Design, Implementation, Results, and Key Learnings: Case Study of a Novel Single Trip, Perforated, Multi-Zone, Isolated, Frac Pack Completion - Keong Subsea Development, South China Sea Floater Operations

Many large wells have been drilled in the Gulf of Mexico's Lower Tertiary play. These wells are completed with single-trip multizone systems, and they have gross perforated lengths exceeding 1,500 ft. The main difficulty in perforating these wells is the high-pressure environment (~20,000 psi). Under these conditions, the challenges are to create sufficiently large entrance holes in the casing, minimize the high-risk of equipment damage due to gunshock, and minimize the amount of perforating debris created. Perforating several intervals in a single run is required to complement single-trip multizone systems. Perforating all zones simultaneously in one trip saves time and reduces risks when compared with stacked completions requiring multiple trips for each zone. Safety and cost reduction are extremely important in deepwater operations. Risk control is very important because gunshock and/or debris problems can lead to multimillion dollar losses in non-productive time, and in extreme cases, gunshock problems can lead to lost wells. To undertake these challenges, a new Low Perforating Shock and Debris (LPSD) gun system was used. In comparison with standard high-pressure guns, the LPSD gun system produces much less gunshock and negligible amounts of debris; thus, minimizing gunshock risk and reducing cleanup runs typically needed to recover perforating debris. LPSD guns produce negligible amounts of debris because LPSD guns contain all the metallic components, including the shaped charge cases, which remain virtually intact inside of the guns. A key element in planning these perforating jobs is gunshock prediction to evaluate if the equipment will be able to withstand the transient loads produced by the perforating guns. The gunshock prediction process is described in detail in this paper. For a typical 4-zone 1,500 ft gross length perforating job, the time needed from picking up the first gun to laying out the last gun averages 84 hours. All zones are simultaneously perforated, which eliminates three perforating runs per well, saving approximately 9.2 days per well while minimizing personnel exposure. By perforating the largest high-pressure wells in the Gulf of Mexico's Lower-Tertiary play with LPSD guns, we minimized personnel exposure, minimized debris and reduced execution time up to 72%.

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Multizone Casedhole Frac Packs and Intelligent-Well Systems Improve Recovery in Subsea Gas Fields

Burton

Gilbert

Fleming

et al. 2019

SPE Drilling &Amp; Completion

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Summary A nine–well subsea development project has been completed using casedhole frac packs (CHFPs) for sand control and multizone intelligent–well systems (IWSs) to improve recovery from a series of shallow, low–pressure gas reservoirs. In these wells, CHFPs have been installed to provide reliable sand control over the long, low–net–to–gross–ratio sand/shale target sequence: typically, three to six frac packs per well. This outer CHFP completion is then augmented with a multizone IWS, consisting of isolation seals, surface–controlled zonal–isolation valves, and downhole–pressure/temperature (DHP/T) gauges. The IWS string is run as a separate inner string to provide flow–monitoring capability and allow shutoff of zones producing high water volumes. This critical water–shutoff capability eliminates the risk of one or more high–water–production zones loading up and killing adjacent low–pressure gas zones, with the associated loss of reserves. To date, a total of nine wells have been completed and are being produced from three subsea gas fields. To maximize recovery from the fields’ numerous but relatively thin gas reservoirs, production wells are completed over three to six separate intervals. These frac–packed intervals are then grouped to allow flow control and pressure/temperature monitoring to occur through up to six surface–operated interval control valves (ICVs) and associated downhole gauges. This combination of sand control and intelligent–well control has provided an ability to perform multirate tests (MRTs) and pressure–buildup (PBU) tests on each reservoir interval to detect the start of water production or identify other impending production issues. After approximately 6 years of production service to the October 2018 date of this paper, 16 of the 34 zones completed in the nine–well project have been shut in to eliminate high water production. These water–shutoff actions performed using the surface–controlled ICVs are estimated to have improved gas–recovery factors from 50 to 60% without requiring rig intervention. This paper describes the reservoir challenges addressed and the completion–design and –operating practices used in this successful program.

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Design, Implementation, Results, and Key Learnings: Case Study of a Novel Single Trip, Perforated, Multi-Zone, Isolated, Frac Pack Completion - Keong Subsea Development, South China Sea Floater Operations

Cited by 4 publications

References 14 publications

A new method to optimize the fracture geometry of a frac-packed well in unconsolidated sandstone heavy oil reservoirs

A new method to optimize the fracture geometry of a frac-packed well in unconsolidated sandstone heavy oil reservoirs

Perforating Large High-Pressure Wells with Low-Shock and Low-Debris Gun Systems

Multizone Casedhole Frac Packs and Intelligent-Well Systems Improve Recovery in Subsea Gas Fields

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