Successful Deployment of Stiff Lower Completion Assembly in Harsh Drilling Environment: Engineering Analysis, Best Practices, and Lessons Learned

Abstract The objective of horizontal and deviated wells is to maximize reservoir contact improve sweep efficiency and well productivity. However, conventionally completed horizontal wells have a high risk of gas upwelling and water cone formation, which can significantly impair well efficiency. Several parameters influence the production profile along the well, including the heterogeneity of reservoir, permeability, and pressure, also the presence of fractures and frictions effects. Inflow Control Devices (ICDs) were developed to regulate the production inflow along the well by delaying gas or water breakthrough; maximize sweeping and reduce or eliminate future well intervention. These devices provide uniform production and flow contribution along a sand face completion in horizontal and inclined wells, thus ensuring the extension of the well life with higher recovery efficiency. The primary goal of this study is to successfully deploy a stiff Lower Completion Assembly, incorporating packers and ICDs, in a challenging wellbore within a mature field. This objective was particularly significant due to historical issues in the same field where Lower completion became stuck, necessitating costly sidetracking operations. The deployment faced additional challenges posed by the 3D well profile and the long lateral section where the Lower Completion assembly was deployed. Dedicated reaming runs were performed to smooth the wellbore before deployment, adding complexity to the operation. The deployment of the stiff Lower Completion assembly required meticulous planning and execution. Specialized hydraulic-set packers and reactive-element packers were selected to isolate water zones effectively. Modular sleeves were utilized for precise interval segmentation, facilitating efficient treatment distribution across multiple stages. The completion design was tailored to address the unique challenges of the wellbore, ensuring optimal reservoir contact efficiency amidst the complexities of the 3D well profile and long lateral section. Lower completion deployment in challenging wellbores often faces common challenges such as stuck packers, inadequate reservoir contact efficiency, navigating 3D well profiles, completing long lateral sections, and preparing the wellbore for deployment in extended horizontal sections through dedicated reaming runs. To address these challenges, it is crucial to use specialized packers designed for specific wellbore conditions, optimize completion designs for efficiency, and focus on meticulous planning and execution.