World's Longest 9-5/8" Cased Hole Gravel Pack with Multizone Alternate Path System in Offshore Malaysia

PETRONAS completed well K on field KNB in offshore Malaysia by pushing the limit of the distance between two target perforation zone with 9-5/8″ Cased Hole Gravel Pack Alternate Path System (APS). This Alternate Path System installation is the world's longest successful application of the technology where the two target zones are separated with 3,300ft of blanks and the Gravel Pack treatment is pumped in a single trip. Multizone Alternate Path Gravel Pack System has been successfully installed in various field in the world, allowing multiple target zone to be treated at the same time through a transportation tube installed on the blank pipe and screens commonly known as shunt tube. This technique eliminates the need for multiple assembly run, perforation, wellbore clean up, and gravel pack pumping. Additional challenge arises in well K where the two target zones are 3,400 feet apart, and a trajectory with maximum deviation of 60 degrees, posing a risk of not being able to reach TD and perform the gravel pack treatment in an effective manner. The main gravel pack treatment was performed using viscoelastic surfactant (VES) fluid, which specifically designed to a certain viscosity allowing the fluid to flow through the shunts (high shear environment) while maintaining it's proppant suspension capability. Intensive discussion and simulations has been made, specifically for the tubing movement and feasibility checks for all interfacing components. Lessons learned from previous jobs are incorporated to ensure the operation runs smoothly. Installation of the 9-5/8″ Cased Hole Gravel Pack with Alternate Path System was successful. The completion string has 3,300 ft of blank pipe section, and swellable packer was used to isolate zones that can be of interest to be exploited in the future. The Quantum Packer was set, and a good annular pressure test was obtained. The tool was then released from the packer and then moved to reverse position to perform tubing pickle. The alternate path system features one main flow path from the tubing which allows the reverse friction test, circulation test, injectivity test, and matrix acidizing to be performed on the top zone only. Once the acid treatment of the top zone is done, a screen out drill is performed prior to the main gravel pack treatment in which screen out is achieved as planned, and the service tool was moved to reverse position to clean the string from remaining gravel and pulled out of hole. The upper completion string was then run in the hole as per tally and landed successfully. The success of the world's longest 9-5/8″ Cased Hole Gravel Pack with Alternate Path System has shown that with excellent planning, proper risk assessment, and flawless communication, anything is possible. This success also highlights SLB's Alternate Path System's ability to significantly reduce operational time in multiple zone sand control installation and HSE exposure, which in turn makes a profitable and economical well.