SPE 143431

Well Production Enhancement Results with Inflow Control Device (ICD)

Completions in Horizontal Wells in Ecuador
Ivan Vela, Petroamazonas; Lumay Viloria-Gomez, Ricardo Caicedo and Francisco Porturas, SPE / Schlumberger

Copyright 2011, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE EUROPEC/EAGE Annual Conference and Exhibition held in Vienna, Austria, 23–26 May 2011.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents of the paper have not been
reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect any position of the Society of Petroleum Engineers, its
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Abstract
Reservoir performance is dependent upon system interaction between the completion hardware, the wellbore reservoir section
and its connection to surface.
A-priori condition used to design a robust completion solution are housing units capable of draining and collecting fluids
along the entire completion length and simultaneously produce oil while delaying more mobile fluids. Therefore the
completion design should focus on:
a. Those scenarios that are expected to have greater impact in the producer wells: These include for example PI
increase, adjusting drawdown pressure, flux balancing, delaying early entry of high mobile water or gas along the
entire completed interval, well clean-up through time and extending well production life.
b. Wether it is expected to accelerate initial production or balanced management of the field. The goal in both cases is
to achieve efficient area drainage and uniform sweep while not leaving by-passed oil in the ground.
c. Whether the contingency plans are for, alternative re-completions or preparing the wellbore for future operations
such as EOR related activities to stimulate production from much lower oil residual saturations.
d. Having hardware ready that allows changes in operational modes from producer to injectors or viceversa, or permits
installation of slim hole units, technologies to enhance porosity or permeabilty, reduce viscosity and mobility ratios,
implement fine reservoir characterization models, avoid reaching ultra-high WCUT too soon or to implement
intermediate EOR operations to slow down this tendency.
In Ecuador, an operator has completed several wells equipped with ICDs, in both consolidated and non-consolidated
reservoirs and with variable rock and fluid properties including viscosities varying between 4 to 47 cP.
This paper describe the combination of ICD design, geo-steerirng, calibration with real-time log data, installation procedures
and fluid historical production results through time.

Introduction
Block 15 is located in the Oriente Basin of the Amazon jungle in Ecuador. The main fields are: Paka Sur and the Eden Yuturi.
Both are clastic reservoirs with variable fluid and rock properties. Fluid viscosities varies areally with several PVT regions e.g.
4 cP, 8 cP, 12 cP, 17 cP, 19 cP, 21 cP and to 47 cP and their respective API gravities. Figure 1 shows the location of Block 15
together with a general stratigraphic column, showing the formations completed with ICDs.
Geologically the Oriente Basin is part of the upper Amazon River drainage system and covers an area of approximately 80,000
km2 which is very prolific for oil and gas production. It is geologically continuous with the Putumayo basin in Colombia and
the Marañon basin in Peru, separated only by geological arches located north and south east of the basin.
The fields initial production was with low deviated wells and completed conventionally, resulting in an irregular flux, without
adjusting pressure, selective reservoir drainage, strong water coning, well interference and non-optimal area sweep and leaving
by-passed oil. Other wells were completed with dual solutions to produce from two zones simultaneously.
From 2007, ICD completions are evaluated against how challenges are met at the reservoir level balancing uneven inflow and
improving area sweep efficiency. At the completion level to increase well productivity and well longevity.

This paper presents a comparison of the results of 5 wells including 4 completed with ICDs. Well 1 is a conventional
completion presented only to show main challenges. Well 1 production is lifted with two serial pumps while the ICD wells
only with a single one. Well 2 and Well 3 were completed with a 6 5/8” ICD in a non-consolidated reservoir and Well 4 and
2 SPE 143431

Well 5 (recent well) are completed with ICDs of 4 ½” and in a consolidated formation. The operational challenge for all the
wells is to produce oil with low water production rates.
Nodal analysis was applied to design pre-completion scenarios, to show the ICD potential and benefits. Then best cases were
selected by interrogating available reservoir fluid and rock properties and compared at anytime with the conventional well
completion performance.
The final ICD completion design is calibrated with real-time data prior to placing the ICD hardware in the ground facilitated
by the operational flexibility of chosen removable housing option . All wells were geo-steered.

Background
Well 1 production history (Figure 2) shows a rapid decrease of pressure and an associated decrease in oil production. This is
because it was completed conventionally and its production lifted with two pumps coupled in series and in an optimal initial
reservoir environment in 2005. Therefore the initial production is high, however it declines rapidly through time. This type of
completion is prone to strong coning and not allowing for an efficient reservoir drainage. The strong coning interfere with
recent neighboring wells placement and its performance. The historic production of Well 1 completed without ICDs in a non-
consolidated formation, 17 cP viscosity fluid and in a low angle deviated well, show high water rate production (currently the
WCUT is greater than 90%). The completion has not “responded” to variable rock properties in front of the completed sand
face. Futhermore, poor pressure adjustment has resulted in a very high drawdown pressure since start of the well. The pressure
decay from about 2000 psi (start of well production) to about 1000 psi and effects of pump frequency handling. Well 1 is also
affected by an irregular and non-uniform area sweep and generating high interference to new infill wells.

The following challenges were identified when looking for ICD completion potantials and benefits: decrease or stabilise water
production, adjust pressure and achieve a more uniform reservoir drainage and mitigate the well interference due to coning
expansion of low deviated wells. Another challenge was created by the presence of fluids of varying viscosities and
consequently with large mobility contrasts.

ICDs were considered as an alternative to conventional completions in order to: a) minimize the water entry rate, b) to
stimulate low to moderate intervals while optimising the contribution of better pay zones to increase production and c) extend
well production life, leaving the water in the ground.

The selected ICDs are nozzle based which introduced a controlled pressure drop through nozzles, the number and size of
which are determined through simulations. This reduced the pressure drop across the sand face of the completed zones, thus
delaying water breakthrough depending on fluid mobility ratios and minimizing risk for by-passing reserves and handles
lateral heterogeneity. Figure 3 shows two main types of formations: uniform and heterogeneous lithology. With no ICDs the
well completion will be prone to strong Heel-Toe effect, non-uniform reservoir drainage, and non-optimal pressure
adjustment. Furthermore, horizontal wells completed in this type of reservoir environment will not produce along the entire
wellbore, because conventional completions do not adjust pressure as ICDs do, resulting in long section being passive and not
contributing to oil production.

ICD theory
The pressure drop through a nozzle is a result of the static energy in the fluid being converted into kinetic energy and absorbed
in the fluid downstream of the nozzle. As described by the Bernoulli equation, nozzle based ICDs are independent of fluid
viscosity. This pressure drop is described by:
ρ v2 q
ΔPN = Cu , v=
2 Cv 2 A
Where: ΔPN = pressure across ICD nozzles, Cu= units conversion constant, ρ= density of fluid, v= velocity, Cv= dimensionless
flow coefficient for the nozzle, q = rate and A= total cross section area of the nozzles

At the reservoir sand face, Darcy law:

μL ⎛ q ⎞ k
ΔPF = ⎜ ⎟ ⇔ v= ΔPF
k ⎝ A⎠ μL
ΔPF = pressures across formation, ρ = fluid density, v = fluid velocity, q = flow rate, A = total cross section area of the nozzles,
k = permeability, μ = viscosity.

The constant Cv is determined by nozzle geometry and flow with a typical dimensionless value between 1.0 and 1.5. When
fluid flows through a nozzle, the pressure inside the high velocity flow down stream of the nozzle is significantly reduced
locally.
Types of Inflow Control Device ICD
There are basically three types of Inflow Control Devices (ICD).
SPE 143431 3

1. Channel-type ICD: which enforces a specific differential pressure at a specific flow rate by means of helical channels with
pre-set diameter and length.
2. Orifice-type ICD: which is similar to the nozzle-type with respect to the flow characteristics, differing in material
technology and fluid viscosity responses.
3. Nozzle-type ICD: in which fluid enters the screen and then flows between the screen jacket and the base pipe through these
nozzles causing a pressure drop. The pressure is dependent on the fluid density and velocity, but independent of fluid
viscosity. Nozzle based ICD has been installed in all 10 wells in Ecuador. Figure 4a shows details of a nozzle based ICD
integrated with sand control for producer and injector wells. The ICD completion components and are wire wrapped screen
over the base pipe, the ICD nozzle housing, centralizers, swellable packers (optional), and connectors. Nozzle based ICD
equipment prototypes for production and injection (Figure 4b) and its interaction at reservoir level are governed by Darcy´s
law and towards the ICD completion hardware by the Bernoulli principle. Figure 4c show a nozzle-type ICD flux pattern. The
amount of pressure drop is dependent on the fluid density and velocity, but independent on fluid viscosity.
Removable house nozzle based ICD hardware (Figure 4d) permits the operator to re-dimension, refine and to increase or
decrease the number of the ceramic nozzles according to the well production expectation and reservoir characteristics and are
easily installed on-site. The removable house ICD option is the only alternative which allows the operator to update the
completion design with LWD data whereas closed ICD system (already welded) which cannot be open at the wellsite and do
not offer flexibility to re-calibrate or update the model.
The ICD removable house nozzle system is a very flexible hardware and non-time consuming when it is desired to update the
design and can be done just before placing the completion architecture in the ground.

ICD function and operation

As fluid enters the screen, it flows between screen jacket and base pipe into the housing and through the ceramic nozzles
(Figure 4c). When fluid enters the nozzles, the potential energy is transformed into kinetic energy, which is absorbed in the
main flow through the base pipe, thus resulting in a pressure drop between the annulus and the tubing. Different nozzle sizes
are available, making it possible to design the ICD completion to the required well geometry and flow rate.

The ICD nozzle setting can be pre-set, or alternatively, the nozzle setting may be performed on the pipe deck. The wire
wrapped screen is solely for sand control purposes and for the described case history its function is only to allow flow and not
impose an additional pressure drop.

Nozzle based ICD viscosity independence is demonstrated on Figure 5, which shows the results of the ICD qualification test:
pressure drop as function of flow rate for different test fluids. Tests have been run with various viscosities ranging form 1 to 33
cP. The pressure drop is independent of this viscosity variation. The tests show a linear relationship with fluid density. For
example at the same surface rate, minimal and insignificant ICD’s pressure-drop, ΔP changes against viscosity change
downhole. Furthermore the ICDs can self regulate flow variations, because the reservoir ΔP is a linear function of fluid
velocity and viscosity (Darcy law) while the ICD ΔP is a function of the velocity squared and fluid density (Bernoulli
equation).

Figure 6 shows an example of a pressure response of a heterogeneous formation in a well completed conventionally and
another completed with ICDs. The ICDs reduce influx variations across shaly sands and anywhere heterogeneity occurs along
the wellbore.

Methodology

Simulation challenges in Block 15, prior to drilling

Horizontal wells were chosen for ICD completions rather than normally deviated well, due to reservoir thickness, oil column
and strong water drive to maximize production.
Intially a series of feseability simulation scenarios were directed towards sensing the ICD performance versus a conventional
completion and ICDs potentials for handling expected PI, available pressure drawdown, flux contribution along the entire well
and potential reduction of water cut.
Simulations were performed with a hydraulic nodal analysis simulator to compare the performance of a conventional screen
versus a completion with ICDs.
The base case is selected, the criteria being a comparative inter-play between pressure, flux contribution from the reservoir
into the well and water cut reduction potentials and ranges.
The results showed an efficiency improvement in water breakthrough delay (breakthrough of high mobile phase may occur
anywhere along the completion) and enhances production.

For non-consolidated formations, most of the the results showed an efficient water breakthrough delay and average WCUT
was reduced from about 87% in the conventional completion to about 61% using ICDs in the final completion.
4 SPE 143431

From the ICD base case to post-completion performance evaluation

A numerical model of the well is created using field rock and fluid properties as input. Simple models are built describing the
near well-properties by creating a synthetic permeability profiles using data from openhole logs. Initially a series of simulation
scenarios were run directed towards matching the historical production data with selected borehole geometry.
The general methodology comprise the following steps:
a. Initial data evaluation and sensing in which time is used to define goals, identify reservoir challenges, risk and operational
aspects of the project. This step is recommended to start as early as possible. Very often special equipment it is required to
produce special equipment with unique specifications. Figure 7 shows the two types of ICD equipment specifically designed
and manufactured for Block 15. For consolidated reservoir the ICD is 4.5” base pipe, and for non-consolidated reservoirs the
ICD equipment produced in 6 5/8” base pipe.
b. Following preparation and evaluation of multiple scenarios comparing the ICD performance and benefits with alternative
completions. Then one or more base cases are selected for further and detailed evaluation. A preliminary completion Tally is
taylored and delivered both to the operator and to the service company to assit in pricing, logistics, manpower and completion
equipment movement.
c. The final base case selected is subject to re-calibration or refinement with permeability and saturation profiles from LWD
data. This is the last opportunity, if necessary, to define nozzle sizes, their number, location of packers, zones to be by-passed
or isolated with blank pipe and to include other required completion elements. The final Tally is delivered to the field
engineers to assemble the final completion architecture.
d. The ICD is then installed.
e. Well clean-up is performed, which is a very important step.
f. The well is opened to production. Its is recommended that low pump pressure and pump frequency be applied until the well
is stable. Conventional completion takes longer time before production is stabilised. ICD completions stabilise in shorter time.
g. The final step is post-completion follow-up of the ICD performance.

Selecting the size of insert screens, number of screens sections and nozzle configuration
Input for designing the ICD completion geometry included saturation, desired inflow distribution, pressure profiles and nozzle
based ICD specifications for a series of nozzles size options as well as internal diameter of the insert screens. A valuable input
could also be the current drawdown pressure, particularly if the well is located in a mature field that is depleted and
experiences well interference from pre-existing producers.
A number of simulations were run to determine sensitivity to annular flow (i.e. collapsed or open annuli) along the wellbore.
This was done to determine if it was beneficial to use swellable packers.
Ultimately the ICD and nozzle combination was selected for each well, the criteria being a comparative inter-play between
pressure and flux contribution from the reservoir into the well over time.

Geosteering
Precise placement, landing and geo-control of well trajectory is a must to achieve success and to minimise both structural and
sedimentological uncertainity.
If the measurements depart from the original ICD nozzle size and configuration are refined and reset at wellsite before
running in the hole with the use of fully adjustable ICD.
In Well 2 geo-control maintained the well within the 800 ft “M-1” non- consolidated sandstone without caolin and 5 ft below
the sandstone with caolin. The fluid has high viscosity about 47.6 cP and strong acquifer (Figure 8).
Well 3 in non-consolidated formation presented challenging geo-steering because of shaly lenses that can make geo-steering
data hard to interpret. Exiting from the casing point (Heel) it was possible to identify a well defined shale lens with Gamma
Ray values of about 120 GApi and lower resistivity. During the 900 ft horizontal section the presence of this shale lens was
detected constantly and the drilled trajectory was placed just below it. In the final portion, the Main “T” sandstone changed
properties showing a decrease in resistivity probably due to a lateral facies changing. Finally it was possible to obtain about
82% of sand penetration in the whole horizontal section (Figure 11).
Well 4 placement was done with PeriScope* in a consolidated formation, with a total length of 775 ft MD, showing a constant
resistivity of 180 ohm.m and GR around 30 Gapi and with 14 ft maximum depth of investigation above the the drilled
trajectory, it was placed 20% closer to the formation top compared with plan. The drilled trajectory was placed above the plan
in order to stay closer to the Lower “U” Top. The 774 ft of geo-steered section was drilled in clean and oil saturated sandstone
as showed by the Gamma Ray and resistivity logs. The objective formation was encountered vertically isotropic, as expecting
from the offset wells. The formation features allowed the LWD to detect the reservoir top 14 ft TVD above the borehole and
confirm the presence of an anticlinal structure as expected from seismic data (Figure 14).
Well 5 reached an angle of 90.37 degrees and an azimuth of 210.52 degrees and was navigated inside the objective. The
wellbore traversed a 60 ft clay lense, giving about 747 ft of good consolidated sandstone pay zone and good petrophysical
characteristics (Figure 17c).
The average resistivity was between 500 to 600 ohmm and the GR log of about 50 API. GR logs also indicate the influence of
lateral facies changes where it reaches about 60 API.
SPE 143431 5

Geo-steering, accurate navigation and real time review of data measurements allowed verification of ICD modeling and ICD
completion design.

Field installation
Based on reservoir challenges of Block 15 the criteria was for nozzles to be pre-set based on anticipated reservoir
characteristics, fluid properties, well configuration and flow rates. Nozzle pre-set is normally in the order of pressure drop
from toe to heel to have an effect and accordingly to well PI. Nozzles can be changed at rig-site in case of reservoir formation
heterogeneities. Below are the results of only four wells completed with nozzle based ICDs:
1. Well 2, 8.5” OH, 6 5/8” ICDs non-consolidated reservoir, completed in January 2009 (Figure 9).
2. Well 3, 8.5” OH, 6 5/8” ICDs non-consolidated reservoir, completed in September 2008.
3. Well 4, 6 1/8” OH, 4 1/2” ICDs consolidated reservoir, completed in October 2008 (Figure 15).
4. Well 5, 6 1/8” OH, 4 1/2” ICDs consolidated reservoir, completed in August 2010 (Figure 16d).
Well 2 completed in a non-consolidated formation performed initially as expected. Initially the WCUT was lowered to about
20%, which initially was expected to be 60%. Well 2 required post-completion treatment because of secondary plugging
effects of drilling fluid and shale estabiliser. To date the well has recovered in terms of pressure, increased flux and lower
WCUT.
The well drilled in a non-consolidated sandstone is 8.5” OH borehole diameter and the ICD completion has 6 5/8” OD.
The well was navigated 800 ft MD inside the “M-1” principal zone without caolin, with an average resistivity of 26 ohm-m. It
was estimated to have located the well 5’ TVD below the caolinitic sandstone. Figure 8 shows the geo-steered drilled sandface
and more challenging lateral heterogeneity. Figure 9 shows the final ICD completion layout and the location of a few short OH
packers that were installed to further minimize risks related to the annular flow, erosion or plugging of the screens, at initial
conditions. The well is expected to collapse during production life time.
Well 4, is the first horizontal well completed with ICDs in a consolidated formation at Block 15. Accurate placement of well,
navigation and real time geo-control data allowed a review and calibration of the ICD base case modelling and to verify the
final ICD completion. ICD nozzle size and configuration was refined and reset at wellsite before running in the hole with the
use of fully adjustable ICD. Figure 13 shows the location of Well 4 over the simulation grid. Figure 15 shows the final
completion layout. The OH packers minimize the risks related to the annular flow, including erosion or plugging of the
screens. The water breakthrough simulation with ICDs decreased water rate significantly compared to the conventional
completion.

Production results and performance

Well 2 historic production profile (Figure 10): this well required treatment because of drilling fluids and shale stabilizer near
wellbore damage. After a post-completion workover chemical treatment, both oil rate and pressure recovered. The presence of
the ICDs facilitated the post-completion treatment by ensuring the uniform distribution of the chemical treatment along the
screen. Note that initial WCUT is about 35% with ICD completion rather than the expected 74% with a conventional
completion. After five months WCUT rose to 60% while the simulation of the conventional completion showed an expected
82%. After 14 months of production the WCUT is stabilized at 82% whereas the predicted WCUT with a conventional
completion was 95%. ICD`s also maintained WCUT rates constant for longer periods in a 47.1 cP viscosity fluid, before
increasing slowly. Furthermore, ICD`s doubled well PI, due to the well clean-up added benefit of the ceramic nozzles and its
viscosity independence.
Well 3 included a non-consolidated reservoir, high viscosity fluid and sinusoidal well trajectory and strong lateral acquifer.
ICDs assisted in a slow rise of WCUT which simulations show to have about 80% initial WCUT. Here the ICDs after 25
months of production show about 90%. Furthermore ICDs assisted in the well clean-up and well recovery, re-vitalising oil
production which allowed a slow and non-abrupt rise in WCUT. After efficient drainage, the well is subject to an added value
workover to increase well PI, by re-completing unit Lower “U” (the well is not producing from the “T” unit). This well had a
PLT log, showing efficiente drainage along the completion.The hardware is ready when EOR techniques are defined as
appropiate to recover remaining residual oil saturations (Figure 12).
The production performance of Well 4 which was completed with ICDs was compared with that of an offset well without
ICDs, in a consolidated sandstone. Well 4 initial WCUT was expected to be more than 34 %. After 4 months of monitoring
both pressure and lowered WCUT is about 24%. Offset wells are already showing decay in oil rate and pressure, and
increasing water rates. Well 4 has been a candidate for a PLT log however due to good performance has been delayed several
times. Current WCUT is about 60% after about 28 months of continous oil production (Figure 16).
Well 5 (Figure 17e) was drilled in a consolidated reservoir Lower “U” and included installation of ICDs. The oil rate after 5
months of production show “dry” oil, because the ICDs have stabilised both pressure and WCUT. Simulation of a
conventional completion show an expected inicial WCUT of between 10 to 16 %. Here the ICD response show “zero” WCUT
for about 4 months then rising slowly to 16 % (this oscillation is due to changes in frequencies of the ESP pump). ICDs have
minimised an abrupt rise of the WCUT and have maintained reservoir pressure which has allowed a uniform area sweep and
efficient oil recovery. ICDs have stabilised reservoir pressure, WCUT and enhanced production with more “dry” oil.
6 SPE 143431

Recomendations for the future

ICD completions have proven longevity and are ready in the ground for future alternative production enhancement approaches.
Advances in real time reservoir simulation grid updates, not necessarily detailed history matches, permit to sense of major
influences of the ICD completion complemented with availability of more dense seismic cubes or vintage seismics and more
dense populated rock and fluid properties. The existing ICD completion is ready to enhance future production solutions.
It is advisable run future simulations scenarios directly in the seismic cube to identify by-passed oil and to plan alternative drill
trajectories to drain remaining oil lenses. Surely new styles of number crunching will emerge and all will benefit by having a
completion architecture ready to receive and react together with new production enhancing stimulation techniques to increase
the hydrocarbon recovery factors.

Summary
ICDs installed in all wells in Ecuador, having variable fluid viscosity, borehole geometries, length and reservoir challenges
show good performance with increased oil production, lower water production, adjusted reservoir pressure and extended
production life. To date, no sand production has been reported. Early ICD feasibility and simulation of the base case and
several scenarios facilitated an efficient field operation and an early and timely opening of the well to production.
The removable housing option has been selected for all wells in Ecuador and is valuable for calibrating ICD completion
scenarios with real time data just prior to placing the ICD completion hardware in the ground.
The positive results from this ICD installation will allow production of zones that otherwise would be left undrained due to
expected early water breakthrough. ICDs delayed mobile fluids reaching ultra-high WCUT levels early.
It is concluded that Inflow Control Device proven technology is beneficial and successful in Ecuador, and its application and
installations will be extended to other fields.

Acknowledgements
We want to acknowledge our colleagues in Petroamazonas: Jose Reina, Jonny Lomas, Alex Iza, Oscar Morales and Christian
Vega for valuable discussions and input during this work, and Schlumberger Sonia Liliana Castellanos and Olivier Humbert
for cooperation and service during the planning, execution and completion phase.

References
1. E. Davila, R. Almeida, I. Vela, J. Pazos, K. Coello, F. Chinellato, Olivier Humbert and Francisco Porturas, First Applications of
Inflow Control Devices (ICD) in Open Hole Horizontal Wells in Block 15, Ecuador, SPE123008, LACPEC, Cartagena, Colombia,
31 May-3 June 2009.

Figures

Figure-1: Location of the Block 15 Field, Oriente Basin in the Ecuadorian Amazon, one of the main oil fields in Ecuador.
SPE 143431 7

Figure-2: Historic production of Well 1 completed without ICDs in a non-consolidated formation “M-1”, 17 cP viscosity fluid and in a
low angle deviated well. Here, two pumps were incorporated in the upper completion to aid production. The well is prone to strong
coning and high water rate production (currently the WCUT is greater than 90%). The completion has not “reacted” to variable rock
and fluid properties in front of the completed sand face. Futhermore, poor pressure adjustment has resulted in a very high drawdown
pressure at start of the well and decaying more rapidly than expected. Notice: the pressure decay from about 2000 psi (at initial well
production) to about 1000 psi and effects of pump frecuency handling. Besides Well 1 will be affected by an irregular and non-
uniform areal sweep and generating high well interference to new infill wells.

Figure-3: Example of reservoir challenges: homogeneous or layered reservoir (variable rock properties), both affected by strong Heel-
Toe, preferential flow over high permeable intervals. A conventional completion (without ICDs) may not be able to minimise the risk in
gas or water coning, will limit drainage from Toe part of the well and the entire system result in a reduced well PI and leaving
reserves behind.
8 SPE 143431

Figure-4: Detailed nozzle based ICD hardware integrated with sand control for producer and injector wells. a) ICD completion main
components, ICD unit together with wire wrapped screen over the base pipe, ICD nozzles housing, centralizers, swellable packers
(optional), and connectors. b) ICD equipment prototypes for producion (left) and injection (right) and downhole interaction at the
reservoir (governed by Darcy Law) and towards the ICD completion hardware (Bernoulli Principle) and flow inside the production
pipe. c) Flux visualization in a cross-section of a a nozzle based ICD which needs an absorbing chamber downside of the nozzles. For
nozzle-type ICD the fluid enters the screen (shown by the arrows) and then flows between the screen jacket and the base pipe
through these nozzles, where the nozzles cause a pressure drop. The pressure drop is dependent on the fluid density and velocity,
but independent on fluid viscosity. d) ICD removable house hardware where the ceramic nozzles are installed on-site, extensive
material technology options from stainless steel to high Cr alloys (harsh reservoir environments). Nozzle sizes available today are:
1.6 mm, 2.5 mm and 4mm. The added benefit of this flexible system is an quick design update integrating LWD real time data, done
just before placing the completion in the ground and without consuming valuable rig time.
SPE 143431 9

Flow [BPD]
0 100 200 300 400 500 600 700
5
700
4.5
33 cP 600
4
11 cP
Nozzle pressure [MPa]

3.5

Nozzle pressure [psi]

7 cP 500
3 5 cP
400
2.5 2 cP
1 cP
2 300
k 1.15
1.5
200
1
100
0.5

0 0
0 20 40 60 80 100 120
v2
Δp = kρ Flow [m³/d]
2
Figure-5: ICD viscosity independence, qualification test: pressure drop as function of flow rate for different test fluids. Tests have
been run with various viscosities ranging form 1 to 33 cP. The pressure drop is independent of this viscosity variation. The tests
show a linear relationship with fluid density. For example at the same surface rate, minimal and insignificant ICDs pressure-drop, ΔP
changes against viscosity change downhole. Furthermore, the ICDs can self regulate and balance flow variations, because the
reservoir ΔP is a linear function of fluid velocity and viscosity (Darcy law) while the ICD ΔP is a function of the velocity squared and
fluid density (Bernoulli equation).

Figure-6: Pressure response comparison: heterogeneous reservoir completed with two options: a conventional completion (slotted
liner) and with an ICD completion. Notice how the ICDs react anywhere changes in fluid or rock properties are present and without
compromising production rates of high inflow from high permeability streaks. Here the drawdown pressure adjustment to optimising
the contribution of better pay zones, while stimulating the intervals with moderate and low permeability to produce more. The
conventional completion only show significant drawdown pressure dynamic range at the Heel of the well, which will result in
premature coning and leaving parts of the well without contributing to production (interval from where the drawdown pressure
becomes nearly constant). The conventional completion will not handle mobility contrasts and early entry of high mobile phases and
the general observed tendency is: WCUT will increase more rapidly.
10 SPE 143431

Figure-7: ICD hardware has two main components: ICD housing and sand control component as shown in the schematical
representation of an individual joint of the ICD completion equipment specially manufactured for ICD installations, Block 15, in
Ecuador. a) ICD completion for a non-consolidated reservoirs, here the base pipe is 6 5/8”, the slot opening is dimensioned
accordingly with the particle size granulometry and the screen part is longer and apart from facilitating the entry of hydrocarbons has
as well an integrated ICD - sand control function of erosive particles, b) ICD hardware for a consolidated reservoir, the ICD sections
are shorter, usually sections of blank pipe are integrated with the ICD hardware. For consolidated formations the screen part is
shorter and its function is only to address fluid, the slot opening is larger, usually there is no need for control of solid particles. Both
cases: consolidated and non-consolidated formations, the material specs and length of each joint and slot opening usually depend
on the reservoir environment characteristics.

Figure-8: Well 2: Geo-control maintained the well 800 ft within the M-1 non- consolidated sandstone without caolin and 5 ft below the
sandstone with caolin. The fluid has high viscosity about 47.6 cP and strong acquifer. Notice the by-passed interval at the Heel of the
well, because of low sand count.
SPE 143431 11

5 to 6: Blank pipe and an oil swellable packer (heel) 13: BTC box 17: X-over
6: Oil swellable packer 14 to 15: ICD joints 18: BTC box
9 to 11: ICD joints 16: Oil swellable packer 19 to 22: Seal Receptacle,
12: Blank pipe X-over, Spacer, Double Poppet wash down shoe
End of string

Figure-9: Well 2: example of a final ICD completion architecture of 6 5/8” and installed in a non-consolidated formation. The main
components are: ICD joints, blank pipe (to by-pass a non-pay zone at te Heel of the well), and oil swellable packers. A-priori there is a
base case, therefore this ICD completion lay-out is refined with the input of the LWD data, and done just before installing the
completion in the ground.

Well reconditioning

Figure-10: Production profile of Well 2. The well required treatment (because of drilling fluids, shale stabilizer and near wellbore
damage) after a post-completion workover chemical treatment, both oil rate and pressure recovered. The presence of the ICD`s aided
the treatment by ensuring the uniform distribution of the chemical treatment along the screen. Notice: initial WCUT is about 35% (ICD
completion) expected 74% (with a conventional completion), after five months WCUT raised to 60% while the simulation of the
conventional completion showed an expected 82%. After 14 months of production the WCUT is stabilized at 82% (the predicted WCUT
with a conventional completion was 95%). ICDs also maintained WCUT rates constant for longer periods in a high viscosity fluid 47.1
cP, before increasing slowly. Furthermore ICDs doubled well PI, due to the well clean-up added benefit of the ceramic nozzles and its
viscosity independence.
12 SPE 143431

RES

GR

GR
/

PeriScope

GR

Top Main T

Shale lens

Hee
l Toe
Drilled Planned
j j
0 - 0 1 -

Figure-11: Well 3: geo-steered in a non-consolidated formation, was challenging because of the presence of shaly lenses that can
make the geo-steering data hard to interpret. Exiting from the casing point (Heel) it was possible to identify a well defined shale lens
with Gamma Ray values of about 120 GApi and lower resistivity. During the 900 ft of horizontal section the presence of this shale lens
was detected constantly and the drilled trajectory (in blue) was placed just below it. In the final portion, the Main “T” sandstone
changed properties showing a decrease in resistivity probably due to a lateral facies changing. Finally it was possible to obtain about
82% of sand penetration in the whole horizontal section.

Figure-12: Historical production of Well 3 non-consolidated reservoir, high viscosity fluid and sinusoidal well trajectory and strong
lateral acquifer. ICDs assisted in a slow rise of WCUT which simulations show to have a initial WCUT of about 80%. Here tha ICDs
after 25 months of production show about 90%. Furthermore ICDs assisted in the well clean-up and well recovery, re-vitalising the
well oil production allowing a slow and non-abrupt raise of WCUT. After efficient drainage, the well is subject to an added value
workover to increase well PI, by re-completing unit Lower “U” (today the well is not producing from the “T” unit). This well had a PLT
log, showing efficient drainage along the completion.The hardware is ready when EOR techniques are defined as appropiate to
recover remaining oil.
SPE 143431 13

Figure-13: Location of Well 4 in the simulation grid. The attribute display show Sw areal distribution, per August 2008. Notice: the
location of two neighbouring low deviated wells landed in the structura high. ICD completion was selected based on the benefits to
adjust pressure, minimize coning, neighbor well interference and to minimize water coning at the Heel and Toe parts of the well in a
consolidated sandstone reservoir.

RES

GR

GR U/D

PeriScope

GR

Lower U Top

Drilled Trajectory

Planned Toe
Hee

0 - 0.2 -
Lower U Base 2000

Figure-14: Well 4 placement with PeriScope*, consolidated formation, with a total length of 775 ft MD, showing a constant resistivity
of 180 ohm.m and GR around 30 Gapi and with 14 ft maximum depth of investigation above the the drilled trajectory placed 20%
closer to the formation top compared with plan. The drilled trajectory, in blue, was placed above the plan (brown) in order to stay
closer to the Lower U Top. The 774 ft of geo-steered section were drilled in clean and oil saturated sandstone as showed by the
Gamma Ray and Resistivity logs. The targe formation was found to be vertically isotropic, as expected from offset wells evaluation.
The formation features allowed the LWD to detect the reservoir top 14 ft TVD above the borehole and confirm the presence of an
anticlinal structure as expected from seismic data.
14 SPE 143431

4: Tubing joint blank pipe
5: Oil swellable packer
6, 8, 10, 12: 7 ICD joints
13: Tubing joint
14: Oil swellable packer
15, 17, 19, 21: 7 ICD joints
22: Tubing joint
23: Oil swellable packer
24, 26, 28, 30: 7 ICD joints
31: Tubing joint
32: Oil swellable packer
33: Slotted tubing joint
34: BTC Pin
35: Stinger Seal Receptacle
36: BTC spacer joint
37: BTC Wash Down Shoe

Figure-15: Well 4 final ICD completion architecture for a consolidated formation in a very thin reservoir section. LWD data assisted
in refining the base case and to define the final ICD completion including the location of all completion elements, formation interval
zonation, location of swellable packers and fluid volumes estimation based on fluid saturation curves and the permeability profile.

Figure-16: Historical production performance of Well 4 completed with ICDs in a consolidated sandstone. Well 4 initial WCUT was
expected to be more than 34 %. ICDs after 4 months are monitoring both pressure and lowered water cut was about 24%. Offset wells
is already showing decay in oil rate and pressure, and increasing water rates. Well 4 has been a candidate for a PLT log several
times, however due to good performance has been delayed several times. Current WCUT is stable at about 60% after about 28
months of non-stop oil production.
SPE 143431 15

a)
Final ICD Completion Tally

Oil Swellable Packer

Oil Swellable Packer

Oil Swellable Packer
Water Swellable Packer

Water Swellable Packer
Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD

Nozzle Based ICD
Blank pipe
Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe
Blank pipe
Blank pipe
Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe

Blank pipe
Blank pipe
Blank pipe
Blank pipe
10218

10232
7 ICDs

6 ICDs

8 ICDs
9211

9532

9626

9868

e) Well 5 , historical production, the ICD completion contribute to lift ”dry” oil already for 5 months

Figure-17: Well 5 example of the best Synergism Operator Asset Team and Service Company. Unique detailed display section of all
steps followed to install a sucesfull ICD nozzle based completion, showing team work departing from simulation of the base case
(should be ready before drilling), fine-tunning of the design with LWD logs, volumetric interpretation of petrophysical data, geo-
control and navigation data (paramount to land the well at the right place and the right time), the final ICD completion installed and its
historical production profile. a) Completion lay-out resulting from refining the base case with LWD data and last chance to zone and
compartmentalise the wellbore, b) petrophysical evaluation of LWD logs, very useful for formation zonation based on correlations
between GR, Resistivity, and Neutron-Density logs, include the permeability and saturation profiles valuable input to evaluate the
production potential of the ICD completion, c) composite of basic LWD logs from geo-steering, d) completion hardware installed in
the ground, e) historic production performance of Well 5, consolidated reservoir Lower “U” and after installation of ICDs.The oil rate
after 5 months of production show “dry” oil, because the ICDs have stabilised both pressure and WCUT. Simulation work of a
conventional completion show an expected inicial WCUT between 10 to 16 %, here the ICD completion response show “zero” WCUT
for more than 4 months.