SPE-175817-MS

Case Studies of Formation Isolation Valves for ESP and Intelligent

Completions in Multi-Lateral Wells and Horizontal Wells
Muhammad Shafiq, and Ali Adlene Arraour, Schlumberger

Copyright 2015, Society of Petroleum Engineers

This paper was prepared for presentation at the SPE North Africa Technical Conference and Exhibition held in Cairo, Egypt, 14 –16 September 2015.

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 officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.

Abstract
This paper describes case-studies of Formation Isolation Valve design, completion options, installations,
well bore access for Intelligent Completions and successful replacement of electrical submersible pump
(ESP). These completions are installed for production optimization in multilateral and horizontal wells.
ESP completions has a long history in oil field and intelligent completions have been nearly stared 15years
back.
Isolation Valves have been installing for over 20 years and more than 2000 wells have been
successfully completed. In few wells upper completions have been successfully recompleted with ESP.
The technology has provided real value in these ESP wells and also in intelligent completions wells.
There are several measures such replacement of underperforming ESP systems, sidetracks in more
prolific zones and upsizing of the pumps have been taken. The formation isolation valves were used with
ESP completion to protect reservoir formation from drilling and work over fluids during replacement of
pump. This saves fluid cost, rig time, reduce rig cost, avoid formation damage and improve productivity.
Few benefits are below:
● Allows multiple pump replacements without killing the well
● Isolates formations without applying kill fluid to the formation
● Reduces fluid losses during completion installations
● Improves well productivity by preventing formation damage
● Reduces costs associated with well interventions
ESP systems with formation isolation valve are delivering the industry the solution to achieve
production targets while protecting reservoir damage due to kill fluid during work over operations for
pump replacement and at the same time allowing access to mother bore for stimulation and logging in ESP
and Intelligent Completions.
2 SPE-175817-MS

Introduction

Intelligent completions
An intelligent completion combines permanent downhole sensors and flow control devices which allow
the operator to monitor, evaluate, actively manage and optimize the performance of the well and field.
Initial application of intelligent completions was in sub-sea wells to complete and produce multiple
horizons from a single wellbore without the need of intervention. Additional cost of the intelligent well
completions was easily justified when compared to extremely high cost, and risk of intervention in sub-sea
wells.
Today intelligent well completions are being used onshore and offshore to manage and optimize
production, improve recovery, manage water production, back allocate production, monitor mechanical
integrity of the wellbore and reduce environmental impact all while reducing overall cost by reducing the
required number of wells and associated facilities.

Electric Submersible Pumps (ESP)

Less than 10% of the world’s producing oil wells flow naturally the remaining 90⫹% are produced by
some form of artificial lift, and many of these wells are equipped with electric submersible pumps (ESPs).
Modern ESPs use downhole sensors to monitor pump, and motor parameters such as pressure, temper-
ature, vibration, current leakage and motor temperature along with well flow parameters. Variable speed
drive (VSD) technology allows control of the pump and motor speed to match well conditions thereby
maximizing well productivity, extending the life of the pump motor and other downhole equipment.
Conventionally ESPs have been used in wells which are incapable of natural flow due to low reservoir
pressure, and/or high water cut, where ESPs provide cost effective production boost from these less
efficient, older reservoirs.
More recently ESPs are also being installed in wells which are capable of natural flow; to better
manage the natural reservoir energy, improve the efficiency of reservoir pressure maintenance, and to
boost wellhead pressure for surface transport of fluids to production facilities.

Benefits of integrating ESPs with intelligent Completions

Intelligent completion technology can be used in the following applications:
● Wells producing from multiple zones or commingling multiple reservoirs.
● Horizontal wells exploiting reservoirs with a high degree of heterogeneity.
● Multilateral wells to control flow from individual branches.
● Wells using downhole oil/water separation and disposal.
The benefits of integrating intelligent completions technology with ESP installations, include:
● ESP energy can be dedicated to lifting oil rather than water, by choking and/or shutting off water
producing zones.
● Greater drawdown can be applied to lower productivity zones.
● Flow profile along long horizontal sections can be managed to avoid early water breakthrough.
● ESP size may be reduced to better match oil lifting requirements.
● Size of downhole ESP gas separator and gas handling equipment can be reduced.
● Wear-and-tear due to slugging and inclusion of gas is reduced.
● The well can be shut-in at the sand face while pulling the ESP to surface, thus maintaining well
control and minimizing formation damage
These benefits result in higher production, improved recovery, and reduced lifting costs
SPE-175817-MS 3

Isolation Valve technology

The First isolation valve where used in a drill stem test (DST) Technology for isolation and pressure test
the reservoir, that proven technology been developed and enhanced for a long term usage as a completion
product to Protect the reservoir from fluid loss and provide a reliable barrier while increasing efficiency
and maximizing overall recovery.
The DST proven Technology been extrapolate and stretched keeping the same concept including the
rotating bidirectional sealing ball, power source, and J-slot mechanism for counting cycles—all in
existence since 1982. To adjust to a more harsh environment and longer term usage.
The first completion Formation isolation valve introduced in mid-90’s, resolved the problem, saving
the customer days of rig time and money by mitigating risks, preventing damage to the formation and
operating without the need for intervention.
Now With more than 20 Years of maturity this technology offers a variety of new triggers Mechanism
that been introduced to the market to diversify the usage and create more flexibility to the completion
design, never less all those triggers will share a common base which is the Ball and Mechanical actuation
feature

Figure 1—Mechanical Isolation valve

Figure 2—Isolation Valve Triggers

y Tubing Triggered Based Isolation Valves

One of its main benefits is that it can be opened and closed mechanically and opened remotely applying
tubing Pressure pulses without intervention. To operate it mechanically, the operator runs a shifting tool
at the end of wash pipe, perforating string, or coiled tubing. When the shifting tool is passed through the
valve, the ball either opens or closes with a gas-tight seal, and the shifting tool unlatches from the latch
collet of the valve, allowing retrieval.
The Tubing Triggering method remote-opening feature enables the operator to open the valve without
conventional intervention techniques. Cycles of tubing pressure, in a number predetermined by an integral
indexing mechanism, are applied against the closed valve.
4 SPE-175817-MS

y Annulus Actuated Isolation valve

Uses the annulus pressure as the reference for cycling. Increasing tubing pressure above the maximum
differential to cycle and then bleeding this pressure off below the minimum differential to actuate. The
annulus indexers must complete a fixed number of cycles before allowing the valve to open the ball.
This triggering method allows performance of other pressure operations, such as packer setting and
tubing tests, prior to opening the valve.

y Surface controlled Isolation valves

This valve function as a lubricator with bidirectional barrier above and below the sealing ball, the ball is
opened remotely from a support vessel through application of a pressure in the hydraulic control lines.
Most of those valves are true fail as is valves that eliminate the risk of loss of well control in case of
system failure, which has critical importance in well suspension application.

y Mechanical Isolation valve

Most of the listed valves will share a common mechanical triggering system design to allow a mechanical
opening or closure with a dedicated Shifting tool. To operate it, operators runs a shifting tool at the end
of a wash pipe, tractor, slick line, perforating string, or coil tubing. When the shifting tool passed through
the valve, the valve either opens or closes.
The Predominant position that the isolation Valve been taking as well Barrier due to the bidirectional
Isolation and multi cycling that it offers pushed the industry for better control on implementing new
guidelines and Industrial standards for those valves, The API 19V/ISO 28781 standards that prescribes the
requirements for subsurface barrier valves and related equipment for use in the petroleum and natural gas
industries. Subsurface barrier valves provide a means of isolating the formation or creating a barrier in the
tubular to facilitate the performance of well operations before and after production or injection.
The standard defines:
o Functional characteristics
o Product material requirements
o Quality control, defined by quality grades Q1 and Q2
o Design criteria
o Design validation, defined by qualification levels V1, V2, and V3
o Design changes
o Documentation requirements— operations manuals and product identification Barrier Valves and
Related Equipment)

Figure 3—Subsurface barrier valve validation grade summary

SPE-175817-MS 5

Figure 4 —Subsurface barrier valve types

Isolation Valve Applications and Benefits

This multipurpose valve, makes it possible for operators to have a high level of confidence in formation
isolation Valve. With its ability to hold pressures from above and below & their robustness construction
and reliable service the isolation valve has become a key component in completion designs establishing
a remarkable track records.
The valves can also be used as a downhole lubricator to enable Perforating Guns (Shoot without kill
technic) and long strings of service equipment to be run and retrieved while the formation is completely
isolated.
It provides a two-way barrier for work overs of electric submersible pumps, Upper completion removal
or similar operations, underbalanced drilling, and general completion operations. It can also be used to
suspend or temporarily abandon a well for few years in certain cases. Other application been stretched
Packer installation and Log reach well access through intelligent completion. Due to the advance in the
Technology and proven sealing mechanism the valves boundaries are been pushed to extreme conditions
as HP/HT or Ultra deep set as it has a higher differential rating than a flapper type fluid-loss device.
Case Histories
Rapidly growing ESP market characterized by harsher environments requiring more complex technical
applications & alternate deployement with the constrain of maintaining well integrity all the time, the need
of an optimized design became a necessity mainly when ESP replacement cost is greater than 5 times the
cost of the ESP itself, Work over cost become directly be imbedded In the early well requirements.
Most of ESP Traced Wells completed using Isolation valve in Horizontal and / or a Multilateral wells
configuration the basic design to allow a selective production and isolate the lower section of the reservoir
during the Work-Over phase has been drastically changed adding new requirements in the top of
preventing wells from kill fluid and skin damage, most operators are using the combination of ESP/
Isolation valve/ Intelligent completion / Monitoring require in additional of the mentioned applications:
● Allow Stimulation and Logging with or without ESP in Place
● Large ID through completion to Allow Big size Inner string (Tractor or TCP Gun’s)
● True multi-Lateral Production selectivity
● Well Barrier Valves complying to Industrial standards
● Intervention less Barrier valve Actuation
● Flexibility for Cable deployed ESP Completion design
● Mono or Dual Barrier in Place during retrieving of ESP
● Replace ESP without pulling lower Completion
In order to achieve all those requirement during completion design the focus is on three main axes: ESP
Deployment, Completion design and Intervention, the three aspect of the well design has to assimilate
well integrity all the time this is why those proven well design’s (Options – 1, to 6) been Implemented
to cover all aspect of the scope of work and been optimized in the completion design Option 07 to 09
6 SPE-175817-MS

integrating and covering most of the requested requirements, as completion and recompletion of the well
changing the ESP will be done in less complicated fashion avoiding retrieving an expensive Lower
completion and from surface closing the Barrier valve for well Integrity perspective.

Completion design

Completion Option-1
Isolation for Under-balanced Perforating
Feature and Benefits
y No Kill fluids, no damage, no stimulation intervention, low skins, higher PI’s
y No intervention trip required when completion is ready to flow
y Well Production can be suspended for long term and open remotely
y Usage of Oriented Guns for selective perforation
Limitation
y Gun size through production Tubing

Figure 5—Underbalanced perforating

SPE-175817-MS 7

Figure 6 —The FIV system for underbalanced perforating

8 SPE-175817-MS

Figure 7—Oriented perforations in the horizontal section

Figure 8 —Single Trip Multilateral IC

SPE-175817-MS 9

Completion Option-2
Single Trip Multiple Zones [Laterals] Intelligent Completion using MFIV for Reservoir Accessibility

Feature and Benefits

y Accessibility to Mother bore
y Permanent Monitoring with Quartz Gauges

Limitation
y No Possibility for ESP Completion

Completion Option-3
Horizontal well Two Trip ESP Completion using MFIV for Reservoir Accessibility & Well control

Feature and Benefits

y Total Well Isolation during ESP Work over
y Accessibility to Mother bore
y Simple and easy to deploy

Limitation
y Mechanical Actuation to Actuate the barrier Valve
y Need to kill the well during decompletion
10 SPE-175817-MS

Figure 9 —Horizontal Well Two trip Completion with MFIV

Completion Option-4
Two Trip ESP Completion using MFIV for Reservoir Accessibility & Well control
Feature and Benefits
y Both Laterals isolated during ESP Work over
y Accessibility to both Laterals
SPE-175817-MS 11

y Quartz Gauges with ESP

Limitation
y No Flow control over Laterals

Figure 10 —Dual lateral well with MFIV & monitoring

12 SPE-175817-MS

Completion Option-5
Two Trip ESP Completion using MFIV for Reservoir Accessibility & Well control

Feature and Benefits

y Selective Production from Upper Lateral
y Permanent Monitoring – Quartz Gauges with ESP (Noise Immune Telemetry)
y Lower lateral isolated during ESP work over
y Quartz Gauges with ESP

Limitation
y Upper lateral not isolated during ESP work over
y Intervention in upper lateral not possible
SPE-175817-MS 13

Figure 11—Selective Dual lateral well with MFIV & monitoring

Completion Option-6
Two Trip ESP Completion using MFIV for Reservoir Accessibility & Well control
Feature and Benefits
y Selective Production from both Laterals
y Permanent Monitoring – Quartz Gauges with ESP (Noise Immune Telemetry)
14 SPE-175817-MS

y Both Laterals isolated during ESP Work over

y ICV’s can be Installed at shallower depth
Limitation
y No intervention possible in either lateral

Figure 12—Dual lateral well with MFIV & Upper I.C

SPE-175817-MS 15

Completion Option-7
Horizontal well Two Trip ESP Completion using HWMC & SFIV for Reservoir Accessibility & Well
control

Feature and Benefits

y Total Well Isolation during ESP Work over
y No intervention needed to operate the Isolation Valve
y Full bore Through the lower completion
y Accessibility to Mother bore
y SFIV to allow Well Barrier Surface actuation (well Integrity)
y Permanent Monitoring with Quartz Gauges
y ESP decompletion without Pulling lower completion
16 SPE-175817-MS

Figure 13—Horizontal Well two trip with HWMC and SFIV

Completion Option-8
Single Trip Dual Lateral Intelligent Completion with ESP using HLWM and MFIV for Reservoir
Accessibility
Feature and Benefits
y Logging inside Mother bore possible
SPE-175817-MS 17

y Quartz Gauges with ESP - Noise Immune Telemetry

y Two ICV’s - Selective Production from each Lateral
y HLWM Connect System - Connect/ disconnect capability
y Replace the ESP without retrieving the Smart Completion
y Independent of the ESP Design (Y-tool or Pod)
y SFIV to allow Well Barrier Surface actuation (well Integrity)
y ESP decompletion without Pulling lower completion

Figure 14 —Single Trip Dual Lateral IC with SFIV & Y-Tool

18 SPE-175817-MS

Figure 15—Single Trip Dual Lateral IC with SFIV & POD

Completion Option-9
Two Trip ESP Completion using SFIV as Well Barrier
Feature and Benefits
y ICV Shallower
y ESP completion not Connected to IC
SPE-175817-MS 19

y Surface controlled Isolation valve Actuation

y Design will Allow future CDESP deployment
y Dual Barrier with SFIV and Deep Set Safety valve
y ESP decompletion without pulling lower completion
y Allow Rigless ESP retrieval if cable deployed

Figure 16 —Dual Lateral Well with SFIV & CDESP

Lessons Learnt
The Usage of Surface actuated Valves (SFIV’s) coupled with a Hydraulic wet mate connect become a
necessity for well suspension, and ESP retrieval as the Surface formation Isolation Valve will allow
multiple ESP change without pulling the lower intelligent completion inducing multiple additional rig
time and complexity by retrieving the associated packers, hydraulic controls lines and clamps that magnify
20 SPE-175817-MS

the risk of a complex and long fishing jobs, the surface controlled valve is typically a CC 19V bubble tied
Sealing ball that open Under 2000 psi differential pressure and qualified as pre-production Valve.
In the case of Rigless Intervention design, Acceleration in customer demand supported by recent
emergence of deployment companies as:
● CT deployed
● Cable deployed
● Slickline deployed
● Shuttle deployment
Completion Option – 9 will be considered as it’s always preferable to Have the SFIV as a Minimum
recommended measure of primary well and have the TRSSSV as secondary Measure with a Pressure
balanced and a redundancy system mainly when a deep set design is required.

Conclusion
The discussed Completion Options from 1 to 6 are a deployed design around the world for ESP
completion in a Horizontal and Multilateral well’s that proven to have certain limitation when further
application or a change are required during the life of the well, Option 7 to 9 offers a more simplified and
optimized completion design that will allow a future upgrade of the well when ESP is retrieved, also
substantial well cost saving by leaving the lower completion in place during the retrieving of the ESP &
inducing a significant saving in rig time during retrieval and rig cost by allowing a lighter Rig to perform
the Decompletion, Importantly the three unique optimized well designs will be fully complying to the well
control procedure, allowing well integrity with the surface operated isolation valve and flow control valve.

Acknowledgments
The authors want to thanks all contributors involved in those designs, In Particular to Mohammed Aly
Sadek, Alaa Fouad and Aly Emam.

References
1. S. M. Mubarak; T. R. Pham; S. S. Shamrani, and M. Shafiq,, Using Down-Hole Control Valves
to Sustain Oil Production from the First Maximum Reservoir Contact, Multilateral and Intelligent
Well in Ghawar Field: Case Study. IPTC 11630, Dubai, U.A.E., 4 – 6 December 2007
2. Khalid Al-Mohanna, Khaled Kilany, Mark K Rooks, Riza Iskandar, SPE, Saudi Aramco, and
Muhammad Shafiq, SPE, Schlumberger, SPE 149057,” Pioneer Application of Hydraulic Line
Wet Mate Connect System in combination with a Pod ESP in Dual Lateral Intelligent Completion
Well” presented at the 2011 SPE Saudi Arabia Section Technical Symposium and Exhibition held
in AlKhobar, Saudi Arabia, 15–18 May 2011
3. Khalid S Al-Mohanna, Suresh Jacob, Larry Ma; SPE, Saudi Aramco, and Muhammad Shafiq,
SPE, Schlumberger, SPE-164147-MS. New Generation Intelligent Completion System Integrates
DownHole Control with Monitoring in Multilateral Wells, Manama, Bahrain. 10-13 Mar 2013
4. M.A. Ali, SPE, Schlumberger, M. Shafiq, SPE, Schlumberger, SPE 08065, “Integrating ESPs
with Intelligent Completions: Options, Benefits and Risks,” presented at the 2011 SPE Saudi
Arabia Section Technical Symposium and Exhibition held in AlKhobar, Saudi Arabia, 10 –12
May 2008
5. Fathi Ghodbane (Schlumberger) | Achille Tiribelli (Groupment Sonatrach-Agip) | Ahmed Daoud
| Giovanni Minneci (Groupement Sonatrach Agip) | Ahmed Mahmoud Dahroug (Schlumberger),
Productivity Increase Using the Combination of Formation Isolation Valve and Dynamic Under-
balanced Perforation, SPE-106400-MS Published : European Formation Damage Conference, 30
May-1 June, Scheveningen, The Netherlands - Published -2007
SPE-175817-MS 21

6. Oguzhan Guven (Schlumberger) | Dan Thai (Schlumberger) | Joao Mendonca (Schlumberger) -

Case Study: Surface-controlled Formation Isolation Valves and Their Application as a Barrier for
Temporary Well Suspension- OTC-23997-MS - Offshore Technology Conference, 6-9 May,
Houston, Texas, USA - Publication Date - 2013