SPE 88525

Hybrid Monobore Completion Design: An Application for Multilayer Reservoir

Indra C Ibrahim, SPE, Krisjahbana Joenoes, SPE; VICO Indonesia, Howard Otten, Baker Oil Tools

Copyright 2004, Society of Petroleum Engineers Inc.

both scenarios might be a compromise for future wells. This
This paper was prepared for presentation at the SPE Asia Pacific Oil and Gas Conference and was especially relevant for wells, which had significant
Exhibition held in Perth, Australia, 18–20 October 2004.
shallow rate potential, along with significant volumes of low
This paper was selected for presentation by an SPE Program Committee following review of
information contained in a proposal submitted by the author(s). Contents of the paper, as
rate productivity deeper in the well. Also liquid loading was
presented, have not been reviewed by the Society of Petroleum Engineers and are subject to becoming more of an issue in the 4 ½” producers so reducing
correction by the author(s). The material, as presented, does not necessarily reflect any
position of the Society of Petroleum Engineers, its officers, or members. Papers presented at tubing ID enables wells to produce longer and improve
SPE meetings are subject to publication review by Editorial Committees of the Society of ultimate recovery. For the above reasons, the subject well was
Petroleum Engineers. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers is completed as 3-1/2” monobore as long string and 3 ½” dual
prohibited. Permission to reproduce in print is restricted to a proposal of not more than 300
words; illustrations may not be copied. The proposal must contain conspicuous selective in short string to optimize the production gas and oil.
acknowledgment of where and by whom the paper was presented. Write Librarian, SPE, P.O.
Box 833836, Richardson, TX 75083-3836, U.S.A., fax 01-972-952-9435.
Introduction
VICO Indonesia is the operator of the Sanga-Sanga PSC in
Abstract East Kalimantan – Indonesia (Fig.1). VICO has four major
fields that produce approx 900 MMCFD and 30,000 BLPD.
Completion Design is a key factor, especially in Gas field There are over 200 reservoir units, and there is approximately
management, and completion design can have a large affect on an equal number of depletion drive and water drive reservoirs.
gas deliverability and the liquid production through out the The reservoirs range in size from 1bcf to >100bcf and
lifetime of a well. This paper describes a novel solution to historically wells have been as dual string completions (Fig.2).
producing gas from multi layered gas intervals, such as
encountered in VICO Indonesia’s operating area in East In 1997 a new completion strategy was adopted and since then
Kalimantan. The paper is focused on a completion in the most wells have been completed as 4 ½” Monobore
Semberah Field, which utilises a novel combination of both completion (Fig.3).
conventional and monobore completion types. Essentially
having a selective single string completion dedicated to The well which this paper details is located in the Semberah
producing the shallower reserves, whilst following a Field which was discovered in January 1974 and is located in
monobore concept for the second string to deplete deeper the northern most area of the PSC. Semberah contains
reserves. multiple oil and gas reservoirs, with production from depths of
1000' to 10,000'. Facilities for Semberah Fields were
Historically the conventional completion type in VICO was completed in 1991. To date 68 wells have been drilled and
either dual or single string (23/8”, 27/8” or 31/2”) with several almost half of the reserves have been produced from over 250
selective zones. These completions consisted of multiple reservoir tanks, with peak oil and gas rates of 15,000 BOPD in
components, SSD, multiple packers, single packers, dual 1995, and 180 MMCFD in 2000 respectively. Currently
packers that had numerous sealing areas. Some completions Semberah facilities consist of four LP compressors, two MP
became very complicated and the completion materials compressors and produces 6000 BOPD and 90 MMCFD of
themselves became a significant part of the cost of gas. The gas is transported via pipeline to the Bontang LNG
rercompleting or drilling the well. Facility where it is converted to LNG for distribution and sale
to the SE Asia market.
To address this issue a special team was formed in 1997 to
review completion procedures on a holistic basis. A 41/2” Completion History
monobore concept was developed to reduce the initial
completion costs and to initiate low cost rigless well The completion philosophy within VICO has changed
interventions to access future reserves. This change was considerably over the years. In the early field developments
pursued and has reducing the drilling and recompletion costs between 1970 and 1994, the philosophy was to use mutiple
by up to 20%, and VICO has benefited from implementing the strings. Typically the well was drilled 12-1/4” through the F
mechanically simpler, rigless interventions. However with zone and 9-5/8” casing was run. An 8-1/2” hole is drilled as
many reservoirs depleting in pressure and producing the production casing and a 7” liner is run to total depth. These
significant water volumes as well as the monobore requiring a were then completed with two production strings with
bottom up perforating strategy it was apparent that the best of selective completions. The tubing strings were either 3-1/2” or
2 SPE 88525

a combination of one 3-1/2” and one 2-3/8” tubing string. Case History
There were usually long string completion in the 7” liner, two Field characteristic
selectives between packers and behind sliding sleeves in the 9-
5/8” and a short string completion. Typically a completion The subject well was drilled on the crest of the Semberah
required 3 single packers and 1 dual packer, 3 sliding sleeves Anticline. It was a vertical hole at 1,000 ft then kicked off
and 3 FL connectors resulting in a total of 14 sealing areas, directionally with maximum angle of 20 deg to reach the first
which could be subject to leaks and communication. reservoir target at 3,850 ft TVDSS, drilling continued whilst
dropping angle to a total depth of 6,475 ft TVDSS. This well
Many difficulties were encountered during the installations of is considered primarily a reservoir management location, due
such a completions, resulting in crooked tubing because of to number of reservoirs that are not developed in other wells.
excessive setting weights, packer failures, tubing conveyed
perforating (TCP) guns not fired, sliding sleeve not moving, Well Drilling
retrievable plug problems due to junk on top and The Semberah Well was spudded on December 2003.
communication due to erosion and corrosion in the tubing Electrical logging and sampling was performed in the upper
strings. In some cases, the completions had to be pulled before section with PEX-BHC and MDT before running 9-5/8”
production had even begun. The preferred perforating method casing to 4,404’.
was to utilize TCP, to achieve deep penetration /
underbalanced perforating. These guns were hung off both the After the cementing and casing in place, the 8-1/2” hole was
long and short strings, which prevented production logging drilled until final TD at 6,665’, where PEX-BHC and MDT
tools to be run across perforated zones for reservoir evaluation logs were also run.
purposes.
Proposed Completion
In 1994, a team was formed to review and evaluate the current The well was completed as hybrid 3-1/2” monobore (Fig-4).
drilling and completion philosophy and they recommended The completion uses 3-1/2” production tubing as both short
implementing a monobore program. The recommendation was string and long string. The completion was run in three
to simplify these completions by utilizing a 4-1/2” monobore sections: The initial run was a 3-1/2”x 7” x 9 5/8”Flex lock II
completion from total depth (TD) to the surface. These types liner hanger and ZXP with 10ft extension. However due to the
of completion are less expensive to drill and complete with reservoir pressures expected standard tie back seals could not
around saving of over $ 200,000 per well down to the the be used, Baker Oil Tools offered a design which included
deepest zone at 14,000 ft. These completions are mechanically placing 4.00”ID packer Seal Bore Extension below the Flex
simpler initially because there was no tubing strings and Lock II. Thus providing a means of tying into the liner hanger
perforating can be done without the workover rig and it is with the Dual Completion and a smaller cross-sectional area,
quicker to add and isolate zones. If additional deliverability is limiting the force pushing up. The 3 ½” slimhole type II
required, more zones can be perforated to provide extra gas landing collar with ball seat and 2 pump down plugs provided
rate. With a monobore tubing string, it is not feasible to a method to set the hanger before cementing. The HR
perforate with TCP. The conventional wireline method is hydraulic setting tool allowed the liner to be rotated while
feasible, but has underbalanced limitations, both because of cementing. A concern was the 20ft shoe track and having
restrictions with the length of the lubricator and the risk of accurate displacement during cementing. If the plug did not
bird nesting the wire if guns are blow uphole. Initially for bump there was a chance of having a wet shoe. The dual plug
deeper low permeability sands VICO adopted modular guns system allowed careful monitoring of the cementing until the
allowing them to safely perforate underbalance. Subsequent plug landed and sheared the indicating sleeve. This gave the
zones would be perforated shallower in the wells using e-line cementer a valid displacement volume for the following plug
after isolation of the deeper zones if depleted or watered out, and so over displacing was avoided. When cement was job
using bridg plugs. completed, the tools were released and cement was reversed
out above the liner.
The 4-1/2” monobore provides the necessary producing rate
compared to two strings of 3-1/2” tubing. However in the The second stage was to run the Baker FH hydraulic single
lower permeability reservoirs, this 4-1/2” monobore is packer: with a TCP-gun Y-Block Model to sting into PBR
susceptible to liquid loading problems. In addition with below the liner hanger. TCP guns were used to allow under
several zones open at once and large variations in pressure balance perforation and to flow test immediately after guns are
some wells were shown to suffer from cross flow. This fired. On top of the single packer, a Baker LXE tubing
situation was experienced in conventional selective disconnects was installed to release from the FH packer and
completions (with several zones open behind one SSD) as well allow the re-connection of the upper completion.
as in monobores. Cross flow occurred from a higher pressured
to a lower pressured zone. However, when the flowing bottom The third stage was to run a hydraulic dual packer with a TCP-
hole pressure eventually drops below the shut in tubing head gun conveyed in the tail of its short string. The 3-1/2” long
pressure, the zone will start to contribute and produce gas. string was latched to the hydraulic single packer. A SPM was
run about 60 ft above the dual packer. The last step was to run
3-1/2” tubing as the short string and sting into the dual packer.
SPE 88525 3

Both of the zones were unloaded by N2 gas to achieve under Cost effective
balance condition, a bar was dropped, to initiate perforations In term drilling and completion cost, there would be some
and the well was tested. additional cost for offset 3-1/2” tubing, TCP guns, a liner
hanger and accessories but since we do not run casing 4-1/2”
to the bottom. Average additional total cost is around $ US
Flexibility Usage 100,000 compared to the conventional monobore completion
As Shown in Fig-4, using 3-1/2” tubing provides better but still less compared to the conventional selective
hydraulic performance than 4-1/2” tubing. This is already completion type that was used before in VICO.
proven in Semberah Field where it has been found that some
wells are killed by mist water flow, as the gas pressure from
the reservoir could not overcome the slip velocity to bring the Conclusions
mist water to the surface. The larger flowing area in the tubing 1. The hybrid monobore completion has been demonstrated
will create less hydraulic force upward. By using 3-1/2” to be a technical and economic alternative to the 4-1/2”
tubing, smaller flowing area will be given and more force monobore.
upward will be create to the mist rather than the larger one and 2. The hybrid monobore completion has a very good
let the mist bring to the surface. application in multilayer reservoirs.
3. It gives more flexibility in producing in VICO’s case,
As the oil production is also constantly in decline, there is a allowing continue to produce gas.
need to find a way to increase oil production without leaving 4. It allows increased production whilst not sacrificing
gas production as a second priority. This hybrid monobore reservoir management.
provides a solution if an oil zone is found as well as other gas
zones in the same well. The oil still can being produce by
using the short string and the gas is produced from long string Acknowledgements
with monobore technique. The author would like to thank BP , ENI, EPICOIL Universe,
the management of VICO Indonesia, BP Migas to publish this
Deliverability paper.We also would like to thanks to Ronald Gunawan,
The Monobore completion technique provides only one size Semberah Asset Team and Drilling Department for support
production string from the TD to the surface. It has been and discussion.
selected as a completion strategy in VICO Indonesia. The
technique is applied to 4-1/2” as production tubing cemented
in 8-1/2” hole. As most of the reservoirs are stackedon top of Nomenclature
one another, as a typical fluvial-deltaic sedimentation, the TCP: Tubing Convey Perforation
reservoir management become critical. Many problems occur PBR: Polished Bore Receptacle
especially if several zones are open at one time and as zones BHA: Bottom Hole Assembly
deplete at different rates. Cross flow, liquid holds up are PPG: Pound Per Gallon
limitations imposed by the size of the production string, FTHP: Flow Tubing Head Pressure
resulting in reduction of the well deliverability. Commingling ID: Inner Diameter
production from some zones would not achieve the optimum TD: TotalDepth
production since due to cross flow. For some case, by isolating
the low-pressure zone to avoid the cross flow means
sacrificing that zone which is not good reservoir management. References
Hybrid monobore technique provides the maximum control 1. Ismanto, B., Mike Hass, John Dyer: “New Well
for the upper zone without leaving the monobore concept for Architecture Successfully Optimizes the development
lower zone. Long string using 3-1/2” tubing maintains an even of fluvio-deltaic Multi-layered Gas Field” paper SPE
ID to provide that intervention tools can go down without any 64394
significant restriction. The short string also uses 3-1/2” tubing 2. Gunawan, R., and Dyer, G.R:”Tubing Size
to optimise flow rate. Later in well life, gas can be produced Optimisation in Gas Depletion Drive Reservoirs”, paper
from the long string as in the monobore type wells, while the SPE 37001 presented in 1996 SPE Asia Pacific Oil and
short string provide the low pressure gas or even oil from the Gas Conference, Adelaide, October 28-31.
upper zone. If the FTHP is too high in long string side, the 3. “Matrix Engineering manual, Well Performance”,
short string can also act as production tubing by use both Schlumberger Dowell manual.
tubing strings and isolate the oil zone. From production 4. Brown, K. E., and Lea. F.:”Nodal System Analysis of
optimisations point of view, this completion type is more Oil and Gas Wells”, JPT (Oct.1985) 1751.
reliable instead of conventional monobore. This type can 5. Ikoku, Chi U., Natural Gas Reservoir Engineering, John
produce more without sacrificing reservoir management. Willey & Sons (1984) 141.
4 SPE 88525

Fig-1 Semberah Field in in East Kalimantan

FINAL WELL SKETCH
Semberah - 58
GL = 57.1 ft, DF = 91.6 ft
Tubing hanger

13-3/8"Csg,68.0 ppf K-55 at 423'

SPM at 991'

9-5/8"Csg, 47.0 ppf N-80 BUTT at 1,400'

2-3/8" 4.7 ppf N-80 CS Uncoated Tubing
SPM at 2,001'
Locking Snap latch
7" OTIS BHS Dual Packer at 2,224'
2-3/8" X-Nipple at 2,259' 2-3/8" SSD at 2,260' ( Open ) Aug. 20, 2002
2-3/8" Ported Sub w/ Fill disc at 2,295'
2-3/8" XN-Nipple at 2,301'
2-3/8" MTR at 2,312'
Perfs : 2,383' - 2,395' ( F-76A ) O
Perfs : 2,404' - 2,410' ( F-76A ) BB
Squeezed Perfs2,403' - 2,421' (F-76A)

2-3/8"BXE-Connector at 2,667'
7" BAKER FHL Packer at 2,686'
Squeezed Perfs : 2,722' - 2,732' (F-80A) 423 psi (3.0 ppg)

2-3/8" LXE-Connector at 5,829'

7" BAKER FHL Packer at 5,848'
2-3/8" SSD at 5,884' ( Closed )

Perfs : 5,935' - 5,949' ( I-93A ) GG G

Initial Rate 1 mmcfd 54 psi FTHP 48/64" chk 2-3/8"LXE-Connector at 6,131'
60% BSW 5K ppm Chloride 2,200 psi SITP
( June 22, 2000 ) 7" BAKER FHL Packer at 6,150'
2-3/8" SSD at 6,192' ( Open ) July 05, 2000

Perfs : 6,206' - 6,232' ( I-98A ) FF G

Initial Rate 3.7 mmcfd 240 psi FTHP 48/64" chk 2-3/8"LXE-Connector at 6,361'
10% BSW 8 Kppm Chloride 2,340 psi SITP
7" BAKER FHL Packer at 6,380'
( June 20, 2000 )
2-3/8" SSD at 6,416' ( Closed )

Perfs : 6,440' - 6,449' ( I-103B )

6,464' - 6,501' ( I-104A ) DD G
6,522' - 6,533' ( I-105A )
2-3/8"LXE-Connector at 6,585'
7" BAKER DB Packer at 6,602'

2-3/8" SSD at 6,635' ( Closed ) w/ PX-Plug and prong

2-3/8" XN-Nipple at 6,668 ' w/ PXN-Plug and prong
2-3/8" MTR at 6,700'
TOF at 6,790' +/-
3,700 psi,10.4 ppg J-70A :6,869'-6,892'(23')
3,650 psi,10.1 ppg J-71A :6,931'-6,955'(24') Initial Rate 0.8 mmcfd 40 psi FTHP 48/64" chk
45% BSW 2 K ppm Chloride 2,500 psi SITP
4,070 psi,10.7 ppg J-76A :7,325'-7,340'(15') ( June 16, 2000 )
4,070 psi,10.6 ppg J-76A :7,357'-7,367'(10')
3,500 psi,9.1 ppg J-77B :7,402'-7,410'(8')
CALCULATE BHP = 2,950 psi
PBTD at 7,503'
7" Liner, 29.0 ppf L-80/N-80 BUTT at 7,508'
TD at 7,510' Spud date : 11-Dec-1995
Prepare by : FB Drawn by : FB Checked by : SI Recompletion C om pletion D ate :
Date : 230304 Date : 230304 Date : 230304 D ate : May 30, 2000

Fig-2.1 Dual Completion Schematic

SPE 88525 5

Fig-2.2 Dual Completion Schematic

W ELL SK ETC H
Sem berah -64 Perfs : I-70A /71A
DF Elevation : 103.96 Ft. Zero is DF : 23.4 Ft above hanger

20"Csg @ 97'

13-3/8"Csg,68.0 #/ft K-55 BTC @ 499'

9-5/8"Csg,47.0 #/ ft N-80 BTC @ 2385'

293 Jts, 4-1/2"Csg, 11.6 #/ ft Hydrill 563

Perfs : 7555'- 7570' (I-70A ) G

Perfs : 7590'- 7596' (I-71A )
7638'- 7664' (I-71A ) G

CC

Perfs : 7733'- 7741' (I-72B ) G

BB
Perfs : 8570'- 8590' (I-88A ) AA G

EZSV (PBTD) @ 8,650'

FC @ 8,948'
4-1/2"Csg, 11.6 #/ft Hydrill 563 @ 8950'
TD @ 8,950'
Spud date : 13-May-2003

Prepared by : FB Drawned by : FB Checked by : EDI |X| New Completion

Remarks :
Date : 010903 Date : 010903 Date : 010903 Date : 110603

Fig-3 Monobore Completion Schematic

6 SPE 88525

tAs

WELL SKETCH
Semberah # 68
Tubing hanger
DF Elevation :23.4 ft
1 Jt,3-1/2"Tbg CS 9.3 # N-80
X-Over,3-1/2"CS PIN x 3-1/2"CS PIN
3-1/2"(3)Pup Joints CS 9.3 # N-80 3-1/2"(2)Pup Joints CS 9.3 # N-80

30" C sg
13-3/8"C sg,68.0 #/ftK -55 BTC @ 477'
103 Jts,3-1/2"CS Tbg,9.3 #/ft N-80 100 Jts,3-1/2"CS Tbg,9.3 #/ft N-80

Future perforations
G -75A :3,268'- 3,272' 1,440 psi 3-1/2"SPM CS w/Dummy Valve Type R/A "JDC @ 3190'
X-Over,3-1/2"CS Box x 2-3/8"EUE Pin @ 3286' 3 Jts,3-1/2"CS Tbg,9.3 #/ft N-80

W /L Lock Snap Latch@ 3306' 3-1/2"(1)Pup Joint CS 9.3 # N-80

9-5/8"G T D ualPacker51A w /60 K Sherring @ 3,313'
X-Over,3-1/2"CS Box x 2-3/8"EUE Pin @ 3317'
2-3/8"X-N ipple @ 3,337' 2 Jts,3-1/2"CS Tbg,9.3 #/ft N-80
Ported Sub @ 3367' 3-1/2"Baker "CMD"SSD CS w/2.75 "X" @ 3382'
2-3/8"XN -N ipple @ 3,388' 1 Jt,3-1/2"CS Tbg,9.3 #/ft N-80
X-Over,2-3/8"CS Box x 2-3/8"EUE Pin @ 3405' 3-1/2"(3)Pup Joint CS 9.3 # N-80
2-3/8"Mech. Firing Head @ 3406'
Perfs : 3,430' - 3,440' ( G-77A ) BB
3,448' - 3,460' ( G-77A )
3-1/2"(3)Pup Joint CS 9.3 # N-80
14 Jts,3-1/2"CS Tbg,9.3 #/ft N-80
3-1/2" LXE C onn C S w /2.75 "X" @ 3,916'
3-1/2"(1)Pup Joint CS 9.3 # N-80
9-5/8"FH Single Packer51A 2 Retw /60 K @ 3,935'
3-1/2"(1)Pup Joint CS 9.3 # N-80
3-1/2"Baker "CMD"SSD CS w/2.75 "X" @ 3980'
Baker M od D D Shock A bsorber @ 4015'
Y-Block Sub
Perfs : 4,039' - 4,052' ( I-72 A ) AA

TOL @ 4,171'
7" x 9-5/8" Liner Hanger w/ Packer
7" Pup joint
X-over 7" x 5"
5" Seal Bore Extension
X-over 5"x 3-1/2" G-22 Seal Locator Assembly

9-5/8"C sg,47 #/ftN -80 BTC @ 4,407' YY

TOC @ 4,492'

77 Jts,3-1/2"CS Hyd Tbg,9.3 #/ft N-80

Perfs : 5498' - 5508' ( I-97 A )

5508' - 5515' ( I-97 A )

Landing C ollar @ 6,643' 3-1/2"(2)Pup Joint Ksi CS Hyd 9.3 # N-80

Single FloatC ollar@ 6,649'

3-1/2"C sg,9.3 #/ftN -80 C S H ydrill@ 6,662'
TD @ 6,672'(M D )

Prep. by : FB Drawn by : FB Checked by : ER Date : 25-Dec-03 Rev'd. by : - Date : -

Remarks :
Date : 260404 Date : 260404 Date : 260404 | | New Completion
Petroleum Engineering & Development Dept. - JKT

Fig-4 Hybrid Monobore Completion Schematic