Enhanced Single-Trip Intelligent Completion Installation with ESP and a Downhole Wet-Mate

Abstract A cost-effective approach to improving reservoir management and optimizing production involves the use of electrical submersible pumps (ESP) with the incorporation of intelligent completion systems. By employing hydraulic downhole wet-mate connector technology, the operator is able to leverage the benefits of intelligent completions for managing multizone production. This approach significantly reduced intervention costs and mitigated the operational challenges associated with ESP replacements. Often, the operator is faced with significant challenges in managing multizone production in wells equipped with Electrical Submersible Pumps (ESPs) and the complexities of ESP replacements. To address these issues, Intelligent Completions were integrated with a hydraulic downhole wet-mate connector. This integration enabled the retrieval of the upper completion, including underperforming ESPs or safety valves, without the need to kill the well or remove Intelligent Completion system components such as zonal isolation packers and inflow control valves (ICVs). This paper explores further optimizations that streamline the deployment process, allowing it to be completed in a single trip without disconnections. This improvement has substantial positive impacts on health, safety, and environment (HSE), reduces formation exposure, simplifies deployment complexity, and lowers capital expenditures (CAPEX). The innovative single-trip intelligent completion system with ESP and downhole wet-mate connector streamlines the installation process by eliminating the need for ICVs and zonal feedthrough isolation packers to be run on drill pipe. All completion components are installed in a single trip without disconnecting the wet-mate during well completion. The lower completion zonal feed-through isolation packers are set using a surface hydraulic pump via the packer setting control line, followed by setting the ESP packer by applying tubing pressure against a slickline plug. This system was successfully deployed in the Middle East, resulting in a significant time saving of 34 hours of rig time. The complexity and HSE risks were mitigated by removing the need to pull the drill pipe with control lines and large clamps, and by isolating the formation during tubing hanger landing. All well objectives were achieved, with all equipment deployed successfully in a single trip, confirming the integrity of the packers and the successful functioning of the ICVs. This paper, thus, delves into the innovative implementation of an enhanced single-trip intelligent completion system featuring Electric Submersible Pumps (ESP) and downhole wet-mate technology. It also emphasizes the use of control-line set zonal feed-through isolation packers, showcasing the novel aspects and benefits of this approach.