The oil industry has lately seen the introduction of more complex, purpose built multilateral wells of the TAML (Technology Advancement Multilateral) levels 4 and 5 categories. The debris management issues, junction integrity and the risk involved in the well construction are still perceived as operational challenges to operators. In reviewing the risk profile, operators and service companies alike have sought to look into techniques outside the realm of conventional well construction methods. Expandable tubular technology is one such area. The manufacturing concept is to form a junction with a 9-5/8" trunk casing branching into two separate 7" liner legs. This junction is then pressed and formed in order for it to be able to pass through the drift ID of 13-3/8" casing. The junction is then reformed downhole using an innovative downhole swaging process.

This paper describes the process of deploying the TAML level 6 multilateral junction in the Erb West Field (offshore Malaysia) during the EWDP-A Revisit 4 Campaign (well EW-117S1). The discussion follows the full cycle of well construction for a level 6 multilateral junction. It encompasses the well planning phase, the deployment and the installation phase, the lateral drilling phase, and finally the completion of the level 6 multilateral well. The result is a multilateral well construction technique which eliminates the debris management, reduces well construction risk and provides a hydraulically sealed junction, integral with the trunk casing.

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