Summary

This paper presents a field-proven case study from Abu Dhabi demonstrating how a dual-zone smart completion system—integrating interval control valves (ICVs), permanent downhole gauges (PDHGs), gas lift mandrels (GLMs), and advanced digital solutions—successfully restored production in an integrity-challenged mature well. The study details how real-time zonal control and digital zonal allocation enabled selective and commingled production, eliminated the need for a replacement well, and delivered measurable production uplift and capital savings.

What value did the solution deliver?

Postcompletion results confirmed significant operational and reservoir performance gains:

• approximately 1,000 BOPD from the upper zone with <2% water cut
• additional 300–400 BOPD from the lower zone during commingled production
• ~25% incremental inflow improvement versus pretreatment conditions
• natural lift support for the lower zone provided by the upper zone, eliminating artificial lift
• capex savings of USD 4.8 million by avoiding a replacement well
• zonal flow allocation via a digital solution, which enabled commingled production through a single-string intelligent completion instead of the complex dual-string design used historically.

Operational efficiencies included eliminating future rigless workovers, reducing reliance on wireline gradient surveys and PLTs, and enabling dynamic inflow optimization through real-time monitoring.

What are smart completions and how do they enhance zonal production control?

Smart completions enable reservoir-level control and monitoring by integrating downhole flow control and sensing technologies into the completion string. In this case, the system included

• dual-zone hydraulic Vana™ interval control valves (ICVs) with multiple choke positions
• permanent downhole gauges (PDHGs) for pressure and temperature monitoring
• gas lift mandrels (GLMs) for future artificial lift flexibility
• a programmable surface control system for automated valve actuation.

Together, these components allowed operators to remotely adjust inflow from each reservoir zone, monitor downhole conditions in real time, and manage production without rig-based or wireline intervention.

Learn more about SLB intelligent completion technologies.

Why is this a breakthrough for mature field redevelopment?

The candidate well had been shut in due to casing communication, water holdup, and integrity constraints that threatened access to one of the reservoir zones. Instead of abandoning a zone or drilling a replacement well, the operator implemented a dual-zone smart completion as a rehabilitation strategy.

Key breakthroughs included

• successful deployment of intelligent completions in a high-risk integrity well
• restoration of dual-zone access after section milling and 7-in liner tieback
• full hydraulic and electrical integrity verified to 6,500 psi
• seamless integration of completion hardware with digital zonal allocation workflows.

This approach established a repeatable framework for rehabilitating mature wells with complex integrity and flow challenges.

Abstract

To maximize production across two distinct reservoirs, ADNOC onshore initiated the deployment of its first smart completion in a high-risk integrity well. This study outlines the planning and execution phases, highlighting the successful use of a light workover rig to install a completion equipped with interval control valves (ICVs), permanent downhole gauges (PDHGs), and gas lift mandrels (GLMs) into a 7-in casing tieback. The solution enhanced zonal isolation, improved inflow performance, and enabled real-time inflow/outflow control, preparing the well for sustained natural flow without further intervention.

Comprehensive engineering simulations, risk assessments, and system integration tests were conducted to validate tool functionality and the deployment of multiple control lines through the packer, ICVs, and PDHGs. Collaboration between ADNOC onshore and SLB ensured site readiness and special equipment provisioning through multiple rig visits and continuous evaluations.

The wellbore was meticulously cleaned to remove debris that could obstruct the installation of smart completion assemblies. Challenges encountered at various depths were resolved using scrapers, magnets, and junk baskets. After reaching target depth, wireline operations confirmed packer setting depths. These cleaning techniques offer valuable reference for similar operations across the UAE and internationally.

The smart completion enabled real-time control, production optimization, improved zonal isolation, and inflow control via dual-sensor monitoring, which can result in higher production rates and improved efficiency. By monitoring downhole conditions in real-time, operators can quickly detect and address any production issues, reducing downtime and increasing well availability. It also eliminated the need for a replacement well, rigless workovers for selective production, wireline gradient surveys, and PLTs for zonal allocation—delivering significant operational efficiencies and cost savings.

This case study demonstrates the successful deployment of smart completion technology in a challenging environment, showcasing the benefits of real-time monitoring and control for enhanced reservoir management and hydrocarbon recovery. It provides actionable insights and best practices for future smart completion projects in similar scenarios.