Objective was to complete two ~16,000 ft MD offshore, openhole, horizontal wells with inflow control device (ICD) screens and hydraulic packers in a cost-effective and risk-reduced manner. A major goal for the lower completion was to eliminate running washpipe for fluid circulation and intervention string for hydraulic packer setting to reduce rig time, equipment costs and operation/safety risks. A cost effective check-valve inflow control device (CV-ICD) screen solution, as described herein, was used on these two wells to achieve both of these purpose.
CV-ICD consists a nozzle with a 1) ceramic ball to seal against it's throat and 2) porous aluminum plate to retain the loose ball until injection pushes it against the throat. Extensive testing was performed under target conditions to ensure a 5,000psi differential pressure rating for setting open hole hydraulic packer.
Strict adherence to technical details helped transform the relatively simple concept of a ball-type, CV-ICD into a robust and reliable technology. The results of the extensive laboratory testing, as discussed herein, demonstrated: 1) HTHP functionality of the CV-ICD before/after exposure to wellbore fluids, 2) removal of the aluminum "cage" only after the ball is no longer required, and 3) acceptable flow performance of the ICDs with/without the loose ball present. Strict manufacturing and onsite QAQC procedures proved indispensable for success, especially given the challenging environment offshore.
Fluid circulation through the toe valve without washpipe was achieved while running the screen in wellbore. After reaching target depth (TD), the toe valve was closed there by allowing the string to be pressured up to set the hydraulic packers. The tubing pressure was successfully increased to ~5,000 psi against CV-ICDs to set the hydraulic packers. Overall, the completions were a success as discussed in more detail herein, along with valuable lessons learned.
The case studies presented herein demonstrated costs and risks associated with using a washpipe to deploy ICD screens to TD can be significantly reduced with a novel yet cost-effective CV-ICD solution. The integration of check ball with an ICD, while simple in concept, provide significant value if the strict adherence to technical details, rigorous testing and diligent quality control are followed.