Field D is a mature offshore field located in East Malaysia. A geologically complex field having multiple-stacked reservoirs with lateral and vertical faulted compartments & uncertainty in reservoir connectivity posed a great challenge to improve recovery from the field. Severe pressure depletion below bubble point and unconstrained production from gas cap had contributed to premature shut-ins of more than 50% of strings. As of Dec 2019, the field has produced at a RF less than 20%. Initial wells design consisted of conventional dual strings & straddle packers with sliding sleeves (SSD). Field development team was challenged for a revamp on completion design to enhance economic life of the depleting field.

In 2015, as part of Phase-1 development campaign, nine wells including four water injectors were completed initiating secondary recovery through water flood. An approach of Smart completion comprising of permanent downhole monitoring system (PDHMS) and hydraulic controlled downhole chokes or commonly known as flow control valve (FCV) was adopted in all the wells in order to optimize recovery from the field and step towards intervention-less solutions. Seeing the benefits of intelligent completion in Phase-1, Phase-2, drilled and completed in 2019 – 2020 has been equipped with new technology "All-electric Intelligent Completion System" in 4 out of 8 oil producers. The new design addresses the reservoir complexity, formation pressure and production challenges and substantial cost optimization, phasing out the load of high OPEX to CAPEX.

Installation of "All-electric Intelligent Completion System" has proven to be an efficient system compared to hydraulic smart completions system. It requires 50% to 75% less installation time per zone and downhole FCV shifting time is less than five minutes compared to several hours full cycle for hydraulic system. The new system has capability to complete up to 27 zones per well with single cable. It gave more options and flexibility in order to selectively complete more zones compared to hydraulic FCVs which requires individual control line for each zone. Future behind casing opportunities (BCO) have been addressed upfront, saving millions of future investment on rig-less intervention. In addition to that, non-associated gas (NAG) zones have been completed to initiate in-situ gaslift as and when required avoiding the dependency on aging gaslift facility.

The scope of the paper is to show case the well design evolution during Field D development and highlight on how smart completion has evolved from original dual completion to hydraulic smart and recently to electric smart system, how it has contributed to cost and production optimization during installation and production life and also support the gradual digitalization of the Field D. In the end it demonstrates the optimized completion design to enhance the overall economic life of the depleting field.

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