Expanding Innovative Approach of Sand Production Well Remediation - Case Study of First Downhole Ceramic Sand Screens for a Gas Well in Malaysia

Abstract

The current state of oil and gas economics has emphasized focus in managing and optimizing production from mature fields. It is estimated that approximately 70% of the world's oil and gas production are contributed by mature fields. Sand production is common as pressure declines and water breakthrough takes place. Clastic reservoirs with unconsolidated formation sand with moderate and high permeability are prone to produce sand under these conditions. In gas producing environments, conventional sand control can place demands for continued expensive remediation investment through the wells producing life as high gas velocity increases the chances of erosion and failure of downhole equipment. Gas reservoirs have always been an integral part Malaysia's oil and gas business. As the well the portfolio expands to cater for the regional energy demand, focus on fit for purpose sand control in gas wells is crucial in ensuring continuous production delivery to customers. As a current practice, sand production has been handled by standalone metal screens or combined with gravel packing. One of the cheaper options available in the market is the ceramic sand screen that allows for rigless installation while providing durable material which is resistant to erosion caused by high gas velocity for a continuous production as the ceramic material is 10 times harder than steel (Jackson et al., 2015) and it is more resistant to corrosion in comparison to steel (Wheeler et al., 2014). This paper will focus on the revival strategy of a gas well with a currently damaged screen due to erosion. As this is the first through tubing ceramic sand screen deployment in a gas well in Malaysia, a feasibility process was put place to ensure safe operation and deployment success. Depending on the current well completion profiles, the assessment includes selection of sand screen specification, actual installation sequence, methodology in ensuring safe and successful deployment of ceramic sand screen downhole are focused. The study and assessment has provided future reference for superior downhole sand control options in gas well applications.

Erosion of sand screens by solid particles: a review of experimental investigations

“…The standalone screen (SAS) can effectively minimize sand production by retaining sand particles with a specified size in the formation and hinder sand entrainment with the produced fluids. However, SAS itself is frequently susceptible to sand erosion, which may affect its efficiency, and in the worst cases, the screen may totally fail to perform sand control (Nizar Musa et al 2017; G. K. Wong et al 2003). Therefore, the degree by which SAS undergoes erosion at expected operational conditions and reservoir characteristics must be examined as part of sand control design.…”