Development of the Alba Field—Evolution of Completion Practices, Part 2: Openhole Completions, Conventional Gravel Packing After Drilling With SOBM

Abstract

Summary Chevron has been successfully drilling and gravel packing openhole horizontal wells in the Alba field (central North Sea) since 1998, and 13 openhole gravel-packed (OHGP) wells drilled with water-based mud (WBM) are currently in production with no history of sand production. Although these wells have been hugely successful with significant net present value (NPV) returns, it was recognized that the future, mature redrill and infill targets cannot sustain the current costs associated with traditional OHGP completions. The challenge was to develop alternative techniques to maintain the benefits of OHGP wells but to achieve a low-cost well and completion concept to assist in realizing new drilling opportunities. Drilling the shale above the top of the reservoir and the productive interval in a single hole section would require removing conventional requirements for setting an additional casing string and changing over to a water-based system before drilling into the reservoir. This would save costs but raises a question concerning the gravel-packing operation. Hitherto, attempts to gravel pack that involve alpha/beta placement techniques using an aqueous carrier fluid following drilling with oil-based systems have had only limited success. The prospective problems were examined by extensive laboratory tests carried out cooperatively by Baroid and Chevron. A new, synthetic oil-based mud (SOBM) formulation was developed, and compatible displacement fluids and procedures were devised. Based on this work, 1,500 ft of shale and reservoir were drilled, a liner that was predrilled over the reservoir section was installed, and screen was run inside the liner. Gravel was pumped using brine as the carrier fluid, and complete gravel placement was achieved. The well has achieved productivity levels at least as good as existing WBM wells. A second well completed in the same manner has given a similar performance. This combination of a liner system and SOBM fluids offers several advantages. There is the prospect of considerable savings with respect to operating time, cementing, and drilling fluids. The liner also gives protection to the screen. This new approach, which represents potential large savings in costs and excellent productivity, is considered applicable to other types of completions when it is desirable to drill with oil-based mud even though conventional thinking would have called for water-based drill-in fluid. This consideration applies to targets in the Alba field and worldwide.