An operator facing the need for sand control in multiple maturing fields investigated the possibility of using expandable technologies to address their needs. Years of production and the onset of water production has affected that need. After an extensive study of rock mechanics and properties and how sand production might be initiated based on these properties, the investigation for an optimized sand control technique began. A systematic approach ensued between operator and Service Company in an attempt to define an optimized solution for sand control in each of these fields. Conventional cased hole gravel packs were excluded due to the need for a larger flow area for handling the high gas rates. Open hole gravel packing was investigated yet ruled out due the exposed unstable shales during the packing operations. Ultimately the optimized solution led to the deployment of an expandable screen system to ensure sand control for the remaining life of each well. The undesirable shales were isolated with the installation of expandable blank pipe and expandable packers. Expandable screens were positioned across the clean sand bodies. Many wells had multiple sand bodies exposed. These separate reservoir sections were isolated with expandable blank pipe and packers as well. The entire expandable assembly was deployed in a single trip and hung off in the parent casing with an expandable hanger. Sand-free production data obtained from more than 20 wells will be presented and discussed. Expandable technologies provided the operator with a sand control technique that previously didn't exist., After exploring this new technology, the operator conducted multiple installations of expandable sand screen for sand control in the maturing fields of the Mediterranean Sea. This became the new philosophy for sand control by the operator in the Mediterranean Sea as well as other parts of the world where they have sand control needs. Introduction In December 2001, an in-depth sand production risk analysis study was conducted on the Miocene Age Gas Reservoirs located in the Mediterranean Sea (1). Sand production prediction modeling analyses were conducted for the Baltim, Temsah, and Port Fouad Fields. Baltim Field sand production analysis was performed considering the Messinian gas reservoir zones of the Abu Madi formation. The Temsah Field analysis was performed considering the Serravallian reservoir sands known as Lobe 1, Lobe 2, and Lobe 3. Finally the Port Fouad Field sand prediction was conducted on the Tortonian Gas Reservoir Sands of the Wakar Formation.
A total system analysis approach was applied to achieve the desired results for a National Oil Company (NOC). The Service Company and NOC worked very closely together to optimize production from a gas well in the General Field near Reynosa, Mexico.The horizontal gas well, General 16H, was drilled and completed in February 2007. Once the well was placed on line, it initially produced up to 40 MMscf/day (1.132 MMcm/day) before settling at a rate of 18 MMscf/day. Average daily production from other wells in this area is 4 to 5 MMscf/day. Production optimization included determining via nodal analysis how system pressure losses affected total production. The system was analyzed from three points of view: from the reservoir to the surface, near the sand face, and at the surface. The team used an analytical model to determine the drawdown effect, establishing the loss of pressure in the reservoir as a function of rock properties, well and reservoir geometry, well position within the reservoir, and reservoir fluid properties.Without a joint effort and understanding between the NOC and the Service Company, the results would have never been achieved. Working diligently together enabled both parties to understand what was required to meet the initial objective of production optimization. The solution presented itself in the form of expandable screens, which provided a much greater inflow area than other methods available.
Industry interest is turning to alternative means of production for the massive reserves located in the Bitumen Region of Canada's Tar Sands. Currently, the region has over 100 installations of sand screens/slotted liners in both injection legs and production legs using Steam-Assisted Gravity Drainage (SAGD) technology. Due to the sensitive nature of the environment, multiple wells must be drilled from a single pad. With the average depths of these wells between 200 and 400 m and lateral lengths between 800 and 1,000 m, a floating sand screen provides assurance that the sand screen will reach the desired depths.The most typical method of floating the sand screen to bottom uses paraffin to plug the flow access of the screen during installation. In shallow depth wells, the paraffin must be capable of handling differential pressure between the annulus and inside diameter of the screen or liner assembly equivalent to the hydrostatic pressure and any surge pressures encountered during the installation process. The use of paraffin to plug the sand screens currently limits the differential capability to less than 200 psi.A new technology has been developed that allows for sand screen installations without relying on paraffin wax to withstand differential pressure. This new technology uses a hydro-mechanical valving system incorporated into the screen design to temporarily close off the screen while being run in the hole. This paper will describe how this technology can provide a reliable, time-saving solution for SAGD installations when floating sand control screens in the hole is required. This solution provides a unique alternative to the methods currently being used to install sand screens with SAGD technology in the rapidly growing Canadian market for bitumen recovery.
Since the inception of expandable sand screen technology in the late 1990's, it has seen its ups and downs during its inaugural and acceptance phase. Expandable premium screen technology has seen in recent years an increase in the number of applications in several oilfield typologies. From high rate gas producers to Oil production up to the most challenging gas storage application expandable screens have shown to be a reliable completion for a variety of well types.As with any new technology there were lessons learned. This knowledge led to the fine tuning of the entire system and required adjustments to the operation procedures and design parameters in order to improve its reliability. The ultimate goal of any technology is to reduce operational cost, maximize productivity, and deliver a reliable completion for many years to come.
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