SPE 108877
Advanced Well Completions Result in Enhanced Well Productivity
And Recovery in Saudi Aramco's Offshore Fields
D. Hembling, A.H. Sunbul, SPE/Saudi Aramco, G. Salerno, SPE/Baker Hughes
Copyright 2007, Society of Petroleum Engineers
This paper was prepared for presentation at the 2007 SPE Asia Pacific Oil & Gas Conference
and Exhibition held in Jakarta, Indonesia, 30 October1 November 2007.
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Abstract
The offshore sandstone reservoirs in Saudi Arabia are
characterized by high production potential due to the
nature of the reservoir, consisting of clean coarse sand
with an active bottom water aquifer and in some areas, a
gas cap as a drive mechanism.
In recent years, horizontal wells have replaced
conventional wells in Saudi Aramco due to their
improved deliverability and recovery efficiency. The
initial completion method selected by Saudi Aramco was
open hole for horizontal wells completed in carbonate
reservoirs and cased hole cemented with selective
perforation strategy for horizontal wells completed in
sandstone reservoirs. This completion method was
troubled by nonuniform flow profiles resulting in less than
optimal well performance.
The main driver for advanced well completions (AWC)
has been the increased demand for better performance
from horizontal and MRC wells. In addition to Saudi
Aramco strategy to minimize water and associated gas
production, key performance indices (KPIs) such as:
BBL oil per day (BOPD)/rig day, $/BOPD, and net to
gross ratio are used to obtain an ultimate goal of
reducing the unit development cost ($/BBL) and
sustaining well deliverability. Selection criteria for AWC
is linked to an integrated team approach where
completion forums for new increments are used to
review development requirements, KPIs and determine if
AWCs can enhance well performance and reduce
development costs.
This paper will describe an innovative AWC strategy that
has increased well productivity and recovery compared
to previous horizontal well completion methods. The
paper will show the evolution of AWCs in Saudi Aramco
starting with the use of passive Inflow Control Devices
(ICD) allowing production optimization by delivering
uniform inflow along the entire horizontal section and
active intelligent completion technology for lateral inflow
control in MRC wells. The paper continues to discuss the
benefits associated with the integration of AWC
technologies such as mechanical and swell packers for
zonal isolation, off-bottom cementing for sidetracks,
combining active and passive inflow control in the same
well, and the future use of adaptive ICDs for water and
gas shut-off and advanced downhole monitoring
systems with distributive temperature to allow real time
production logging capabilities. Actual field data will be
presented to validate findings and support conclusions.
Background
Three major offshore fields, Z, M and S, in Saudi Arabia,
are sandstone reservoirs with good petrophysical
properties. These fields have been producing since the
mid-fifties, and the production mechanism is a strong
water drive. Natural depletion and proximity of the water
created a new challenge for sustained production.
Horizontal wells were introduced in the early 90s to
optimize rate and maximize recovery.
In 2002, Saudi Aramco introduced two new completion
technologies in order to increase completion efficiency.
One completion concept utilized stand alone mesh
screens with passive ICDs and mechanical open hole
packers while the other utilized expandable sand
screens and isolation sleeves. The introduction of these
new open hole completion technologies have reduced
the time required to complete the well, and allow an
overall completion cost reduction of 10% for the passive
ICD completion compared to cementing and perforating,
mainly due to saving rig time.
Following the introduction of the new open hole
completion trial tests, a company-wide review of all
horizontal well completions was performed. The study
showed that the worst performing horizontal wells were
the cemented and perforated or pre-drilled liner
completions in the offshore sandstone reservoirs where
2 SPE 108877

only a small fraction (20% to 40%) of the net pay

encountered produced. This resulted in early water or
gas break through and lost well productivity. In addition,
the associated water production resulted in the initiation
of sand production from the wells and the negative Liner Hanger Packer Inflow control device Mechanical open hole packer
impact on back pressure caused by three phase flow
effects in the pipeline network. Figure 2. Horizontal completion schematic.

Case histories showed that early water breakthrough
from cemented and perforated completions resulted in a
severe drop in the individual well productivity. The early
water breakthrough was associated with poor inflow
profiles caused by permeability variations and/or
formation damage from perforating. A typical horizontal
well performance for cemented and selectively
perforated completion is shown in Fig. 1.
100
The system is deployed in the open hole of the
horizontal well with either self-energizing hydrostatic
annular open hole or swell packers for zonal isolation.
The packers are placed based on changes in formation
properties as seen from logging while drilling (LWD) data
to compartmentalize the horizontal section. Since the
amount of hydrocarbon produced through a single ICD is
a function of a pressure drop through the device itself,
velocity is always below any critical erosional rate. Also,

the inflow control device, along with the open hole

FLM.P_1

annular packer eliminates annular flow, thus eliminating

%

hot spotting (increase in flux rate), a source of

mechanical failure in screen completions.
0

7200

7400

7600

7800

8000

8200

8400

8600

8800

9000

Completion Evaluation and Validation

100

So far, 110 (as of end July 2007) completions with stand

FALMD.GR_1
GAPI

alone mesh screen utilizing passive ICD design coupled

with the new annulus isolation packers were run in
0

different hole sizes (6 1/8 and 8 1/2) throughout the Z,

Figure 1. Typical inflow profile for cemented and M, and S fields. This new completion was installed in
perforated horizontal well. either new wells or workovers, where a sidetrack was
performed.
Both open hole completion methods (The expandable
screen and the passive inflow control devices with Also the passive ICD completion was coupled with other
screens) were extensively evaluated and monitored. technologies such as Multilateral (ML) and artificial lift
systems (Electrical Submersible Pump (ESP) and In-situ
The expandable screen completion suffered sharp Gas Lift) to optimize production and maximize recovery
production decline because of early water breakthrough. during the entire well life. A breakdown of the number of
Again, like the cased hole completions, the early water wells is shown in the Figures 3 and 4.
breakthrough was associated with nonuniform inflow
profiles induce conning. The additional benefit provided
wells with Passive ICD run
by expandable screens (larger postexpanded internal history as of july 07
diameter (ID), proximity of the screen to the formation
8 1/2" OH
with reduction of annular flow) turned out to be less s ize
valuable when compared to a uniform inflow profile 6 1/8" OH
along the entire horizontal section offered by the passive s ize
56.4%
inflow control screens.

The other open hole completion method selected, stand

alone mesh screen with inflow control devices and
mechanical open hole packers for zonal isolation1 (See 43.6%
Fig. 2). The system consists of standalone mesh sand
screen fitted with a proprietary low velocity flow
regulator. The objective of this regulator is to prevent
highly productive zones from producing too much; hence
allowing the pressure in the wellbore to be lowered to
pull harder on the more nonproductive zones. If the well
path is close to either water and/or gas, it will minimize Figure 3. Wells completed with passive ICD and annular
any undesired coning effects that lead to premature packer.
water and/or gas breakthrough.
 SPE 108877 3

For the workover campaign in the Z-field, and similar

offshore fields, the same technology was used for a
Type of ICD completion run in Saudi Arabia
smaller hole size. The well was sidetracked out of the 7
and an off-bottom cement job was performed to provide
isolation of the formation above the reservoir, including
the gas cap. This completion application allows
6; 5% 7; 6%
exploiting the reserves left behind, in thin oil section.
4; 4%
Figure 6 shows average production gains associated
with the 7 side tract wells whereas Fig. 7 shows the new
inflow profiles as seen from post completion production
logs.

93; 85% ML with DIACS

rate
ESP
WC %
Insitu Gas lift
only ICD

Figure 4. Wells completed with Passive ICD and annular

packers are classified as AWC. before WO
After WO

Figure 5 is a PLT comparison between some of wells in Figure 6. Production data for Z-4.
the same areas/field produced at similar rates. It is
evident from the comparison between wells completed
conventionally (cemented and pre-perforated liner) and
the one completed with ICD and annular packers that
the amount of oil produced per unit feet is more uniform
in the second case. This is quantified with less coning
problems.

M1 Cemented Liner
Flux B/D
per ft

Figure 7. Spinner log profile for the well Z-4.

1500 3000 The results from the workover program indicated a
M2 Pre-perforated Liner three-fold increase in production rates with water
Flux B/D

production minimized. Figure 7 shows a spinner log

per ft

profile.

1000 2000 Review Section-Key Performance Indicators

The Key Performance Indicators (KPIs) used by Saudi
H1 ICD with annular packers Aramco to evaluate the performance of their wells are
expressed mainly on two factors bopd/rig days (this ratio
per ft

will give an indication based on the production rate to the

Flux
B/D

total rig days needed to complete the well) and

sustaiblity of well production rate.
1000 2000
M3 ICD with annular packers These two KPIs for a conventional completion (cased
and perforated) is set at 100 bopd/rig day and sustaing
per ft
Flux
B/D

the rate for 2 to 5 years. The new completion

methodology adopted (ICD and Annular Packer) was
1000 2000 evaluated and compared. The KPIs increment from this
Horizontal length, foot technology to conventional completion is 43%, equal to
an addtional 43 bopd/rig day.
Figure 5. Conventional vs ICD Technology (from PLT The increase is related not only to a reduction in days
data). needed to complete the well2 but also an increase in
sustained production.
4 SPE 108877
For a multilateral well the KPI growth of another 3%
equals to additional three bopd/rig days, compared to a
single lateral ICD/annular packer completion.
Evolution for Passive ICD Completions
The continued evolution of the passive inflow screens
involved:
1. The utilization of artificial lift3, 4 to handle future water
production or target reservoir locations partially
swept by bottom water allowing continued
production and to achieve incremental reserve
recovery after the well had stopped or reduced
producing due to water breakthrough. Coupling the
two technologies together allowed the energy
provided by the lifting source to be distributed since
the best zones along the horizontal section will not
dominate. Four wells are completed so far with this
technology.
2. Following the successful integration of natural gas
cap lift with the passive inflow screens in the Z and
M fields, a new completion design was required for
wells in the S field as this field has no gas cap to
utilize for lift. The new completion design for the S
field wells utilized the combination of ESP and
passive inflow screens, Fig. 9. The ESP design
utilized a mechanical reservoir control valve (RCV)
to isolate the formation while pulling the pump. This
design protected the downhole sand screens and
formation from fluid losses and associated formation
damage during workovers to replace the ESP.
Seven wells are completed using this technology
3. The next step was to increase reservoir contact with
a multilateral design utilizing passive ICDs in each
lateral. The design involved running a multilateral
level 4 completion in the Z field. Both laterals were
completed with the inflow control screens with
mechanical open hole packers to provide annular
isolation. The downhole monitoring system was
placed in the main bore, Figs. 10 and 11. This
completion type will be able to exploit more than one
zone (multiple stringer), and provide real-time
downhole pressure and temperature monitoring for
individual laterals. Six wells are completed using this
technology.
4. Reducing open hole compartment length to increase
overall horizontal well completion efficiency. This
completion methodology involved reducing the
standard open hole compartment length from an
average of 500 ft down to a nominal 75 ft length
utilizing slip on type swelling packers along the
horizontal section to increase the efficiency of the
horizontal well system. Using this approach, when
one interval or compartment experiences high water
or gas breakthrough, the impact on the overall well
production will be reduced. Figure 8 shows a
comparison between a PLT run in well M-5 where a
75 ft compartment was used. The PLT run (Blue
line) shows uniform contribution, overlap to the PLT
there is a simulation performed where one
zone/compartment at the heel is intentionally
brought to 100% water production (Purple line).The
Orange line is the same simulation just using same
parameters but a 300 ft zone compartment length,
turning one zone to water. What the plots shows is
that a smaller compartment will translate into a more
optimum production strategy, with less water
produced with time. The optimum approach will lean
towards a compartment per each inflow control
device.
Actual PLT, dry
Production-Blue line
Purple line One
compartment 100% water
(75 ft compartments)
Orange line- One
compartment 100% water
(300 ft compartments)
Figure 8. Comparison between a real PLT from the well.
Completion Selection Strategy
In an effort to optimize new field developments and
ensure the usage of appropriate levels of technology,
Saudi Aramco utilizes both integrated teams and a
workshop approach that includes all design and
operational stake holders including service companies.
The workshops are organized to provide individuals with
a detailed overview of the geology, reservoir,
management objectives for recovery and depletions,
production targets, sustainability, challenges, and target
KPIs. The workshop deliverables include: 1) a revised
development plan focused on drilling and completion
optimization, 2) A comparison showing the improvement
to the original KPIs associated with the utilization of new
or advanced completion technologies, 3) List challenges
and exit strategies to mitigate new technology risks, and
4) A detailed list of items requiring management support
to facilitate meeting development timelines.
Whats Next
The utilization of these advanced completion
technologies have proved to be very effective in
improving sustainable well productivity. Future
improvements will include:
SPE 108877 5

1. Decrease compartment length down to individual
joint size (38 ft) utilizing slip on type swelling packers
along the horizontal section to increase the
efficiency of the horizontal well system. Using this
approach, when one interval or compartment
experiences high water or gas breakthrough, the
impact on the production will be reduced. This will
also minimizes the risk of killing the well especially
when water encroaches in the upper section of the
horizontal, a common occurrence induced by heal to
toe effect.
2. Test next generation downhole monitoring systems
along the horizontal section to provide real time
evaluation, removing the need for expensive logging
campaigns and associated production shutdowns.
This benefit will be achieved utilizing technologies
such as advanced distributed temperature survey
(DTS) fiber optics, and downhole flux couplings to
provide two trip capabilities for electronic array
system such as multi-point temperature pressure,
water cut, and resistivity. Field trials are planned for
next year.
3. Field test for water and gas adaptive passive ICD
systems. These new systems will be designed to
react to changes in produced fluid densities caused
by the onset of water or gas production. As the
produced fluid density changes, the ICD will react by
shutting off flow, hence controlling influx of water or
gas into the affected compartment and lower total
was or gas production to the surface. Two concepts
are currently being evaluated for field trail testing.
Combining the smaller compartment size with
adaptive ICD technology will further enhance the
value creation of these completion systems.
6. Drill-in completions. Saudi Aramco is reviewing drill-
in completion concepts that will allow passive ICD
completions to be drilled into place, hence extending
the length and reservoir contact for these
completions, reducing the associated problems of
stuck pipe and landing the completion off-bottom.
Acknowledgements
The authors would like to thank Saudi Aramco for their
permission to publish this paper and the information
within, and extend their thanks to Baker Oil Tools for
their adequate cooperation and continuous support.
References
1. SPE 85332. New-Technology Application to Extend
the Life of Horizontal Wells by Creating Uniform-Flow-
Profiles: Production Completion System: Case Study.
2. IPTC 10177. New Technology to Increase Oil
Recovery by Creating Uniform Flow Profiles in
Horizontal Wells: Case Studies and Technology
Overview.
3. SPE-106354. Integrating Advanced Well Completion
Technology Improved Performance & Maximize Recovery
- Case History.
4. IADC/SPE SPE-103621. The Evolution of Advanced Well
Completions Results in Enhanced Well Productivity and
Recovery in Saudi Aramco's Offshore Fields.
Nomenclature
DTS = Distributed Temperature
Survey
ESP = Electrical Submersible
Pump
ICD = Inflow Control Device
ID = Internal Diameter
RCV = Reservoir Control Valve

4. DNA tagging capabilities inserted into the individual

compartments will provide a means to identify water
production. The DNA will be specific to each
compartment and soluble in produced water. As
water production onsets, a surface reader will
identify from what compartment the water is coming
from, saving the cost of well intervention for PLT
logging.

5. Downhole power generation and wireless intelligent

well completion systems. Currently, it is very
challenging to combine ESP with an intelligent well
completion as reliable of downhole electronic wet-
mate connections are not available. Saudi Aramco is
partnering with service companies to develop and
test both downhole power generation systems,
wireless telecommunications, and extended life
battery systems to allow the ESP to be recovered
while keeping the intelligent well completion in the
lower wellbore and allow deployment of intelligent
well completions into multilateral wells.
6 SPE 108877

ESP PACKER

ESP with:
Inflow control device/ Open hole
ESP PUMP packer
SPACE OUT JOINT Off-bottom cemented
Reservoir Control Valve

RESERVOIR CONTROL VALVE

Stage Tool
LINER PACKER LINER HANGER ECP(2) Open Hole PACKER ICD PREMIUM SCREEN

Figure 9. ESP with Inflow Control Device.

SPE 108877 7

Multilateral Level 4,
inflow control devices / OH packer & ICV

Figure 11 ICD with Insitu Gas lift

Figure 10. Multilateral well.

Figure 11. Inflow control device coupled with in-situ gas lift.