A Field Application of Successful Installation and Sequential Activation of 15,000-psi Rated Hydro-Mechanical Multi-Stage Completion in Peripheral Deep North Kuwait Jurassic Asset for Improved Completion Efficiency and Well Productivity

Abstract

Optimization of permanent liner completions in the North Kuwait Jurassic Gas (NKJG) reservoirs has been an ongoing challenge progressed on a steep learning curve within the last decade. Various completion options are field-tested in determining the optimal completion hardware and activation methodology. The asset's objectives have been multi-dimensional: preserve natural fractures, minimize formation damage, segregate, stimulate and activate optimally, while installing permanent completions hardware efficiently, which can withstand 15,000-psi differential pressure at high temperature and sour gas environment and sustain production for the well life of over 20 years. NKJG faces the enormous task of increasing the hydrocarbon production potential by over 200% within a short time period. The reservoirs are high-pressured and high-temperature (HTHP) gas condensate assets with tight matrix properties (i.e. <0.1 mD permeability), in variation with naturally fractured sections within flow-zones separated into eight segments. Preserving the natural fractures, removal of near wellbore damage and segregating flow-zones based on lithology and critical reservoir properties are important especially in peripheral subsurface locations, where the realization of full reservoir potential is not only essential for production success, but also required for appraisal of boundary conditions. For realizing these objectives, the asset custom-designed a multi-stage completion system with hydro-mechanical liner hanger packer, open-hole packers, hydraulic anchor and multiple frac ports set and activated as a drop-ball system. Due to the high completion loads, differential body and packer rating are manufactured to 15,000 psi using corrosion resistant alloy throughout, with the PBR and seal-bore assembly designed to withstand differential pressures and contraction during multiple fracturing events. Custom-designed multi-stage completion assembly (MSC-HP) was successfully installed, sequentially hydraulic-fracced and commingle-tested on flowback. Customized operational guidelines were established including a pre-set success criterion, openhole and caliper log sequences, tie-back cementation and subsequent clean out trips, followed by hole conditioning and reamer runs to compute the final drag and friction forces. Differential sticking risks were mitigated by avoiding the "pressure ramps" exacerbated by differential depletion evident in the area. Reservoir was segmented in three distinct intervals to maximize flow potential. As a result, the asset's objectives were successfully met, with the additional benefits of proving multiple zone activation, each with a complicated sequence of operational events, performed sequentially in four days. This paper documents the project cycle from successful planning and design, to installation and execution phases of the MSC-HP in peripheral deep NKJG asset. Key learnings and critical factors, which led to the successful well results in spite of less favorable subsurface location are summarized. Added complications due to the severe NKJG specs will be discussed as the number of global analogues is scarce leading to limited opportunities for the industry to learn from in unconventional/conventional mix layered carbonates.