Innovative Approaches to Pilot Well Planning and Verification for the First Fiber Optic Spoolable Array

Abstract A newly developed, global first spoolable fiber optic gauge system offers an economical solution with continuous, multi-point Annulus and Tubing pressure-temperature monitoring at sand face. This system enables real-time well management, including zone identification, leak detection, and production efficiency optimization. The approach to prepare, plan and deploy world's first such field installation is described and covers the construction, factory acceptance and system integration testing, operational logistics and risk burndown activities. Initial performance evaluation is assessed. The trial well was planned for a single-trip installation, where Inflow Control Devices (ICDs), special openhole swell packer, reference gauges, feedthrough production packer, and safety valves were deployed together. The engineering design involved running the prototype array system in annular space between 3 ½″ completion tubing inside 6 1/8″ open hole. The array included various critical components and accessories assembled and secured under specially designed protective clamps to achieve a running diameter of 5 ¾″ with recommended 3/8″ clearance. All connections to the downhole cable were made with pressure-testable metal-to-metal compression fittings. Pre-job assessments and cross-team planning facilitated risk mitigation. Following bench testing and component level qualification, the prototype system was built and ready to be deployed in a single trip in simulated test well demonstrating that the spoolable array can be installed and accurately detect dynamic real well conditions including pressure, temperature, Distributed Acoustic Sensing (DAS), Distributed Temperature Sensing (DTS), and Vertical Seismic Profiling (VSP). Following system level test of array, pilot well array was built based on specific depth spacing for plan well, incorporating all design and operational lessons learnt during the simulated deployment. The full final system was tested per factory and shipped to middle east for installation. Detailed planning, logistics handling, torque and drag analysis, complete well on paper activities, rig visits for optimized layout design of spools and staging, will enable a successful installation in pilot well that included field calibration and verification of the in-well performance of the fiber gauge system both during Run in Hole (RIH) and after final deployment. Several intricate tools and subassemblies made this very complex meticulously planned operation. Success criteria will be evaluated immediately at installation. The performance evaluation will continue at 1, 3- and 6-month time periods to establish the long-term reliability and robustness. Novel spoolable monitoring system utilizing Bragg-Grating allows tracking pressure and temperature changes in oil wells. System includes a spooled deployment mechanism to minimize rig time, a method for accessing continuous annulus and tubing pressures, a technique to ensure tubing string alignment, and a redundant architecture that supports fault-tolerant operation. With precise data, operators better estimate fluid production, enhance operational efficiency and cutting costs. Ultimately, this innovation promises significant cost savings, minimizing disruptions to production activities.