Evaluation of Erosion Resistant Ceramic Coated Through Tubing Sand Screen Installation in Peninsular Malaysia

Abstract

Wells that are producing with high gas oil ratio (GOR) or gas wells with sand production exhibit highly erosive environment due to their high fluid velocity. Well A, oil producer and Well B, gas producer in Peninsular Malaysia had experienced sand production issues since 2017 which caused the wells to be beaned down and subsequently shut in. The conventional metallic screen is not suitable for these wells as the screen will be impaired rapidly due to erosion. In 2021, erosion resistant ceramic coated Through Tubing Sand Screen (TTSS) have been successfully piloted in these two wells to produce with manageable sand production. In order to select the right technology, Gas Screen Erosion Test (GSET) and Mechanical Strength Test were conducted as qualification requirement to ensure the screen operating envelope can accommodate the wells’ erosive environment. Once the technology is qualified, detailed design of the screen was established to specify the screen opening size, screen length, location and conveyance method. Post-installation, the opening up of the well is in accordance with the bean up procedure to avoid sudden surge or high velocity flow that can damage the screen. In addition, acoustic sand monitoring and sand sampling were also performed to monitor any solid production. The wells’ performances were then monitored for 3 months flowing period prior to the screen retrieval for visual inspection and pilot result evaluation. The ceramic coated Through Tubing Sand Screen (TTSS) was successfully installed in both wells despite multiple operational challenges encountered during installation process. Both wells showed satisfactory production performance with minimal sand production observed. Based on these promising results, the technology is planned to be replicated in wells with similar erosive environment. This paper will cover the end-to-end process of ceramic coated Through Tubing Sand Screen (TTSS) pilot installation including technology selection, screen design, execution, operational challenges and well performance.