First use of a Newly Developed High-Density Brine in an Oil-Based Screen Running Fluid in a Multilateral Extended Reach Well: Fluid Qualification, Formation Damage Testing, and Field Application, Offshore Norway

Abstract

Abstract When used for running sand control screens, low-solids, oil-based completion fluids (LSOBCF) maintain reservoir wellbore stability and integrity while minimizing the potential risks of losses, screen plugging, completion damage, and productivity impairment. Until now, using LSOBCF as a screen running fluid (SRF) has been limited by fluid density. The design, qualification, and first deployment of an LSOBCF that incorporates a newly developed, high-density brine as the internal phase to extend the density limit is discussed. The following parameters were examined as part of the preliminary qualification: rheology performance, long-term stability, fluid loss (filter-cake repair capability), reservoir fluid and drill-in fluid (RDIF) compatibility tests, emulsion breaking test, production screen test (PST) on 275 µm screen, crystallization temperature [true crystallization temperature (TCT) and pressurized crystallization temperature (PCT)], and corrosion rate. The fluid was then tested for formation and completion damage performance, where the high-density, brine-based LSOBCF exhibited minimally damaging behavior in the core-flow tests. As a result of the positive observations made during these wide-ranging laboratory tests, this new high density-based brine was deemed as a good candidate in an LSOBCF for high-density SRF applications. Viable LSOBCF with densities up to 1.50 SG have been designed. This paper details the design and field application of a 1.45 SG LSOBCF. Calcium bromide (CaBr2) brine is commonly used during the discontinuous phase for LSOBCF applications that require fluid densities up to 1.38 SG. For higher density requirements, LSOBCF use a cesium formate brine as a discontinuous phase. Using the new developed brine in the discontinuous phase provides viable LSOBCF up to 1.50 SG. The base brine has a good environmental rating, is pH neutral, and provides improved safety during low-temperature/high-pressure conditions. As a standalone fluid, the new brine can achieve densities up to 1.80 SG, with acceptable TCT and PCT values for North Sea applications without using zinc or formate-based brines. After laboratory qualification, the final fluid formulation was deployed on a dual lateral oil producer well with 9.5 in. horizontal reservoir section lengths of 2315 and 1696 m. After drilling the sections using an engineered low equivalent circulating density (ECD) oil-based RDIF (OB RDIF), each section was sequentially displaced to 1.45 SG LSOBCF. The lower completion, consisting of 5.5 in. screens equipped with autonomous inflow control devices (AICD) and swellable packers, was successfully run to bottom without significant issues. The field application demonstrated evident operational efficiency gains. The positive pre-deployment formation response test (FRT) results have been verified by well productivity data. The process to qualify the brine for first-use application in LSOBCF is described, and laboratory testing (including FRT), mixing and logistical considerations, field execution, and well productivity are discussed.