Innovative Multilateral Well Construction System: Accelerated Development and Integrated Capabilities

Abstract This paper discusses the development of an innovative multilateral well construction system, showcasing its swift progression from conceptualization to implementation. The system’s creation was characterized by an efficient and accelerated process, resulting in a solution that seamlessly integrates multiple customer-specified requirements with existing robust capabilities. The system was specifically developed for use on the AkerBP operated KEG (Kobra East Gekko) field development in the Alvheim area, offshore Norway. Historically, individual branch control multilateral systems have not been installed in tri-lateral wells within the Alvheim area, with one previous attempt resulting in only partial success – hence a new system was required. The system development commenced with a comprehensive analysis of existing multilateral well construction methodologies, identifying gaps and inefficiencies. Leveraging this insight, an interdisciplinary team of operator, service company, and third-party personnel collaborated to define system requirements resulting in a forward-thinking multilateral well construction system. The emphasis was on expediting the development lifecycle without compromising quality, reliability, or safety standards. Through meticulous testing and simulation processes, the system’s components were refined to optimize performance as defined in the initial stages of the development. This iterative testing phase, including an extensive System Integration Test (SIT) not only ensured the robustness of the system but also facilitated the integration of an extensive number of intelligent upper completion configurations. These new capabilities, collectively elevate the efficiency and precision of the multilateral well construction process. A collaborative approach ensured flawless project execution all the way from definition, through complete design and development, detailed operations planning, and finally field execution. An accelerated definition phase was completed, and in the following 12 months a complete level 5 pressure-isolated multilateral system was developed, including rigorous testing and validation of several new components. The extensive System Integration Test (SIT) was conducted in several stages – both in test facilities in the USA and Norway – to ensure both the multilateral system itself met requirements, but also confirmed compatibility with many different intelligent upper completion configurations, including zonal isolation packers, inflow control valves and gauge carriers. The first KEG tri-lateral well was successfully completed in Q1 2023, including installation of the upper completion being run through both junction systems. This was followed by successful installation of the system on the remaining three KEG tri-lateral wells by Q4 2023. A significant reduction in installation times and associated NPT has also been observed when installing the new system. The successful deployment of this multilateral well construction system marks a milestone in the industry, presenting a scalable and adaptable solution for new and existing wells. The accelerated development process, combined with the integration of multiple innovative capabilities, positions this system as an example for adapting existing technology to well construction requirements bringing the benefits of multilateral field development to new applications.