bottom hole assembly of world-record length at 2,600 ft was installed in Malaysia in November 2019 where three zones were simultaneously gravel packed in a single trip utilizing shunt tube technology. This sand control completion was successfully executed with a combination of sand control pumping and sand control tools, unconventionally performed by two different service providers. The well consisted of three zones of interest approximately 1,000 ft apart. The bottomhole assembly was designed with two shunted cup packers for zonal isolation and shunted 12-gauge wire wrapped screens across each perforation. The shunts were left open ended below the cup packers, allowing the carrier fluid to exit the zone below with minimal friction. Downhole memory gauges were deployed along the washpipes for post job evaluation. Diligent lab testing was performed to select the carrier fluid, a clarified high-grade xanthan polymer with good 20/40 proppant suspension with less formation damage and acceptable dehydration to avoid bridging inside the shunts. Detailed risk assessment that was performed during the planning stage focusing on interfaces, equipment limitations, expediting, and decision flow charts between the two service providers led to flawless execution at the wellsite. Compared with conventional stack-pack completion, significant time savings of approximately seven days was observed with this single-trip design; the concept of open-ended shunts below the cup packers replaced the majority of the shunted blank pipes with standard blank pipes, eliminating the time required to install jumper tubes. Good results were observed during the injectivity test in addition to the well already having losses of 20 bbl/h. Hence, no acidizing was required prior to the gravel-packing operation. Based on surface monitoring, there was clear indication of sequential packing from the top zone to the bottom-most zone via shunt tubes, followed by a final screenout. Findings were further verified after performing the downhole bottomhole gauge analysis using the retrieved data from the memory gauges. The well has been in production since December 2019.

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.

PETRONAS embarked on a new challenge to drill and complete 5 wells with high bottom hole temperature (BHT) of 180°C and highly deviated fractured carbonate with high velocity gas producers. These wells utilized 7" big bore production tubing with new material 17CR instead of the expensive cold worked 22CR duplex stainless steel (DSS). As the first application of 17CR production tubing material in the world, a lot of risks were taken into account and mitigated via various approaches from planning engineering stage until execution. These mitigation measures included the qualification of material and connection; operational details involving parties from different disciplines to ensure smooth and efficient deployment of 17CR tubing. In addition to that, optimization opportunities were explored to further increase running efficiency and reducing flat time while ensuring tubing integrity is intact. The successful deployment of 17CR were attributed to the following: Connection modification from JFE BEAR to JFE BEAR DR-PK to minimize the risk of galling around the metal-to-metal seal area on the newly developed 17CR CRA materialTubing was racked back in double joints per stand offline during installation using offline activity cantilever (OAC) deck available on a tender assisted rig to improve running timeUtilization of side door elevator instead of single joint compensator to enable running tubing in double.Usage of Flush Mounted Slip (FMS) dressed with pre-qualified low penetration dies, to ensure sufficient gripping on the 17CR tubing OD surface without being affected by the surface scale which is known to have with high hardness valueUsage of low penetration dies instead of non-marking type hydraulic tong to reduce tubular running cost With the above mitigation measures put in place, the project was delivered with high efficiency in terms of tubular running speed achieving up to 14 joints per hour on 7" high alloy CRA tubing with extremely low number of rejection rate (0.3%) for the entire project. Utilization of 17CR as an alternative to 22CR DSS has also contributed direct cost saving of up to USD 8.2 mil to the project.

Gravel packing in a multilayer reservoir during an in?ll 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 signi?cantly 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 ?uid-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 con?guration, it was determined that the reduced inner diameter (ID) in the shifter might have been a causal factor, thereby restricting the ?ow 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 ?uid 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.