Chapter 4-G

SAUDI ARAMCO WORKOVER MANUAL
Drilling Technical Department September 2013

___________________________________________________________________________________________________________________________
CHAPTER 4 COMPLETION PRACTICES

SECTION G INFLOW CONTROL (ICD) COMPLETION
___________________________________________________________________________________________________________________________
INFLOW CONTROL DEVICE (ICD) COMPLETION
1.0 INTRODUCTION
Back
2.0 INFLOW CONTROL DEVICE (ICD)

2.1 System Design and Principle
2.2 Types of ICD’s
2.3 ICD Variations
2.3.1 Tube / Channel Based
2.3.2 Nozzle Based
2.3.3 Labyrinth Based
2.3.4 Temporary ‘Closed’ ICD’s
2.3.5 ICD’s with Sliding Sleeve
2.4 Advantages of ICD’s
3.0 OPENHOLE PACKERS

3.1 Mechanical Packers
3.2 Swelling Packers
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
INFLOW CONTROL DEVICE (ICD) COMPLETION
1.0 INTRODUCTION
Horizontal wells have been globally used to maximize reservoir contact and
ultimately improve well performance. Variations in permeability, pressure and
frictional pressure drop along horizontal sections can create non-uniform inflow
profiles which can lead to early breakthrough of water or gas in reservoirs with an
aquifer and/or gas cap. Breakthrough typically occurs in regions of high
permeability or at the heel of the lateral section in homogenous reservoirs. This
ultimately leads to a reduction in reserve recovery and well performance.
The focus area and selection criteria for Inflow Control Device (ICD) completions
should focus on wells that exhibit one or more of the following conditions:
• High differential pressure between the heel and the toe.

• High permeability or flow contrast between the various compartments.
• Fractured horizontal wells.
• Horizontal wells overlain by gas zones or underlain by water zones.
• Future extended reach horizontal wells
An ICD system is openhole completion equipment that is installed to equalize

formation fluid flow across the reservoir face from heel to toe. It is designed to
prolong the life of the well by delaying or decreasing the water/gas breakthrough.
Each system consists of tubing or casing, a well-specific number of ICD’s and
Openhole Packers for zonal isolation.
2.0 INFLOW CONTROL DEVICE (ICD)
The ICD is the completion equipment used to introduce a slight flow restriction to
the production stream to aid in distributed inflow along the entire openhole
production zone. In long horizontal wells without gravel packs or ICD’s, production
flow along the annulus typically results in higher influx toward the heel of the well
when compared to the toe. This is a result of less restriction to flow in the annulus
compared to the inside of the liner or tubing. ICD’s that are strategically installed in
the wellbore prevent annular flow by minimizing the imbalanced inflow at the heel.
This results in an equalized drainage of the oil column and reduces the risk of early
gas or water coning into the wellbore. The balanced inflow also eliminates “hot
spots” in the heel section which may cause severe erosion to the completion
equipment.
1 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.1 System Design and Principle
All of the ICD designs use the principle of induced pressure drop to achieve
inflow regulation; however, they differ in the way they create the desired
pressure drop. The Baker product uses a helical path design while
Weatherford and Schlumberger uses a combination of orifices and channels,
and Halliburton’s design incorporates a tube of varying length to induce
pressure drop in the inflow control device (ICD). Baker improves the ICD
technology using the labyrinth flow path design which is practically less
sensitive to the effect of fluid viscosity. All of the systems require an effective
openhole packer to create horizontal compartments based on LWD and FMI
data in some carbonate reservoirs. The compartment sizes and total
production targets for the well are determined by reservoir characteristics.
The induced pressure drop is a pre-set design based on target reservoir
conditions and required equalization. Each ICD has a pre-set flux rate
associated with it and therefore, based on the number of ICDs run per
compartment, a compartment size and total well rate is obtained.
An ICD system is typically designed using two basic setups: one for high PI
sandstone targets and one for lower PI carbonate reservoirs. The sandstone
reservoir application is designed to provide a 20 psig pressure drop for a total
production rate of 200 BOPD. In the sandstone design, a premium sand
screen is used to provide protection to the ICD and to offer effective sand
control for the well.
The ICD system designed for carbonate reservoirs utilizes a strainer to
protect the ICD from well debris. The strainer is more cost effective
compared to utilizing sand screens for this function. It is also common to run
blank joints of tubing in carbonates to lower the overall cost of the
completions and to isolate non-productive zones. The combination of blank
and ICD joints is optimized based on LWD data and reservoir requirements.
In general, the carbonate system is designed to provide a 100 psig pressure
drop at a rate of 300 BOPD.
2 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.2 Types of ICD’s
ICD’s are available in various designs. To create a pre-set pressure drop

from the reservoir / tubing annulus to the production tubing internal diameter,
there are four ICD methods currently in use:
a) Channel / Helix
b) Nozzle
c) Tube
d) Labyrinth
Combining the ICD with sand screen provides sand control and prevents the
ICD from being plugged in the open hole. For sandstone formations, screen
(Sand Screen) is used specifically for sand control. The screen is normally
20 ft long with 200-350 micron opening size in the premium screen. For
carbonate formations, screen (Strainer/Debris Barrier) is used to prevent
ICD plugging due to wellbore debris. This debris barrier is normally 3 ft long
with 40 to 100 gauge wire-wrap screen with up to 500 micron opening.
3 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.3 ICD Variations
Several types of ICD’s are available in the market now. These include:
2.3.1 Tube / Channel Based

Tube- and channel-based ICD systems operate on the same principle.
Desired pressure drop is obtained as a result of friction flow through
the tubes or channels and flow is dependent on fluid viscosity. The
designs of both Baker Equalizer and Halliburton Equiflow are based
on this principle.
4 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.3.2 Nozzle Based

Nozzle technology provides a controlled pressure drop proportional to
fluid velocity squared. The size of the nozzle is predetermined
through flow modeling to create a given pressure drop at a given flow
rate. By altering the nozzle size or quantity of nozzles, the desired
pressure drop and resultant flow rate can be achieved.
Examples of ICD products that are based on nozzle design are:
• Schlumberger / Reslink ResFlow (producing wells)

• Schlumberger / Reslink ResInject (injector wells)
• Weatherford FloReg (sandstone)
• Weatherford CARDS (carbonate)
Schlumberger / Reslink Resflow
5 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
Schlumberger/Reslink ResInject
Weatherford FloReg ICD
6 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.3.3 Labyrinth Based

Labyrinth based technology is an improvement from the channel
based technology for the highly viscous oil environment. The labyrinth
flow path design is strongly dependent on the fluid density and
practically insensitive to viscosities up to 300 cp and due to this effect,
the water will always be choked more than oil.
Baker is the only company that can provide the labyrinth based ICD
technology.
Labyrinth Flow Path
Baker Equalizer SELECT ICD
7 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.3.4 Temporary ‘Closed’ ICD’s

The basic function of the closed ICD system is to temporarily prevent
flow through the ICD’s and to create a pressure-tight flow path
through the liner. This system also provides a method to
simultaneously open all ICD’s once the lower completion is in place.
An innovative choke valve accomplishes this delay until production
inflow is desired.
Using a closed ICD system eliminates the requirement to use an inner

workstring while also allowing full circulation through the shoe in case
of well control concerns or difficulty reaching TD. All mechanical
zonal isolation packers can be simultaneously set hydraulically
without the need for individual ‘cup-type’ methods, saving rig time in
the process. Additionally, openhole mud displacement and spotting
treatment fluids to minimize formation damage is more easily and
efficiently accomplished in this manner.
Baker MTV (Multi-Tasking Valve) is the only version of the temporary

closed ICD product that has been installed in Saudi ARAMCO wells.
Baker Multi-Tasking Valve (MTV)
8 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
2.3.5 ICD’s with Sliding Sleeve

It is a combination of the ICD technology with the proven Sliding
Sleeve technology. Similar to the closed ICD, this technology
eliminates the requirement to use an inner workstring when running
the Sliding Sleeve in closed position.
The basic function of the ICD with Sliding Sleeve is to expand the
capabilities of the passive inflow control by giving the adaptability
feature to overcome unexpected changes of the well behavior during
the production life. The technology allows for a complete water or gas
shut in for cases of water or gas coning.
Another prime distinguishing feature of the ICD with Sliding Sleeve is

the capability of selective zonal production, stimulation or treatment.
The Sliding Sleeve can be selectively opened or closed with shifting
tool using standard coiled tubing or wireline tractors.
Examples of ICD products with the Sliding Sleeve are:
• Baker Equalizer Select Plus

• Schlumberger Open/Close
• Weatherford FloReg RC
Weatherford FloReg RC ICD
9 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
Schlumberger Open/Close ICD
2.4 Advantages of ICD’s
ICD advantages can be summarized as follows:
• Balances inflow for drawdown differences

• Delays and decreases breakthrough of unwanted fluids
• Improves reservoir sweep
• Reduces effects of permeability variations
• Decreases rate of high mobility fluids.
• Increases robustness to offset unexpected reservoir conditions
• Improves ultimate reservoir recovery
• Prevents injected fluids from entering only into the heel of the well, high
permeability areas or fracture zones
• Reduces the risk of losing injectivity over time in unconsolidated sands
• Reduces unwanted fracturing effects during injection
• Prevents loss of reserves in producers due to early water breakthrough
10 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
3.0 OPENHOLE PACKERS
Openhole packers are an integral part of an ICD System design and provide zonal
isolation to configure individual compartments in a long horizontal wellbore.
There are two general types of Openhole Packers currently being used by Saudi
ARAMCO as part of the ICD completion:
• Mechanical Openhole Packers

• Swelling Packers
The Mechanical Openhole Packer is preferred in the situation where immediate

zonal isolation is required.
3.1 Mechanical Packers
Mechanical packers used in openhole contain a non-inflatable packing

element that is usually a composite elastomer. An average of six packers are
installed and mechanically and / or hydraulically set as an integral part of the
lower assembly to provide a barrier between the casing and wellbore.
Shifting a balance sleeve allows wellbore hydrostatic pressure to enter an
atmospheric chamber to provide proper setting force to the element. A lock
mechanism holds this setting force in place even if the hydrostatic pressure is
removed. Additional setting force can be applied at any time by increasing
the hydrostatic or applied pressure at the packer.
Saudi ARAMCO has approved three mechanical openhole packers:
• Baker MPas Packer

• Petrowell/Weatherford CSI Packer
• Halliburton ZoneGuard Packer
11 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
Run-in
Set
Baker MPas Packer
Petrowell/Weatherford CSI Packer
12 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
Multi node element package

with unique element back-
up system prevents element
extrusion
Halliburton ZoneGuard Packer
The table below shows Saudi ARAMCO Standards for openhole mechanical packers:
Hole Size Completion Size Running OD OD with 2000 psi rating Max OD
5½" 3½" 5.000" 6.35" 7"
6⅛" 3½" 5.000" 6.35" 7"
6⅛" 4½" 5.625" 6.6" 8.25"
8½" 5½" 8.000" 9.9" 12"
13 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
3.2 Swelling Packers
The swelling packer is a zonal isolation device based on the principle of

swelling properties of rubber when exposed to hydrocarbons. The packer
can enlarge up to 200% of its original volume to seal the annulus around the
casing to isolate producing zones. Once installed, the rubber retains its
flexibility and adapts to shifts in the formation over time to provide continuous
seal integrity. Its self-healing properties make this packer applicable for
essentially all applications that do not require immediate zonal isolation.
Swelling packers are comprised of a sealing material that increases in
volume and expands radially outward when a particular wellbore fluid
contacts the elastomer. The elastomer may be configured to swell in
response to either a hydrocarbon or water. Swelling packers enable reliable
and permanent annular isolation to enable water control in openhole
completions.
Installation of swelling packers does not require a skilled operator or

mechanical manipulation, which saves rig time and cost savings. The packer
is installed across a formation barrier and left in place. It can be used for
openhole and cased hole and can be easily manufactured for non-standard
casing sizes.
Swelling packers are not appropriate for all applications due to the length of
time that is required to fully set, normally 14 to 30 days. Another drawback of
swelling packers is that the sealing material may extrude due to differential
pressure. Anti-extrusion, or anchoring, devices in the form of end-rings have
been utilized as a means of mediating this drawback. The end-rings typically
include petals that expand outwardly by the force of the swelling seal
material. While the end-rings may provide a benefit in cased hole
installations, it is believed that they may deter sealing in open hole due to the
ovality or eccentricity of the wellbore along its length. Non-uniformity in the
cross-sectional and wellbore dimensions means that the annular gap to be
sealed may vary substantially from point to point. It also means that the
dimension of the annular gap is often unknown.
Saudi ARAMCO has approved five swelling openhole packers for both full-
size and short, slip on versions (‘constrictors’):
• Halliburton/Easywell Swellpacker
• Schlumberger Respack
• TAM FreeCap1 and FreeCap2
• Baker REPacker and REBarrier
• Weatherford Genisis and Morphisis
14 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
The normal full-size length is 3-5 meters and dependent on pressure integrity
requirements. The slip-on packer is approximately 1 foot in length.
Halliburton/Easywell Swelling Packers
Gauge Ring w/ inner O-ring Set Screws

ResPack Polymeric
Schlumberger Respack Packer
15 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
Weatherford Genisis Packer
Baker REPacker
16 of 17
___________________________________________________________________________________________________________________________

___________________________________________________________________________________________________________________________
The table below shows Saudi ARAMCO Standards for swelling packers:
Bonded 3m
Hole Completion OD 1000 psi Max 500 psi Max

Size Size Standard OD OD Remarks
non-
2⅞" 3.550" in-gauge hole 4.04" feedthrough
3⅞"
non-
2⅜" 3.500" in-gauge hole 4.23" feedthrough
5.125" in-gauge hole 6.04" feedthrough

5½" 3½" non-
5.000" in-gauge hole 6.00" feedthough

6⅛" 3½" non-
non-
6⅛" 4½"

8½" 5½" non-
Slip-On 1 foot
Hole Completion OD 240 psi Max 100 psi Max
Size Size Standard OD OD
3⅞" 2⅜" 3.500" N/A 3.89"
5½" 3½" 5.125" in-gauge hole 5.91"
6⅛" 3½" 5.75" in-gauge hole 6.75"
6⅛" 4½" 5.75" in-gauge hole 6.34"
8½" 5½" 8.000" in-gauge hole 9.17"
17 of 17

Chapter 4-G

Uploaded by

Copyright:

Available Formats

You might also like

Chapter 4-G

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Chapter 4-G

Uploaded by

Copyright:

Available Formats

SAUDI ARAMCO WORKOVER MANUAL

Drilling Technical Department September 2013

CHAPTER 4 COMPLETION PRACTICES

INFLOW CONTROL DEVICE (ICD) COMPLETION

2.0 INFLOW CONTROL DEVICE (ICD)

3.0 OPENHOLE PACKERS

CHAPTER 4 COMPLETION PRACTICES

INFLOW CONTROL DEVICE (ICD) COMPLETION

• High differential pressure between the heel and the toe.

An ICD system is openhole completion equipment that is installed to equalize

2.0 INFLOW CONTROL DEVICE (ICD)

CHAPTER 4 COMPLETION PRACTICES

2.1 System Design and Principle

CHAPTER 4 COMPLETION PRACTICES

2.2 Types of ICD’s

ICD’s are available in various designs. To create a pre-set pressure drop

CHAPTER 4 COMPLETION PRACTICES

2.3 ICD Variations

2.3.1 Tube / Channel Based

CHAPTER 4 COMPLETION PRACTICES

2.3.2 Nozzle Based

Examples of ICD products that are based on nozzle design are:

• Schlumberger / Reslink ResFlow (producing wells)

Schlumberger / Reslink Resflow

CHAPTER 4 COMPLETION PRACTICES

Weatherford FloReg ICD

CHAPTER 4 COMPLETION PRACTICES

2.3.3 Labyrinth Based

Labyrinth Flow Path

Baker Equalizer SELECT ICD

CHAPTER 4 COMPLETION PRACTICES

2.3.4 Temporary ‘Closed’ ICD’s

Using a closed ICD system eliminates the requirement to use an inner

Baker MTV (Multi-Tasking Valve) is the only version of the temporary

Baker Multi-Tasking Valve (MTV)

CHAPTER 4 COMPLETION PRACTICES

2.3.5 ICD’s with Sliding Sleeve

Another prime distinguishing feature of the ICD with Sliding Sleeve is

Examples of ICD products with the Sliding Sleeve are:

• Baker Equalizer Select Plus

Weatherford FloReg RC ICD

CHAPTER 4 COMPLETION PRACTICES

Schlumberger Open/Close ICD

2.4 Advantages of ICD’s

ICD advantages can be summarized as follows:

• Balances inflow for drawdown differences

CHAPTER 4 COMPLETION PRACTICES

3.0 OPENHOLE PACKERS

• Mechanical Openhole Packers

The Mechanical Openhole Packer is preferred in the situation where immediate

3.1 Mechanical Packers

Mechanical packers used in openhole contain a non-inflatable packing

Saudi ARAMCO has approved three mechanical openhole packers:

• Baker MPas Packer

CHAPTER 4 COMPLETION PRACTICES

Baker MPas Packer

Petrowell/Weatherford CSI Packer