A new Middle Eastern record was set with a 29-stage StackFRAC® system in a tight carbonate, extended-reach well. Despite severe doglegs and a 6,700-ft lateral, the system deployed flawlessly—every sleeve shifted, every stage completed. Innovation, precision and planning allowed this multistage performance.
YASSIR KHALED, Packers Plus Energy Services
Originally drilled in 1994, a vertical well, located in a tight carbonate formation, was completed as a single producer in a green field. However, due to its significant distance from the Gathering Center (GC) and the reservoir’s low productivity, the well was unable to sustain natural flow and remained shut-in for over 15 years. It later experienced intermittent production before being shut in again for a sidetrack operation.
To maximize production potential, the well was converted from a vertical cased hole into a horizontal well. The primary objective was to optimize production from the main reservoir while also conducting an exploratory study in a secondary formation through a pilot hole. A multi-stage fracturing (MSF) system was selected for completion to enhance recovery from the primary reservoir. The completion design incorporated multiple stages and flow compartments, determined data using open-hole logs, and included a 4.5-in tubing string for the upper completion. To further boost production, the well was ultimately equipped with an electric submersible pump (ESP).
THE CHALLENGES
Well completion presented several critical challenges that demanded innovative engineering solutions and meticulous planning.
One of the primary obstacles was the well’s high dogleg severity (DLS), which ranged between 9° and 10° per 100 ft. This extreme curvature made it particularly difficult to run the long bottom hole assembly (BHA) through the whipstock, given the intricate trajectory required to reach the target zones.
Another significant challenge was managing the exceptionally long lateral section, which extended 6,700 ft. The presence of anticipated faults and highly fractured zones along this stretch added further complexity and necessitated the strategic placement of packers, to ensure effective zonal isolation and maintain well integrity.
Competitors had previously struggled to complete wells under comparable conditions, often failing to deploy nearly half of the planned stages. As a result, they were forced to fall back on a cemented liner approach, limiting production potential and increasing the likelihood of intervention challenges near the well’s toe section, where limited coil weight availability in extended-reach wells could restrict operational effectiveness.
This underscored the need for a robust and adaptable completion strategy—one that could overcome both geological and technical barriers to achieve a successful multi-stage completion, where others had fallen short.
THE SOLUTION
The operator implemented a comprehensive completion strategy, consisting of 27 fracturing stages and two blank stages. The blank stages were strategically incorporated to isolate highly fractured zones, ensuring better control over the acid fracturing process and reducing potential complications. For this operation, Packers Plus TuffSEAL™ packers were selected, due to their compact design—featuring a short length and minimal outside diameter—which minimized wellbore stress during deployment. These packers were particularly well-suited for the well’s high dogleg severity (DLS), offering reliable sealing performance in challenging geological conditions.
Thorough planning was crucial to the success of this well. Detailed torque and drag analysis and tubing movement assessments were conducted, to ensure operational integrity throughout the deployment process. Additionally, a reamer bottom hole assembly (BHA)—designed to mimic the stiffest section of the multi-stage completion (MSC) BHA—was used to drift the open hole before installation. This proactive approach helped optimize wellbore conditions and facilitated smooth deployment and reliable long-term performance of the completion system, Fig. 1.
Furthermore, the Packers Plus Debris Sub was utilized, providing a barrier to prevent debris from entering the lower completion during tie-back operations. The entire system was designed to leverage advanced logging while drilling (LWD) technology data for optimal stage placement.
RESULTS
Successful execution of the 29-stage StackFRAC® system in the tight carbonate formation represented a major operational milestone. This project not only set a new record for the highest number of stages ever installed in the Middle East, but it also marked the largest multistage completion by Packers Plus outside of North America.
The completion system was deployed smoothly to the planned depth, demonstrating the effectiveness of the pre-planning stage, as well as the robust design of the StackFRAC® system used. All FracPORT™ sleeves opened successfully, with no operational issues, demonstrating the reliability of the system under the well's complex geological conditions. This flawless execution was pivotal in maintaining the integrity and efficiency of the acid fracturing process, ensuring that each stage was completed, as intended.
A key factor in this success was the ePLUS® Retina Monitoring System, which provided real-time confirmation of each FracPORT™ activation. Its instant feedback capability significantly enhanced operational confidence, streamlined decision-making and minimized delays, allowing the team to transition efficiently between stages.
The project not only met its operational goals, but it also set a new standard for future jobs in challenging environments, Fig. 2. WO
YASSIR KHALED holds a bachelor’s degree in petroleum engineering from the Australian University in Kuwait. He began his career in 2013 as a logging while drilling (LWD) field engineer. He later advanced into operational coordination roles for LWD and Directional Drilling. Mr. Khaled also contributed to the Global Governance Team for Drilling Services at Baker Hughes, gaining broad industry insight. Since joining Packers Plus in 2024, he has served as a Business Development manager in the Middle East, where he focuses on commercial strategy, market development, and strengthening client relationships across the region.
PACKERS PLUS is a leading supplier of lower completion solutions, providing field-proven stimulation technology for horizontal wells, with superior production results in numerous formations around the world.