Improving Completion Reliability by Integrating ESPs, Intelligent Completion and Zonal Downhole Monitoring Using a Compact Horizontal Wellhead

Abstract

The paper presents an oil well completion integrating multilaterals, intelligent completions, permanent downhole monitoring systems, electric submersible pump (ESP) and a horizontal wellhead system. The reliability of the completion was improved by using a concentric tubing system that avoided the use of a downhole wet connect tool to disconnect the intelligent completion control lines during ESP workovers. The concentric production tubing design enabled the separation of the intelligent completion from the ESP tubing. The intelligent completion was installed as a first run with a big bore 7 inch tubing in the upper section. The ESP was later installed inside the 7 inch tubing as a second trip. This separation between the intelligent completion and the ESP production tubing enables ESP workover without disturbing the control lines of the intelligent completion. Each of the technologies used in this well are well-established in the industry and have extensive track record but industry survey indicate that the case presented in this paper is the world's first completion integrating all this technology in a single installation. This unique and challenging integration was required to meet well requirements and to build field experiences for future applications in more challenging environments that require ESPs and intelligent completions. The paper discusses the drivers for this integrated completion, completion design, individual equipment, preparation, field experience during installation and the performance of the system during production. Three simulated cases of inflow optimization are presented to show the capability of intelligent completion to monitor and optimize inflow without well intervention. The paper also presents details of the special compact horizontal wellhead that integrated the multiple tubing hangers and wellhead spools while maintaining the overall height of the wellhead. The completion has been successfully installed and the lessons are being applied in designing future installations.