IBP 1331_12 Simultaneous Sand Control and Liner Cement System: Keeping Well Productivity by Optimizing Drilling and

Completion Operations in Mature Fields S, A.N.1, Calderon, A.2, Silva D. N. Barbosa2,V. P.3, Petrobras S.A.

Copyright 2012, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Oil & Gas Expo and Conference 2012, held between September, 1720, 2012, in Rio de Janeiro. This Technical Paper was selected for presentation by the Technical Committee of the event according to the information contained in the final paper submitted by the author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute opinion, or that of its Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Oil & Gas Expo and Conference 2012 Proceedings. .

Abstract
The need to reduce oil extraction costs by increasing the recovery factor in mature fields unconsolidated sandstone reservoirs motivated the development of drilling and completion techniques that integrate the various interfaces of engineering the well, resulting in a final well configuration that provides maximum oil production at a lower cost. Due to the continued growth of drilling and completion of new wells or deviation of old wells in the design of mesh density field with an advanced degree of exploitation, Petrobras took the challenge to seek options for projects well, in order to maintain productivity and reduce their construction time, with the optimization of drilling and sand control systems. To achieve these goals, Petrobras developed the SCARS Simultaneous Sand Control and Liner Cementing System, a pioneer technique in the global oil industry, which consists of a one trip sequence of operations in which sand control screens and liner are installed followed by the open hole gravel pack operation performed with the alpha and beta waves deposition technique, using a non aqueous system as a carrier fluid. The sequence is completed by liner cementing in the same trip. The great success of this project was based on the definition of a specific application scenario and demands allowing optimization of the system. This project started with the development of a non aqueous system as a gravel pack carrier fluid in order to perform an open hole gravel pack with the alpha/beta wave deposition technique along with the development and optimization of SCARS procedures. This article details the planning and execution phases of this project and also presents a broad description of the technical aspects.

1. Introduction
The typical scenario of producer wells in deep and ultra deep water Campos Basin, is large packages of shales, on the top of a relatively shallow unconsolidated sandstone reservoir. Most of the large production wells in those sandstone reservoirs require sand control due to the poorly consolidated formations. Open hole gravel pack (OHGP) is still the most popular solution for sand control in offshore deepwater reservoirs.

______________________________ 1 Master, Petroleum Engineer - PETROBRAS SA 2 Petroleum Engineer PETROBRAS SA 3 Mud Engineer PETROBRAS SA

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The main goal of this project is to enable to sidetrack old wells in mature fields that produce with high BSW or in wells with damage in the sand control system. The project allows drilling the 9 5/8 production casing, the build up and the horizontal section with 8 bit, keeping the original size of the screens. The conventional sidetrack window opened in the 9 5/8" casing is done with 8 1/2" drilling the shale section to the top of the reservoir, where a liner 7 " is lowered and cemented. The horizontal section in the reservoir is made with 6 1/8 " bit, which does not allow installing the sand control screens larger than 4 1/2" diameter. This configuration requires a significant loss of production to the new well and a longer time for its execution, with two stages and the use of two types of drilling fluid, as the 8 " phase is drilled with synthetic fluid and the 6 1/8 "phase is drilled with water based drill in fluid. The introduction of this new technology, SCARS, that started with the use of non-aqueous fluid for Horizontal Gravel Pack, successfully tested in well Marlin A (Ref. 1), makes it possible to open a window in 9 5/8" production casing and simultaneously drill shale and sandstone formations with a bit diameter of 8 1/2" . This drilling fluid composition is based on N-paraffin, already commonly used in high slope drilling on shales. The same fluid, with small adjustments in the formulation and tighter control of the drill solids particles size, is used to drill the sandstone horizontal section. The 5 1/2 " sand control screens connected to the 7 liner are lowered with the alternative of performing or not, the horizontal Gravel Pack, depending on the characteristics of the sandstone, and cementing, or not, the liner, depending on the need to isolate hydrocarbon formations, or aquifer, above the reservoir. The task of defining the non-aqueous fluid to perform the operation of open hole gravel pack in horizontal wells has been conducted in conjunction with the Service Company Baker Hughes. Several numerical and physical simulations were carried out in order to: Establish rheology limits to ensure the formation of alpha and beta wave in non aqueous fluid. Optimize the design of the gravel carrier fluid to ensure a rheological behavior close to newtonian and a minimum viscosity for a given density, including evaluations of formation damage, physical and chemical stability of the system and the wetting agent support; Evaluate mechanisms of alpha wave deposition and packing quality with different densities propants. The next stage was the development of equipment to allow running liner and screens, gravel packing and liner cementing in one only trip. The LCGP system (Liner Conveyed Gravel and Cementing Tool Packing) carried by Halliburton, is a system that provides the installation of liner and screens, performing gravel pack operation in the horizontal section with alfa and beta deposition system, followed by cementing the liner. The system allows isolation between the horizontal section, equipped with screens, and build up section, the above excerpt from the liner, to be cemented.

2. First operation of Gravel Pack Horizontal, with deposition of alpha and beta waves, using non-aqueous fluid as a carrier of the gravel, BRMULGP: Offshore Well MRL A
In May 2007, the first Horizontal Gravel Pack operation with alpha and beta waves deposition, using non-aqueous fluid as a carrier of the gravel, BRMUL GP (Ref. 1), was performed in an offshore well, MRL A,. In this well, the drilling phase of 12 1/4" was performed using synthetic fluid, followed by running and cementing 9 5/8" casing at the top of the reservoir. The same fluid, with particular care in the solids control during drilling and constant monitoring of their properties was used to drill the 8 1/2" horizontal phase in the reservoir. After the drilling, the well was conditioned and the drilling fluid, BRMUL DIF, was replaced by synthetic BRMUL GP, a 14.5 lb / gal calcium bromide emulsion in N-paraffin, presenting newtonian behavior and low viscosity (<20cp) to enable the implementation of Open Hole Gravel Pack with alpha and beta waves. The Gravel Pack was carried out with 16/20 mesh ceramic in Carapebus formation, Marlin sandstone, in the measured depth range of 2998 - 3371 m, and 250 micron screen. The end result, after the formation test showed a well PI = 70.7 m3/dia/Kgf/cm2, and DR = 1 (zero skin) and the entire horizontal section contributing to the production (PLT), demonstrating the successful implementation. 2

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3. System development and evaluation LCGP (Halliburton System) - Field tests

Considering the importance of this innovative technology, Petrobras decided to conduct a sequence of three tests, with increasing degree of complexity, to evaluate the various technological aspects involved, with minimal risk of operational problems or loss of the test-well.

3.1. LCGP (Halliburton) First Field Test: onshore well In December 2009, the first test of this system was held in a onshore deviated well in Rio Grande do Norte Operation Unit, with the main objective of testing the especial cementing system developed by Halliburton to LCGP. Three screens were run coupled to the 7" liner, in order to simulate gravel circulation without addition of proppant in and evaluate the pressure losses associated with the system. The cementing operation of the liner was made successfully, isolating the zones of interest for the subsequent completion. The area below the liner, where the screens were installed, was not used to produce, and the extent of the drilling below the zone of interest has only served to provide space for positioning the assembly. (fig.1)

Figure 1: Onshore deviated well project

3.1.1 . LCGP (Halliburton) - Onshore deviated well composition Screens Lower gravel pack Modulus with no-go reducing adapter and the indicator coupling reference for positioning and spacing of the inner assembly. The positioning tool, located Shurmac should weight this indicator to set the precise position of the tool to pump gravel. Upper Gravel pack Modulus - The Shrouded MCS is the piece of equipment through which proppant flows. An outer shroud directs the flow downwardly to prevent the radial wall jetting since the component is positioned in an open well, unlike the conventional operations of gravel, which it is always positioned within production casing.

Rio Oil & Gas Expo and Conference 2012 Isolation Module - 2 ECPs (External Casing Packers) were installed in the composition. The ECPs have the functions to isolate and also of packer seal bore of conventional operations. They isolate the lower screen annular from the cementing above, avoiding the cement spotting on the void below. Cementing Modulus with Circulation Window (CMCS) - The CMCS is the equipment through which the cement is pumped. It is equipped with a check valve to prevent flow back after the slurry displacement. 7 " liner, 26 lb / ft, 80 L-13% Cr and five joints of liner 7.5 / 8", 39 lb / ft, 80 L-13% Cr Cementing Module

3.1.2 . LCGP (Halliburton) installation and cementing pumping job After balancing and pressure test, the service tool was connected to the 9 5/8 " packer and the system was run into the hole. The ball was launched and the packer was set at 97m. After the release of the service tool, the ECPs were inflated with 2500psi. With the tool in position, a completion fluid circulation test was made to simulate the gravel pumping, at 2, 4, 6 and 7 bpm flow rates. The tool was positioned at the reverse position and circulated direct for cooling of the liner. Then the gravel port was closed and tested at 1000 psi for 5 minutes. For the liner cementing, a viscous pill has been previously positioned between the upper and lower cementing tools, in order to prevent a possible return of the cement to the annulus between the service tool and the liner. Then the string was tested at 1500 psi, the service tool pulled back to a depth of cement return and the ECPs were tests with 500 psi. Finally, the cement sleeve, located at 836m, was opened to allow cement slurry pumping to the liner annulus. The top of the cement was calculated to 191m, in order to ensure that no cement return would reach the window (fig.2).

Figure 2 LCGP installation sequence

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TIME (hours)
Fluid circulation 9,5 ppg Spacer pad pumping 15,6 ppg Cement Slurry 15,6 ppg Spacer pad displacement 15,6 ppg Fluid displacement 9,5 ppg Cleaning circulation 9,5 ppg Operation end

Figure 3: 7liner of onshore well cementing job

The installation and cementing job with LCGP was completed as the operational program. To confirm the result, CBL / VDL / CAST-V logging was performed with extension tubes to the bottom of the screens in order to check if any cement volume decanted showing absence of cement in the annular.

3.2. LCGP (Halliburton) Second Field Test: offshore well B in Marlin Field As the first test well was accomplished successfully onshore, the following step was to test Halliburton system LCGP in an offshore well. The next operation was performed in an offshore well B in Marlin Field, in which it was intended to assess not only the cementing of the liner, but also the execution of an operation Horizontal Gravel Pack. This well was chosen for this first offshore test just because of its characteristics: the gravel packing operation was not mandatory, since sieve analysis results allowed a stand alone completion and liner cementing was not necessary either, thus reducing the risks inherent to testing of new technologies. Considering that the well trajectory would cross the main fault in the east of Marlin field, at depths of 2177m and 2401m, and sandstones of the Miocene at about 2000m, the 13 3/8" casing shoe was planned to 1800m, and the drilling BHA 12 1/4" and N-paraffin base fluid was continued to a depth of 2700m with an inclination of 57 degrees, where the 9 5/8" was set, (fig. 4).

Pumping rate(bpm)

Pressure(psi)

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Figure 4: Project - offshore well B in Marlin Field

3.2.1 . LCGP (Halliburton) composition and installation Simple modifications were introduced to optimize the assembly as an important result of the lessons learned in the first onshore test well. Considering a series of problems during well drilling, the gravel pumping simulation was cancelled. The assembly was run in hole with no problems with the same sequence as the previous test. The end of the string was positioned 1.8 m above the projected, since it couldnt advance, but that would not compromise the sand control operations as it was decided to complete the well stand alone. Three swell packers were run with the screens for zonal isolation. Attempts to inflate the ECPs were made, unsuccessfully, as the pressure did not exceed 2200 psi, at 0.25 bpm. A possible explanation was a problem in the tool, that could have kept the cement jacket inadvertently open, thus allowing flow to the formation between the casing shoe and the ECPs or through the ECP_in case it was leaking. The string was pulled 38 m out of the hole to convert the LCGP tool to cementing mode, and pressurization cycles were repeated to try to identify a potential non-compliance of the ECPs. The tool was pushed down back to position and inflating ECPs procedure was repeated by pressurizing the annular to 1700 psi, gradually increased up to 2700 psi. This time the results were positive and the ECPs were apparently energized correctly. With the service tool in the test position, it was made an attempt to test the ECPs for leak, without success, since it was noticed a pressure drop in the void between the liner 7 ", the formation (shale), the ECPs and shoe 9 5 / 8 ", with the pressure stabilized at about 120 psi. Thus, due to uncertainty about the leak tightness of the ECPs, and since liner cementing was not compulsory, it was decided to cancel the 7 " liner cementing operation. 6

Rio Oil & Gas Expo and Conference 2012 The LCGP installation was completed, but unfortunately it could not be tested as planned due to a series of problems during construction of the well and considering that the goal was to test the implementation of the Open Hole Gravel Pack and cementing the liner, the first offshore well test was inconclusive, since none of the objectives was achieved.

3.3. LCGP (Halliburton) Third Field Test: offshore well C in Marlin Field The last test was performed in a sidetrack offshore well C in Marlin Field (fig. 5). The sidetrack was drilled with BRMUL DIF and replaced for BR Mul GP fluid during well conditioning. No problems related to running screens and wash pipes were reported . A flowback was reported and monitored for 30 minutes after several pumping tests were performed. Since no variation in the level of the tanks was noticed, this behavior has been attributed to the compressibility of the fluid.

screen

screen

screen

screen

Figure 5: Offshore well C in Marlin Field During the friction tests performed before the operation, high pressure losses were observed. Because of that, to avoid fracturing the formation, the gravel pack pumping job was performed in a lower than usual rate, about 4,5 bpm in average. Because of the low rate, the alpha wave dune height was high enough to cover the screens. The gravel pumping with the LCGP system was successfully performed (fig. 6).and the technology was considered validated. Even though the beta wave was stopped prematurely, in a premature screen out, there was full coverage of the screens during the alpha wave. An amount of 2110 lb of Carbolite 20/40 was placed in the annulus between screens and the formation.

Figure 6 : Gravel Pack Pumping - well C in Marlin Field, Campos Basin, offshore Brazil 7

Rio Oil & Gas Expo and Conference 2012 After the job, further investigations were carried out to try to identify the possible causes of excessive friction loss on the tool. It was recommended not to use 5" wash pipes, as they create a more restrict annulus to the fluid returning path. That will reduce the bottom hole pressure and increase the operational window to ensure the quality of the next SCARS operation. Well C started producing in May 2011 with an average oil rate of 2500 m3/d with no sand production.

4. Conclusions
SCARS enables "Infill drilling" projects, through re-entries in pre-built vertical wells in mature fields. The strategy includes opening a 8 window in the 9 5/8casing, drilling build-up and reservoir sections in the same phase, enabling the use of conventional screens, OHGP and sand control equipment; A remarkable advantage of SCARS is the reduction of time and costs in the construction of the well, since build up and horizontal stages are drilled in a single phase. Also, the use of a unique nature fluid during drilling and sand control operations reduces significantly the time of mud pits cleaning and procedures for replacing well fluids. The development of a non aqueous completion fluid presenting rheological requirements to be used as a carrier fluid on gravel pack operations makes it possible to perform OHGP in reservoirs sensitive to aqueous fluids; It is important to consider that SCARS is a new technology associated with the advantage of drilling deviated intervals and horizontal section in a single phase. The operational risks must be evaluated in order to guarantee an operational pressure window that allows a drilling fluid density compatible with the simultaneous exposure to shale and the sandstone reservoir, which may sometimes be depleted, present shale instability and/or differential sticking issues.; This new technology has the advantage of maintaining of the original diameter of sand control screens in sidetrack, thus avoiding the need to reduce production rates; SCARS allows versatility to adapt the well to different projects as, depending on the study of particle size distribution of the formation, it may be performed horizontal gravel or stand alone, and also it is possible to cement or not the liner. Only if there is a permeable formation that needs to be isolated, cementing will be mandatory, otherwise, the cement will be optional.

5. Acknowledgements
The authors want to thank Petrobras, Baker Hughes Drilling Fluids and Halliburton Brazil for allowing the publication of this paper.

6. SI Metric Conversion factors

SI Metric Conversion factors ft. x 3.048 bbl x 1.589 873 lbf/100 ft.2 x 4.788 026 lb/gal x 1/198 264 lb/bbl x 2.853 010 cP x 1.0 mL x 1.0 psi x 6.894 757 micron x 1.0* GPM x 4.381 264 F (100F -32)/1.8 bpm x 6.289 E 01 = m E 01 = m3 E 01 = Pa E +02 = Kg/m3 E +00 = Kg/m3 E - 03 = Pa s E+00 = cm3 E+00 = kPa E -06 = m E - 08 = m3/s = C =m3/min 8

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7. References
1- Arago A.F.L. et AL: Primeira Operao de Gravel Pack Horizontal com Fluido No Aquoso e Onda Alfa e Beta, na Indstria do Petrleo, Petrobras - Campo de Marlim, VII SEP, 2008.

2- Arago A.F.L. SPE, Petrobras; L. Quintero, SPE, Baker Hughes Drilling Fluids; A.L. Martins, SPE, A. Calderon, SPE, and A. Sa, SPE, Petrobras; A. McKellar, SPE, Baker Hughes Drilling Fluids; and A.D. Gabrysch, SPE, Baker Oil Tools A Novel Approach for Drilling and Gravel Packing Horizontal Wells in the Presence of Reactive Shales Using a Solids-Free Synthetic Fluid SPE 102295, presented at the SPE Annual Technical Conference and Exhibition, 24-27 September 2006, San Antonio, Texas, USA 3- Calderon A. et al: Sistema de Conteno de Areia e Revestimento Simultneos SCARS, SEP, 2010.

4- Calderon A, Magalhes, J.V.M. de, SPE, Oliveira, T.J.L. de , and Martins, A.L., Petrobras AS Designing Multiple Alpha waves Open Hole Gravel Pack Operations SPE 107615, presented at the European Formation Damage Conference, 30 May-1 June 2007, Scheveningen, The Netherlands.

5- Martins, A.L., SPE, Magalhes, J.V.M. de, SPE, Ferreira M.V.D., Calderon A., SPE, S, A.N.de, SPE, Petrobras Sand Control in Long Horizontal Section Wells presented at Offshore Technology Conference, 47 May 2009, Houston, Texas.

6- Tinoco, D.M. et al: Relatrio do LCGP no poo 7-MRL-203H-RJS, 2010.

7- Tinoco, D.M.; Gonalez, L.P.; Piedade, T.S.: Relatrio do LCGP no poo 7-CAM-1302D-RN, 2010.

8- Tocchetto, A. et al: LCGP Open Hole Horizontal Gravel Pack and Liner Cementing Operation Procedure Halliburton, 2009. 9- S, A.N. et al:Relatrio interno Petrobras - PD 11324 Projeto de Perfurao de Trechos de Build-up e Reservatrio em nica fase de poos horizontais em arenitos friveis e completados com gravel pack, 2012.