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DC166209 DOI: 10.

2118/166209-PA Date: 19-June-14 Stage: Page: 165 Total Pages: 17

Intelligent Completion Inside Uncemented


Liner For Selective High-Rate Carbonate
Matrix Acidizing
A.W. Kent, SPE, D.W. Burkhead, SPE, R.C. Burton, SPE, K. Furui, SPE, S.C. Actis, SPE, K. Bjornen, SPE,
J.J. Constantine, SPE, W.W. Gilbert, SPE, R.M. Hodge, SPE, L.B. Ledlow, SPE, M. Nozaki, SPE,
A. Vasshus, SPE, and T. Zhang, SPE, ConocoPhillips

Summary Ekofisk wells have illustrated the difficulty of achieving effective


This paper describes the design, testing, installation, and perform- cement along lengthy reservoir targets. The openhole fully com-
ance of the first fully completed well by use of an intelligent inner pleted solution combining an accessorized uncemented liner with
completion inside an uncemented liner with openhole packers for an inner intelligent-completion string will allow operators to push
zonal isolation. The well-design concept evolved from technical the limits in terms of lateral length while maintaining full control
challenges associated with completing long cased-and-cemented over producing and nonproducing zones.
laterals in the mature Ekofisk waterflood. The term fully com-
pleted implies full reservoir access along the pay length for pro- Introduction
duction and high-rate matrix acid stimulation by use of limited The Ekofisk field is in the central part of the North Sea, off the
entry for fluid diversion within well segments. southwestern coast of Norway. The sea depth in the area is
The paper covers the development and qualification of custom 230–250 ft. The Ekofisk field produces from the naturally frac-
openhole 75=8-in.-liner components that can handle high differen- tured Ekofisk and Tor chalk formations of the early Paleocene and
tial pressures and severe temperature fluctuations of 200 F; the late Cretaceous. The reservoir chalk has high porosity but low
marriage of this complex liner with a five-zone intelligent-comple- permeability, with an oil column of approximately 1,000 ft at
tion system; and results from 1 year of system-integration testing. depths ranging from 9,000 to 11,000 ft below sea level. Typical
The paper also discusses the strategic placement of both mechani- oil gravity is between 30 and 40 API, with average hydrogen sul-
cal openhole and inner-string packers based on caliper and drilling fide content of 35 ppm (0- to 300-ppm range) and 2.5 mol% car-
logs; challenges met and overcome during installation; and com- bon dioxide. With an initial pressure of 7,100 psi, Ekofisk was
prehensive downhole-gauge data that confirms the performance of originally developed by pressure depletion and was expected to
each component before, during, and after the stimulation. have a relatively low recovery factor of approximately 17%. Her-
The Ekofisk field waterflood began in 1987 and continues to mansen et al. (1997) describe a significant increase in gas/oil ratio
date, exceeding expectations for improved oil recovery while miti- (GOR) from 1,500 to 9,000 scf/STB in 1986 because of depletion
gating reservoir compaction. As the waterflood matures, new wells below the bubblepoint of 5,560 psi at 268 F. Since then, limited
are more often found partially water-swept. Limited infrastructure gas injection and comprehensive water injection have contributed
for lifting and handling the high water production has led to to a substantial increase in oil recovery. Large-scale water injec-
increased emphasis on isolating these water-swept intervals. tion started in 1987, and experience has shown that water dis-
Cased, cemented, and perforated completions have traditionally placement of the oil has been more effective than expected, with
been used for this service. Effective placement of cement is chal- current projections indicating a recovery factor exceeding 50%.
lenging in horizontals 4,000–8,000 ft in length, where rotation of Repressurization of the reservoir has returned the field average
the liner is not possible and high effective-circulating densities GOR close to the original value of 1,500 scf/STB (Agarwal et al.
limit rates during cementing. Wide variations in reservoir pore 2000). Scale-inhibitor treatments have been performed regularly
pressures, often in excess of 2,000-psi difference along the lateral, since 1996 to combat the high barium sulfate scaling potential
are typical of the Ekofisk chalk and compound the difficulties of related to floodwater and formation-water incompatibility (Todd
cementing. As a result, a new method for zonal isolation has been and Yuan 1990). Compaction of the soft, high-porosity chalk pro-
developed to ensure the success of future infill-drilling campaigns. vides an additional recovery mechanism. This reservoir compac-
The design and careful planning that went into the fully com- tion has resulted in subsidence of the seabed, which is now at
pleted openhole uncemented-liner strategy resulted in a successful more than 30 ft in the central part of the field. As a consequence
field trial and has proved this solution to be an effective alterna- of water injection, the rate of subsidence has slowed significantly;
tive to cemented reservoir liners in long horizontals where zonal however, current projections indicate that subsidence will con-
isolation is critical. Use of the intelligent-well system (IWS) al- tinue at a few inches per year for the remaining life of the field.
lowed offline acid stimulation without rig, coiled-tubing, or wire- Hermansen (2008) provides a more detailed account of how the
line intervention. What would have traditionally been a significant waterflood has affected the Ekofisk field development.
water producer, with three water-swept zones totaling nearly Completion practices at Ekofisk have evolved over time. Ini-
2,000 ft across a 4,000-ft reservoir section, has turned out to be tial vertical wells were cased, perforated, and acid fractured. As
one of the best oil producers in the field, with nearly zero water horizontal wells were introduced to the field, the long horizontal
cut. Production results show high productivity with highly nega- sections were also cased and cemented. The heavy-walled produc-
tive acidized-completion skins. tion liners were then perforated in 10-ft clusters (also known as
With large investments in intelligent completions to provide stations), typically at 1 shot/ft, every 200–500 ft along the length
zone-specific inflow control and water shutoff, isolation outside of the lateral. The wells were then stimulated with acid by bull-
the liner becomes much more important. Over recent years, the heading alternating stages of pad and acid with ball sealers for
diversion. These cluster-perforation designs typically showed
high initial productivity followed by sharp production declines
Copyright V
C 2014 Society of Petroleum Engineers
(Snow and Hough 1988). Production-logging results indicated
This paper (SPE 166209) was accepted for presentation at the SPE Annual Technical that many of the perforation clusters were not effectively stimu-
Conference and Exhibition, New Orleans, 30 September–2 October 2013, and revised for
publication. Original manuscript received for review 23 October 2013. Revised manuscript lated, with some clusters, typically at the heel of the well, receiv-
received for review 20 March 2014. Paper peer approved 15 April 2014. ing far more acid than required and others receiving little or no

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Norway Acid Stimulation Injection Volume History Data


100 bbl of 28% HCI Dissolves 139 ft3 of Chalk Matrix (PHIE = 35%)
1,000

Deformation Status
Acid Injection Volume, bbl\station

Severe
Minor
None
100
Unconfirmed

10

1
Individual Wells

Fig. 1—Sample of 28 wells. Each bar represents a well. Acid-injection volume per station is defined by the acid volume divided by
the number of localized entry points for acid to reach the reservoir face.

acid. This ineffective treatment diversion was often made worse by scale-inhibitor treatments later in the life of the well. This led to the
performing remedial acid treatments by bullheading additional acid Ekofisk 2/4-B-19C (hereafter referred to as B-19C) well design.
into the wells, generally into the previously stimulated intervals with- The objectives of the new B-19C openhole uncemented-liner
out reaching the untreated perforation clusters. The large volumes of completion are to enhance well productivity and recovery; provide
acid placed into a limited number of perforation clusters weakened water-shutoff capabilities and selective zone access for scale/acid
the rock and, coupled with reservoir compaction and associated chalk treatments; allow stimulation and remedial scale treatments without
movement, led to liner buckling. Liner buckling then led to the loss rig, coiled-tubing, or wireline intervention; and provide adequate
of zonal access and, in extreme cases, pipe failure and loss of the liner stability to improve well access and prolong well life.
well. Restricted access to the reservoir liner impeded well interven-
tion and remedial opportunities. Fig. 1 illustrates the correlation
between high acid volume and casing failures. Functional Requirements for the Uncemented
A short (fewer than 10 ft) interval of multiple perforations, or Liner and Intelligent Completion
perforation cluster, is a station. As shown in Fig. 1, wells with acid- As the B-19C uncemented-horizontal-completion team worked on
injection volumes greater than 100 bbl per station have a much the design, a number of functional requirements were established
higher liner deformation and failure rate than wells stimulated with to improve well performance, reservoir management, and reser-
lower acid volumes per station. The high-failure wells are all clus- voir-liner integrity. These functional requirements include:
ter-perforated wells where large volumes of acid were injected into • Uncemented reservoir liner with openhole packers, provid-
few perforation clusters across a long treatment interval. ing effective hydraulic isolation of water-swept intervals while
To improve acid stimulation and reduce casing deformation allowing high-pressure/high-rate acid stimulation and oil produc-
and well failures, a new class of wells was introduced to the field. tion from target oil zones
These new, fully completed wells were perforated along the entire • Full completion of entire length of productive zones, by use
horizontal section and used limited-entry techniques to distribute of high-rate matrix-acid stimulation, in place of acid fracturing, to
acid more evenly over the reservoir intervals. Perforations were improve post-acid completion skin, improve well productivity,
generally spaced at one hole for every 10 ft of reservoir net pay and minimize liner deformation for extended well life
along the horizontal section, with stimulation volumes on the • Ability of reservoir-drilling fluid system to allow for effec-
order of 20 bbl of 28% hydrochloric acid (HCl) per perforation. tive acid cleanup of mud and filter cake without causing compati-
These new completion techniques proved successful in providing bility issues
high-productivity completions with low well-failure rates. Post- • Surface controlled access to productive zones in the horizon-
stimulation skin values have been found to be from 4 to 4.5 tal lateral to allow
(Furui et al. 2012a, b), whereas liner deformation and well failures * Unlimited downhole-valve manipulations (open/close)

have decreased, as shown in Fig. 1. In Fig. 1, the wells stimulated without wireline or coiled-tubing intervention
with fewer than 100 bbl per station are the fully completed wells, * Flow control into and out of each zone during stimulation,

where each perforation represents a station when spaced at least production, and scale-inhibitor squeezes
10 ft from adjacent perforations. * Uniform acid stimulation of entire length of each zone

The new fully completed designs were first implemented in hori- * Uniform scale-inhibitor treatments and remedial-acid treat-

zontal wells with cemented liners, but as confidence in the designs ments along entire length of each zone
increased, conceptual planning moved to openhole designs with * Well-test flexibility

uncemented liners. An early field trial of the fully completed well * Measurement of zonal pressure/temperature data

design in an openhole, uncemented-liner completion proved favor- • Ability to run the predrilled reservoir liner as a solid, pressure-
able, with no liner deformation seen after 3 years of production. To sealed liner to allow
further improve the fully completed well designs, it was desired to * Elimination of an inner string, as normally required with a

combine the benefits of a surface-operated, IWS for downhole-flow conventional predrilled liner
control with limited-entry diversion to provide uniform acid distribu- * Circulation and rotation, if required, while running the

tion along pay intervals in an uncemented liner. Although primarily liner through the openhole
designed to assist in the initial acid stimulation, these benefits would * Ability to circulate and maintain well control while run-

help achieve more-effective diversion during remedial acid and ning the IWS completion string

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DETAIL VIEW
Water Adjacent Oil Zones

9½-in.
Openhole

Liner Hanger Packer

1358-in.
Surface Casing Rock Openhole Expansion ACV ASP
Anchor Packer Joint Toe Isolation
Valves
108 4-in. Intermediate Liner

DETAIL 7 5 8 -in. Uncemented Liner

Fig. 2—A conceptual drawing of the uncemented liner showing the relative positions of liner components.

* Pressure activation of all liner components, including open- tem (Fig. 2). All components were designed with a drift diameter
hole packers at one time equal to or larger than the 6.125-in. drift diameter of the 75=8-in.
* Elimination of tubing-conveyed or wireline-perforating liner. An expanded view of the 75=8-in. liner is provided in Fig. 2
operations to show the relative position of these liner components. A descrip-
• Allow for successive acid stimulation of each zone after tion of each 75=8-in.-openhole-liner component is provided here to
moving the rig off location, without the need for wireline or explain its purpose.
coiled-tubing intervention
• Ability of completion equipment to resist pipe movement and Liner-Hanger Packer. The ISO14310V0 liner-hanger packer
stress failure as a result of thermal and hydraulic loads induced dur- was tested to 100,000 lbf in tension and 275,000 lbf in compres-
ing stimulation, water injection, or production operations sion with 7,500-psi applied pressure. The liner-hanger packer
• Ability to handle stimulation differential pressures between would be activated hydraulically using a ball drop sub as soon as
zones of up to 5,000 psi the liner was landed on bottom.
• Ability to handle temperature change of 200 F during
stimulation. Toe Isolation Valves. Two valves would be run in series at the
shoe of the liner. Both valves would be run in the open position while
running in hole to allow for pipe fill. A battery-powered, electronic-
Design Features of the Uncemented Liner type valve would be run on bottom as the primary valve and set to
Completion automatically close on a timer an estimated 12 hours after reaching
The drilling of the 91=2-in. horizontal lateral in the Ekofisk and Tor TD. Pressure activation would allow for the valve to be reopened if
chalk reservoirs would be performed by use of an 11-lbm/gal oil- premature closure occurred. A ball drop-type valve would be run
based (“oil-based” indicates inverted phase) emulsion containing above the electronic valve as a contingency, in case the electronic
60 lbm/bbl calcium carbonate. This system is unique in that it lays valve did not close as planned. The main function of both toe valves
down an oil-wet calcium carbonate filter cake, which can be con- was to provide permanent hydraulic isolation in both directions once
verted to a water-wet filter cake once acid is applied and the pH is closed. During actual well operations, the primary valve worked as
lowered (Luyster et al. 2011). The water-wet filter cake, consisting intended and the backup valve was not activated.
almost entirely of calcium carbonate, can be dissolved with HCl,
allowing for effective stimulation of the entire completion length. Metal Expandable Openhole Packers. These specially designed
After drilling the reservoir section, a dedicated trip with a stiff openhole packers (Hazel et al. 2013) would be positioned in the
roller-reamer assembly would be made. This roller-reamer assembly liner string to provide hydraulic isolation between strategically
was designed to imitate the stiffness and geometry of the reservoir defined zones in the horizontal section. Design requirements
liner and liner components as closely as possible. Multiple 9.44-in.- called for the packers to provide hydraulic isolation at up to
diameter stabilizers were stacked between pony collars over a total 5,000-psi zone-to-zone differential pressure in openhole sizes up
length of 100 ft behind two 9.5-in.-diameter reamers. This was the to 101=2 in. Porosity and resistivity responses generated by log-
same length as the stiffest openhole liner assembly, two adjacent ging-while-drilling (LWD) tools during the drilling process would
openhole packers, and an anchor (Fig. 2). The purpose of the reamer be used to differentiate pay zones from zones that had been swept
assembly was to smooth out any doglegs and remove any problem- by the waterflood. The entire well team was involved in determin-
atic ledges in the openhole section. A regular bullnose was run on the ing which zones required isolation, by use of the location of
bottom of this assembly to reduce the risk of accidental sidetracking. faults, caliper data, porosities, water saturations, and pressure
This reamer run would also provide a field estimate of drag for cali- data. Two openhole packers were placed at the end of each zone
brating torque-and-drag models before running the reservoir liner. to provide zonal isolation during stimulation and production. The
Once the wellbore was conditioned, a 75=8-in. 51.2-lbm/ft openhole packers would be set hydraulically by pressuring the
Q125, metal-to-metal seal, 6.125-in.-drift, openhole liner system entire length of the liner to a pressure differential of 10,000 psi,
would be run to total depth (TD) in the 91=2-in. horizontal lateral thereby permanently deforming the packers’ 20-ft metal expanda-
on drillpipe. ble sleeve. Outside the metal expandable sleeve, 42 hydrogenated
A number of components would be run as part of the liner nitrile butadiene rubber elastomeric elements provided additional
design to meet the functional requirements of the completion sys- bidirectional seal integrity.

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0.687-in. Nominal 0.601-in. API


Wall Minimum Wall

Fig. 3—Cross section of ASP installed in 75=8-in., 51.2-lbm/ft liner.

The openhole packers were designed to provide hydraulic isola- expand up to a maximum of 36 in. because of cool down during
tion between all zones during the acid-stimulation and production stimulation. Actual movement of the expansion joints in the B-
phases. The key challenge was the stimulation design case of inject- 19C completion was expected to be less than 18 in. in all cases,
ing 75 F acid at 60 bbl/min. Because of the tremendous forces depending on the chosen length of each zone.
exerted by the large thermal and hydraulic loads during acid stimula-
tion, special consideration was given to allowing for liner contraction Acid-Soluble Plugs (ASPs). These plugs (Fig. 3) served to
and stabilization of the openhole packers. Without such provisions, • Allow for running of a pressure-tight liner, thus enabling the
tensile forces within the 75=8-in.-liner string would exceed 600,000 pressure activation of all liner components.
lbf. Such high tensile forces could cause the openhole packers to slip • Eliminate the need to perforate the liner, providing reservoir
along the formation, resulting in possible acid leakage around the access by dissolving the plugs with acid.
packers and loss of ability to seal in the openhole. • Prevent fluid loss while running the intelligent inner-comple-
tion string. Each of the plug’s ports was drilled with a 0.20-in. en-
Rock Anchors. Rock anchors were designed to minimize liner trance hole to create a limited-entry effect during stimulation. The
and packer movement during stimulation and production. Each diagram illustrates the geometry of the liner ports and ASPs.
rock anchor would consist of two sets of three independent slip
segments that were designed to tolerate variations in openhole di-
Acid-Circulating Valves (ACVs). ACVs would be included at
ameter from 91=2 to 101=2 in. A single rock anchor was positioned
one end of each productive zone to allow for acid to be circulated
adjacent to or between each set of openhole packers in near-gauge
into the wellbore after running and setting the intelligent-comple-
hole, thereby providing additional anchoring support of up to
tion system. The purpose of the acid-circulation process is to effec-
200,000 lbf for the packers. Dual anchors (also known as toe
anchors) were designed specifically for the liner shoe with a cu- tively place acid in the 75=8-in.-liner/IWS-string annulus of the
targeted treatment interval and dissolve the ASPs described previ-
mulative anchoring capability of 600,000 lbf. The anchors would
ously. This operation is described in more detail later in the paper.
be positioned to minimize the risk of acid exposure during stimu-
With the plugs dissolved, the stimulation process could proceed.
lation, because acid would likely weaken the rock in which the
The ACVs were run in the closed position, allowing for a pres-
anchors were set. The rock anchors were designed to be hydrauli-
sure-tight liner while running in hole and the subsequent open-
cally activated at 3,000 psi.
hole-packer-setting process. Dual ACV-shifting tools were run as
part of a subsequent liner-cleanout trip. Below the shifting tools, a
Expansion Joints. One expansion joint would be run near the specially designed valve-position-logging tool with memory gauges
middle of each zone to relieve tensile loads that were expected to was run to verify that the ACVs had been successfully shifted to
develop during stimulation because of thermal contraction and the open position. A closed ACV would have prevented acid from
ballooning. The expansion joints were designed to release at being spotted to dissolve the ASPs, thus preventing access to the
5,500-psi differential pressure during the openhole-packer-setting zone of interest. Rupture disks, installed in the ACV flow ports,
process. Hydraulic expansion during the pressure-setting process prevented fluid losses until the intelligent-completion string was
would be prevented by establishing two confining fixed points, safely in place. Fig. 4 shows a diagram of the ACV, an ACV-shift-
one at the bottom and one at the top of the liner. Toe anchors ing tool, and the memory-logging tool.
would serve as the fixed point on bottom in case the liner did not
reach TD, and the liner hanger would serve as the fixed point at
the top of the liner. The upward piston force on the liner hanger Design Features of the Intelligent Well System
would be reduced by applying annulus pressure during the pres- The B-19C upper-completion configuration was dictated by two
sure-setting process. The expansion joints were designed to requirements: reservoir production zonal control and stimulation

Pre-shift antenna Post-shift antenna


hidden exposed

Shift ACVs while tripping out Logging tool detects shifted ACVs

Rupture disk ports isolated Rupture disk ports aligned

Fig. 4—Drawing of two ACVs. On the left, an ACV-shifting tool is shown engaged in the ACV-shifting profile. On the right, a shifted
ACV is shown with a logging tool. The logging tool senses the exposed antenna, thereby confirming the ACV position.

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Surface Input A&B

Surface Input A&B


Surface Input A&B

Surface Input A&B

Surface Input A&B


Zone Input A&B
Surface Input C

Surface Input D
Surface Input C

Surface Input C

Surface Input C
Surface Input E
Surface Input E

Surface Input D
Surface Input C
Surface Input E

Surface Input C
Surface Input D
Surface Input C
Zone Input C

Zone Input D
Zone Input E
Close A
Open A

ASV Set

Surface Input A&B


TEC

TEC

TEC

TEC
TEC
TFC

ASV

TEC

Surface Input D
Surface Input C
Surface Input E

ASV Operate
TRDHSV
ASV Set
Close A
Open A

TEC
Close
Open

Tubing Hanger
Zone A Zone A Open Open Production
Close Close Open Close Packer
ICV Packer Open Close
Zone D Zone E

Zone C
Zone B ASV

Fig. 5—IWS inner-completion-control architecture. The tubing-encapsulated conductor (TEC) is an electrical cable that transmits
downhole gauge data. All other lines shown in the figure are hydraulic control lines.

zonal control. The ability to selectively shut off water-swept sec- each packer’s location (Fig. 5). Although the production packer
tions was considered critical for well performance and reserves re- served as the pressure barrier above Zone A, an additional feed-
covery, and has proved to be invaluable. This entailed use of a through zonal-isolation packer was placed above the Zone-A ICV
dedicated IWS string with multiple control valves and packers to to anchor the string and reduce vibrations during stimulation that
be run inside the 75=8-in. production liner. Stimulation rates of 60 could potentially damage the control lines and other components.
bbl/min far exceed production rates, demanding maximum Unused feed-throughs on the Zone-A packer were left unplugged
through-bore diameter. Within the 75=8-in. 51.2-lbm/ft uncemented to prevent a trapped volume between this packer and the produc-
liner’s 6.125-in. drift, flow-control components with 31=2-in. 10.2- tion packer.
lbm/ft connections and 41=2-in. 12.6-lbm/ft tubing were the largest
components possible, while still accommodating the control-line Dual DHPT-Gauge Subs. DHPT measurement was considered
flatpack running on the outside of the IWS string. Above the liner essential for stimulation and production control. Quartz oscillator
top, the 103=4-in. production casing allowed upsizing to 51=2 in., 17- transducer gauges were installed to measure both tubing and
lbm/ft and 20-lbm/ft tubing. The annular safety valve (ASV) and annulus pressure and temperature in each zone. This allowed res-
tubing-retrievable downhole safety valve (TRDHSV) were simi- ervoir characterization and stimulation diagnostics to be per-
larly 51=2 in. Sizing of upper-completion components was less formed after acid injection. In addition, the gauges provide early
influenced by production criteria than by stimulation requirements. identification of water breakthrough, allowing valve positions to
be configured for optimal producing conditions.
Flow-Control Architecture. The existing 183=4-in. 10,000-psi
wellhead limited the penetration count at the tubing hanger to Control Line/Flatpack. Protection of control lines was a critical
eight lines. A five-zone IWS plus downhole pressure and tempera- design requirement. Encapsulation of control lines, eliminating
ture (DHPT) gauges, a TRDHSV, and an ASV required too many bare-line exposure to the annulus, was the goal. Protection of lines
lines for the tubing hanger when using direct hydraulic-control in areas of high flow velocity was of particular concern. Cross-
architecture. As such, a multiplexed control architecture was coupling clamps were installed on every joint and specialty
used, synchronizing two interval-control valves (ICVs) on a single clamps were used in locations such as TRDHSV, ASV, and the
line with single-line-switch (toggled) functionality. As a result, tubing hanger. Incoloy-825 control line was specified throughout
the five production zones could be controlled by four hydraulic the system. All control-line terminations used state-of-the-art
lines in total, lowering tubing-hanger-penetration count from nine metal-to-metal fittings with isolated-tension anchoring to protect
to eight. Fig. 5 illustrates the flow-control architecture for the control-system integrity in the event of external pressure or
well with the eight lines at the tubing hanger (far right). induced tension during installation.

ICVs. Variable-position sliding-sleeve valves were installed in


Feed-Through Production Packer. A 103=451=2-in. feed- each zone. Full tungsten carbide trim was used for tolerance of
through production packer was installed above the uncemented extreme-stimulation internal-flow velocities of more than 130 ft/
liner. This ISO14310V0-rated packer is designed for acid stimula- sec and port-flow velocities of more than 150 ft/sec in fully open
tion, production, and gas lift service; each component accommo- position. These ICVs operate by indexing sleeve actuation, pro-
dated control lines for downhole IWS functionality. The 51=2-in. viding 14 valve positions from fully open to fully closed. Syn-
production-tubing string was crossed over to 41=2 in. directly chronization of sleeves between two ICVs provides multiple
below the production packer. Five out of seven line feed-throughs control combinations: both zones closed, both zones full open,
were required to accommodate the four hydraulic-control lines one zone open and one closed, and so forth. Fig. 6 illustrates the
and one electronic gauge line (Fig. 5). wellbore configuration.

Zonal-Isolation Packers. 75=831=2-in. feed-through zonal-isola- Contingencies. Intelligent-well ICVs offer a mechanical alterna-
tion packers were set in blank sections between the openhole tive in the event that remote control is not available. Profiles are
packers separating reservoir net-pay intervals. Up to six feed- present in all trim to mechanically shift a valve to each of the 14
throughs were used, depending on the zone-control architecture in positions, typically with a wireline stroker. Gas lift valves and the

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TRDHSV
13 5 8 × 5½-in. ASV

5½-in. 17 Ibm/ft Tubing

5½-in. Gas Lift Mandrels


7 5 8 × 3½-in. Feedthrough
10¾ × 5½-in.. Zonal-Isolation Packers
Feedthrough Production
Packer
3½-in. DHPT Gauge Sub
135 8-in 73 8 × 3½-in. Feedthorough
Surface Casing Anchor Packer 3½-in. Interval-Control Valve

10¾-in. Intermediate Liner

4½-in. 12.6 Ibm/ft Tubing

75 8-in. 51.2 Ibm/ft


4½-in. 12.6 Ibm/ft Tubing 3½-in. 10.2 Ibm/ft Tubing Uncemented Liner

Fig. 6—A conceptual drawing of the uncemented liner with IWS inner-completion string showing the relative positions of comple-
tion components.

annular safety valve were installed in the upper tubing string as a vide a reliable pressure seal until the liner and IWS equipment
contingency for flow assurance. were installed and the acid stimulation was ready to be executed.
At that time, the ASP must be dissolved to provide access to the
Equipment Testing and Modeling reservoir. A range of plug designs was reviewed and tested. Alu-
minum was selected as the best material for this application
Tubular-Stress Modeling. Extensive tubular-stress modeling because it is readily soluble at atmospheric pressure and reacts
was performed on the IWS tubing string for the entire well, but vigorously with 15% HCl. Initial testing of the ASP prototypes at
extra effort involving an expert consulting company was placed 150–250 F and 300-psi pressure indicated the plugs could be rap-
on the tubing section between the production packer and the toe idly removed with 15% HCl. However, testing at higher pressure
of the well. This area involved the most complexity and the high- revealed that the reaction rate was pressure dependent and the
est risk, because a new tubular design involving new components, time to breach the plug (breakthrough time) with acid could be ex-
multiple zones, and new loading conditions was being simultane- cessive for thick-walled ASP designs. To accurately predict the
ously implemented. The well team identified at an early stage that time required to remove the ASP with acid, an extensive testing
high tensile loads would develop in this section of the well because program was started to measure acid-breakthrough times at down-
of thermal cooling during high-rate stimulation with cold treating hole pressure and temperature. Numerous ASP designs were
fluids. Ballooning forces, caused by high bottomhole-treating-pres- tested with various acid formulations until a design was identified
sure conditions combined with partially depleted zones, would fur- that provided the required pressure integrity and a companion
ther increase these already severe tensile loads. acid formulation was developed to give an acceptable break-
A robust modeling tool (Mitchell 1996) that accounted for ther- through time of approximately 17 minutes at the formation tem-
mal effects was used to model the combination of these treating perature of 275 F (Fig. 7).
conditions. As suspected, modeling results validated the severity of
the combined loads and were very useful in defining the maximum
Tool-Qualification Testing. The rock anchors, expansion joints,
downhole-treating-pressure criteria that could be tracked in real
ACVs, and openhole packers were new designs with no field runs.
time to avoid tubular failures.
As such, they required rigorous qualification programs to ensure
they survived the trip in hole and remained functional before, dur-
Drilling-Fluid Optimization. After dissolving the ASPs, the acid ing, and after the high-rate matrix-acid stimulation. The following
must traverse the liner/openhole annulus to reach the chalk reser- are examples of tests performed as part of the qualification
voir. Although the chalk is highly acid soluble, there were concerns programs:
that the oil-based mud (OBM) occupying the annulus and the OBM • ACV flow testing to ensure sufficient flow area for spotting
filter cake on the borehole wall could impede acid/chalk-contact- of acid for aluminum-plug dissolution and to calibrate discharge
stimulation treatment. To minimize the potential of the OBM coefficient required for post-stimulation analysis (Fig. 8)
impeding the access of the acid to the chalk reservoir, an acid-re- • Compressive and tensile load tests of rock anchors set inside
versible OBM (Luyster et al. 2011) was used to drill the reservoir cemented test fixture with unconfined compressive strength of
section. This oil-external-mud system was designed to be reversed 1,500 psi to replicate the chalk borehole (Fig. 9a)
to a water-external state on contact with acid to allow ready access • Expansion-joint-function testing in mud with high solids
of the acid-treatment stage to the filter cake and chalk reservoir. content and 5 /100-ft dogleg severity at the expected reservoir
Laboratory testing of the reversible OBM was conducted to opti- temperature of 275 F
mize the formulation with regard to drilling performance (e.g., rhe- • Comprehensive pressure- and temperature-cycle testing of
ology, fluid-loss control, thermal stability) and acid reversibility. openhole packers to simulate pressure setting, stimulation, produc-
The results shown in Fig. 7 led to the selection of the reversible tion, and depletion scenarios in hole sizes up to 101=2-in. diameter
OBM with a calcium-carbonate-weighting agent for this well.
Contingency-Integration Testing. In addition to the qualifica-
ASPs. Among the innovative design features of the fully com- tion programs mentioned previously, multiple contingencies were
pleted, uncemented liner were the ASPs. These plugs must pro- prepared in case the toe valves did not function as intended or a

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Reversible OBM

Standard OBM
w/BaSO4 w/CaCO3 w/CaCO3
Before Acid

Little to no Best filter Little to no


cake cleanup cleanup AI Plug + 15% HCI + time
cleanup
After Acid

Fig. 7—Effect of a 15% HCl solution on filter-cake samples and an ASP. These tests were conducted at the expected reservoir tem-
perature of 275º F.

Pressure Drop vs. Flow Rate For 4 ea. × 0.20-in. Flow Ports was required to move the 1.7-specific-gravity (SG) ball out of the
Pressure Drop = 1.98244 ∗(Q / n)2 ∗ SG / (C 2 ∗ d4) recess, and 3 bbl/min for the 1.3-SG ball.
n = 4, SG = 1.0, C = 0.66, d = 0.20-in
5,000 • Drifting of liner components with retrievable hook-wall
4,500
packer.
• Drifting of liner components with cup-type straddle-packer
4,000 ΔP - Best Match Calculation
assembly (Fig. 9c), including rotation-operated drag-block ball
Pressure Drop, psi

3,500 ΔP - Actual Measurement


valve (Fig. 9d).
3,000
2,500 Qualification of Intelligent-Well Valves
2,000
To achieve successful acid stimulations in Ekofisk, high treating
1,500 rates (on the order of 60 bbl/min) are used to force the acid deep
1,000 into the chalk formation. A benefit of intelligent-well technology
Used C = 0.66 to obtain best match
500 is that it allows surface-controlled isolation or access to a specific
0 interval allowing selective stimulation of the reservoir. Unfortu-
0.0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0
nately, no test data were available to determine the reliability of
Flow Rate, bbl/min the IWS during the high-rate acid treatment and during subse-
quent production operations. To determine the performance of
Fig. 8—Pressure drop vs. rate during ACV-flow testing. The the IWS under well-treating conditions, a computational-fluid-
actual measurements matched calculations for a discharge
coefficient (C-factor) of 0.66.
dynamics (CFD) model was created to predict the velocity and
pressure losses across the specific geometry of the IWS valve. Af-
ter a number of model runs, it was determined that the maximum
leak developed before all liner components could be set. To allowable pressure drop of 300 psi at 60 bbl/min could not be
ensure compatibility with this unique liner design, the following avoided without a substantial redesign of the hydraulic valve. As
system-integration tests were performed: a result, additional CFD work was conducted and a final compro-
• Pumpthrough test of toe-valve ball through ACV internal mise of 500-psi maximum differential pressure across the valve at
recess (Fig. 9b). The tests indicated that a pump rate of 5 bbl/min 60 bbl/min was accepted. After completing the CFD-modeling

b c d

Fig. 9—Images of the (a) rock-anchor cemented pull-test fixture, (b) toe-valve-ball/ACV pump-through test, (c) cup-type straddle-
packer elements, and (d) rotation-operated drag-block ball valve.

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4½-in. Full Tubing 4½-in. Full Tubing


Joint Joint

7-in. 29 Ibm/ft liner 4½-in. Full Tubing


Joint Joint
Gauge Mandrel with
Dual PT sensors
3½-in. ICV
2

1 Tubing flow (valve closed)


4½-in. Cross- 4½-in. Cross-
2 Annular flow (valve open)
Coupling Clamp Coupling Clamp

Fig. 10—Diagram of the flow loop designed to test and measure friction-pressure losses across various IWS components inside
the liner during high-rate matrix-acid stimulation. Flow Path 1 represents frictional pressure losses through intervals upstream of
the zone being treated. Flow Path 2 represents annular frictional pressure losses in the zone being treated.

work, a full-scale flow test of the control valve and associated frictional pressure drop than what would be seen in the well. To
equipment was scheduled. validate frictional pressure loss and flow-rate measurements, two
Requirements for the flow test included full tubing joints and pressure gauges were installed downstream
• Determine if the system would remain functional after expo- of the test fixture. By comparing this measured pressure loss with
sure to a flow rate of 60 bbl/min for 1 hour. published empirical data, the flow rate could be confirmed and the
* Would pressure losses be excessive at design rates, limit- effect of adding friction reducer was established for various rates.
ing acid-stimulation effectiveness? Testing was completed with full functionality of the dual sen-
* Would components be damaged by vibration under high- sor gauges and hydraulic valve. However, with the test fixture dis-
velocity-flow conditions? assembled, it was observed that the control-line bypass-protector
* Would components be damaged by erosion during high- plate had broken in two. Vibration had caused the small retaining
rate flow? cap screws to back out of their tapped holes, thereby allowing the
 Validate the CFD model by measuring pressure drop across protector plate to enter the flow stream and separate. A simple
different areas within the system. redesign of the plate-retention method proved successful at pre-
* Determine pressure drop across the hydraulic valve for venting vibration-related damage. The image in Fig. 11a shows
water flow and for water with friction reducer. the broken protector plate after the initial post-test inspection. To
* Determine pressure drop across clamps and control lines in the right is the new design (Fig. 11b), which survived a full hour
the liner for water flow and for water with friction reducer. of annular flow at 60 bbl/min.
To run these tests, a flow loop was designed to allow flow
straight through the valve internal diameter (ID) with the valve
closed, or through the open valve into the annulus (Fig. 10). The Operational Highlights During Reservoir Drilling
flow loop included a hydraulic valve with an internal diameter of and Completion Installation
2.75 in. and 5.940 in.2 of flow area through the valve ports in the The complex nature of the naturally fractured chalk in the Eko-
open position. A 31=2-in. gauge mandrel with dual pressure and fisk field makes it challenging to predict the pattern of the water-
temperature sensors was included upstream of the hydraulic valve flood, leaving the details of the final completion to be decided
to measure the differential pressure across the valve ports. Other only after the well has been drilled. A sophisticated logging plan
pressure points included measurements of the pressure loss across was implemented to better characterize the wellbore and improve
a cross-coupling clamp and the annular pressure loss between the hole-conditioning efforts. Among the LWD tools was a deep
tubing and casing. A 7-in., 29-lbm/ft (6.184-in.-ID) liner was used directional electromagnetic (DDEM) tool (Constable et al. 2012),
in place of the planned 75=8-in., 51.2-lbm/ft (6.251-in.-ID) liner which helped with trajectory planning during drilling. Approxi-
because of tubular availability; this resulted in a slightly higher mately halfway into the Tor formation, the DDEM readings

a b

Fig. 11—Photos of two control-line protector plates installed at the IWS valve flow ports. (a) The damaged protector plate from the
first IWS flow-loop test. (b) The retaining mechanism was redesigned and successfully prevented damage to the protector plate in
a subsequent flow test.

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10,000 Resistivity (Rh), Units of Resistivity (Ohm-m)


1.00 15.87
1.42 24.02
10,100 2.03 34.20 Modeled Faults
2.89 48.69
4.11 69.31
10,200 5.85 98.68
8.33 140.48
Build to 94°

TVD, ft
11.85 200.00
10,300 Upper Tor

10,400

10,500

10,600
5,200 5,700 6,200 6,700 7,200 7,700 8,200
THL,ft

Fig. 12—DDEM image showing resistivity 50 ft from the wellbore radius, with true vertical depth (TVD) and true horizontal length
(THL). Distinct changes in the DDEM image correlate well with fault lines captured in the reservoir model. The narrow black line is
the well path, which was adjusted while drilling to access the oil-saturated Upper Tor interval.

indicated that the well was being drilled into the lower, wet layers and the string was worked to reach TD. Actual hookloads were
of the target Upper Tor formation, near the border of deeper Tor plotted against torque and drag-modeling results while the liner
layers. After passing through a fault, higher resistivity values was being run (Fig. 14).
were seen above the well and the decision was made to increase After the 75=8-in. liner was run to TD and the liner hanger was
the hole angle from 90 to 94 , steering up and into oil-filled for- successfully set, a retrievable, hook-wall service packer was run
mation. The presence of subseismic faults and layers with high and set immediately below the liner hanger for pressure setting all
water saturations also plays an important role in the decision on openhole equipment. A leak developed at 8,200 psi while attempt-
where to blank off sections with openhole packers and solid liner ing to pressurize the liner and prevented us from reaching the
joints vs. where to expose the liner to the reservoir by use of designed 10,000-psi setting pressure for the openhole packers.
ASPs. Fig. 12 shows the point at which the decision was made The service packer was then reset at different depths and the liner
to build to 94 in an effort to remain in the oil-saturated Tor leak was found near an openhole packer at the top of Zone B. An
interval. injection test with mud indicated the size of the leak matched the
Formation-pressure points in the shallower Ekofisk formation, flow area of the openhole-packer-setting ports. Before retrieving
at the heel of the horizontal well, revealed lower-than-expected the service packer, it was used to pressure set all liner components
reservoir pressures. Anticipating higher pressure in the deeper Tor below the leak with 10,000 psi. A cup-type, straddle-packer
formation, loss-control material and wellbore-strengthening tech- assembly was then run as per the contingency plan and proved
niques were used to manage mud losses to the low-pressured heel successful in setting all 17 remaining pressure-activated liner
interval. Drilling concluded 500 ft shallower than planned be- components above the leak. Although the exact leak source in B-
cause of increasing formation pressure and water saturations. 19C was not pinpointed, subsequent testing and investigation of
Maximum pressure differential across the reservoir had increased the openhole-packer design has led to improvements to the pack-
to 1,600 psi, which would make cementing the liner very chal- er’s sliding-end-seal geometry that further minimize the risk of
lenging. LWD logs indicated five pay zones of 1,400 ft in total failure.
and four water-saturated intervals, making zonal isolation abso- A five-zone IWS inner string was then successfully installed
lutely critical for long-term production. In terms of the basis of with full functionality of hydraulically controlled valves, mechan-
design, the B-19C well was an ideal candidate to field trial the ical-isolation packers, and pressure and temperature gauges for
uncemented-liner technology for its capability to provide zonal each interval. Because of the known liner leak at the top of Zone
isolation. A five-zone completion was selected with two openhole B, it was decided to spot 15% HCl through the valve at the bottom
packers between each adjacent interval for zonal isolation in of the IWS string across Zones A and B to dissolve the aluminum
openhole. plugs before setting the isolation packers. This was instead of
Pipe-conveyed, multiarm mechanical caliper logs revealed relying on bursting the ACV rupture disks to establish the re-
that most of the 91=2-in. openhole was well gauged, with hole di- quired flow path after setting the isolation packers.
ameter ranging from 9.7 to 10 in., well within the openhole- The isolation packers were set and, as expected, the pressure
packer specifications. Three mechanical calipers, two four-arm in each zone diverged from equilibrium to approach their respec-
powered calipers, and one six-arm environmental measurement tive interval-reservoir pressures (Fig. 15). This implied that every
sonde caliper were run in tandem to collect these data. A bore- stage contained some aluminum plugs already dissolved by the
hole-imaging tool provided an additional two diameter measure- 15% HCl. It also confirmed the status of positive zonal isolation
ments for a total of 18 radius measurements in the logging in the openhole. The pressure and temperature data from each
assembly. Results from ultrasonic LWD caliper readings were in zone proved to be invaluable from all planned events and even
very close alignment with mechanical logs. Fig. 13 shows caliper- some unplanned events.
log comparisons of a washout (in red) section and the undergauge
(in blue) toe section. These logs were carefully evaluated to deter-
mine the optimal openhole-packer-setting depths. A stiff reamer Acid-Stimulation Results
assembly was then run to bottom to remove any localized doglegs After moving the rig off location, lines were laid to the well and a
or ledges that might prevent the 9.2-in.-maximum-outside-diame- dedicated stimulation vessel moved into position for the acid
ter liner equipment from reaching TD. Two doglegs induced addi- treatment.
tional drag while pulling out of hole with the reamer assembly. As noted previously, the Ekofisk B-19C well encountered a
These two dogleg sections were reamed until the assembly could number of oil and water intervals. After reviewing the LWD logs,
drift the openhole without hanging up. the completion liner was set up to stimulate five oil zones and to
The 75=8-in.-uncemented-liner makeup and running operation isolate wet zones with openhole packers. This completion design
went well until the last 800 ft from TD, where sticking occurred is summarized in Fig. 16.

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Column Headers
MD measured depth, ft C 3D composition (column cd)
a 2-diameter, powered caliper 1 cX hole cross section (column cd)
b 2-diameter, powered caliper 2 d 2-diameter, borehole imager
cr 6-radii, EMS caliper D 3D composition (column d)
AB 3D composition (columns a, b) dX hole cross section (column d)
cd 3-diameter, EMS caliper

Scale (columns a, b, cr, cd, d)


Diameter 8–12 in. Washout >10.5 in. diameter shaded in red
Radius 4–6 in. – – – 9.50 in. diameter gauge hole

Scale (columns AB, C, cX, D, dX) Radius, in.


Gauge hole
4 4.25 4.5 4.75 5 5.25

MD a b cr AB cd C cX d D dX

11,600

11,650

15,100

15,150

Fig. 13—Caliper-log comparisons for one washout (red) heel section and the undergauge (blue) toe section.

Hook Load, klbf Inclination, °


100 150 200 250 300 350 400 0 20 40 60 80
0
B19-C 75 8
-in. liner with openhole packers
1,000 Min Wt. Hel. Buckle (Trip In)
Trip In –25 ft/min, gauge hole
2,000 Actual Trip In

3,000
4,000
5,000
Run Measured Depth, ft

6,000
7,000
8,000
9,000
10,000
11,000
12,000
13,000
14,000
15,000

Fig. 14—Measured hookload values (orange) compared with simulated values. The actual hook load diverged from simulation
results at approximately 14,000-ft measured depth, the same depth at which the build to 94º was made.

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B-19C Isolation Packers Set: Zone Annulus Pressure Table 1 summarizes ASP-dissolution results after soaking
Zone A Zone B Zone C Zone D Zone E with the 15% HCl/mutual-solvent system and after pumping the
4,200 main acid treatment with 28% HCl. The average open-perfora-
4,100 Isolation
tion area was estimated to be 44% of the design area after the
4,000 Packers Set 15% HCl/mutual-solvent soaking process. This was slightly
lower than our target open area of 67% before starting the main
Pressure, psi

3,900
3,800
acid treatment. However, after the main acid treatment, the aver-
age plug open area rose to approximately 69% of the design
3,700
area. Assuming all the ASPs have been at least partially dis-
3,600
solved, the average hole diameter is estimated to be 0.13 in. after
3,500 the 15%-HCl/mutual-solvent soak process, and 0.17 in. after the
3,400 main 28%-HCl treatment compared with the 0.20-in. design di-
3,300 ameter. Although both the ASP and ACV holes are the same di-
–10 –5 0 5 10 15 20 25 30 ameter, flow through the ACV ports follows a more-tortuous
Elapsed Time, min path, which results in a lower C-factor. All calculations are by
use of a C-factor of 0.80 for the ASP and 0.66 for the ACV ports
Fig. 15—Measured annulus pressure vs. time from five IWS
(Fig. 8).
zone gauges during the isolation-packer-setting process. Pres-
sure diverges at the moment the isolation-packer elements After dissolving the ASPs, the flow path for the 28% HCl used
make contact with the 75=8-in.-liner ID. in the main acid treatment is through the ASP holes (Fig. 17c).
The acid exits the 75=8-in.-liner/IWS-string annulus through the
Each completion interval (A, B, C, D, and E) was equipped 0.20-in. ASP holes and the four ACV holes at the bottom section
with an IWS assembly consisting of a surface-controlled valve of each treatment interval. As in a conventional cased-hole lim-
providing flow access to the formation and pressure and tempera- ited-entry treatment, frictional pressure losses resulting from high
ture gauges ported to tubing and annulus (Fig. 17a). velocity flow through the small plug holes limit the amount of
Each zone was selectively stimulated starting from Zone E fluid exiting through any one point in the liner, thereby distribut-
(heel zone) to Zone A (toe zone) by use of the IWS flow-control ing flow more evenly along the openhole-treatment interval. At
valves. design acid rates of 0.7 to 1.3 bbl/min per perforation, average
For each treatment, the IWS valve in the treatment zone is fluid velocities discharging through the 0.20-in. holes in the liner
opened. Tubing pressure is then increased to break the rupture and into the openhole range from 300 to 550 ft/sec and provide
disks in the ACVs, allowing fluid displacement to the target inter- perforation pressure losses in the 1,000- to 3,000-psi range. These
val. The initial freshwater filling inside the tubing is followed by high perforation pressure losses are far greater than the frictional
a 15%-HCl and mutual-solvent mixture pumped at a low rate pressure loss caused by the flow along the 75=8-in.-liner/41=2-in.-
(Fig. 17b). IWS-string annulus, and are also greater than formation-break-
Acid pumping continues until the entire 75=8-in.-liner/IWS- down and treating-pressure differences along the openhole-com-
string annulus has been displaced to acid. This places the 15%- pletion interval.
HCl/mutual-solvent acid system in direct contact with the ASPs, The main acid treatments consisted of pumping 75 gal of 28%
which seal the holes in the 75=8-in. liner and isolate the formation. HCl per foot of completion interval at high rate, followed by
The ASPs are then soaked for a few hours depending on downhole approximately 150 gal of freshwater overflush per foot of interval.
temperature, during which leakoff is monitored to determine the At design pump rates, downhole pressures at the reservoir face
rate of plug dissolution. The HCl/mutual-solvent acid system is typically start out at or above formation-parting pressure and very
then displaced with freshwater and an injectivity test pumped at quickly drop to less than the fracture pressure as acid enters the
maximum rate consistent with well-pressure limits. At the end of chalk formation. This pressure behavior indicates that the bulk of
the injectivity period, a hard shutdown is conducted to determine the acid-stimulation treatment is pumped under matrix-injection
the instantaneous shut-in pressure and allow calculation of the conditions conducive to wormholing of the near-wellbore chalk
number and equivalent flow area for the dissolved ASPs. If suffi- reservoir. A pressure plot of a typical zone treatment is provided
cient flow area has been exposed by the acid, then the main acid in Fig. 18.
treatment can proceed as planned (Fig. 17c). If the flow area is As shown, bottomhole pressure at the reservoir face is greater
deemed insufficient to pump the main acid treatment, then another than formation-parting pressure when the acid is pumped down to
HCl/mutual-solvent treatment is pumped and another soak and the reservoir. Once the 28% HCl reaches the chalk face/reservoir
injectivity step is conducted. face, pressure rapidly drops to less than fracture pressure and into

10,100 8,000
Zone E

Zone D

Zone C

Zone B

Zone A

10,150 7,000
10,200 6,000
Wellpath
Pressure, psi

10,250 Reservoir Pressure 5,000


TVD, ft

10,300 4,000
10,350 3,000
Producing Pressure
10,400 2,000
Water

10,450 1,000
Water Water Water
10,500 0
11,500 12,000 12,500 13,000 13,500 14,000 14,500 15,000
MD, ft
100
0

0
PHIE

BVW

VSH
%

%
50

50

50

Fig. 16—Well trajectory and log-derived oil- and water-saturation predictions. Formation and producing pressure is plotted to
show expected pressure differentials between isolated intervals. In the log on bottom, porosity (PHIE) is in red, bulk-volume water
(BVW) is in blue, and shale content (VSH) is in gray.

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Openhole
Packer IWS Isolation
9½-in. Openhole × 75/8-in. Liner 75 8-in. Liner × IWS String
Annulus Annulus
Packer IWS Value
ASP ACV
DHPG 3½-in. Tubing (0.20-in. holes) 4½-in. Tubing (4 × 0.20-in. Holes)

Fig. 17—Sequence diagram showing (a) the relative position of zone-flow-control and -isolation equipment, (b) the initial acid-cir-
culation path through the burst ACV rupture disks, and (c) high-rate matrix-acid stimulation through the dissolved plug holes and
ACV ports.

the matrix-injection realm. As the acid wormholes through the determine stimulation effectiveness and to provide skin values for
chalk formation, reservoir-face pressure continues to decline as initial-rate forecasts and later production evaluation.
pump rate increases. This injectivity improvement can be used to A summary of zone-permeability and acid-stimulation results
calculate skin evolution during the course of the treatment in a for the Ekofisk B-19C openhole completion are provided in
manner similar to that introduced by Paccaloni and Tambini Table 2. As shown, all zones were successfully stimulated.
(1993) and later extended by Hill and Zhu (1996). An analysis These openhole-stimulation results are similar to those seen in
showing the evolution of effective wellbore radius vs. injection cased-and-perforated, fully completed wells in the field (Furui
time is provided in Fig. 19. et al. 2012a, b).
As shown, the effective wellbore radius grows from approxi-
mately 5 ft, corresponding to a skin of 2.5, at the time acid first
reaches the reservoir face to roughly 33 ft, corresponding to a skin Initial Production Results
of 4.4, at the end of the treatment. The large increase in effec- After conclusion of acid-treating operations, the B-19C well was
tive wellbore radius after fracture closure is considered strong evi- turned over to field-production operations. The well was flowed
dence that the bulk of the stimulation benefit comes from acid back at increasing rates with all zones open, and after approxi-
wormholes dissolved through the formation (Furui et al. 2012a, mately 3 months of stabilization time, a well test was conducted.
b). This type of analysis is performed for each zone in the well to The objectives of this test program were to check the mechanical
function of the sleeves, determine any zone-to-zone communica-
tion, and acquire data on the rates and types of fluids flowing
TABLE 1—B-19C ACID-SOLUBLE-PLUG OPENING RESULTS
from the various completed intervals (Table 3).
The test showed that all downhole gauges were functioning as
After Main
designed, allowing both annular and tubing pressure and tempera-
After Acid
ture from each zone to be recorded. The test program confirmed
Soaking Treatment
communication between the three bottommost Tor zones: Zones
ACV ASPs Total (% of Holes (% of Holes
A, B, and C. It also indicated that one zone, Zone D, contributed
Stage Zone (Holes) (No.) Holes Open) Open)
more water than the others. After obtaining this information, the
water-bearing zone, Zone D, was shut in to reduce the well’s
1 E 4 21 25 38% 85% water cut and to lighten the fluid column. With this adjustment,
2 D 4 7 11 67% 70% the well now requires less gas lift gas during startup after shut-ins.
3 C 4 35 39 38% 67% Subsequent testing has also shown that oil production has not
been significantly affected, as shown in Fig. 20. An added benefit
4 B 4 63 67 39% 66%
of shutting off the water-producing zone, Zone D, was that the
5 A 4 56 60 38% 58%
well’s sulfate-scaling potential was significantly reduced. This in

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B-19C Zone B Treatment


9,000 180
Annular Pressure Acid Injection at Reservoir Face
8,000 160

7,000 140

Friction Reducer Concentration, gal/Mgal


Fracture Closure Pressure
6,000 120

Wellhead density, ppg


Pressure, psi

Slurry rate, bpm


Acid at ICV
5,000 100

4,000 Reservoir-Face Pressure 80


Rate
3,000 Acid at ACV 60
Friction Reducer
2,000 Concentration 40

1,000 20
Wellhead Density

0 0
480 490 500 510 520 530 540 550 560
Time Elapsed, min

Fig. 18—High-rate matrix-acid-stimulation data vs. time for Zone B.

turn means less intervention for scale squeeze and potentially a not providing an effective seal. As a result, the small acid-treat-
prolonged lifespan of the well. ment communication seen between Zones C and B and between
The low water cut measured in the early flow tests of the B- Zones B and A is thought to be the result of matrix communica-
19C well also indicated that the openhole packers had withstood tion brought on by high-rate acidizing at both ends of the inter-
the high-rate acid treatment and were effectively isolating the zone blank sections.
water zones from the acid-stimulated oil zones. Review of acid- Overall production results from the well have been encourag-
treatment data had shown some pressure/temperature communica- ing. Despite lower-than-expected reservoir pressures and reservoir
tion late in the acid treatments of Zones B and C. Analysis of the net-pay length, the B-19C well is producing at rates above expect-
magnitude and duration of these leaks indicated they were small ations. The use of an intelligent-well-completion system in this
leaks; however, even a small leak while pumping acid could pro- well allowed the very-low-pressure Zone E and the marginal
vide a flow path for high-pressure water during production opera- Zone D intervals to be completed with the better intervals seen at
tions. Fortunately, the production data of the well have shown that the toe of the well. This would not have been possible with a con-
the high-pressure water zones along the horizontal section are ventional completion.
effectively isolated.
As shown in Fig. 16, the differential pressures between the
water zones and producing pressures in the oil zones range from Early Life Production and Functionality Update
1,000 to 2,000 psi. At these high pressure differentials, significant Production stabilized at approximately 3,500 STB/D after 1 year,
water production would be expected if the openhole packers were and water cut has steadily increased since then, from 5 to 25%

Ekofisk B-19C Zone B Skin Evolution


10,000
rwa = rw = 0.4 ft and Skin = 0
9,000 rwa = 1.7, skin = –1.5
rwa = 5, skin = –2.5
8,000 rwa = 10, skin = –3.2
rwa = 20, skin = –3.9
7,000 rwa = 33, skin = –4.4
First Acid at Perfs
6,000
Acid Treatment Data
DP, psi

5,000 Overflush

4,000

3,000

2,000

1,000

0
0.01 0.1 1 10
Injection Time, hrs

Fig. 19—Pressure change vs. time. The light-green data points were measured when acid was being injected at the reservoir face,
resulting in matrix-wormhole growth and an increase in the effective wellbore radius (rwa). The dark-blue data points were meas-
ured during the post-acid overflush, during which time wormhole length remained at a constant 33 ft.

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TABLE 2—B-19C ACID-STIMULATION RESULTS

Average Post-
Completion- Interval Zone Maximum Effective Stimulation
Zone KL Value Permeability Pump Rate Well Radius Skin Value
Stage Zone Length (ft) (md-ft) (md) (bbl/min) (ft) (Skin)

1 E 199 103 0.52 32 30 4.34


2 D 117 234 2.00 10 35 4.49
3 C 281 762 2.71 37 30 4.34
4 B 444 848 1.91 54 33 4.42
5 A 404 764 1.89 46 56 4.95

TABLE 3—B-19C WELL-TEST RESULTS

Zone Status (O ¼ Open, X ¼ Closed) Flowing Flowing


Oil Rate GOR Water Wellhead Wellhead
A B C D E (STB/D) (scf/STB) Cut (%) Pressure (psi) Temperature ( F)

O O O O X 3,580 1,417 4.0 995 197


O O O O X 3,564 1,417 2.4 995 197
O O O O X 3,395 1,248 2.9 950 187
O X O O X 3,409 1,243 1.6 947 191
O X X O X 3,439 1,304 0.6 971 192
X O O O X 3,347 687 1.0 941 180
O O O X X 3,539 1,406 0.0 1,020 187
O O O O O 3,119 1,267 0.2 931 187

(Fig. 21). Monthly sampling has indicated that the produced water completion objectives, the B-19C well has delivered better-than-
presents low scaling potential and does not require isolation. projected production results despite lower-than-expected reservoir
Table 4 shows the status of IWS-component functionality pressures and net-pay lengths; provided water shutoff in Zone D
through the first 19 months of production, with months of func- to reduce scaling potential; allowed interventionless stimulation
tionality listed in parentheses for each failed component. of each fully completed interval with zonal isolation; and pro-
Although some downhole gauges have stopped transmitting duced to date with no indication of deformation or reduced pro-
data, functional annulus-pressure gauges in Zones C, D, and E ductivity because of liner-stability issues.
indicate that the zonal isolation between those three zones has During the design phase, diligent engineering practices
been maintained since the well was put on production (Fig. 22). reduced the risk of implementing this new completion technique
with customized equipment:
• Tubular stress and CFD modeling were crucial in determining
Conclusions appropriate specifications for the custom completion compo-
An openhole uncemented completion with a five-zone IWS was nents that would be exposed to high flow rates, pressure, and
successfully installed in the Ekofisk B-19C well. In terms of the temperature fluctuations.

(a) B-19C Production First 10 Months


Oil Rate GOR WCT

Conduct well test Close Zone D


5,000 10 (b) B-19C Sulfate Content
* * *Choke increase
Close Zone D
4,500 9 800
*Choke increase
4,000 8 700 *
SO4 Content, mg/l

3,500 7 600
WCT, %
Oil Rate, STB/D

500
GOR, scf/bbl

3,000 6
400
2,500 5 300
2,000 4 200
1,500 3 100
1,000 0
2 150 200
1,500 1 Days Since Start of Production
Time scale for Fig. 20b
0 0
0 50 100 150 200 250
Days Since Start of Production

Fig. 20—(a) Production data vs. time, annotated to show choke increases and closure of Zone D. (b) Sulfate content increased with
water cut (WCT) approximately 175 days after start of production. Barium sulfate scaling potential was reduced by closing the IWS
valve in Zone D.

178 June 2014 SPE Drilling & Completion

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DC166209 DOI: 10.2118/166209-PA Date: 19-June-14 Stage: Page: 179 Total Pages: 17

B-19C Production Months 12–19


Oil Rate GOR WCT SO4 TABLE 4—B-19C COMPONENT FUNCTIONALITY FOR
5,000 100 FIRST 19 MONTHS
4,500 Producing Zones: A,B,C,E 90
Isolated Zones: D
4,000 80 Annulus Tubing

SO4 Content, mg/l


Zone Gauge Gauge ICV
Oil Rate, STB/D
3,500 70
GOR, scf/bbl

3,000 60

WCT, %
2,500 50 A Failed Failed OK, open
2,000 40 (6 months) (6 months)
1,500 30 B Failed Failed OK, open
1,000 20 (5 months) (5 months)
500 10 C OK OK OK, open
0 0 D OK Failed OK, closed
350 400 450 500 550 600 (7 months)
Days Since Start of Production E OK OK Failed, open
(3 months)
Fig. 21—Production data vs. time for production months 12–19. Above production OK OK N/A
Zone D has remained closed because of high water cut (WCT)
packer
and scaling potential.

• Subsequent qualification testing to the design specifications • IWS flow control allowed selective stimulation of each fully
confirmed equipment capabilities at downhole conditions; led completed interval.
to improvements in the mud and acid formulation; and identi- • The ACVs operated as designed, providing the initial acid-cir-
fied a shortcoming of the cross-coupling clamp, which was then culation path in each interval.
modified to prevent damage during high-rate acid stimulation. • The ASPs were dissolved with a unique 15% HCl solution,
• Physical testing at downhole conditions also improved under- thereby exposing holes in the predrilled reservoir liner that pro-
standing of data collected during stimulation and production. vided the limited-entry fluid diversion necessary for effective
Accurate frictional-pressure-loss data from surface flow testing stimulation of each interval. Soaking times were longer than pl-
improved stimulation analysis and evaluation of the B-19C- anned because of cooler downhole temperature. Modifications
completion performance. to the ASP design have been made to optimize breakthrough
During the reservoir drilling and completion-installation and dissolution times for future wells with ASP liners.
phase, precautions were taken to further reduce operational risk: • Zone tubing and annulus gauges provided real-time differential
• Pipe-conveyed mechanical-caliper logs supported the acoustic- pressure, which was valuable when attempting to maximize
caliper data recorded while drilling. This suggests that open- stimulation rate without exceeding burst pressure ratings of the
hole-packer placement could be dependent on the drilling logs, tubulars in isolated zones. This contributed to excellent acid-
and the dedicated logging trip could potentially be eliminated wormhole growth and highly negative completion skins in each
for time saving on future wells. zone.
• The stiff reamer assembly conditioned and drifted the openhole • Small pressure communication was observed during high-rate
to TD after reaming two tight spots. Although the reamer as- acid stimulation of the bottom three intervals. Comprehensive
sembly can remove potentially problematic ledges, it does not post-stimulation analysis suggests this leak is because of matrix
provide an accurate indication of deteriorating hole conditions, communication after high-rate acidizing from both ends of the
such as solids deposition or excessive filter-cake buildup. The interzone blank sections. Completions of similar design have
liner string had to be worked down slowly through the last 800 demonstrated that increasing the distance between openhole-
ft of 94 deviated hole section. The cause of increased drag in packer pairs, or shot-to-shot spacing in cemented and perforated
this section has not been pinpointed. wells, between adjacent zones can improve zonal isolation.
Stimulation of the B-19C well was completed according to • Successful isolation of the water-swept intervals between Zones
plan: C, D, and E, where openhole-packer pairs were separated by

B-19C Downhole Flowing Pressure and Zone Annulus Pressure Months 12–19
Zone C Annulus (Open) Zone D Annulus (Closed) Zone E Annulus (Open) Zone E Tubing

4,500
4,000
3,500
ΔP (Zone D to Zone E) = 2,000 psi
Pressure, psi

3,000
2,500
2,000
1,500
1,000
500
0
350 400 450 500 550 600
Days Since Start of Production

Fig. 22—Gauge data vs. time for three annulus gauges (Zones C, D, and E) and one tubing gauge (Zone E). Zone D is shut-in. Zone
D annulus pressure indicates the packers between Zone D and adjacent zones are holding differential pressure of approximately
2,000 psi. Zone E tubing pressure indicates the downhole flowing pressure.

June 2014 SPE Drilling & Completion 179

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DC166209 DOI: 10.2118/166209-PA Date: 19-June-14 Stage: Page: 180 Total Pages: 17

longer distance, confirms that zonal isolation can be achieved Anthony Kent is a senior completions engineer for ConocoPhil-
and maintained with the B-19C openhole-liner equipment. lips Norway. He supports technology development projects
related to openhole zonal isolation and interventionless lower-
completion solutions. Kent has previous experience in deep-
Acknowledgments water well testing in the Gulf of Mexico (GOM) and Brazil. He
holds a BEng degree in mechanical engineering from Vander-
The authors wish to thank ConocoPhillips management and bilt University and is a member of SPE.
PL018 license partners ConocoPhillips Skandinavia A/S, Total
E&P Norge A/S, Eni Norge A/S, Statoil Petroleum A/S, and David Burkhead is a regional well-operations adviser for Cono-
Petoro A/S for their permission to publish this paper. Special rec- coPhillips in Houston. He supports all facets of field develop-
ment and operations, including drilling, completions, and well
ognition is made to the entire B-19C team, both onshore and off- intervention. Burkhead has previous operations and planning
shore, whose dedication and hard work resulted in a successful experience in Norway, Qatar, Vietnam, Indonesia, Kazakh-
well design and completion operation. The numerous service stan, the GOM, and the onshore US. He holds a bachelor’s
companies who worked together seamlessly in both the design degree in petroleum engineering from the University of Okla-
and completion phases are also recognized for their roles in the homa, is a registered professional engineer, and is a member
collaboration that was necessary for success. of SPE.
Bob Burton is a senior completions engineering fellow for Cono-
coPhillips’ Global Drilling and Completions Technology Group,
References supporting completion design and technology development
Agarwal, B., Hermansen, H., Sylte, J.E., et al. 2000. Reservoir Characteri- work. During his 30-plus-year career, he has held petroleum-
zation of Ekofisk Field: A Giant, Fractured Chalk Reservoir in the engineering assignments in the US, UK, and the Middle East
Norwegian North Sea–History Match. SPE Res Eval & Eng 3 (6): before joining ConocoPhillips’ Houston-based Drilling and
534–543. SPE-68096-PA. http://dx.doi.org/10.2118/68096-PA. Completions Technology Group. Burton holds a bachelor’s
Constable, M.V., Antonsen, F., Olsen, P.A., et al. 2012. Improving Well degree in chemical engineering from Georgia Institute of Tech-
Placement and Reservoir Characterization with Deep Directional Re- nology, Atlanta, Georgia, and a master’s degree in petroleum
engineering from the University of Southern California and is
sistivity Measurements. Presented at the SPE Annual Technical Con-
also a registered engineer in California and Texas.
ference and Exhibition, San Antonio, Texas, 8–10 October. SPE-
159621-MS. http://dx.doi.org/10.2118/159621-MS. Kenji Furui is a completion geomechanics engineer for Cono-
Furui, K., Burton, R.C., Burkhead, D.W., et al. 2012a. A Comprehensive coPhillips Norway. He is an expert in the area of rock mechan-
Model of High-Rate Matrix-Acid Stimulation for Long Horizontal ics, sand control, borehole and casing stability analysis, well
stimulation, and well-performance evaluation. Furui is the re-
Wells in Carbonate Reservoirs: Part I–Scaling Up Core-Level Acid
cipient of the 2013 SPE Cedric K. Ferguson Medal. He holds a
Wormholing to Field Treatments. SPE J. 17 (1): 271–279. SPE- bachelor’s degree in mineral resources and environmental en-
134265-PA. http://dx.doi.org/10.2118/134265-PA. gineering from Waseda University, Japan, and master’s and
Furui, K., Burton, R.C., Burkhead, D.W., et al. 2012b. A Comprehensive PhD degrees in petroleum engineering from the University of
Model of High-Rate Matrix-Acid Stimulation for Long Horizontal Texas at Austin.
Wells in Carbonate Reservoirs: Part II–Wellbore/Reservoir Coupled-
Steve Actis is a regional well operations adviser for Conoco-
Flow Modeling and Field Application. SPE J. 17 (1): 280–291. SPE- Phillips in Houston, supporting business unit well operations,
155497-PA. http://dx.doi.org/10.2118/155497-PA. knowledge sharing, and critical well planning. He has more
Hazel, P., Singh, H., Baardsen, J., et al. 2013. Open Hole Packers Provide than 30 years of well-operations experience in Europe, Asia,
Zonal Isolation for a High Pressure Acid Stimulation within a Chalk the GOM, the Middle East, and South America. Actis holds a
Reservoir. Presented at the SPE Annual Technical Conference and Ex- bachelor’s degree in petroleum engineering from the Colo-
hibition, New Orleans, Louisiana, 30 September–2 October. SPE- rado School of Mines, and is a member of SPE.
166391-MS. http://dx.doi.org/10.2118/166391-MS. Kevin Bjornen is a completion-fluid specialist in Bartlesville,
Hermansen, H. 2008. The Ekofisk Field: Achieving Three Times the Orig- Oklahoma. He supports ConocoPhillips’ global field operations
inal Value. Presented at the 19th World Petroleum Congress, Madrid, by supplying in-house testing services for a wide range of com-
Spain, 29 June–3 July. WPC-19-3966. pletion and fracturing fluids. Bjornen has been working in the
Hermansen, H., Thomas, L.K., Sylte, J.E., et al. 1997. Twenty Five Years industry for 25 years, primarily in fracturing operations and frac-
of Ekofisk Reservoir Management. Presented at the SPE Annual Tech- turing laboratory support. He holds a bachelor’s degree in ge-
ological engineering from the Colorado School of Mines and
nical Conference and Exhibition, San Antonio, Texas, 5–8 October.
a master’s degree in petroleum engineering from the Univer-
SPE-38927-MS. http://dx.doi.org/10.2118/38927-MS. sity of Oklahoma.
Hill, A.D. and Zhu, D. 1996. Real-Time Monitoring of Matrix Acidizing
Including the Effects of Diverting Agents. SPE Prod & Fac 11 (2): Jesse Constantine is a principal completions engineer for Con-
95–101. SPE-28548-PA. http://dx.doi.org/10.2118/28548-PA. ocoPhillips’ Global Drilling and Completions Technology
group. He has nearly 30 years’ experience in the oil and gas
Luyster, M.R., Patel, A.D., Ravitz, R., et al. 2011. New Approach for
industry, with a background in flow control and completion
Completion Applications With Higher Internal Phase Inverts Utilizing technologies. Constantine has spent the last 14 years focusing
Innovative Surfactants. Presented at the SPE European Formation on the development, planning, and implementation of intelli-
Damage Conference, Noorwijk, The Netherlands, 7–10 June. SPE- gent-well systems.
144131-MS. http://dx.doi.org/10.2118/144131-MS.
W.W. (Trey) Gilbert is a completions engineering fellow for
Mitchell, R.F. 1996. Comprehensive Analysis of Buckling With Friction.
ConocoPhillips’ Global Drilling and Completions Technology
SPE Drill & Compl 11 (3): 178–184. SPE-29457-PA. http:// group. He specializes in sand control, intelligent-well systems,
dx.doi.org/10.2118/29457-PA. and subsea integration. Gilbert holds a master’s degree in civil
Paccaloni, G. and Tambini, M. 1993. Advances in Matrix Stimulation engineering from Oklahoma State University, is a registered
Technology. J Pet Technol 45 (3): 256–263. SPE-20623-PA. http:// professional engineer in Wyoming, and is a member of SPE.
dx.doi.org/10.2118/20623-PA. Richard Hodge is supervisor of the ConocoPhillips Wells Fluids
Snow, S.E. and Hough, E.V. 1988. Field and Laboratory Experience in laboratory in Bartlesville, Oklahoma. The Wells Fluids group pro-
Stimulating Ekofisk Area North Sea Chalk Reservoirs. Presented at vides technical support for hydraulic fracturing, acidizing, dril-
the SPE Annual Technical Conference and Exhibition, Houston, ling, and completions. Hodge has 40 years of experience in
Texas, 2–5 October. SPE-18225-MS. http://dx.doi.org/10.2118/18225- completions, stimulation, and formation-damage prevention
MS. and remediation.
Todd, A.C., and Yuan, M. 1990. Barium and Strontium Sulfate Solid-So- Lewis Ledlow is a regional well-operations adviser for Conoco-
lution Formation in Relation to North Sea Scaling Problems. SPE Phillips in Houston. He has more than 35 years of US and interna-
Prod Eng 5 (3): 279–285. SPE-18200-PA. http://dx.doi.org/10.2118/ tional experience working with a variety of well completions,
18200-PA. ranging from gravel-packed, unconsolidated sandstones to

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fracture-stimulated unconventional reservoirs and acid-frac- Arne Vasshus is a senior reservoir engineer for ConocoPhillips Nor-
tured carbonates. Ledlow is an SPE Distinguished Member who way. He supports subsurface well planning through identification
has served SPE as a Distinguished Lecturer, Chairperson of an and justification of new well locations. Vasshus has previous expe-
SPE Forum Series, and Chairperson of the Gulf Coast Section— rience as a consultant on production-optimization projects in Nor-
Production Operations Study Group, as well as serving on way and as a reservoir-simulation-software instructor in Australia.
numerous SPE program and steering committees. He is a former He holds a master’s degree in reservoir engineering from the Uni-
Chairperson of the Completion Engineering Association. versity of Stavanger and is a member of SPE.
Manabu Nozaki is a senior completions engineer for Conoco- Tao Zhang is a staff completions engineer for ConocoPhillips
Phillips’ Global Drilling and Completions Technology group. He Norway. He has been the accountable completions engineer
is an expert in the area of sand-failure analysis, casing-stability for the B-19C well. Zhang has previous experience in openhole
analysis, inflow-performance evaluation, and well-stimulation standalone screens, hydraulic fracturing, gravel packing,
evaluation. Nozaki holds a bachelor’s degree in environmen- sand control, acid stimulation, and production engineering in
tal and resources engineering from Waseda University, Japan, Bohai Bay and the South China Sea. He holds a bachelor’s
and master’s and PhD degrees in petroleum engineering from degree in petroleum engineering from China Petroleum Uni-
Texas A&M University. versity and is a member of SPE.

June 2014 SPE Drilling & Completion 181

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