Various sand control completion techniques have been applied to address sand production issues in Field A. The sand production challenges are often aggravated with decreasing reservoir pressure and increasing water cut due to fields maturity. Conventional gravel pack methods such as circulation pack or high-rate water pack were effective and has high reliability in controlling sand production. However, these methods often resulted in high initial skin (subjected to gravel sizing, completion fluids, screen sizing, etc.) which affect the well productivity. For wells with fines migration issues, the skin will further build-up as the well produce over time. In addition, these sand control methods are associated with higher installation cost. In order to address these issues, Resin Sand Consolidation technique was successfully applied as primary sand control in Well 8 to prove its reliability, productivity, and cost effectiveness. It was the first application for a new development well in Field A and second in PETRONAS Carigali Sdn. Bhd. (PCSB) Malaysia fields (first implementation in 1998). This paper explains the detailed workflow from candidate selection to execution, challenges, and results from this successful pilot. There were three reservoirs completed in Well 8. The perforation strategy utilized 4 SPF 10/350 degree phasing self-gravitated oriented perforations which was executed under dynamic underbalance conditions to achieve optimal perforation tunnel cleanup. The perforation interval was kept short (< 10 ft) to ensure uniform treatment. One of the key steps in achieving successful resin placement is formation injectivity. Acid was pumped and injectivity tests were conducted before and after pumping to assess the effectiveness of acid treatment. The data acquired from the step rate test was used to determine the Fracture Closure Pressure (FCP) and Fracture Extension Pressure (FEP) where it will define the maximum pumping rate during the sand consolidation treatment. Identification of maximum pumping rate is crucial to ensure optimum displacement of resin into the formation during execution. Pre-acid injectivity results showed poor injectivity in all 3 reservoirs with treating pressures recorded more than the MASTP limit to reach pumping rate of 2 bpm. Near well bore damage removal treatments were executed using mud acid (15% HCl + 1.5% HF) followed by post-injectivity test which showed improvement in treating pressures. By the end of the operation, a total of 68 bbls of treatment fluid was successfully pumped into all three reservoirs. Well tests acquired during unloading and production phase have shown good results exceeding the target rate set during FDP with no sand production observed. It is expected that this new way of sand control for new wells could contribute towards reducing sand production issues in Field A while at the same time provide an incremental gain in oil production. The success of this pilot would open-up more opportunities in PCSB and other operators towards the implementation of similar sand control method for new development wells.
Objectives/Scope In 2014, number of exploratory wells were drilled and tested in Umm Niqa (UN) Field located in north Kuwait NE which approved a new discovery in Lower Fars (LF) reservoir. LF is unconsolidated, sub –hydrostatic- sand stone reservoir with highly sour and moderate corrosive environment (H2S 8% and CO2 4%). Subsequently additional wells were drilled to evaluate the production potential of UN field. With rig on location UN wells are completed with test (Progressive Cavity Pump) PCP and tested. During the initial testing period the PCP is run at different speeds to evaluate the well productivity, water cut, and determine sand-free draw down to enable selection of suitable completion PCP for production. Methods, Procedures, Process Well UN-X is one of the developed wells which is perforated in LF sand in overbalanced condition using 4-1/2" (High Shot Density) HSD guns with 0.83" entrance hole diameter at 12 shoots per foot. During initial testing with test PCP, the pump tripped due to high torque because of sand production (up to 60%). Five runs were performed to clean out the wellbore and repeated test PCP runs failed due to high sand production. Coordination between FDHO (Field Development Heavy Oil) and Discovery Promotion Team was conducted to perform quick sand analysis to LF sands from offset sand distribution since subject well has no available sieve analysis. Based on the outcome of sieve analysis, decision was made to utilize one of the available SAS (Stand Alone Screen) designed for LF sand in another field to control sand production. It was agreed by both teams to install SAS in the subject well to mitigate the sand problem and minimize cost due to NPT (Non-Productive Time) of the rig. SAS was installed and the potential zone in UN-X could be tested successfully with tubing PCP. No sand problem was observed during testing and after testing while clean out operation there was no sand. Results, Observations, Conclusions Well test showed an average liquid rate of 124 BFPD with 37% WC (predominantly completion brine). The well was put on production on November 2016 and producing till date without any sand problem. Novel/Additive Information This paper will include discussion on the approach used to select a sand control method for cold and heavy oil production. The results of sieve analysis was in the middle between sand screen and gravel pack but based on the team experience in sand control and the nature of heavy oil and its relatively low oil production rate, the decision was made to install SAS and that was proved to be prudent decision.
Many small oilfields in poorly sorted and highly non-uniform unconsolidated formations with high fines content cannot be developed economically using the preferred sand control method, gravel pack. ‘J’ Field in Malaysia is a small oilfield with marginal economics that was developed successfully using stand-alone screen (SAS), a cost-effective open hole (OH) sand control method. Deployment of SAS in ‘J’ Field does not meet the industry-accepted criteria for sand control methods but provided the operator adequate sand control while fulfilling its economic needs. Recent advances in OH sandface completion technologies such as multi-layer mesh screens, inflow control devices (ICDs), and zonal isolation using swellable packers provided improved performance and reliability of recent SAS installations. This project marks a few firsts in sand control screen technology: World's first installation of multi-layer mesh screenMulti-layer mesh screen is the current state-of-the-art in premium mesh screen technology. It uses several layers of woven metal mesh filters of gradually decreasing micron rating and diffusion-bonded together, which creates a filter that provides better plugging resistance and solids retention capacity.Malaysia's first installation of tube-type ICDICDs are passive flow control devices that are used in OH horizontal (Hz) wells to delay the onset of water breakthrough and minimize its effect by balancing inflow from toe to heel or between high-perm and low-perm zones. ICDs are integrated with sand control screens for use in unconsolidated formations. Swellable packers are used in ICD completions to provide compartmentalization. This paper highlights the recent success of utilization of these cost-effective OH sandface completion technologies in the development of ‘J’ Field.
Kuwait Oil Company (KOC) is operating two Heavy Oil fields. Field A aims at production by Cyclic Steam Stimulation (CSS), followed by steam flood. Field B envisages primary recovery through cold production, followed by non-thermal Enhanced Oil Recovery (EOR). This requires drilling and completion of large number of wells. Implementing Well, Reservoir and Facilities Management (WRFM) and Smart Field approach will be a key requirement for operation excellence in these fields. Currently both fields have some wells in production, mostly as single isolated wells or wells in 5-acre/ 10-acre spacing. These pilot projects aimed at de-risking the commercial phase, which is to follow in the coming years. These wells are the training ground for young KOC staff to learn how to work in integrated teams using WRFM processes. WRFM processes are tailor-made for KOC's operating environment. These processes include Digital Oil Field based on Exception Based Surveillance (to flag out only those wells and facilities outside of their operating envelope and/or optimization window) and Production System Optimization. This would help to eliminate operational bottlenecks, leading to optimization in manpower to deal with large number of wells. It is expected to be achieved by combining existing best practices of International Oil Companies (IOC) with existing KOC applications, leveraging successful global practices. The paper shall highlight the timeline, activities and organizational changes underway to effect the transformation from existing operation to a larger and more complex development that includes continuous drilling, completion and well intervention (CWI) and facilities installation occurring simultaneously. The implementation of WRFM Processes along with Digital field will achieve the production and operation goals by reducing well, artificial lift, and facility downtime. This innovative production optimization system by enabling efficient decision-making process shall lower the cost per bbl. and reduce down time by implementing automated surveillance workflow.
Kuwait Oil Company (KOC) is operating two Heavy Oil fields. Field A aims at production by Cyclic Steam Stimulation (CSS), followed by steam flood. Field B envisages primary recovery through cold production, followed by non-thermal Enhanced Oil Recovery (EOR). This requires drilling and completion of large number of wells. Implementing Well, Reservoir and Facilities Management (WRFM) and Smart Field approach will be a key requirement for operation excellence in these fields. Currently both fields have some wells in production, mostly as single isolated wells or wells in 5-acre/10-acre spacing. These pilot projects aimed at de-risking the commercial phase, which is to follow in the coming years. These wells are the training ground for young KOC staff to learn how to work in integrated teams using WRFM processes. WRFM processes are tailor-made for KOC's operating environment. These processes include Digital Oil Field based on Exception Based Surveillance (to flag out only those wells and facilities outside of their operating envelope and/or optimization window) and Production System Optimization. This would help to eliminate operational bottlenecks, leading to optimization in manpower to deal with large number of wells. It is expected to be achieved by combining existing best practices of International Oil Companies (IOC) with existing KOC applications, leveraging successful global practices. The paper shall highlight the timeline, activities and organizational changes underway to effect the transformation from existing operation to a larger and more complex development that includes continuous drilling, completion and well intervention (CWI) and facilities installation occurring simultaneously. The implementation of WRFM Processes along with Digital field will achieve the production and operation goals by reducing well, artificial lift, and facility downtime. This innovative production optimization system by enabling efficient decision-making process shall lower the cost per bbl. and reduce down time by implementing automated surveillance workflow.
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