Completions in the digital age: A true end-to-end approach

The success of any completion is not governed solely by flawless execution during the deployment process. Success must be measured equally on the ability for any reservoir to deliver its true potential for a timeframe in line with expectations. The Weatherford approach to ensuring success is two-fold: 

• Expanding the use of advanced completion deployment techniques, using industry-leading radio frequency identification (RFID) technology 
• Implementing cutting-edge reservoir surveillance and control technology, designed to aid the decision-making process with the ability to react in real time. 

Traditionally, completions have involved a series of mechanical and hydraulic processes aimed at preparing a well for production, including casing, cementing, perforating, and installing downhole hardware. The Weatherford focus is to reduce the overall time taken to complete wells while keeping the focus on the end goal, which is ultimately to ensure wells produce optimally for as long as possible. 

REDEFINING COMPLETION DEPLOYMENT 

Fig. 1. The TR1P™ single-trip completion system capitalizes on RFID technology to cut rig time, reduce risk, and enhance downhole tool functionality while installing both upper and lower completions.

If we look at how a conventional multi-trip completion is installed, procedures and technology performance is generally not the cause for concern. What strikes the fear into the drilling and completions world is the time and associated cost it takes to install these completions, particularly in the deepwater space. 

Weatherford RFID technology has taken its rightful place within the completions arena as a key enabler to commission wells more efficiently, in a way that promotes optimal reservoir startup. In a nutshell, the Weatherford RFID portfolio (Fig. 1) comprises remotely operated devices (i.e., sleeves, barriers, etc.) that promote a completely intervention-free approach to installing completions.  

The benefits were clear, and, as a result of successful installations in deepwater in West Africa, the operator realized a rig time reduction of 30+% per well. Since then, we have leveraged the successes and learnings of the campaign to evolve the offerings and expand adoption across numerous regions globally.  

DATA DRIVES DECISION-MAKING 

Quite simply, data drives the decisions by providing the foundation for understanding subsurface conditions and predicting future reservoir performance. By understanding the data, we can transform any uncertainty into actionable insights that help guide the decision-making process. 

Fig. 2. Distributed fiber optic data provides a complete picture of events occurring in real time across the whole well.

As the industry evolves, the importance of fiber optic-enabled downhole data is showing signs of increased adoption across the energy sector. Weatherford has been at the forefront of fiber optic technology since 1998, when the fiber brag grating-based pressure/temperature gauge was introduced. The introduction of this technology enabled reliable, high-precision data gathering in both standard applications, as well as some of the more hostile environments. The latter include high-pressure/high-temperature (HPHT), steam-assisted gravity drainage (SAGD), and high-rate gas wells. 

Single-point pressure/temperature measurement is the cornerstone of any reservoir model. However, with the increased adoption of distributed fiber optic sensing, the ability to monitor multiple events across the entire length of the well in real time is game-changing. The Weatherford ForeSite Sense portfolio has the ability to monitor single-point pressure/temperature and multiphase flow, in addition to gathering distributed fiber optic data in the form of DAS, DTS and DSS—all on a single cable, Fig. 2.  

Weatherford is also applying the same measurement philosophy from a predictive failure standpoint. Applications, such as ESP performance and downhole tool health monitoring, are paving the way for operators to plan well maintenance campaigns in advance to help reduce the amount of downtime to a more manageable level. 

DESIGNING FOR COST-EFFECTIVE DEPLOYMENT, OPTIMIZED PRODUCTION AND LIFE EXPECTANCY 

In order to fully recognize the potential of this technology, we need to address five key areas, and the impact they have on the well’s lifecycle, Table 1. 

TRANSFORMING DATA INTO RESULTS 

It would be fair to say that downhole data is most valuable, if you have the ability to act. Without the in-well technology to change the well dynamics relative to what the data is telling you, the likelihood is that well intervention/remediation will be required, which carries a significant cost. Weatherford is acutely aware of the fact that the need for electrification, digitalization and automation has been fast-approaching. 

Intelligent completion systems are the pathway to delivering the results at a reservoir level. Weatherford embarked on our intelligent well journey in the early 2000s but made the decision a few years ago to address reservoir challenges by the means of digital/electrification and introduce to the industry a true electrical production optimization platform.

Fig. 3. The Weatherford AMP™ All-Electric Interval Control Valve completion platform built for well production optimization.

The AMP all-electric completion system (Fig. 3) uses the same fundamental platform to optimize well performance across two specific areas: 

• Inflow Control—Precise electrical control over the variable choke flow trim, combined with integral pressure/temperature gauges, allows real-time decision-making to tailor the inflow/injection profile to what the reservoir dictates. 
• Gas Lift Optimization—Utilizes the same customizable flow trim for gas-lifted wells, allowing the operator to optimize gas injection rates through multiple orifice diameters without the need for intervention. 

THE FIELD OF THE FUTURE 

Fig. 4. Field of the future.

Weatherford has a clear vision of the direction in which our digital journey is going to take. The stage is set. From initial completion design, through optimized deployment, diagnostics, decision-making and actioning, the time to recognize the field of the future is here, Fig. 4. 

The premise is clear: a truly integrated digital oil field designed to enhance asset performance, using real-time, remote operations, and advanced optimization.