SPE-192879-MS

A Case Study on the Effect of Production Segmentation Completion

Technique PSCT and Inflow Control Devices ICD on the Optimization of

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Horizontal Well Performance

Ahmed Alshmakhy, ADNOC; Ruaa Abdalla, ADNOC Onshore

Copyright 2018, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 12-15 November 2018.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
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consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
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Abstract
Horizontal wells have been drilled extensively in recent years where several challenges have been faced
such as increased cost, short well life, limited accessibility, uneven stimulation, less productivity and water
production. Although similar issues encountered in all reservoirs, tight reservoirs impose extra difficulty
given their complexity and inherited limited productivity. In order to optimize flow profile and extend the life
of horizontal wells, several techniques were implemented including Production Segmentation Completion
Technique (PSCT) and Inflow Control Devices (ICDs).
Initially, a single well simulation study was conducted to determine and evaluate the effectiveness of
using a dual completion string and ICDs in a horizontal well with open hole across a carbonate reservoir
which generally suffering from rapid increase of water-cut due to high drawdown around heel. A review
of literature and internal well cases were conducted to highlight the heel to toe effect and early water
breakthrough issues.
As a result a novel multi-zones completion technique was proposed and implemented, this design
comprises running a lower completion (LC) as isolation string and an upper dual completion, the hole heel
will produce from the open hole (OH)-LC annulus through the short string (SS) and the toe will produce
through LC through the long string (LS) stung-into LC. This design provided a method to choose the
most appropriate horizontal section and demonstrated the value of having dual completions in terms of oil
gain and water management as well as improved accessibility. This approach is then compared with the
option of utilizing ICDs as a sophisticated method to control flow and manage production from different
compartments of the openhole.
Field results supported the success of segmented completion project providing future opportunity to
optimize the production configuration of horizontal wells. Thus, reducing number of wells and increasing
production. Execution of this project increased production by about 1.3x versus single completion well,
accessing deeper horizontal areas, with an optimized cost in addition to saving time. On the other side, inflow
control devices were used extensively in industry with a large chance of success when planned well. On the
simulation model, ICDs were added and different sensitivities were tried to decide on the best configuration.
2 SPE-192879-MS

Implementation of such optimization tools in early stages may be crucial to mitigate potential well issues
that are difficult to cure later in well life. This complex and high profile project was executed against a
background of limited time frame and resources. Project team demonstrated ability to adapt and succeed
when presented by a truly unique challenge. A comparison study was essential to decide on best approach.
To date, PSTC technique is the first to be implemented in UAE and the Middle East.

Statement of Theory and Definitions

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Commonly openhole wells suffer from limited accessibility, uneven contribution and rapid increase in
water-cut due to high drawdown around heel. Simulation cases and several production logging results in
horizontal wells have been studied and all indicated higher productivity at heel versus toe using conventional
single completion technique. Some wells produced at toe less than 20 percent relative to heel production.
This study serves as a feasibility analysis to optimize the well preformance by decreasing the water cut
(WC) and increasing the recovery factor with the use of both PSCT and ICDs. Several simulation scenarios
were tested to understand the added value of smart completions compared to standard well completions.
Intially, the simulation model built based on real field data was run with a single openhole horizontal
well, further PSCT and ICDs were added to the model to optimize the well preformance and better control
the water cut. This paper also sheds the light on a field case where PSCT was successfully implemented.
The model was then used to select appropriate method as an alternative horizontal well completion and
demonstrated the value in terms of oil gain, water reduction and improved well accessibility.
Simulation showed an increased well productivity with multiple entry points, at heel and toe, as confirmed
by field results. In addition, it improved well accessibility and enhanced skin towards toe improving well
productivity.
Over the past 10 years, Inflow Control Devices were used in hundreds of wells to enhance reservoir flow
and are now considered a mature well-completion technology. As their name indicates, ICDs allows a better
control to the fluid-flow path from the reservoir to the wellbore (Al-Khelaiwi et al,2010). The mechanism
of the ICDs is highly related to exerting high pressures at high permeability zones and allowing higher
drawdown in low permeability zones according to the Bernoulli equation (Wibawa et al, 2008):

[1.1]

where v is the velocity, g is the gravity, z elevation, p is the pressure and ρ is the density. The restriction
to the fluid flow in the high permeability areas combined with the physics of the fluid flow in the resevoir
enables the ICDs to equalize the flow along the well length, see Figure 1. Thus, ICDs significantly assist and
provide reliable performance in HP/HT conditions, enhance compatibility with existing downhole control
and incremental-positioning systems, and enable a close-loop reservoir optimization. They could also be
implemented to choke the flow or shut it off completely. ICD allows friction pressure control along the
horizontal length which in return reduces the Heel-Toe effect and equalizes productivity, which might also
delay the water cut and improve well preformance.

Figure 1—Illustration of the flow rate and drawdown without ICDs (left) and with ICDs
(right) for a homogeneous reservoir with varying permeability (Halliburton web page).
SPE-192879-MS 3

The second alternative was tested using the simulation model and further implemented in the field where
the flow from both wings (compartments) of the well where segmented using a simple dual completion
configuration. This leads to less toe/heel effects. Generally, dual completion provides control on gas or water
coning which results in lost wells especially when high permeability zones exist at heel. Other potential
benefits include horizontal hole accessibility improvement, even and effective stimulation, less congested
area/anti-collision risk and reduced well cost.
Other publications discussed the new completion concept and the hydraulic analysis of the system versus

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the traditional vertical single completion (alshmakhy et al, 2017). Field testing and simulation results will
be discussed in detail in this paper.
Also, multi segmented well technique was used in an ongoing simulation stud to determine and evaluate
alternative methods of completion to optimize production from horizontal wells in carbonate reservoirs,
where different sensitivities are done to come up with the best well configuration.

Description and Application of Equipment and Processes.

The simulation of fluid flow was done with Eclipse, using a 3D mechanistic model for a carbonate reservoir.
A high resolution static model was built using Petrel software. The model was built using real field data.
The reservoir where the model was built has an upper zone with high permeability and a lower zone with
low permeability, Taking into consideration the heterogeneity and the cyclicity of the reservoir it could be
accepted that an intelligent well completion can significantly provide added value compared to the standard
well completion configuration (Drakeley et al, 2001).
As far as well/reservoir performance is concerned, the investigation was done using a line-drive system;
initially openhole horizontal well was introduced to the model. Further, smart completion was added to
optimize the well performance see Figure2.

Figure 2—Simulated horizontal well with ICDs (Jaafar,2016)

Results
Simulation Results
The flow simulation was initially done on a single horizontal well, where the recovery factor reached up
to 40 %. To further increase the recovery factor, ICDs were initially added to the single horizontal well
completion where several sensitivities were tested including varying flow coefficients, cross sectional areas,
inner diameters of each nozzle and the space between each nozzle (Jaafar et al, 2017). The flow coefficients
for the ICDs at the toe side of the well were slightly increased and the spacing between the nozzles was
reduced, respectively. Dual completion was then introduced to the model, see Figure 3, where different
sensitivities on the length of the strings was done, ICDs were then added to the LS to further optimize the
well performance.
4 SPE-192879-MS

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Figure 3—Proposed completion (Alshmakhy, A. and Caicedo, 2017)

Adding ICDs to the single horizontal well with 3000ft length completion increased the recovery factor
by 9%, extended the plateau of production when compared to the conventional completion, the control of
opening and closing of ICDs against the different permeability zones, also delayed the water when compared
to the conventional completion (see Figure 4). Similarly was the results of dual completion extra recovery
factor was achieved by varying the length of the both strings keeping a threshold of 3000ft for the LS.
Additional incremental increase of 5.5 % in the recovery factor was achieved by adding ICDs to the
LS of the dual lateral. A separate feasibility study needs to be conducted, to check the applicability of this
technique in the field.

Figure 4—Oil production rate (left axis) and water cut (right axis) of
adding ICDs (solid line) compared to the base case (dashed line)
SPE-192879-MS 5

Field Results
The dual completion technique was implemented in an onshore field different to where the model was built
considering architecture of the reservoir with no significant vertical heterogeneity. Several choke settings
were tested using the dual completion as shown in figure 5. The long string extends to the lower part of
the well towards toe. The short string is located mainly in the vertical section where production from heel
is conducted. Table 1 contains the sequence in which these tests are conducted. A total of ten tests were
conducted in which the first three used only one choke manifold at surface. Later a second choke manifold

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was installed and allowed for separate production of each string.

Figure 5—Dual Completion Production Test

Table 1—Dual Completion Production Test Sequence

Test LS choke size, /64" SS choke size, /64" Comment

1 20/24/28/32 SI

2 SI 20/24/28/32

3 20/24/28 20/24/28 One choke manifold

4 20/24/28 20/24/28 Two choke manifolds

5 SI 28/24/20

6 20 20 Two choke manifolds

7 16 20 Two choke manifolds

8 20 20 Two choke manifolds

9 20 16 Two choke manifolds

10 24 20 Two choke manifolds

Table 2 summarizes results of first two tests with only one choke at surface. First the well was allowed to
flow through the long string alone through increasing chokes of 20, 24, 28 and 32/64" respectively. Wellhead
pressure ranged from about 1400 to 1300 psi as choke size was increased. Liquid rates increased from about
1200 to 2800 bpd with increasing water cut of 10-16%. Out of 5000 ft of horizontal open hole, 3120 ft was
open to flow through the long string. Productivity per foot ranged from about 0.40 to 0.9 bpd/ft as choke size
increases. This test proved the significant contribution of the toe section with more than 2700 bpd of liquid
rate obtained at surface compared to considerably less production achieved with initial single completion.
6 SPE-192879-MS

Second, the well was allowed to flow through the short string alone through increasing chokes of 20,
24, 28 and 32/64" respectively. Wellhead pressure ranged from about 1300 to 1200 psi as choke size was
increased. Liquid rates increased from about 1100 to 2300 bpd with increasing water cut of 0-18%. Out of
5000 ft of horizontal open hole, 1549 ft was open to flow through the short string. Productivity per foot
ranged from about 0.7 to 1.5 bpd/ft as choke size increases. This test showed ability of water management
as zero water cut was observed at smaller choke.
Also, by comparing wellhead pressure when each of the strings was tested, isolation of the two

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compartments was confirmed. Apparently the installed packers were sealing as evidenced by the sudden
increase of wellhead pressure measured at long string from about 1300 to 1600 psi when flow from long
string was ceased and short string was opened. In terms of production, theory of proportional production
to length was confirmed as more production was observed from long hole, flowed throw the long string,
compared to less length at heel. Production uplift a same chokes ranged from 8 to 12% in favor of long
string with an enhanced return with higher flow rates. However, in terms of productivity per unit length,
uplift was still in favor of short string, producing form heel, with more than 60% increase. The productivity
uplift was increasing with smaller choke/less flow rate. This is an indication of better performance of long
string at higher chokes (need for higher drawdown). By testing well using this approach, an alternating
test strategy (Goat Milking) was attempted which may be recommended to optimize production and avoid
arguments on fair ways of comparison.
Test 3 used one choke manifold at surface with both strings producing simultaneously at chokes 20, 24,
28/64" respectively. Wellhead pressure was about 1200 psi with liquid rate of 1100 to 1800 bpd and water
cut of 0 to 17%. No production improvement was realized with this approach versus producing from each
individual string as done in tests 1 and 2. Results are summarized in table 3.

Table 2—Dual Completion Production Test Summary (Individual Long string and Short string)

Liquid Production Productivity(bpd/ Productivity

Case Choke (/64") WHP (psi) Rate (bpd) WC(%) Uplift (%) ft) Uplift (%)

20 1415 1230 10 7.52 0.394 –

Dual Long String 24 1397 1698 10 11.9 0.544 –

Test 3120 ft 28 1349 2305 16 11.3 0.739 –

32 1300 2776 14 12.1 0.889 –

20 1282 1144 0 – 0.739 88

Dual Short String 24 1258 1518 11 – 0.98 80

Test 1549 ft 28 1212 1960 15 – 1.27 71

32 1160 2305 18 – 1.49 68

Table 3 summarizes test results of test 4 with both strings produced simultaneously with separate choke
manifolds at surface. Wellhead pressure ranged from 1000 to 1200 psi with a combined liquid rate of 2000
to 3100 bpd and total water cut of about 11%. Test 5 results' summary is also included in table 3. In test
5, only flow was allowed from short string with a wellhead pressure of about 1000 psi and liquid rate of
1000 to 1700 bpd. These values were less than wellhead pressures and liquid flow rates obtained with test
2 indicating possible depletion. Water cut was generally comparable to values obtained with test 2 at bigger
chokes. However, differences were recorded at a smaller choke with about 12% water cut recorded in test
5 versus zero water cut (WC) in test 2.
In comparison, higher wellhead pressures were observed on single string when produced commingled
with long string versus producing it individually. Also, generally less WC was observed with commingled
SPE-192879-MS 7

production (maximum of 12% vs. 14% at choke 28/64"). In terms of production, an uplift of more than 80%
was realized. In fact, production was more than doubled at 20 and 24/64" chokes.

Table 3—Production Test Summary (Individual Short string and dual strings commingled)

Case Choke (/64") WHP(psi) LS / SS Liquid Rate (bpd) WC(%) Productivity

Uplift (%)

Short String 20 1056 960 12.3 –

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Test 1549 ft
24 1056 1183 12.7 –

28 1027 1678 14 –

Long String 20 1124 1182 1969 11 105

Test 4913 ft
24 1086 1134 2411 12 104

28 991 1065 3121 12 86

Table 4 summarizes flow results from history when standard single string was the completion. Figure 6
shows flow performance of subject well before installing the dual completion. It displays wellhead pressure,
oil rate, liquid rate and water cut. Until April 2015, well was tested with conventional separator. Later multi-
phase tester was used. For the sake of the analysis, data obtained from conventional separator was used.
At the end of flow test, using the conventional separator, less than 1000 BOPD was produced and more
than 20% WC. Also, more than 300,000 barrels of oil were produced and about 200,000 barrels of water
were injected before installing the new dual completion. Yet, as illustrated in table 4, more than 70% of
production uplift was realized when results of dual completion production test was compared with initial,
with standard single, production test results at similar wellhead pressures. At this point of comparison both
test showed a cumulative WC of 17% and initial production was through 24/64" versus smaller choke of
20/64" for the new dual completion case.

Table 4—Production Test Summary (Single string and dual strings commingled)

Case Choke (/64") WHP(psi) LS / SS Liquid Rate (bpd) WC(%) Productivity

Uplift (%)

Single One 24 971 1013 17 –

Choke 4913 ft

Dual Two 20 963 1048 1795 17 77

Chokes 4913 ft
8 SPE-192879-MS

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Figure 6—Production Test Summary (Single)

Test 6 was conducted with commingled flow through 20/64" choke. Again, results indicated possible
depletion as less production of about 1800 bpd compared to 2000 bpd of liquid obtained with earlier test 4.
Also, slightly higher WC was obtained with test 6 versus test 4.
An attempt to test performance was made on test 7 with 20/64" choke at short string and 16/64" choke
at long string. Results indicated that production ceased to flow from long string at this smaller choke as
indicated by a falling wellhead pressure and less production. At test 8, choke at long string was brought
back to 20/64" and production was back up in line with previous performance at test 8. In test 9, choke at
short string was decreased to 16/64" but flow was still maintained. A final test 10 was conducted with more
than 2000 bpd of liquid rate, and less than 20% WC, which is much higher (almost double) to production
rates obtained at end of test using standard single completion.

Conclusion
This paper investigated the value of adding smart completion on the well performance, initially adding smart
completion both ICDs and dual completion to the model increased the recovery factor (9%) and delayed the
water cut. Moreover, adding ICDs to dual completion further increased the recovery factor by additional
5% in ongoing research to come up with the best well configuration of ICDs in dual completion further
enhancement could be expected Moreover, the field case conducted in a different reservoir supports that
replacing the conventional completion with dual completion increases the well productivity and reduces the
water cut. Overall well design (trajectory & completion) in layered carbonate reservoirs should be optimized
with assistance of mechanistic models. Targeting key geological layers need to be considered to optimize
the well performance and increase the recovery factor, which is currently followed for the ongoing research
SPE-192879-MS 9

Acknowledgments
Authors would like to thank ADNOC for allowing publishing this work.

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