Transforming Challenges into Success: The Synergy of Engineering and Cutting-Edge Technology for Delivering Best-In-Class Water Injector Well

Abstract

Water injector wells often face persistent technical challenges, including drilling complexities, wellbore instability, and completion inefficiencies, leading to significant operational and financial impacts. This study highlights a transformative approach that integrates multidisciplinary engineering expertise with cutting-edge technology to address these challenges. By employing advanced data analysis, innovative tools, and engineering-driven solutions, the team successfully drilled and completed a record-setting water injector well, achieving operational excellence and setting new industry benchmarks.

During well program preparation, the engineering team identified critical challenges, particularly the mother bore integrity, which resulted in deviations from the planned completion process. Analysis of offset wells revealed recurring issues linked to high-stress zones in the region. A multidisciplinary team conducted an in-depth stress map interpretation in collaboration with geological experts, confirming the adverse impact of these stress zones on wellbore stability and formation integrity. To mitigate these challenges, the team optimized the well trajectory and incorporated an innovative anchor technology into the completion design, effectively addressing operational risks and minimizing potential cost losses during the drilling and completion phases.

Following a comprehensive analysis and interpretation by the engineering team, recommendations for optimizing the directional drilling and completion plans were reviewed and approved. The solutions focused on refining the well trajectory to minimize exposure to high-stress zones and prevent fluid loss incidents. As a result, the well was successfully drilled without complete loss events, unlike offset wells. To address operational challenges, the team implemented a groundbreaking lower completion technique, utilizing innovative anchor technology. The system's slip mechanism securely grips the formation with minimal penetration, reducing formation damage while providing a stable, hydraulically set platform to manage operational loads. This anchor system also stabilized the completion string, preventing packer movement and enhancing the reliability and lifespan of downhole components. The integrated engineering plan and execution effectively resolved drilling problems and tubing movement issues caused by injection forces, marking the best-in-class water injector well performance for this field in over a decade. The project culminated in a remarkable achievement, completing the well in just 24 days with zero non-productive time. This success set a new benchmark for operational efficiency and technical excellence in water injector wells’ operations.

This case study demonstrates the transformative potential of integrating engineering expertise with innovative technology to overcome conventional limitations in water injector well design. The application of advanced trajectory planning and the pioneering anchor system showcases a scalable solution for similar challenges in other technically demanding fields. By redefining standard practices, this project underscores the importance of multidisciplinary collaboration and cutting-edge tools in achieving record-breaking performance and operational excellence.