Holistic Approach Recipe for a Successful Deployment of ICD Lower Completion Achieving 31% Time Optimization for LSTK Projects in a Middle East Field

Considering the nature of lumpsum turnkey contracts in the Middle East, multiple performance optimization initiatives have been engineered to accelerate well delivery without compromising well acceptance and compliance criteria. One of the most critical operations in these wells is the successful and efficient running of Inflow Control Device (ICD) as part of the lower completion across ±5, 000 feet of 6⅛-in. open hole lateral. Historically, this operation was associated with severe non-productive events and in worst case scenario, abandonment of entire section and eventual sidetrack. This study discusses detailed engineering analysis to enhance open preparation without a need to perform wiper trip with drilling BHA by creatively optimizing the design of cleanout and reaming bottom hole assemblies (BHAs) and the strategy of logging operation. Historically, dedicated trips were separately performed for borehole logging, open hole conditioning and cased hole cleanout. These trips were combined into a single BHA through application of fit-for-purpose technologies and optimization of operational sequence to minimize completion phase operational time. Moreover, risk of differential sticking while running completion string across highly permeable horizontal lateral was reduced by utilization of optimum completion fluids and efficient centralization program. Finally, an integrated model of real-time monitoring that interlinks trajectory, open hole, and BHA data and produces a sophisticated and accurate simulation of wellbore conditions based on previous logging and tripping data allowing for in-time intervention even prior to running completion string into wellbore. During the completion campaign of over 30 wells, all engineering, operational and monitoring solutions have been implemented and successfully allowed for 31%-time reduction in completion related operation. The creative drilling BHA design enabled elimination of mechanical wellbore risks associated with wellbore tortuosity and under-gauge and washed-out hole and thereby eradicating the need for wiper trip during drilling phase which was conducted to confirm hole conations prior to preforming Wire Line Tough Logging Condition (TLC) operation. This decreased well construction time by more than ±12-24 hours as the drilling BHA was directly pulled out hole to surface after reaching target well depth. Combined BHA strategy and optimization of operational sequence enabled wellbore cleanout, logging, and simulation to be conducted on single BHA run instead of three runs (TLC-logging run, reaming/ dummy BHA run, cleanout BHA run) which reduced overall well construction time by over ±48 hours. The three BHA runs were not historically possible to be combined due to tools and technology limitation as will be discussed in the following manuscript. Finally, proper selection of optimum drilling fluids, and bridging strategy integrated with enhanced centralization program and real-time monitoring system of open hole have successfully ensured the deployment success of ICD lower completion in all wells where the approach was implemented. The manuscript shifts the focus away from fragmented engineering solutions into more integrated and multidisciplinary solutions that maximize the optimization's impact on the entire construction process rather than individual operation. The impact of this project has been acknowledged regionally and established a benchmark on the way of conducting lumpsum turnkey business.