IPTC-17753-MS

Smart Horizontal Well Drilling and Completion for Effective Development of

Thin Oil-Rim Reservoirs in Malaysia
Keng Seng Chan, Rahim Masoudi, Hooman Karkooti, Ridzuan Shaedin, and Mohamad B Othman, PETRONAS

Copyright 2014, International Petroleum Technology Conference

This paper was prepared for presentation at the International Petroleum Technology Conference held in Kuala Lumpur, Malaysia, 10 12 December 2014.
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Abstract
For thin oil-rim reservoirs, well placement, well type, well path and the completion methods shall be
evaluated with close integration of key reservoir and production engineering considerations. This involves
maximizing reservoir fluid contact and drainage, optimizing the well productivity, and optimizing well
life-cycle production profile along the wellbore. Field implementation cases in Malaysia have been shown
that this integrated approach to design and drill horizontal wells can significantly minimize the well count,
enhance the well performance, and improve the ultimate recovery per well in thin oil-rim reservoirs with
varying reservoir complexity and uncertainties.
45 horizontal wells were progressively drilled and all completed with ICD in a relatively flat thin
oil-rim reservoir offshore in peninsular Malaysia. In this successful oil development, well path between
the GOC and OWC was optimized to delay the water breakthrough and reduce the decline trend in
different reservoir sectors with varying horizontal well length up to 2,000 m. Good performance of the
ICD was confirmed by PLT surveys and by tracer effluents evaluation with different type of tracers
implemented in various sections of the horizontal well completion.
For a low pressure thinner oil-rim reservoir in offshore Sabah, horizontal wells were drilled with ICV
completed in the gas cap. This smart well design enables having in-situ gas lift operation during the initial
oil production, and progressively changing to the planned gas-cap blow-down operation for maximizing
the overall hydrocarbon recovery. In another oil-rim reservoir, a long horizontal wellbore with ICD design
was completed with dual-strings to further optimize drawdown pressure distribution along the long
wellbore and improve oil drainage and oil recovery.
This paper is to share not only the lessons learnt in drilling and completion of these smart horizontal
wells but also illustrate the impact of these smart well designs in adding values to the field development
projects.

Introduction
Development of oil-rim reservoirs in Malaysia has been progressively improved over the recent years
through a series of reservoir engineering studies and successful field implementations. Although, typical

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Figure 1Fluid saturation map of a sand distribution in a vast oil-rim reservoir in Peninsular Malaysia. Consist of various stratigraphic and
heterogeneous structural traps, this sand estimated to have >800 MMSTB initial oil in place spread over 7 sectors with 5 distinctive gas-caps
overlying a huge regional aquifer.

Figure 2Subtle balance of driving forces in oil-rim reservoirs is critical to keep the oil-rim in original place.

oil-rim reservoirs are characteristically wedged between a gas-cap and underlying aquifer, they can be
structurally very complicated with faults and flow boundaries, having varying dips and saddles. Oil-rim
reservoirs of various sand thickness can also be stacked and compartmentalized. Aquifer support varied
from reservoir sector to sector, resulting in uneven pressure depletion and fluid contact change. Figure 1
showed such a vast oil-rim reservoir in Peninsular Malaysia.
Early days oil-rim reservoir field development strategy was mainly by drilling a large number of
vertical or low angle wells. Wells are completed with multiple strings in order to produce separately from
various different but stacked sands with significantly large pressure difference. Well-life can be short
producing at high water-cut and high GOR due to wells having partial penetration operated at high
pressure drawdown. For such a well development strategy, idle well rate increase drastically. Currently,
active wells in some key oil-rim reservoirs are far less than 50%. Field oil recovery remains low even after
25 years of continuous production.

Force Balance in Thin Oil-Rim Reservoirs

There are several drive mechanisms dominant in oil-rim reservoirs, namely the gas-cap and aquifer
expansion, viscous and gravity balance, in addition to solution gas expansion drive as shown in Figure 2.

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Figure 3Subtle balance of forces kept this oil-rim in place for 10 years with minimum pressure decline and more even fluid withdraw across the
reservoir.

Figure 4 Model Simulation showing initial oil in place in a sector of the oil-rim reservoir with vertical well penetrations (producers in green and
gas injectors in red).

Producing gas reinjection, controlled pressure drawdown at wells in different reservoir sectors based on
varying aquifer strength and sand layer dip angle, the placement, spacing and completion of the wells
could all affect the balance of these drives (Ref. 1). The art of this balance is to keep the oil rim in place
avoiding drastic migration of the oil rim having a good vertical displacement conformance. Subtle balance
of forces can keep the oil-rim in place for long years with minimum pressure decline and more even fluid
withdraw across the reservoir (Figure 3).
A good example of drive mechanism imbalance which caused a serious oil rim migration is subsequently presented in Figure 4 and 5. Due to the urgent need for gas sales, some of the produced gas in
the above mentioned huge oil-rim reservoir was diverted to market. This action disrupted the stability of
the oil rim and caused a significant migration of the oil rim towards the gas cap (Ref. 2). Significant oil
was trapped and lost in the gas cap due to displacement of oil rim into the gas cap (Figure 5). Most
critically, uncertain oil rim vertical and lateral migration affected the existing well production and greatly
increased the risk of infill well drilling programs. Recent post drilling review showed new infill wells
drilling success ratio dropped to less than 30%. Wells encountered much less oil reserve than expected.
In some sectors, current oil water contact was found to be higher than the original gas oil contact (Figure
6).

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Figure 5Oil migration towards the gas cap due to imbalance of gas reinjection with the aquifer support and fluid production in the above mentioned
oil-rim reservoir sector.

Figure 6 Significant oil rim upward movement clearly demonstrated by a recent post drilling review. Current oil water contact is higher than the
original gas oil contact.

Even though oil-rim reservoir could have a huge underlying aquifer, the bottom water support may not
be adequate in some oil-rim reservoir sectors. Some oil-rim reservoirs in Malaysia have observed a
significant pressure decline. Water and gas injection shall also be implemented if not for the whole field
but selectively in some regions in order to keep the force balance, minimize the oil migration, and improve
oil recovery (Ref. 3, 4 and 5). Injection strategies and method include periphery or fencing, updip water
injection and down dip gas injection (Ref. 3, 4).

Well Placement and Well Type

Many offshore oil-rim reservoirs today still having vertical or low angle wells contacting the thin oil rim
intervals. Figure 7 shows an example of well penetration in a multiple stacked oil-rim reservoir. The
placement of the infill wells was mainly based on a mobile oil saturation map derived from a history
matched dynamic model. For this stacked multiple oil-rim reservoir, complex multiple completions were
implemented in order to simultaneously produce from several sands having uneven layer pressure and
distribution. This conventional approach yielded a huge number of wells (297 strings progressively for the

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Figure 7Convention well placement based on mobile oil saturation but having vertical or low angle wells to penetrate several oil-rim reservoir sand
layers. Complex multiple completions were implemented due to uneven reservoir layer pressure.

above mentioned oil-rim reservoir). This also required a large number of offshore platform structures and
support facilities.
Vertical wells due to limited oil contact, generally have low productivity and require a relatively large
drawdown pressure (500 to 1,000 Psi). They could be quickly producing at high water-cut and high gas-oil
ratio coning bottom water and gas from the gas-cap. Reservoir energies were rapidly drained. Well lives
are short and only 15 strings are currently active. In addition, vertical wells affected limited drainage
volume. Significant bypass oil remained even at very large number of well count. After 25 years of
production, the overall oil recovery remained low (~35%).
In recent years, the drive for drilling horizontal or high angle wells, particularly in offshore oil-rim
reservoirs, yielded much better results. Figure 8 shows a good example of horizontal wells radially drilled
from a single platform. Horizontal well lengths varied (800 m to 1,800 m) depending on the drainage and
sand boundaries. With good reservoir sand contact, the wells fetched good productivity and required low
drawdown ( 100 Psi) to produce. Production can be further enhanced by drilling horizontal wellbores
having an optimum distance from oil water contact. Figure 8 also shows the art of drilling properly the
wells in a reservoir sector having 11 m oil rim thickness and controlling the wellbore distance 5 m or 6
m from the oil water contact. Post drilling production data showed the optimum 6 m as a benchmark. At
6 m, the oil production was significantly improved due to the delay of the bottom water breakthrough (see
production history charts on Figure 8),

Horizontal Wells with Smart Completion

All horizontal wells in this field were completed with inflow control devices (ICD) spaced at every 10 m.
Proper function of these ICDs can be observed by inspecting the results of a series of PLT surveys. Well

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Figure 8 Horizontal well placement in a thin oil-rim reservoir drilled from a single platform. Optimum wellbore distance from oil water contact
was evaluated by comparing the actual performance of the two adjacent horizontal wells drilled 5 m and 6 m from oil water contact. Oil rate and
water oil ratio behavior were clearly different.

Figure 9 1,590 m, ICD completed horizontal well A PLT survey results. Well was flowing at 1,243 BOPD and 217 Scf/Bbl GOR from this low API
gravity oil-rim reservoir. Water-cut was 71% but mainly from the heel (leak?).

A was completed with 157 ICDs on 1,590 m of wellbore length. Figure 9 shows separately, plots of 3
phase fluid cumulative inflows from toe to heel. Total liquid cumulative inflow can be seen as close to
linear, indicative of an even distribution of the pressure drawdown along this relatively non-heterogeneous
drilling trajectory. The well was flowing at 1,243 BOPD with 217 Scf/Bbl GOR. Water-cut was 71% but

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Figure 10 1,820 m ICD completed horizontal well B PLT survey results. Well was flowing at 2,737 BOPD and 187 Scf/Bbl GOR. > 20% production
from toe section. Water-cut was 13%.

mainly from the end of the heel. Almost no water production from toe portions. Well was also completed
with SAS sand control screen with swallable packers. A leak packer at the heel could be the cause of high
water production.
Function of ICD can be further confirmed by inspecting the PLT survey results from the other high
production well (Figure 10). With 1,820 m measured horizontal length, Well B was completed with 182
ICDs. Well was flowing at 2,737 BOPD with 187 Scf/Bbl GOR. Water-cut was 13%, but from toe. The
inflow profile was again close to linear particularly at the first half the wellbore near heel. There are sign
of slow water unloading at the toe. However, 20% of the oil production was from the toe. ICD design of
this well can be adequate to ensure contribution from toe.
With confidence generated by successful smart horizontal well drilling, the field is progressively
drilling phase-wise, increasing well count from 22 to 33 and to 41 wells. Figure 11 shows increasing well
density over the years following the strategy of radial well spacing design, optimized by a well count
optimization model simulation study. Further drilling such radial wells may not be economical feasible
due to low yield of ultimate recovery per well if additional wells are fetching less than 0.22 MMSTB per
well.

Value of Smart Completion

Smart completion certainly costs more. It should add more value, particularly in improving the hydrocarbon fluid drainage and recovery. Evaluation of smart well performance required additional engineering
effort. A noted method is the coupling of a fine grid MSW (Multi-Segmented Well) well model with a
fine grid dynamic sector model (Ref. 6). This method can capture heterogeneity along the wellbore, can
have reliable wellbore pressure gradient and fluid mixture properties, and can correctly model pressure
drawdown distribution particularly at heel of horizontal wells (Figure 12).

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Figure 11Progressive development of a thin oil-rim reservoir by phase-wise smart horizontal wells drilling and completion. Well count vs. Ultimate
Recovery (EUR) shows optimum 41 wells as limited by economics.

Figure 12A Multi-Segmented Well (MSW) model coupled with a dynamic simulation model for evaluation of smart completion horizontal wells.
After Kabir, A., and Sanchez, G., Accurate Inflow Profile Prediction of Horizontal Wells through Coupling of a Reservoir and a Wellbore
Simulator, SPE 119095 (2009)

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Figure 13Results of a MSW coupling model study showing a gain of up to 16% in recovery at well level (left) and a gain of 6% recovery at field
level (right).

Figure 14 Horizontal well drainage depends on pressure drawdown profile along the horizontal wellbore length. Well length and well spacing shall
be optimized to minimize the well count and maximize the field recovery.

Following this method, a study on determining

the smart completion value was conducted for an
oil-rim reservoir in Sabah Malaysia (Ref. 7). Wells
in this field were completed with 5.5 tubing with
ICDs at the spacing of 11 m. ICD ports and port
size was designed to optimize pressure drawdown
distribution and to minimize flux erosion for the
life-cycle production and reservoir condition
change. A fine grid MSW model coupling with a
history matched dynamic model was then used to

Table 1At optimum horizontal well spacing, strong bottom water

drive reservoir recovery factor as a function of permeability range
and relative permeability end-points. (After SPE 36613 Ref. 10)
Permeability Range
K3
3K10
10K30
30K150
150K400
400K1200
1200K

Swc

Sor

Recovery Factor

0.7345
0.6072
0.3972
0.3175
0.2356
0.2042
0.1046

0.164
0.1339
0.1245
0.117
0.1014
0.0955
0.0842

20.02
34.51
41.55
43.38
45.41
46.08
47.44

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Figure 15Inflow profile vs. horizontal length optimization using a fine grid MSW model (Ref. 11)

evaluate the horizontal well production performance with and without ICD installation and operation.
Figure 13 shows, for a studied well and for the whole field, comparison of recovery gains with and
without ICDs. At well level, depending on the reservoir quality and condition, the gain in oil recovery
can be up to 16%. At the field level, the overall recovery factor can be 6%.
Nothing in our endeavors on field development can escape the scrutiny of cost and value balance (Ref.
8). The additional cost incurred by having smart flow control devices shall be checked against the
additional reserve gained. A key economic indicator for well construction is the Well Development Cost
(WDC) as the ratio between cost and value and expressed in the unit of $/Bbl. As a rule of thumb, WDC
far less than 10 $/Bbl shall be very profitable. The WDC can directly correlate with the Net Present Value
(NPV) for a respective field development area.

Horizontal well Drainage Optimization

Horizontal well drainage (Figure 14) depends on well drawdown pressure and pressure drawdown profile
along horizontal wellbore (Ref. 9). The ICD completion design is to optimize drawdown distribution
along the horizontal wellbore. Therefore, horizontal well drainage and recovery mainly depends on
reservoir contact and horizontal wellbore length.
In thin oil-rim reservoirs, well placement between gas oil contact and oil water contact shall be
optimized for delaying water and gas breakthrough as discussed previously. In conjunction, horizontal
well drawdown pressure shall be kept low and typically for ~ 100 Psi or less. For this reason, although
having significantly large inflow volume, horizontal well drainage radius can be relatively small, optimum
horizontal well spacing will then need to be determined. Additional infill horizontal wells will be needed
to increase field oil recovery.
For a strong bottom water drive oil rim reservoir with a stable gas oil contact, optimum well spacing
depends on oil rim thickness and the ratio between horizontal and vertical permeabilities (Ref. 10). At this
optimum well spacing the oil recovery factor depends on sand quality (permeability) and relative

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Figure 16 Example of horizontal well length optimization based on NPV (Ref. 12)

permeability end points. For a 15 m thick isotropic formation with equal horizontal and vertical
permeabilities, the theoretical optimum well spacing can be about 15 m and the corresponding maximum
oil recovery factor can be around 45% (Table 1).
The predicted field recovery factor is 27% for the above mentioned field with 41 ICD completed
horizontal wells, and the well spacing was about 200 m. This implied that more work can be done to
improve the oil recovery in this 15 m thick oil-rim reservoir. Horizontal length can be further optimized
by evaluation of inflow rate profile segment by segment using a MSW model (Ref. 11). It can be best
optimized by evaluation of NPV vs. the horizontal length (Ref. 12). Figure 15 and 16 illustrated for
examples, the results which can be generated by continuous studies in this field using the established
MSW model coupling with the dynamic model.

Dual Strings Smart Horizontal Well Completion

Smart horizontal well completion can be further smartly completed based on targeted different drainage
areas it penetrated. Figure 17 shows a horizontal hole drilled and connected two sides of a saddle region.
The alternative could be drilling two wells instead of one or multilateral wells. The advantage of this dual
string completion is to access two drainage points simultaneously rather one for a single string horizontal
wellbore. A modified dual string completion was implemented to drain separately the reserves from the
two sides. Figure 18 shows some details of this unique completion design. Each of the two 800 m long
strings were both completed with ICDs.
Coupled wellbore and dynamic model simulation first showed that the dual string without ICD
completion could produce more if unconstrained. However, high influx regions shall be choked selectively to minimize risk of erosion and ensure life-cycle production (Figure 19). The model study also

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Figure 17Horizontal well drilling to produce from both sides of a saddle region in a thin oil-rim reservoir.

Figure 18 Dual string horizontal well ICD completion design implemented for producing separately from 2 segments of the reservoir.

Figure 19 Value comparison between completion options and the selection of dual horizontal strings with ICD for implementation.

showed that optimized ICD completion, providing the necessary selective choking, could significantly
reduce this risk. Feasibility of adding active inflow control valves (ICV) was also studied for selectively

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Figure 20 Stabilized initial production from a dual string smart completion horizontal wells. Similar oil rates and trends observed from both long
and short strings.

choking excessive water and gas inflow during the life-cycle production. Nevertheless, this approach was
not adopted due to lowering of the smart horizontal well value.
Two horizontal wells in this field were completed by this dual string ICD wellbore design. Figure 20
shows a stabilized production 4 months after the start-up. Both long and short strings were producing at
similar oil rates and having similar trends. No significant water production was observed year to date.
GOR increased slightly above the solution gas ratio particularly from the long string.

Auto-Lift Smart Horizontal Well Completion

Producing from oil-rim reservoirs may still require designing and implementing a viable artificial lift
method. In a field having multiple stacked reservoirs, the option could be the use of gas production from
the upper predominant gas layers for lifting the oil producing from the lower reservoir sands. Such a
production is scheme is implemented in a field in Sabah Malaysia (Figure 21).
Control of gas production from the section of the completion contacting upper gas bearing sands can
be optimized by actively adjusting the choke of the installed ICVs. Following our benchmark, smart
horizontal well completion was implemented with ICDs to balance the flow by equalizing the pressure
drawdown and delay the water and gas breakthrough. Such a unique multi-zone, multiphase commingle
production greatly enhanced the value of the horizontal wells and field development project.

Oil-Rim Reservoir Development Benchmarks

Perhaps a way to summarize our effort for effectively developing the oil-rim reservoirs is by introducing
one of our workflow (Ref. 13, 14) as a benchmark.

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Figure 21ICV controlled gas production from upper sands as the gas-lift gas to aid oil production from oil-rim reservoir. Horizontal wells in oil
rim completed with ICDs.

Figure 22A graphical workflow showing the entire cycle of oil-rim reservoir development from balancing the drive mechanisms to well drainage
and placement selection, to smart completion design, on to evaluation of production performance, and further development of a reservoir
management plan for operating and maintaining the smart wells implemented for effective development of the oil-rim reservoir.

Figure 22 shows a graphical workflow for the entire cycle of oil-rim reservoir development. It started
from balancing the drive mechanisms to well drainage and placement selection, to smart completion
design, on to evaluation of production performance of the smart wells. It further delineated the need for

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15

development of a reservoir management plan for operating and maintaining the smart wells implemented
for effective and continuous development of the oil-rim reservoirs.

Conclusions and Recommendations

Through a series of progressive engineering studies, practical field implementations and continuous field
performance evaluations in recent years, the resource development teams in Malaysia have collectively
developed several key oil-rim reservoir production strategies, generated more understandings of the
physics and engineering correlations, and determined effective methods of drilling and completing the
smart wells to improve the value of the oil-rim reservoir development.
Several simple conclusions can be made based on information and data provided and implied in this
paper:
1. Oil-rim reservoirs have several drive mechanisms need to be balance in order to keep the oil rim
continuously in place and avoiding significant oil pool transverse and lateral migration.
2. These mechanisms can be controlled by produced gas reinjection to the gas cap, by water injection
selectively in selective regions and by drawdown optimization.
3. Horizontal wells shall be the benchmark well type for producing the oil-rim oil having high
productivity and high drainage volume and having low drawdown pressure to produce substantially more.
4. Placement of horizontal wellbore between gas/oil and oil/water contact shall be carefully studied
for delaying the water and gas breakthrough and minimizing their coning tendency.
5. The use of ICD shall also be preferred for these horizontal wells as this smart completion is
repeatedly proven for generating more uniform inflow along the long horizontal wellbore.
6. Value of the smart horizontal wells shall be determined and balanced with the addition cost
incurred.
7. The recommended method of evaluating the smart well values is a model simulation coupling a
fine gridded multi-segmented well model with a fine gridded sector dynamic model.
8. Initial production from the dual-string smart horizontal wells in Malaysia have demonstrated such
an effective completion for producing simultaneously from two segments of an oil rim reservoir
instead of having more expansive multilateral wells.
9. For stacked reservoirs, gas producing from gas bearing sands from upper sand layers can be
effectively used for lifting the oil from oil-rim beneath.
10. Optimum horizontal well spacing shall be further studies. As the drainage volume is also a
function of pressure drawdown, eventhough smart completion can yield a better profile along the
long horizontal wellbore, the optimum spacing to improve oil recovery can be much lower than
current well pattern design.
11. Theoretical maximum oil recovery shall also be closely evaluated. For thin oil-rim the options to
improve oil recovery other than well spacing is limited. Time to swift to gas-cap gas co-production
or to gas-cap gas blowdown shall be determined in order to accelerate the value gain of the oil-rim
reservoirs.
Again, nothing can escape the scrutiny of cost and value balance. Value of investing in smart well
completion shall be justified. The design of the smart well completion shall aim at maximizing the value
for life-cycle production of the wells. Accordingly, guide for operating these smart wells shall be a key
part of a reservoir management plan in oil-rim reservoir development.

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Acknowledgements
The authors thank the management of PETRONAS for their permission to publish this paper. Thanks are
also due to all members of the PSC project teams and the service providers for their continuous enthusiasm
and dedication to develop the oil rim reservoirs in Malaysia.

References
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Rim Reservoirs: Force Balance Revisited SPE 130388 (2010)
2. Ezzam, A.R., Chan, K.S., and Darman, N., Risk of Losing Oil Reserve by Gas-Cap Gas
Production in Malaysian Thin Oil Rim Reservoirs SPE 132070 (2010)
3. Ezzam, A.R., Chan, K.S., and Darman, N., Breaking Oil Recovery Limit in Malaysian Thin Oil
Rim Reservoirs: Enhanced Oil Recovery by Gas and Water Injection SPE 143736 (2011)
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Rim Reservoirs: Water Injection Optimization IPTC 14157 (2011)
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Coupling of a Reservoir and a Wellbore Simulator, SPE 119095 (2009)
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Reservoirs?, IPTC 16740 (2013)
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Development, IPTC-18128 (2014)
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Horizontal Section, SPE 69431 (2001)
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Strong Bottom Water Drive Reservoir, SPE 36613 (1996)
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Newly Developed Coupled Reservoir and Well Flow Equation, SPE 129038 (2010)
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13. Masoudi, R., et alet al., Smart Well Type and Optimum Completion Designs for Complex,
Multi-Stacked, Compartmentalized, Oil-Rim Reservoirs SPE 159307 (2012)
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