Successful Implementation of Horizontal Openhole Gravel Packing in the Stybarrow Field, Offshore Western Australia

Abstract

Summary Key sandface completion challenges were faced in the selection, design, planning, and execution phases of the openhole horizontal gravel-pack completions in the deepwater Stybarrow field, offshore Western Australia. Only limited technical experience and infrastructure were available in the country to support such a complex operation. Additionally, the lateral reservoir-quality variations and challenging sand/shale heterogeneities have necessitated an early focus on appropriate reservoir-drilling-fluid (RDF) design, detailed sand-screen selection, and gravel-pack modeling to minimize premature screenout during gravel packing and to ensure minimal formation damage. This paper documents the multidisciplinary approach that commenced during the field-appraisal and data-acquisition stages to derive the sand-management plan and that culminated in the successful implementation of four horizontal openhole gravel packs. A novel RDF design, extensive formation-damage testing, and the selection of the circulating gravel-packing technique have led to the successful sand-control implementation, with pack factors in excess of 100%. Attention to detail during detailed design, extensive contingency planning, and diligent execution were major contributing factors in delivering high-quality wells capable of producing as per basis of well design, proved by early production performance. The Stybarrow development represents the first successful implementation of horizontal openhole gravel packing in Australia.