Determining Ceramic Sand Screen Operational Envelop and Service Lifetime Prediction Model

Abstract

Downhole sand control selection plays a vital role in sand free production optimization over the well lifecycle. Design and selection criteria to assess the optimum sand control methodology requires consideration of many inputs to assess the sand control service life. A qualified sand control method, offering high erosion resistance is critical to enhance service life, especially in cases where small particles may be entrained in the produced fluids at high velocity. An integrated approach considering advances in filter media material, allow integration of ceramic components, to redefine operating envelope of sand control screen. In the process of designing and selecting a suitable sand control method for a high-rate gas well application in Norway, ceramic sand screens were considered as a possible solution to manage the high erosion loading expected during production. To estimate the operational limits for stand-alone ceramic sand screens, a series of erosion tests were conducted by a third party research and testing agency defined by the operator to evaluate the erosion behavior of the ceramic filter element. As indicator for erosion the filtration cut point (FCP) of the ceramic filter element was used. The testing allowed the operating envelope of the ceramic screens to be defined in terms of FCP and erosion load. For a specific increase in FCP value the operational limits for a stand-alone ceramic sand screen can estimated. This methodology was then applied to a specific field application to predict ceramic sand screen lifetime for the expected production profile. This paper presents the results of the study, using CFD simulations and, independent industry testing methodology to investigate the suitability and expected service life for stand-alone ceramic sand screen. Understanding the operational erosion risk profiling enables the operator to apply an erosional resistant stand-alone screen approach offering reducing planning, deployment complexity, lower HS&E risk and increased flexibility in optimising the wells production envelope.