Screenless Fracpack with Smart Fracturing System in Cemented Monobore Completion: Offshore Malaysia Case Study

Abstract This paper explores the innovative use of screenless fracpack with a smart fracturing system in cemented monobore completion. Innovative frac pack completion is required to developed marginal reserve in fines prone I-reservoirs. This pilot marks the first application in cemented monobore in Asia Pacific. The study delves into design, implementation, execution, production outcomes, and future recommendations, highlighting a cost-effective solution for sand control in challenging environments. This paper explores the innovative use of screenless fracpack with a smart fracturing system in cemented monobore completion. Innovative frac pack completion is required to developed marginal reserve in fines prone I-reservoirs. This pilot marks the first application in cemented monobore in Asia Pacific. The study delves into design, implementation, execution, production outcomes, and future recommendations, highlighting a cost-effective solution for sand control in challenging environments. The process began by activating the fracture initiation sub at the bottom of the downhole assembly, allowing the smart dart to be launched and positioned onto the target frac sleeve. This activation occurred at a specific pressure, ensuring the cement sheath outside the tubing was broken with a 3000 psi safety margin above the expected UCS. Once the sub was activated, the dart was launched, opening the frac sleeve for the first zone without difficulty. The treatment started with a prefrac pumping diagnostic to calibrate the model, including breakdown, step rate tests, and calibration injections. The main fracturing phase followed, using RCP slurry, a gel sweep, and completion brine to displace the treatment. This achieved an effective conductivity of 1,600 md.ft and a frac half-length of 69m. After the screenless fracturing process, the well was left to cure and then carefully unloaded. The production results showed good productivity and effective sand control, with no proppant flowback observed at the surface. This successful implementation demonstrates the potential for cost-effective and efficient sand control in challenging field conditions. Unlike unconventional applications where overdisplacement of proppants is tolerated, conventional screenless fracpack requires precise volume calculations to ensure optimal underdisplacement, fully propping the near-wellbore with minimal residual proppant. This marks the first use of the smart fracturing system with cemented monobore completion offshore