Intelligent Completions at the Ready

Kevin Beveridge
The merits of intelligent completions are well documented, but their perceived high
Clamart, France
initial costs for design, installation and maintenance keep them out of many
Joseph A. Eck
Rosharon, Texas, USA operators’ development plans. A new offering is likely to change that perception;
these smaller, modular systems lower costs while retaining all the advantages of the
Gordon Goh
Kuala Lumpur, Malaysia larger and more-complex, high-tier systems.

Ronaldo G. Izetti
Petrobras
Rio de Janeiro, Brazil
Intelligent well systems were originally con- Because such vessels are expensive to lease
Maharon B. Jadid ceived in response to the extreme costs associ- and to move, and subsea workovers are typically
Willem Ruys Sablerolle ated with certain well intervention operations in long term, operators are reluctant to contract a
PETRONAS
critical or remote areas, particularly in deep and deepwater rig for a single workover or recomple-
Kuala Lumpur, Malaysia
ultradeep waters. The costs of workovers, recom- tion that does not promise significant return on
Gabriela Scamparini pletions and even some forms of basic mainte- investment. In addition, because these are often
Ravenna, Italy nance on wells in water depths greater than high-rate wells, the cost of lost production
about 150 m [500 ft] are often prohibitively high during shut-in may be a critical consideration
when an
because these operations can be performed only operator is contemplating the merits of an inter-
Oilfield Review Autumn 2011: 23, no. 3.
Copyright © 2011 Schlumberger.
from floating platforms. vention. Taken together, these factors often cause
For help in preparation of this article, thanks to Claire Bullen
and David Nuñez, Houston; and Farid Hamida, Rosharon,
Texas.
IntelliZone Compact, UniConn and WellBuilder are marks of
Schlumberger. 85 40
1. For more on intelligent completions: Algeroy J, Morris AJ, Pressure drop
Stracke M, Auzerais F, Bryant I, Raghuraman B, Water cut in toe zone Water cut in heel zone
Rathnasingham R, Davies J, Gai H, Johannessen O, 80 30
Malde O, Toekje J and Newberry P: “Controlling
Pressure drop,

Reservoirs from Afar,” Oilfield Review 11, no. 3

(Autumn 1999): 18–29.
75 20
Water

Dyer S, El-Khazindar Y, Reyes A, Huber M, Raw I

and Reed D: “Intelligent Completions—A Hands-Off
Management Style,” Oilfield Review 19, no. 4
(Winter 2007/2008): 4–17.
70 10
2. Aggrey GH, Davies DR and Skarsholt LT: “A Novel
Approach of Detecting Water Influx Time in Multizone
and Multilateral Completions Using Real-Time Downhole
Pressure Data,” paper SPE 105374, presented at the 65 0
SPE Middle East Oil and Gas Show and Conference,
500 720 940 1,160 1,380 1,600 1,820 2,040
Manama, Bahrain, March 11–14, 2007.
Time, d
Aggrey G and Davies D: “Real-Time Water Detection and
>
Flow Rate Tracking in Vertical and Deviated Intelligent Detecting water encroachment using downhole sensors. Because water
Wells with Pressure Sensors,” paper SPE 113889, influx at a zone causes a reduced production rate at that zone, the rates will
presented at the SPE Europec/EAGE Annual Conference
and Exhibition, Rome, June 9–12, 2008.
increase in the other zones to ensure the well meets total well constraints,
such as liquid rates or tubinghead pressure set by the operator. This change
3. Sakowski SA, Anderson A and Furui K: “Impact of
Intelligent Well Systems on Total Economics of Field is manifested in a corresponding decrease or increase in pressure drop
Developments,” paper SPE 94672, presented at the between zones. In this production scenario, at about Day 700, water
SPE Hydrocarbon Economics and Evaluation breakthrough at the toe (blue) of a two-zone horizontal well creates a sharp
Symposium, Dallas, April 3–5, 2005. decrease in pressure drop (red) between that zone and the sensor at the heel
of the well. As water production increases from the heel of the well, around
Day 1,160 (green), the pressure drop decreases more slowly. At about day
1,700, with increasing water production from the heel, the pressure drop
increases. (Adapted from Aggrey et al, 2008, reference 2.)

Autumn 1
2 Oilfield Review
operators to postpone needed interventions. Such
Once engineers identify the source of a prob- industry misgivings about the reliability of ICs.
delays can lower production rates over an
lem, they can then shut off, increase or decrease However, because their design and implementa-
extended period of time, cause permanent
flow from any zone using FCVs placed across tion are complex, ICs remain relatively expen-
damage to reser- voir productivity and reduce
each production interval and reconfigure the sive. Consequently, their use continues to be
ultimate recovery, all of which impact total field
completion.2 This may be especially cost-effec- restricted mainly to remote environments and
economics.
tive when initial changes to FCV settings must in wells with very high production rates for
An intelligent completion (IC) can offer an
be further adjusted based on measurements which the cost of intervention and delayed
alternative to interventions. ICs include down-
taken during a flow period following the initial production is extreme.
hole sensors that allow operators to gather flow
remedial operation. More recently, their appeal has widened as
and reservoir data remotely. They are equipped
When ICs were first introduced, companies engineers have learned to use ICs as effective
with remotely actuated downhole flow control
resisted installing them. Engineers questioned, reservoir management tools. Multizone comple-
valves (FCVs) with which operators can adjust
with some justification, the reliability of the tions, waterfloods, gas lift and other systems are
flow from individual production zones.1
systems’ critical components over the life of the more easily optimized through remote
Remote sensors eliminate the need for the
well. Operators were equally wary of the capital downhole monitoring and control than through
most common intervention in multizone wells: to
expenditure (capex) of ICs, which has tradition- interven- tion. In many cases, the return on
identify the location of production-inhibiting
ally been substantially higher than that of con- investment in ICs—through accelerated cash
problems such as water, gas or sand ingress.
ventional completions. As a result, economics flow and increased ultimate recovery—far
Sensors that measure changes in flow rate, tem-
and risk analyses often favored standard com- exceeds the savings realized by avoiding
perature and pressure at specific well depths
pletions over ICs except in remote areas or for interventions. One major operator has calculated
allow engineers to determine in real time which
subsea completions. that 5% of the total economic impact of ICs on its
zone is experiencing production or pressure
Improvements in components and systems business is due to savings on interventions,
decline, without the expense and risk of an
and years of IC use have done much to while 60% is due to reservoir-related revenue
inter- vention (previous page).
overcome increases.3

Autumn 3
 Despite proven reliability and a more
Annulus sensor reads theTubing
Zone 1sensor
reservoir
reads
pressure.
the Zone 2 FBHP.
broadly defined niche for ICs—and because the
original intent of the developers was to use ICs
in rela- tively high-rate wells—the economics of
middle- and low-tier fields are such that
operators continue to use traditional
FCV 1 closes completion strategies rather than risk the capex
of an IC. ICs were also intended to be robust
enough to forestall inter- vention throughout
Shale Zone 1 Shale Zone 2 Shale the life of the well—usually more than 20 years
—since a single intervention in deep water or
other remote area could easily foil any

Tubing sensor reads the Zone 1 FBHP. Annulus sensor reads the Zone 2 reservoir pressure.

FCV 2 closes

Shale Zone 1 Shale Zone 2 Shale

>
Reservoir and flowing bottomhole pressures from remote monitoring and anticipated economic advantage of an IC. This
control. In a multizone IC, each zone is isolated, monitored and controlled. design mandate resulted in ICs that were
The flowing bottomhole pressure (FBHP) may be measured as flow from Zone necessarily large, complex and costly.
2 only (red arrows) by closing the FCV across Zone 1 (top), while reservoir
buildup pressures in the shut-in Zone 1 are measured. By closing the FCV Additionally, over time, as industry providers
across Zone 2 and opening Zone 1 (bottom), reservoir pressure may be sought to increase IC reliability and flexibility,
determined in Zone 2 and FBHP from Zone 1. The principle may be applied to the technology evolved piecemeal. Operators
any number of isolated zones. seeking best-of-class solutions often had to com-
bine components from numerous suppliers
within a single completion configuration. This
created interface challenges that led to
increased risk of equipment failure and
wellsite time and
costs to assemble, test and install completions.
All these factors have conspired to perpetu-
ate the image of wells equipped with remote
monitoring and control as large capital expendi-
tures justified only by high-volume production,
well complexity or locations where intervention
is cost prohibitive or technologically problem-
atic. This article describes redirected efforts
that have given rise to a less complex IC system.
Its design lowers its cost, which allows operators
of average to marginal wells to reap the reser-
voir management benefits of ICs previously
restricted almost exclusively to high-cost or
Engineers have also discovered that ICs can production may be shut off or reduced production logs. This is accomplished by first closing
be instrumental in reducing the number of wells downhole rather than treated on the surface. one zone, which allows the downhole pressure
required to exploit a formation. Reducing well Zonal isolation and pres- sure optimization sensor at the sandface to begin record- ing annular,
count, intervention frequency and intervention- between zones result in higher rates of or reservoir, pressure. At the same time, a sensor
associated delayed production can save opera- commingled flow to the wellbore. The across a fully opened second zone measures the
tors millions of dollars in field development costs, consequence is a net increase in production and FBHP for that zone.
particularly in deep water.4 Fewer wells also total recovery. When the second zone is closed and the first zone
result in less subsea equipment and thus sub- With surface-controlled FCVs, it is also possi- is opened, sensors at the sandface measure the
stantial reduction in capex. Additionally, water ble to periodically measure reservoir and flowing reservoir pressure of the second zone and FBHP
and gas processing units that service ICs may be bottomhole pressure (FBHP) without running from the first zone (above). This tech- nique, which
smaller because excess water and gas can be applied to a number of pro- ducing intervals
4 Oilfield Review
at a time, allows operators to gather a downhole
pressure profile from any zone at any time
without excessive delays in produc- tion for
buildup and without exposure to risk from
interventions. This technique of isolating zones
also enables engineers to collect formation
pressure buildup survey information and a draw-
down profile for productivity index (PI) updates
and changes throughout the life of the well.5
Autumn
high-risk applications.
4. Sakowski et al, reference 3.
5. Chen JHC, Azrul NM, Farris BM, NurHazrina KZ,
Aminuddin MKM, Saiful Anuar MY, Goh GKF, Kaur
PKS, Darren Luke TK and Eddep A:
“Implementation of Next Generation Intelligent
Downhole Production Control in Multiple-Dipping
Sandstone Reservoirs, Offshore East Malaysia,”
paper SPE 145854, presented at the SPE Asia
Pacific Oil and Gas Conference and Exhibition,
Jakarta, September 20–22, 2011.
6. Sharma AK, Chorn LG, Han J and Rajagopalan S:
“Quantifying Value Creation from Intelligent
Completion Technology Implementation,” paper SPE
78277, presented at the SPE European Petroleum
Conference, Aberdeen, October 29–31, 2002.
7. Narahara GM, Spokes JJ, Brennan DD, Maxwell G
and Bast M: “Incorporating Uncertainties in Well-
Count Optimization with Experimental Design for
the Deepwater Agbami Field,” paper SPE 91012,
presented at the SPE Annual Technical Conference
and Exhibition, Houston, September 26–29, 2004.
8. Adeyemo AM, Aigbe C, Chukwumaeze I, Meinert D
and Shryock S: “Intelligent Well Completions in
Agbami: A Review of the Value Added and
Execution Performance,” paper OTC 20191,
presented at the Offshore Technology Conference,
Houston, May 4–7, 2009.
5
 The Value of Flexibility
When operators plan wells in deep water or other 125
isolated locations, it may be clear that avoiding a
single intervention saves enough in operating 100
Reservoirs C, B and A
expense to justify the capital expense of a tradi-
75

Cumulative
tional IC. On the other hand, a single-zone, land-
based well in an area well populated with rigs is Reservoir A
50
unlikely to ever justify the expense of an IC even Reservoir B
if the operator avoids numerous interventions. 25
During consideration of scenarios between Reservoir C
those two extremes—for example multizone
land-based completions—the cost analysis may 0 10 20 30 40 50 60 70
not be so apparent. Shutting off production from Time, months
one zone and opening another through recomple- >
Comparing commingled and sequential production. The production benefits
tion or by shifting a sliding sleeve are relatively of commingling versus an estimated sequential production strategy are
demonstrated in a Gulf of Mexico operator’s production curves. Two FCVs
low-cost propositions built into the original eco-
were installed in this well to control upper and lower producing zones. The
nomics of multizone wells. However, such a strat- operator used on-off controls to shut off production from one zone when
egy calls for the first zone to be depleted before its water cut threatened net production; the result (red) was about a
the next one is opened. Reservoir analysis indi- 28% increase over sequential production estimates (blue).
cates that remotely adjusting downhole FCVs to
commingle zones based on real-time pressure
and temperature data significantly accelerates
production and increases ultimate recovery com- To manage this uncertainty, the operator analysis computer that collects and evaluates
pared with traditional on-off multizone comple- installed ICs that included permanent pressure, sensor output. Variable chokes were placed
tion configurations (above right). flowmeter and densitometer sensors arrayed downhole and at the surface to facilitate remote
This advantage is not always apparent from the sandface to the separator. These are flow control.8
because traditional discounted cash flow mod- monitored through an integrated database and
els used by most operators cannot quantify the
value derived from operational flexibility. 6 This
flexibility depends on the availability of numer-
ous options with which to mitigate well prob-
lems during the life of a well. Having the ability Reservoir Model of Agbami Field
to remotely monitor downhole conditions and
adjust flow from various zones in real time
adds to the number of choices available to the
operator, removing the economic burden of rig- U = upper M = middle L = lower
based interventions.
Remote monitoring and control is a particu-
larly powerful tool for reducing uncertainty
in reservoir properties. For example, as with
many deepwater developments, the operators of 14 MY

the Agbami field offshore Nigeria did not have

substantial reservoir data on which to base Secondary reservoirs
U 16 MY
well plans.7
L 16 MY
Agbami wells are typically completed in mul-
tiple zones within the same faulted reservoir. U 17 MY
Pressure equilibrium indicated the zones are in
Main reservoir
communication, although uncertainties persisted M 17 MY
L 17 MY
in vertical and lateral crossfault connectivity
under dynamic conditions (right). Consequently,
engineers believed that waterflood and gasflood >
Uncertainty about reservoir properties. The pay intervals at Agbami field consist of two principal
fronts would advance through the reservoir at zones. Uncertainty about permeability, fault seals and injection conformance made decisions about
different rates. well count and location problematic. The upper, middle and lower 17 MY sands hold about 80% of the
reserves. Secondary reservoirs include the 13 MY (not shown), 14 MY and 16 MY layers. [Adapted
from Houston Geological Society: “HGS International Dinner June 21, 2004; Agbami Discovery,
Nigeria,” (May 25, 2004), http://www.hgs.org/en/art/209 (accessed August 3, 2011).]

6 Oilfield Review
 The operator identified four categories that
characterized the value added by using ICs:
• incremental recovery through optimized zonal
contributions
• reservoir management through effective void-
age replacement and pressure maintenance
with gas and water injection
Handling sub
Packer
Mounting sub Hydraulic line
Electric line
Filter sub
Dual pressure
gauge
Multidrop module
FCV
Handling sub
>
Smaller IC package. The modular design of the
IntelliZone Compact system allows engineers to
assemble and test the IC package for each zone
before it is shipped to the wellsite. All electrical
and hydraulic connections are welded into place
by the manufacturer. Rig operators need only to
connect lines at the handling subs and no longer
must thread lines through packers and connect
them to FCVs and pressure sensors on site,
resulting in reduced installation time, cost and
risk. A filter sub enhances system durability by
preventing contaminants from reaching FCVs. In
multizone wells, multidrop modules require fewer
hydraulic lines to handle multiple control valves.
Autumn
• optimized infill drilling through better models
based on history-matching of zonal volumes
rather than total reservoir volumes
• operating expense savings through reduction
or elimination of workovers, sidetracks and
pro- duction logging runs to evaluate
injection and production contribution from
individual zones. Using dynamic simulation
models, the opera-
tor concluded that the deployment of ICs on a
field-wide basis at Agbami would deliver
incremental oil recovery of 84 to 138 million bbl
[13 to 22 million m3].9
The Agbami field contains 20 producing wells,
12 water injection wells and 6 gas injection
wells in about 5,000 ft [1,500 m] of water.
Production in 2009 was 140,000 bbl/d [22,250
m3/d] of oil with peak production expected to be
250,000 bbl/d [39,730 m3/d]. Given its size,
location and reser- voir uncertainty, Agbami field
was an ideal candi- date for ICs. But the success
there, in terms of incremental production as a
result of IC installa- tion, also demonstrates the
potential advantages the strategy holds for smaller
fields if the initial capex can be recovered.
Smaller, Modular
In contrast to most IC-candidate wells—those
characterized by multiple high-rate targets— many
average to marginal wells are profitable only when
operators are able to access numer- ous marginal
production zones at the cost of a single wellbore.
Despite the complexity inher- ent in drilling and
completing many of these wells, project
economics often demand that capex be strictly
limited. This forces operators to exchange the
reservoir management capa- bilities of an
intelligent completion for the lower initial costs of
traditional mulitzone completion configurations.
Schlumberger engineers have recently devel-
oped a technical solution to this market-driven issue
by repackaging traditional, high-tier IC technology
into a significantly lower-cost sys- tem. The
IntelliZone Compact modular zonal management
system was developed for deploy- ment in
multizone wells that require fewer choke positions
and are of lower working pres- sures than those of
traditional IC-candidate wells. It is suited for use in
brownfields or mar- ginal fields, in wells that would
otherwise use sliding sleeve completions—most
without mon- itoring systems—and wells requiring
extended well testing. The IntelliZone Compact
system improves recovery in long, horizontal wells
by compartmentalizing them and controls zones in
artificial lift wells by monitoring and controlling
inflow at the sandface.
7
 The IntelliZone Compact system is an open or 100% open.
inte- grated assembly rather than a Like the two-position FCV, the choke
conglomeration of the individual tools that posi- tion is changed one step per actuation
make up traditional ICs. The downhole flow by bleed- ing one line and pressuring up
control assembly includes a packer, a another and can also be configured for line
handling sub and an FCV (left). FCVs may sharing to minimize the number of
be either on-off two-position or four-position hydraulic lines installed. The
chokes. Each assembly can be tested at the
fac- tory and run with a production packer or
an isola- tion packer without slips.
Using frequency shift keying (FSK)
communi- cation technology to transmit
data to the surface, the system monitors
downhole pressure, temper- ature and valve
position every second.10 The data are
transmitted to the surface control system
via a single monoconductor cable. A hydraulic
power unit (HPU) controls all hydraulic line
fluid out- flow, inflow and pressures
required to actuate downhole tools. A
UniConn universal site control- ler functions
as a data-gathering and control plat- form
that operates motor control systems,
downhole tool systems, SCADA and other
com- munication systems.
The control system fulfills several key
func- tions including acquisition and
storage of tool data—annulus pressure,
tubular pressure, annu- lus temperature,
tubular temperature and FCV position. It
also performs the automated sequenc- ing of
valve operations, alarm detection and condi-
tions, tolerance levels, acquisition and
storage of HPU data and remote SCADA
capability.
The system relies on WellBuilder software
for completion design to integrate the
completion planning process from concept to
commissioning. The WellBuilder program
uses reservoir condi- tions, completion
requirements and construction parameters
to generate multiple configurations of the
required number of control lines and oper-
ating pressure envelope limits for each
zone.
IntelliZone Compact two-position FCVs
include a flow control section and an
actuator section. The two-position FCV
may be either open or closed. A single
actuation, accomplished by bleeding one
control line while increasing pres- sure on
another, changes the valve position from
open to closed or vice versa. When more than
one FCV is placed in the well, line sharing
allows reduction of the number of lines to
one plus the number of valves in the hole.
The four-position FCV includes a choke
and an actuator section plus a J-slot
indexer, which controls the choke’s
position; it can be closed, 33% open, 66%
8 Oilfield Review
four-position FCV can also use a multidrop mod- Actuation cycle
ule that allows manipulation of up to three 0 1 2 3 4 5 6 7
downhole valves through a single control line. A
position sensor is integrated into the hydraulic Two-pulse
FCV, which is accomplished by programming Zone 1 multidrop module
Close Open Close Open Close Open Close Open
each FCV to react to a two-, four- or eight-pulse Two-position FCV
signal (right). Since the valves move in a single
direction, a series of pulses may be used to
change them from on to off or through the series Four-pulse
of choke settings. Zone 2 multidrop module
Close Close Open Open Close Close Open Open
Minimizing the number of hydraulic control Two-position FCV
lines in a completion reduces installation com-
plexity—fewer lines require less handling and
splicing. The multidrop module also makes it pos- Eight-pulse
sible to place FCVs at more production zones Zone 3 multidrop module
Close Close Close Close Open Open Open Open
than would otherwise be possible because of a Two-position FCV
limited number of available packer or tubing
hanger penetrations.
The multidrop module is externally mounted
to the tubing within the IntelliZone Compact
sys- tem and is connected to the open and Zone 1
closed ports of the FCV and, in series, to the Two-position FCV Multidrop module
Zone 1 Zone 1
hydraulic control line deployed to the surface. Four-position FCV Multidrop moduleFour-position FCV Multidrop
Downhole instrumentation can also be added to
the flow control assembly as a modular package by
mount- ing pressure and temperature gauges Zone 2
and other hydraulic devices around the tubing Two-position FCV Multidrop module
Zone 2 Zone 2
sub. Two-position FCV Multidrop moduleFour-position FCV Multidrop

Savings in Brazil and India

The savings generated by the IntelliZone Compact
Zone 3
system approach compared with conventional Two-position FCV Multidrop module
Zone 3 Zone 3
intelligent completions systems are derived Four-position FCV Multidrop moduleFour-position FCV Multidrop
from its modularity and standardization. At
about 10 m [30 ft] long, it is half the length of
standard ICs. Because the isolation device,
sensors and flow control valves are packaged
in a single assembly, there are no interface Zone 4 Zone 4
Two-position FCV Multidrop moduleFour-position FCV
issues common to systems built from
components supplied by multiple
manufacturers. This significantly enhances
total system reliability and, because the entire
system is assembled and tested at the point of Zone 5 Zone 5
Four-position FCV Four-position FCV
manufacture rather than in the field, it saves
operator rig time.
The IntelliZone Compact system also helps
operators save time and possible missteps >
Reducing the number of hydraulic lines. In typical completion configurations, each surface-actuated
because the control lines are installed as part of FCV requires a dedicated hydraulic line. A multidrop module interprets pulses from the surface as
the package. Control line handling on site is commands to shift openings of a specific FCV within a well (top). This allows engineers to operate
at least one more FCV than the number of hydraulic lines available. For example, using multidrop
limited to making splices above and below the modules (bottom) allows three 2-position FCVs to be operated on a single control line (black lines,
package as it is run into the well. In standard left) or two 2-position plus three 4-position FCVs on two lines (black and green lines, middle) and up
applications, these lines must be threaded to five 4-position FCVs on three lines (black, green and red lines, right).
through the packers and connected to each con-
trol valve individually; this is a time-consuming
operation fraught with opportunity to damage
lines and components. Because fewer lines 9.Adeyemo et al, reference 8. receiver converts the signal back to the original form.
10. FSK communication technology uses a robust The FSK signal is easily connected to other
require handling, risk associated with splicing frequency modulation scheme that sends digitally communications devices such as those used by
operations is also reduced. encoded data by changing the frequency of a SCADA systems.
transmitted signal. A

Autumn 9
 Perform final inspection.
25
Terminate fittings in the packer.
Arrange control lines and fit
protectors, plates.

Install dual gauge into mandrel.

20
Perform gauge check and pressure
Perform electrical test and check gauge.
Function test FCV.
Connect control line to FCV:
15 flush, connect and pressure test.
Operation

Pass the control line and electric line

through the packer feedthrough ports.
Connect packer assembly to tubing
10 in rotary table.
Pick up packer assembly to the rig floor.
Connect gauge mandrel assembly
to tubing in rotary table.
5
Pick up gauge mandrel assembly
to the rig floor.
Connect FCV assembly to tubing
in rotary table.

0 Pick up FCV assembly to the rig floor.

Standard IC IntelliZone Compact
completion
>
Saving time. Because it has a modular design and can be assembled and tested before arriving at the wellsite,
the IntelliZone Compact assembly is prepared to be run in a well in about half the estimated time required to
reach the same stage using a standard IC installation. Much of the time saved is a result of steps required of
standard IC installations (outlined in red) that are not required when running an IntelliZone Compact completion.

It was these time and cost savings that influ-

or four-position FCV and an FCV position sensor. three zones at once—would have resulted in
enced a Petrobras decision to use an IntelliZone
Since Carapeba is a brownfield, its project eco- most of the acid entering one high-permeable
Compact system in the Carapeba-27 injection well
nomics demanded a low-cost system, which was zone while leaving the other two untreated. Use
of the Carapeba field in the Campos basin offshore
achieved by installation costs that were less of traditional surface-controlled flow control sys-
Rio de Janeiro. Engineers sought to optimize
than those estimated for traditional ICs (above). tems to isolate each zone was not possible
pro- duction from this mature field by replacing
Engineers with an offshore India operator because operation of control equipment for
con- ventionally completed, one-zone wells with
also turned to an IntelliZone Compact solution three zones would require more hydraulic lines
IC three-zone wells. They chose to use an
as it considered how to complete a three-zone than existing penetrations in the company-
IntelliZone Compact IC in an injector well to
well within the economic restraints of a owned wellhead.
optimize reser- voir sweep and to perform
marginal field. They sought to reduce capex The solution included deploying a multidrop
injectivity tests to allo- cate injection rates in
by using already purchased equipment. At the module in an IntelliZone Compact system.
each zone. Both objectives are facilitated by the
same time, they sought optimum return on their Engineers were able to deploy surface-controlled
system’s highly accurate posi- tion sensor.
investment through control of each zone downhole FCVs across all three zones using a
Engineers also needed to monitor and control
independently. Given these two constraints, sin- gle hydraulic line. The systems were deployed
downhole flow remotely through their SCADA
their completion choices were between sliding with a cased hole packer and two swellable
system, which was accomplished through the
sleeves and a sur- face-controlled downhole packers to isolate each zone (next page). Using
UniConn site controller.
flow control system. the multidrop module, engineers could open one
Assembled and tested at the factory, each
Sliding sleeves require interventions to shift zone while the other two were closed, ensuring
component of the three-zone modular comple-
them, and engineers knew that to bring these that acid treat- ments were reaching their
tion included an isolation or production packer,
wells online they would have to perform coiled targets.
a dual pressure and temperature gauge for
tubing–conveyed acid treatments across each
tubing and annulus reading, a multidrop
zone individually. The alternative—treating all
module, a two-

10 Oilfield Review
 The elimination of three of the four control
lines required by traditional systems and of the
need for coiled tubing–based interventions
saved the operator three weeks of rig time. As a
result, the operator optimized production at
165% of the originally expected rate and saved
US$ 1 million within the first two months
follow- ing system installation.
Low-Cost, High-Technology Solution
Optimizing production requires investment.
However, when faced with an asset of marginal
reserves, operators are often left to choose only
from basic completion scenarios for fear that
any incremental production realized through
higher technology will not be enough to pay the
cost of such a solution. This is especially true
when the challenge to increased production is
as technical as that faced by engineers at
PETRONAS com- pleting a field offshore East
Malaysia.
The PETRONAS-operated S-field contains
marginal reserves in unconsolidated heteroge-
neous sandstone reservoirs. Reserves are in a
stacked 40 m [131 ft] thick oil column. Because
of the presence of a large gas cap, engineers
feared breakthrough would prematurely end pro-
duction and cause significant oil reserves to be
bypassed. They also had to consider the
possibil- ity of water invasion from a
moderately strong and active aquifer.11
To reduce well count while maximizing reser-
voir contact, PETRONAS engineers planned
development of the field using 14 horizontal
wells. Horizontal wells create a lower pressure
drop at the sandface than do typical vertical or
deviated wells with equivalent productivity.
This lower drawdown helps reduce the severity
of water coning and gas cresting.12
However, when the horizontal section pene-
trates zones of differing flow properties, those
with higher permeability will deplete first. This
can lead to water or gas entering the wellbore
through the depleted sections of the producing
zone, causing reserves in less permeable areas
of the formation to be bypassed. Once such
break- through occurs, rig-based remedial
operations
11. Chen et al, reference 5.
12. For more on extended-reach drilling: Bennetzen B,
Fuller J, Isevcan E, Krepp T, Meehan R, Mohammed N,
Poupeau J-F and Sonowal K: “Extended-Reach Wells,”
Oilfield Review 22, no. 3 (Autumn 2010): 4–15.
13. For more on inflow control devices: Ellis T, Erkal A,
Goh G, Jokela T, Kvernstuen S, Leung E, Moen T,
Porturas F, Skillingstad T, Vorkinn PB and Raffn AG:
“Inflow Control Devices—Raising Profiles,” Oilfield
Review 21, no. 4 (Winter 2009/2010): 30–37.
Chen et al, reference 5.
Autumn
may be futile or may be unable to return oil pro-
duction to economic levels.
Because zonal property contrasts were high,
PETRONAS had to balance initial influx and Packer
maintain the ability to react to inflow problems
later in the well’s life. To satisfy these require-
ments, IntelliZone Compact completions were Multidrop module
considered as an alternative to passive inflow
control devices (ICDs) for the other six com- FCV
mingled producers.13 Wells in the S-field best
suited for the application were analyzed and
Perforations
Zone 1
ranked based on the well production profile and
dynamic reservoir fluid properties such as
water cut and gas/oil ratio. Different sandface
produc- tion sensitivities for incremental oil,
water-cut reduction, gas/oil ratio profile and
FBHP were also performed.
The two wells chosen for the installation—
Well-A1 and Well-A2—showed positive zonal Hydraulic line
inflow control analysis results compared with Packer
that of the base case of conventional stand-alone
screens. They were completed with integrated
modular completion packages that included Multidrop module
zonal isolation packers, two intermediate and on-
off position FCVs and permanent real-time pres- FCV
sure and temperature sensors. Perforations
The assemblies were delivered to the Zone 2
wellsite as a single joint less than 9 m [30 ft]
long— one-half to one-third the length required
for a comparable conventional IC. The assemblies
were also pretested with electronics and
hydraulic splices welded at the manufacturing
center. Each tested connection was locked to the
assembly and another metal strip was affixed to
the housing to further protect the assembly and Packer
to guard against damage from shock during
installation.
In addition to reducing the risk of Multidrop module
installation failure, these practices shortened FCV
installation time by reducing the number of
connections to be made and lines to be spliced
Perforations
on site. In the S-field case, installation rig time
Zone 3
savings were up to two-thirds per zone compared
with that of con- ventional installation, or the
equivalent of about US$ 400,000 per well
completed.
Following installation, wellbore nodal analy-
sis combined with time-lapse modeling was >
Adapting to available equipment. Using
used to predict production scenarios based on
multidrop modules at each of three zones,
reser- voir deliverability for proposed wellbore engineers were able to control FCVs through
trajecto- ries. Because detailed geologic and a single hydraulic control line (green line).
petrophysical properties for each well were The operator was thus able to use a wellhead
unavailable from a history-matching model, in
inventory instead of having to purchase a more
these were calibrated from offset field expensive one with the requisite higher number
performance. Production simula- tion results of penetrations required in traditional three-zone
IC installations.
indicated how the IntelliZone Compact ICs would
enable zonal production and control in
1
 Production Gain Analysis: FCV Versus Passive ICD
2.4

2.1

1.8

Cumulative oil production, million 1.5

1.2

0.9

0.6

0.3

0
Jan. 2009 Oct. 2009 July 2010 April 2011 Jan. 2012
Oct. 2012 July 2013 April 2014 Jan. 2015
Date
>
Potential gain in ultimate recovery. Field modeling software providing material balance, nodal
analysis and system performance was used to compare estimated ultimate recovery for wells in
the PETRONAS-operated S-field. The well was completed with surface-controlled downhole FCVs
(blue) and compared with a well equipped only with a passive ICD (green). The FCV-equipped well is
projected to ultimately recover 100,000 more barrels of oil than the ICD-equipped wells. (Adapted from
Chen et al, reference 5.)

various reservoir deliverability and production

the valve assemblies were designed using the wells completed with IntelliZone Compact sys-
scenarios. The systems would be especially effec-
following selection criteria: tems. They studied two production scenarios—
tive in controlling inflow from high PI zones by
• zonal control for discrete zones potential production gain and downhole water
using a smaller valve opening, while encouraging
• flow balance from multiple zones and gas shutoff.
low PI zones to flow through a fully opened valve.
• crossflow prevention Under the first scenario, compared with pas-
The IntelliZone Compact design includes
• sufficient capacity for zonal PI differences. sive ICDs, engineers found that active downhole
options for three sizes of FCVs, each with fully
Engineers used integrated field modeling flow control resulted in an additional 15,900 m 3
open, fully closed and two intermediate choke
software that provides material balance, nodal [100,000 bbl] of oil (above). Analysis of the sec-
settings. Based on reservoir simulation models,
analysis and system performance analysis to ond scenario, focusing on downhole gas and
compare the estimated ultimate recovery for the

Zone 1 Zone 2 Zone 1 Zone 2 Gas rate,

Flow rate,
Case Opening, % Opening, % Tubular, psi Annulus, psi Pressure, psi Tubular, psi Annulus, psi Pressure, psi bbl/d Water cut, % MMcf/d PI, bbl/d/psi
Case 0 100 100 2,094 2,092 2 2,096 2,094 2 1,179.2 0.12 0.18
Case 1 100 0 1,877 1,873 4 1,875 2,105 –230 555.4 21.30 0.05 138.9
Case 2 0 100 2,101 2,035 66 2,102 2,100 2 1,067.6 4.85 0.08 533.8
Case 3 33 100 2,095 2,091 4 2,097 2,095 2 1,144.4 0.22 0.19
Case 4 67 100 2,095 2,092 3 2,097 2,095 2 1,143.4 0.21 0.18
Case 5 100 67 2,085 2,082 3 2,086 2,101 –15 1,001.9 0.44 0.16
Case 6 100 33 1,951 1,949 2 1,952 2,100 –148 1,050.6 0.37 0.17
>
Flow control configurations. Measuring zonal production with downhole pressure gauges, engineers studied seven control valve configurations for two
zones in Well-A2 in the S-field. Case 0 established production with both zones fully open. In Cases 1 and 2, by shutting off production from Zone 2 and
then Zone 1, respectively, the operator established the PI and water cut for each zone. Using the results of Cases 0, 1 and 2, engineers were able to
discern that because of its low PI, Zone 1 did not contribute any production when both FCVs were fully open. After testing other combinations, the team
concluded that Case 3, in which the valve controlling Zone 1 is 33% open and the valve at Zone 2 is 100% open, was the optimum configuration.
(Adapted from Chen et al, reference 5.)

12 Oilfield Review
 2,500
50 time, misgivings about system reliability have
been overcome, and such innovations as rotary
2,000 steerable systems and expandable casing have
40
become commonplace. The same can be said of
1,500
the industry’s acceptance of IC technology.
30 Today, industry recalcitrance about ICs
Oil rate,

stems from financial concerns among operators

Water
1,000 uncer- tain about their marginal or maturing
20
assets; operators must see sufficient production
500 increases from remote downhole monitoring
10
and control capabilities to justify the hardware’s
initial costs.
0
0 0 The introduction of a modular system aimed
2 3 4 5 6 7 8
Time, months at providing the industry with the advantages of a
1
traditional IC at a much lower cost promises to
50 satisfy that requirement. This change in percep-
tion will accelerate the adoption of IC
1,200 technology throughout the industry and, in
40
doing so, signifi- cantly impact how operators
1,000 view their marginal and mature fields.
30 With the cost barrier to entry lowered, ICs
800
may extend the life of marginal fields because
the technology to control production at the
Oil rate,

Water
600 20
sandface, without interventions, leads to higher
400 net produc- tion and ultimate recovery through
10
more efficient commingling. Similarly, projects
200 with economic scenarios so fragile that they
0 were shelved for fear the cost of probable future
2 3 4 5 6 7 8
0
Time, months
interventions would negate net profit may now
0
be brought for- ward. By using ICs in these
1 marginal projects,
>
Comparing production profiles. Well-A1 (top), equipped with an operators can save on interventions and reduce
IntelliZone Compact completion, was able to defer water breakthrough initial capex for ancillary facilities. The ability to
(blue) and reach and maintain a higher net oil production profile (green) manage reservoir parameters by controlling flow
than an offset horizontal well (bottom) completed in the same sand. The offset
to slow water ingress at the sandface also allows
well, however, was plagued by water production that resulted in lower net oil
production. (Adapted from Chen et al, reference 5.) operators to plan smaller surface facilities and
reduce water-handling costs, both of which have
significant impact on aging or marginal field
development plans. —RvF

water management, indicated that production-

The asset team compared a production pro-
ending water breakthrough would occur from the
file of Well-A1 with one in an offset horizontal
smaller, more permeable reservoir at the well’s
well completed in the same sand (above). The
heel. By shutting off that zone and opening the
former showed a prolonged period of high net
thicker, less permeable zone at the well’s toe,
oil production while water and gas break-
production would continue.14
through was deferred. The latter suffered from a
Using pressure buildup survey data, FBHP
fluctuating lower oil rate coupled with acceler-
and surface well tests, an asset team studied
ating water encroachment.
pro- ductivity and zonal reservoir deliverability
in Well-A2 to better understand the reservoir.
Technical Solution to a Market Problem
Zonal contribution was monitored using
For years, developers of oil industry technology
permanent downhole pressure gauges, and
have been stymied by an industry reluctance to
production was adjusted through FCVs at each
adopt innovative solutions. Generally, user hesi-
zone. After study- ing seven configurations, the
tancy, particularly regarding tools aimed at the
asset team deter- mined that 33% and 100%
upstream sector, has been grounded in a fear
openings on Zones 1 and 2, respectively, created
that the new system would fail when subjected
optimum flow (previ- ous page, bottom).
to the harsh realities of the downhole
environment. In

Autumn 1
 14. Chen et al, reference 5.

14 Oilfield Review