From Planning to Execution: The Role of Drilling Fluid Engineering in Successful Combined Well Completion Operations

Abstract

The integration of off-bottom liners and lower completions in a single-run operation represents a paradigm shift in well completion strategies. Overcoming technical challenges such as differential sticking, fluid invasion, and inefficient hole cleaning in high-permeability reservoirs requires advanced engineering solutions. This study illustrates the pivotal role of drilling fluid engineering in enhancing wellbore stability, operational efficiency, and formation integrity during a single-run deployment, showcasing a robust framework for mitigating challenges and achieving significant cost and time savings.

This research adopts a systematic approach to design and manage particle size distribution (PSD) for sealing permeable formations. The methodology integrates graphical PSD optimization, enabling precise alignment of bridging material properties with formation characteristics derived from pore size and permeability data. Engineering simulations were utilized to calculate ideal particle size distributions, providing customized solutions mud system. Field deployment protocols incorporated PSD monitoring and maintenance to ensure continuous performance during dynamic drilling operations. The workflow also included recommendations for adjusting PSD to accommodate combined well completion operations, thereby maximizing sealing efficiency and minimizing fluid invasion. The drilling fluid engineering team studied high-technical mud characteristics design to ensure optimal hole-cleaning efficiency, particularly in mitigating differential sticking and fluid loss in high-permeability zones, where permeability reached up to 5000 mD.

The applied engineering workflow delivered outstanding results, setting a new standard for high-permeability drilling operations. The proposed approach was implemented in the reservoir section using a limited selection of bridging materials that were exclusively acid-soluble, avoiding any materials that could cause reservoir damage. This design maintained an overbalance pressure of approximately ±2000 psi and handled permeability levels up to 5000 mD.

Additionally, the integration of advanced simulation models allowed for predictive optimization, ensuring alignment between field execution and pre-designed performance metrics. The combined operation was successfully executed within 24 hours, achieving a 50% reduction in operational time compared to the conventional two-run approach, which typically required 48 hours. The operation concluded with all planned activities completed without deviations, highlighting the impact of pre-job planning and operational precision. The advanced engineering single-run approach not only delivered significant time savings but also reduced overall project costs, showcasing engineering excellence in optimizing operational workflows.

This study highlights a transformative approach in drilling fluid engineering that ensures operational success in single-run deployments. This advanced drilling fluid engineering approach to combining off-bottom liner and lower completion operations emphasizes the importance of collaborative engineering, advanced modeling, and precise execution. The single-run methodology demonstrates significant potential for reducing operational time and costs while maintaining uncompromised safety and reliability.