Autonomous inflow control devices (AICDs) have recently been introduced in the petroleum industry to restrict the production of unwanted fluids, namely water and gas, much more effectively than conventional inflow control devices (ICDs). As with ICDs, AICDs are installed downhole along the completion string to first delay water/gas coning and then restrict their influx, without well intervention, if/when coning such occurs. Unlike ICDs, AICDs selectively choke back water and gas significantly more so than oil. A novel cyclonic AICD was recently developed using computational fluid dynamics (CFD) driven design optimization. The cyclonic AICD's unique internal geometry increases the flow resistance to unwanted fluids based on how their viscosities and densities differ from oil, as initially predicted using CFD and subsequently validated by extensive, carefully controlled single- and two-phase flow tests. The resulting excellent match obtained between CFD and such laboratory tests yielded accurate mathematical models for predicting flow performance over a broad range of flow rates and oil, water and gas properties. The flow performance models were then incorporated into a state-of-the-art dynamic reservoir simulator with multi-segmented wellbore capability to compare the production performance over time for the same well but completed with no ICDs, conventional ICDs, and cyclonic AICDs. A synthetic but realistic three- dimensional (3-D) reservoir model has used that allowed oil, gas and water production. Multiple sensitivity runs were initially performed to optimize the number of compartments using packers for annular isolation, and the number of ICDs per compartment. Once these parameters were optimized, only the ICD type was varied for performance comparison. The results of this systematic, multi-step process, as presented herein, demonstrate that the cyclonic AICD adds significant value to the improvement of oil production by controlling unwanted fluids, such as water and gas, and by preserving the reservoir energy.
The durability of sand screen completions is essential to longer well life, especially for high rate wells with sand screen erosion concerns. An excessive fluid flow enters the conventional screens near the heel or high permeability/fracture zones, causing premature sand control loss. The high rate screens with a simulation-driven approach address this concern by achieving the annulus-to-tubing flow equalization and reducing the influx spike near the heel or high permeability/fracture zone. The study presents a comprehensive modeling approach including a single-well model workflow for initial production screening along the wellbore with different reservoir conditions, which provides input to the novel multiscale 3D-2D-3D computational fluid dynamics (CFD) modeling technique to design or validate high-rate completions for the specific operating conditions. The principle of operation is based on equalizing the production influx along the screen by achieving the distributed inflow control devices (ICD) effect on the basepipe. The modeling approach was used to compute maximum local velocities in the vicinity of the screen near the heel under 39,000 RB/D of ultra-light oil production in one case and 200 MMscf/D of gas production in another. The design methodology is validated through erosion and sand retention tests performed to verify the screens’ correct slot/gauge size. The high-rate completion case history consists of seven deepwater wells with chemical tracers. The novel design and the modeling methodology are validated by physical erosion tests and verified through field installations.
A reliable single-trip openhole multizone completion can significantly lower capital expenditure (CAPEX) by reducing rig time and well count. Recent improvements in openhole packers and enhanced shunt screen technology have enabled multizone openhole gravel pack completions with complete zonal isolation. A multizone openhole gravel-pack completion was installed in the Julimar Field with an enhanced shunt screen system, shunted mechnaical packers (SMP) and shunt tube isolation valves (STIV), to provide improved operating pressure envelope and erosion tolerance. Well design was tailored to derisk the installation and optimize performance of the multizone completion. Extensive reliability testing was undertaken on all new technology for this project. Completions were installed as planned, and the main objectives of sand control integrity, production attainment, and complete zonal isolation with selective production were validated through post-job gravel-pack analysis and subsequent well unloading. The successful implementation of these technologies significantly reduced project CAPEX and enabled access to reserves that would otherwise have been uneconomical to recover. This paper discusses design, execution, and evaluation of the multizone openhole gravel pack (OHGP) completions installed in the Julimar Field. This includes methodology followed for multizone completion selection, development of a new high-temperature formate-based viscous gravel-pack carrier fluid, detailed completion equipment qualification tests, post-job gravel-pack evaluation, and initial well performance from well unload. It is the industry's first field case study of enhanced shunt screens with novel shunt tube isolation valves and high-temperature xanthan-based gravel-pack carrier fluid.
Summary Sand control screens are installed with an internal string (wash pipe) as required which, among other functions, provides a circulation path. In long horizontal wells, running a wash pipe consumes considerable rig time and may limit the ability to reach target depth. In cases in which fluid losses are experienced after screen installation, isolating the open hole with a fluid-loss control valve can be prolonged. This paper describes a wash-pipe-free solution for screen installation using a check-valve inflow control device (CV-ICD). ICD screens are commonly used to delay/restrict the influx of unwanted fluids such as gas or water. The wash-pipe-free solution integrates a check valve with the ICD to prevent outflow through the screen during circulation and allows inflow through the screen when placed on production. This solution uses a check ball that seals against the ICD during circulation but falls back on a porous retainer plate during production. The check ball and retainer plate can be dissolved by spotting a reactive fluid inside the screen or made to erode over time with production. Laboratory testing yielded the following results: the ICD with the check ball was shown to seal up to 5,000 psi; the check ball and retainer plate can be dissolved by a reactive fluid, which can be tailored to bottomhole temperature and the required time of dissolution; and the pressure activation test demonstrated that the maximum differential pressure to seat the ball was less than 5 psi. This CV-ICD solution has been applied worldwide in more than 35 wells, most of which were targeted to avoid running a wash pipe. However, in two wells the technology was successfully used to set openhole packers with a 5,000-psi setting pressure. In this paper, we present the wash-pipe-free ICD screen installation with a dissolvable check valve and the capability of setting a hydraulic packer without a wash pipe or intervention in the open hole. The novel contribution presented herein is the ability to integrate a ball and cage to existing nozzle-based ICDs by using dissolvable material to achieve the preceding results in this application.
Sand control screens are typically installed with an internal string (washpipe) which, among other functions, provides a circulation path. In long horizontal wells, running a washpipe consumes considerable rig time and may limit ability to reach target depth. In cases where fluid losses are experienced after screen installation, isolating the open hole with a fluid loss control valve can take a long time. This paper describes a washpipe-free solution for screen installation using a check valve ICD. ICD screens are commonly used to delay/restrict influx of unwanted fluids such as gas or water. The washpipe-free solution integrates a check valve with the ICD to prevent outflow through the screen during circulation and allow inflow through the screen when placed on production. This solution uses a check ball that seals against the ICD during circulation but falls back on a porous retainer plate during production. The check ball and retainer plate can be dissolved by spotting a reactive fluid inside the screen or made to erode over time with production. Laboratory testing yielded the following results: 1) ICD with the check ball was shown to seal up to 5,000 psi, 2) Check ball and retainer plate can be dissolved by a reactive fluid which can be tailored to bottom hole temperature and required time of dissolution, 3) Pressure activation test demonstrated maximum differential pressure to seat the ball is less than 5 psi. This check valve ICD solution has been applied worldwide in more than 35 wells, most of which were targeted to avoid running a washpipe. However, in two wells the technology was successfully used to set open hole packers with 5,000 psi setting pressure. Washpipe-free ICD screen installation with a dissolvable check valve and capability of setting hydraulic packer without washpipe or intervention in open hole are novel solutions presented in this paper.
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