The Usan deepwater field, located approximately 100km south of Port Harcourt, has multiple oil bearing turbidite sand bodies of varying thickness and permeabilities separated by thin and massive shale intervals making difficult the selection of completion intervals. Fracture height confinement is challenging due to the small stress contrast between the sand bodies and the bounding shales, and variability of stress field in a very compartmentalized environment. Frac pack completions in this deepwater field were designed and executed to fulfill four main drivers:• Ensure sand control completion integrity and long term reliability • Deliver wells with low skin and good wellbore-fracture connectivity along entire completion interval • Maximize reserves by increasing number of sand bodies connected by frac packs • Reduce capital expenditure and installation risk by minimizing number of frac pack jobs This paper illustrates the systematic approach used to optimize the frac pack completions in the Usan field by improving each of the following areas:• Completion brine formulation to minimize emulsion and clay instability problems • Perforation interval to maximize reservoir exposure without compromising frac pack quality • Frac pack fluid testing to ensure low formation damage and stability at wellbore conditions • Frac pack model calibration to improve fracture height coverage and confinement, and net pressure built after tip screen-out (TSO) • Frac pack sensitivity analysis using two simulators accounting for uncertainty of input data and numerical modeling • Post job analysis integrating surface and downhole data • Well flow backs to evaluate initial completion integrity and performance Actual field data from several wells are used to illustrate the evolution of the frac pack completions in the Usan project. The main challenges, lessons learned and improvement opportunities captured during the first two years of the Usan completions campaign are also discussed in detail.
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