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Learning Objectives
Understand the issues and consequences arising from sand production Be familiar with sand management and exclusion options Be able to analyse particle size data and make preliminary sand exclusion recommendations Awareness of the flow capacity impact of sand exclusion decisions Awareness of modes of failure and consequences for sand management
Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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How much?
1-10 lbs/1000bbls or 1MMSCF In heavy oil, amounts could be very large
Creep
unloading stress through movement of a free edge (chalks, shales, silts, some sands)
Ductile failure
flow (chalks, silts)
Impact damage
drilling induced (all)
Grain production
usually sands, others possible
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Brittle Failures
Causes - tension failures, local stress reactions Identification - chips and small, irregular pieces of the formation Location - from formation face near fractures and any free face near a flow area (permeability zone) Problems - fill (sometimes severe fill in wellbore) Prevention - not practical in most cases Control - liners and screens
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Creep
Causes - reaction to a stress in the surroundings Identification - Constricting or collapsing wellbore, usually in plastic behavior formations such as shales and chalks Location - most severe near salt domes or geopressured areas Problems - collapse of wellbore, limits to flow Prevention - usually not practical Control - heavy wall pipe or dual casing
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Ductile Failure
Causes - unconsolidated formation reaction to pressure drop and may also follow chemical change Identification - large quantities of solids flowing like fluidized sand (quicksand), occurs in sands, silts and chalks Location - usual area is near the perfs Problems - obstruction of flow channels, tubulars Prevention - prevent ability to move or pressure drop Control - fractures, gravel packs
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Grain Production
Causes - reaction to drag force exerted by flow Identification - sand produced with flow Location - perfs, wellbore Problems - sand in produced fluids, erosion, perforation tunnel collapse or fill Prevention - rate reduction (is this acceptable?), sand control Control - plastics, gravel packs, fracs
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Unconsolidated Sand
Usually shallow (<8000 ft /2400 m), young (Miocene to recent) deposits While drilling it may be difficult to keep hole open coring difficult Sand grain production begins with any fluid movement Strength from cohesion forces (grain-to-grain friction), but easily washed Sand production increases with produced fluid viscosity and rate Without sand control, some degree of continual sand control is expected
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Some cementing agents Low compressive strengths (<200 to 500 psi) Core can be taken but crumbles easily and must be preserved to maintain shape Openhole completions, possible early in reservoir life, fail when producing conditions change
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Friable Sands
Moderately well cemented Easily cored and cores appear strong Cementing agents are unstable and break down with unfavorable producing conditions May make sand for days or weeks after a completion, then formation stops producing sand until the next workover or shift in productionconditions Most difficult to select effective strategy for
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Costs of remediation?
Treatment costs Loss of PI? deferred revenue
When to control?
Sometimes difficult to decide
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Prediction
When data on stresses and rock strength are known then analyses can be conducted to try and predict sand production. Continual improvements made with acquisition of better quality data from logs and laboratory testing. Better prediction will aid definition of reservoir management strategy, completion design and topsides engineering and therefore field economics. Three techniques form the basis of sand production prediction;
Empirical techniques correlating sand production to a single/group of parameters such as porosity, flow rate, sonic transit time. Analytical techniques known rock strength data is correlated to known stresses. Numerical techniques finite element methods (FEM) with full range of formation behaviour during elastic, plastic and time-dependent deformation events.
Large volume of literature available on sand production prediction and many of these papers have been reviewed as part of this study. There still has not been developed a single widely applicable model.
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Methods of assessment
Logging - principally based on porosity logs Flow testing - bean up well to establish critical drawdown Laboratory testing of core samples
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Other correlations are functions of parameters such as Youngs modulus (E), Poissons ratio () and the bulk modulus (Kb) and these can be derived from the full waveform sonic log. E, & Kb are dynamic (refer to rock properties at sonic velocities). Must be converted to static values. Once this is done there are many correlations for estimating formation strength, such as;
Vsh is derived from the gamma ray log. Output still imprecise - uncertainty reduced by correlating log derived data to core derived data.
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This gives a log derived, core corrected TWC strength profile to use in prediction mode. Prediction based on calculating the critical bottomhole pressure.
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Principles
Particle size analysis (PSA) done by dry sieving or using laser diffraction after sample preparation according to API RP 58 (cleaned, dried and broken up). Dry sieving involves vibrating the sample through a progressively smaller sequence of 18 known sized mesh (2350m - 44m). The weight of material captured on each mesh is measured and a size distribution plotted. Sieving generally underestimates fines content due to aggregation. For laser PSA the disaggregated sample is dispersed in water and light scattering is used to calculate the volume of a particle (assuming sphericity). LPSA can detect particle sizes as small as 0.04m, and will provide a much more accurate estimate of fines particles content. A known issue with sieving is long, thin grains may pass through a certain sieve but still have a mean diameter larger than the sieve opening.
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Laser Diffraction - Sample size depends on particle size but typically <1g; measures down
to 0.04 micron; measures average diameter of particles; sample is fully dispersed; quicker than sieving
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These ratios characterise formation materials and assist in selecting the appropriate size for sand control equipment. The fines content is used to help assess the likelihood of plugging problems with both screens and gravel packs. LPSA produces significantly higher coefficient values than sieve data.
Sieve data U = 2.6 vs LPSA U = 14 Sieve data S = 5.5 vs LPSA S = 43.3 (from previous slide)
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Homogeneous sand
Heterogeneous sand
P ercent R etained
Sieve Opening, mm
When the formation sand size varies enormously, perforate only the higher permeability sands, or consider fracpack
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Gravel Pack, if
d50< 75 microns or d40/d90> 5 or d10/d95 > 10 or Fines (<44 microns) > 5 wt-%
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Definitions
What do we mean by Sand Control? Sand control is the employment of techniques and technologies which are designed to prevent bulk formation material from being produced into the wellbore.
Includes the terms sand exclusion and sand prevention. Typically capital expenditure intensive.
What do we mean by Sand Management? Sand management is the employment of techniques and technologies in the production system to monitor and manage known sand production.
Typically capital and operating expenditure intensive.
The economic impact of either must be evaluated before deciding which strategy to pursue.
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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The onset of sand production in a well directly related to increasing production rate implies there is critical rate below which sand production will not occur. This is the MSFR. Establishing the MSFR involves well rate manipulation to the point where sand is noted. This rate is kept constant until equilibrium is reached, at which point the rate is reduced back to a sand free rate. The MASR is the rate at which sand production can be tolerated through the production system without affecting its integrity.
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Always requires careful control of wells gradual rate changes to avoid shocks to the formation caused by pressure fluctuations downhole.
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Light Oil
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Sand Removal
Removal of fill build up in wells is typically addressed with four techniques;
Workstring; Through-tubing clean-out using coiled tubing; Sand bailers, modified jet pump (uses concentric coiled tubing); Wireline bailing
Circulating fluids usually brine or diesel, sometimes viscosified. Surface facilities to handle and dispose of produced sand require the following steps;
Separate; Collect; Clean; Dewater & Transport
The logistics behind these operations depend on location eg more difficult and costly for an offshore facility. Advantageous to be able to remove produced solids without interrupting production use of de-sanders (hydrocyclones) similar to those used in drilling packages for mud clean-up.
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Exclusion Options
Screenless exclusion
Orientated perforating Sand consolidation Frac packs
Gravel packs
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Screenless
Screenless sand control aims for sand production prevention rather than sand exclusion. The following techniques when used alone or in combination form the basis of screenless sand control;
Optimal/selective perforating (orientation, phasing, shot density and charge size) Selective zonal production avoid high K or water breakthrough zones Tip screen-out (TSO) frac packing Chemical consolidation Proppantflowback control
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Oriented perforating - maximise chance of creating stable perforations. optimise entry hole diameter, perforation length and P. Perforations should also be kept as far apart as possible.
Aim to
Smaller hole, low shot density increases spacing but increases flow and pressure loss per perforation. High shot density reduces drawdown, flow rate and drag forces per perforation. Modelling can be done to optimise. Consider underbalance in combination to achieve success.
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Sand Control
Screenless Selective / Oriented Perforating
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Frac Pack
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Fracpacks
Fracpacks are a short conductive fracture Best suited to heterogeneous sands with a lot of fines d50Fracpack sand = 6-8x d50 Formation sand Allow some fines to migrate through on clean up? Gives higher PI - Skin usually 0 to -2 Must have good frac containment
Thick reservoir No fluid contacts Limited entry perforating
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AS CARRIER FLUID LEAKS INTO FORMATION, IMMOBILIZATION OF PROPPANT (OR SCREENOUT) AT FRACTURE TIP ARRESTS FRACTURE EXTENSION
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SINCE PROPPANT CANT MOVE, CONTINUED PUMPING EXPANDS FRAC WIDTH AND INCREASES PROPPANT LOADING IN FRAC
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Screenless Consolidation
Treat formation in immediate vicinity of wellbore to bond sand grains.
Formation must be treated through all perforations; Consolidated sand mass must remain permeable to well fluids; Consolidation should remain constant over time
Consolidation can include a gravel proppantwith the treatment (can be resin coated). Fibre consolidation carbon fibres mixed with proppant during pumping. interlock and help prevent proppantflowback no curing time. Resin and fibre consolidation are the main methods of proppantflowback control.
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Fibres
Screenless Consolidation
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Sand Consolidation
Technique augments natural cementation Layeral permeability limits treatment to <10ft section at a time thus it can be expensive to apply in long intervals Although new formulations have been developed in the last 5 years, they may degrade over time Reduction in permeability is likely Can be conducted through tubing e.g. with CT Useful as a remedial approach ?
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Frac Pack
Aim to create wide propped fractures which extend beyond the damage zone. Proppant pumped at high rates into the perforations. Main advantages are; Fracturing ensures leak off to the formation and bypasses near wellbore damage Large contact area between proppant and formation makes it effective in formations with fines invasion (increased flow area reduced flow velocity reduced risk of mobilising fines). Not suited to intervals close to contacts or where cement quality is poor as uncontrolled fracture growth could impair well performance. More complex operationally - requires more complex fluids, higher pumping rates, large fluid volumes and more equipment than CHGPs.
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Gravel packs
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Screens - Principles
Sand control using installed screens is designed to exclude all but the finest formation particles from being produced into the wellbore. Effective design of screens requires acquisition of core samples for particle size analysis. Seeking to induce particle bridging and dynamic filtration.
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Slotted Liners
Simplest and cheapest form of installed sand control equipment. Best suited to coarse grained formations which are fairly homogeneous. Slot width set at d10 percentile value from the PSA 1/3 - 1/7 rule suggests particles with a d50 diameter 1/3 of the slot opening will form bridges. Slotting to very low widths (0.001) now possible with laser cutting techniques. Various slot patterns can be cut, with slots either straight sided or keystone shaped (increasing slot width from liner OD to liner ID). Flow performance through slotted liners influenced by slot width, slot density, slot spacing and open area. Slot spacing and density are the most influential parameters for inflow resistance of slotted liners. Determination of slot factor (skin factor) to assess P. Flow effects and interference vary with different slotting patterns.
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Slotted Liners
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Straight slots carry the risk that they can plug if particle concentration is high Keystone slot offers surface bridging with lower plugging potential
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Prepack Screens
Offers a depth filter Layer of granular material fills annulus
GP sand Synthetic proppant
Various designs depending on screen OD/ID and through bore Susceptible to internal plugging if formation sand is heterogeneous
Prepack Applications
Suitable for more heterogeneous sand but fine sands will plug Comparable to gravel pack but
Much easier installation in high angle /horizontal wells Smaller effective borehole ID if formation collapses onto screen Secondary annulus if no collapse shutoff?
Design is based on d50 Prepack = 5-6 x d50 Formation sand Design conservatively to minimise pack plugging
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Premium Screens
Premium screens gradually replacing PPS over the past 10 years. Many types available from Baker, Halliburton, Schlumberger & Weatherford. Differences usually to do with type of filter material being offered. This ranges from Dutch twill weaves to porous metal fibres. More common now for laboratory tests to compare performance before making a selection. Filter media aperture size specified to facilitate selection. Examples are Baker Excluder, Halliburton PoroMax, Schlumberger MeshRiteTM and Weatherford Stratapac, amongst others. Premium screens applicable to wider range of situations than WWS or PPS and have better resistance to plugging/erosion compared to PPS. Due to the use of layers of weaves or mesh they provide a measure of depth filtration. Also allow larger base pipe to be used compared to PPS.
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Premium Screens
Premium Screens
Weatherford Stratapac
Baker Excluder2000TM
Schlumberger MeshRite
Halliburton PoroMax
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Premium Screens
Offer a range of different media
Sintered metal particles Metal weave Multiple layers
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Expandable Screens
Most significant development in last 10 years. Only alternative to GP for conformance to borehole. Weave/mesh type filter media - 100 300m size. Baker EXPress, Halliburton PoroFlex & Weatherford ESS. Deployed in CH & OH - for CH applications in low strength formations perforations should be prepacked. Expandables have the following advantages over other screen types;
Largest screen inflow area Largest ID of any screen type for hole size Filter media forces fluid direction change reduce velocity Lower weight allows deployment in long horizontal Copyright: Pitac Ltd 2011 sections
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Expandable Screens
Use expandable base pipe and normally a mesh screen Expansion ratio around 1.4 : 1 Benefits?
No secondary annulus - if conformed Retain maximum bore for internal access Retain more of PI Can be used for selective isolation
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Baker ESS
All vendors offer ESS but designs vary between suppliers
Source Weatherford
Expandable Screens
Disadvantages are; Additional trips may be required for expansion increased operational costs. Higher cost/lower collapse resistance than other screens.
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Gravel Packing
Retains formation sand by bridging it across the apertures on a layer of gravel Gravel packing is the most common form of sand control Gravel pack design principle #1
Gravel stops formation sand movement, and, Screen stops gravel movement
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Grain Sphericity
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Grain Roundness
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Gravel Sizes
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Slurry pack
High viscosity and gravel concentrations Less settling of gravel Less leak off through perforations poor packing
Non-viscosified aqueous carrier fluid means high leak off pump rates and fluid volumes are large. Created fractures generally short and thin.
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Carrier fluid
Requires to overbalance reservoir pressure Clean fluids- use filtration as per bridging laws Use brines to prevent clay problems
Viscosifier
Linear or crosslinked gels HEC / HPG or VES
Slurry types
High rate water pack low gravel conc. 1ppg Slurry pack - high viscosity carrier fluid + gravel up to 25ppg conc.
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SC Slide 131
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Running in/Squeeze
Circ thru upper screen Circ thru lower screen Copyright: Pitac Ltd 2011
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Gravel Pack
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Prepacked Screen
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Contents of workshop
Causes of sand production Consequences of sand production Sanding prediction What is moving? - grain size distribution Sand management versus sand exclusion Sand Management options Sand exclusion options Technical evaluation strategy Sand control failures
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Physical Damage
Screen Running Damage Erosion during production Corrosion from produced and injected fluids
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Plugging of Screens
Plugging of screens is a real concern as it
Reduces PI Can cause hotspots
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Physical Damage
Screen Running Damage Erosion during production Corrosion from produced and injected fluids
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damage created by overshot while pulling completion similar damage created while running screen in hole
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erosion failure in a non-prepacked screen occurred in less than 1 hour failures usually at the top of the interval in vertical wells
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Sand production causes damage to facilities and resultant curtailment or production shut in.
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Barriers
Inner well
Carbide blast joints Resin coated sand layer
Best Barriers
move interface away from the wellbore
8 Gauge BAKERWELD
These erosion tests, part of a service company, highlight that erosion failure can happen to any screen with any method of covering
SLIM-PAK
Baker Tests
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Weave screens, even with protective shields on the outside are no match for impingement flow of gas or liquid streams containing particles
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Baker Excluder Screen Damage from Trinidad Erosion Damage In A New Generation Screen
No type of outer physical barrier is immune to impingement flow from a solids containing fluid stream - failure is a matter of time at exposure Outer shroud showing erosion damage.
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Baker Excluder Screen Damage from Trinidad Weave Damage on an Eroded Screen
Seam
Upper shroud removed - notice that the major damage is on the seam. This type of damage can occur anywhere a hot spot develops.
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Upper shroud, layer, & support screen removed showing base pipe - notice that the major damage is at the center hole. Considerable erosion from outside to inside is seen here - material blocking some of the holes has fallen out
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SC Slide 173
Erosion hole in screen and adjacent holes were Hole inplugged screen can bedebris seen with
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HOTSPOT
P2 P = P1 - P2 "Hot Spot" Erosion Path
C L
P1
UNIFORM
P2 P = P1 - P2 Copyright: Pitac Ltd 2011 C L
Baker
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Initial Placement
Surface usually not a problem Downhole is the first place to fail
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Failure Points In The flow Path During Frac Or Gravel Packing 1. crossover port 2. casing opposite crossover port 3. annular area between screen and casing wall a. b. c. erosion from high velocity linear flow minimal problem erosion from high velocity flow as the slurry enters a perforation pressure drop in this area during high rate flow (fracs) can collapse screens problems are very rare, but watch clearances
slurry
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Operating Companies
All have internal guidelines for dealing with sand production. Degree of structure reflects size and scope of operations. Differences in implementation between companies. Some address at well level and others look field wide commercial decision. Clear from feedback that economic factors, field location, type of fluid and ease of well access all factor into the decision making process. Increase in application of probabilistic risk assessments in determining the appropriate strategy for dealing with sand prone reservoirs. In bp, choice between risked value of failure to implement sand control versus the cost of incorporation from the start. The view across all companies is similar for selection and design - no formal process exists but selection guidelines and tools are used consistently. All agreed that design must be specific to the situation.
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Operating Companies
Smaller companies tend to;
Have no formal systems documented or in place Rely more on sand control than sand management Rely more on individuals, who often lack specialist knowledge Be forced or choose to bear risks larger companies treat as optional ie use of or the decision to use risk management
Half reported sand failures due to technical reasons eg poor procedures and equipment reliability but also due to personnel issues. Having a project team with suitably experienced personnel is a significant way to improve the likelihood of success. Only one company had designated sand control professionals (happened to be bp, the largest of the respondents). There is a growing realisation that knowledge management and retention is extremely important means of learning, and of avoiding future problems.
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Operating Companies
Performance tracking of sand control completions has also received major focus. George King (formerly of bp) issued a landmark survey of sand control completions in 2005. This was the first industry wide review of the technology and its performance. Since the King survey, there has been a growth in the successful application of screen only completions. Screens now used where 10 years ago a gravel pack would have been an automatic choice. This shift has come about because of;
Improvements in operational practices. Improved understanding of the value of acquisition of relevant data. Improvements in manufacturing processes and quality control. Cost Operational simplicity
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Type of Completion Injectors (soft sand) Screenless Fracs Cased and Perfed Screen Only Completion Expandable Screens* Cased Hole Gravel Pack Open Hole Gravel Pack High Rate Water Packs Frac Pack Total
Production Production Subsidence Failure Failure Failure Design Application Infant % of (failures / Number of Total Well- Failure % of failure % Failure % (failures / wells Years attempts of attempts of attempts well/yr) attempts well/yr)
30 26 61 194 197 387 208 187 842 86 107 337 757 262 1664 613 556 3351 0 0 0 0.5 0.5 0 0 0 1.5 10 27 1.6 0 3.6 2.3 7.7 0.5 2.4 0 0 0 1.03 0.5 0.8 0.48 0.53 0.24 0.07 0.019 0.074 0.056 0.023 0.012 0.016 0.009 0.005 31.3 7.7 41 21.6 3 5.2 4.8 2.7 2 0.0006 0.0016 0 0.0015 0 0 0.003 0.0013
2132
7539
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Manufacturing Companies
All the manufacturing companies have internal processes. The last decade has seen rapid growth in the variety of standalone screen products on the market, particularly in the premium screen sector. The most important new technology since 2000 has been expandable screens. Still not able to compete with gravel packs for fine grained formations but there are now products from 3 manufacturers instead of the original monopoly enjoyed by Weatherford. Manufacturers now offer to provide the engineering analysis which traditionally would have been carried out by the Operating company. Technology development tracking applications in frontier areas eg Arctic Canada with Cold Heavy Oil Production with Sand (CHOPS), deep water horizontal gravel packing offshore Brazil. Significant growth in the availability of Inflow Control Devices (ICD) able to be used in conjunction with standalone screens.
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Relative Costs
Manufacturers were approached for cost data for the various types of sand control methods. To allow a relevant comparison to be made between applicable sand control options a type well was specified, as follows;
A 500m long horizontal section with an 81/2 hole through the reservoir to be completed. Slotted liner to be 7, 29 lb/ft L-80 carbon steel Standalone screens to have 51/2, 17 lb/ft L-80 base pipe Expandable screen nominal OD to be 51/2 Horizontal open hole gravel pack screen base pipe to be 41/2 or 51/2 For an internal gravel pack assume a 7, 29 lb/ft liner has been run, cemented and perforated For frac pack and IGP the screen base pipe to be 41/2, 12.6 lb/ft Screen filter weave/mesh to be nominal 150m
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Cost Data
Normalised Cost (Premium Screen = 1.0)
Method
Baker Slotted Liner SWW Screen Pre-packed Screen Premium Screen Expandable Screen IGP EGP/HOHGP Frac Pack 0.25 0.67 1.0 1.25 2.0 1.2 2.0 Halliburton Schlumberger 0.9 1.0 1.5 1.5 1.8 Weatherford 0.25 0.6 1.2 1.0 1.7 2.0 -
Unit Type
DSP-06 Topside Particle Monitor (Explosion Proof) DSP-06 Topside Particle Monitor (Intrinsically Safe) Subsea Compact Particle Monitor
Cost (US$)
15,000 13,000 40,000
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Cost Data
As expected, gravel packing is more costly in terms of equipment required. No allowance for additional rig time required need an additional 24 36 hours for a gravel pack. For a subsea well = additional US$0.5 0.75MM. For the expandable screen options a further 6 -12 hours rig time should be added for screen expansion (assuming a single trip run/expand operation). If two trips are required an additional 12 24 hours would be required compared to a standalone screen installation. These compare the costs on a purely financial basis. Not all methods are applicable in every situation and it requires careful consideration and matching of the application envelope to the scenario being considered. Sand monitors - given the potential importance of the information being recorded these units are very cost effective compared to the likely cost impact of a loss of system integrity due to erosion.
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