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Formation damage by the drill-in fluid has been identified as a major risk for the Dvalin HT gas field. To ensure the long-term stability and mobility of the mud even after an extended suspension time between drill-in and clean-up of the wells, a novel static aging test under downhole temperature and high pressure was conducted. Experiments have shown that the downhole stability is commonly underestimated when the surrounding pressure is lower than in the field. Thus, a high-pressure cylinder was used in vertical orientation in a heating oven with a pressure pump regulating the pressure up to 200 bar. The reservoir section was drilled with the optimized organo-clay-free oil-based drilling fluid (OCFOBDF) specified in the qualification phase. Tracers in the lower completion were used to identify clean-up from the upper high-permeability streak and the deeper (relatively lower) high-permeability streak. Due to extended wait on weather after drilling and completion of the first of the four wells, the lag time until clean-up was almost 11 weeks (74 days). It could be experimentally shown that the qualified OCFOBDF system weighted with micron sized barite remains mobile without phase separation even after static aging at 160 °C and 200 bar for the maximum estimated lag time between drilling and clean-up of 3 months. The absence of a gas cap in the set-up also better represents downhole conditions in the reservoir section and has shown that it improves the fluid´s stability. The clean-up of the well was successful with a maximum flowrate of 3.0 MM Sm3/d. Analysis of the tracers has proven that clean-up was successful for the entire reservoir section, including the deeper part. It could be concluded that in alignment with the lab tests that the mud fulfilled its requirement to be mobile even up to three months. Because of the superior properties, settling of solids (bridging and weighting material) could be avoided, resulting in no blockage of the (lower part of the) reservoir. The use HPHT aging has been the key to proving the long-term stability and mobility of the combined Drill-In and Completion Fluid. This technique falls outside of current API RP testing practices but is believed to be highly beneficial for qualification of fluids that will be left in the lower completion for long periods, especially in open hole completions under high temperature and pressure.
Formation damage by the drill-in fluid has been identified as a major risk for the Dvalin HT gas field. To ensure the long-term stability and mobility of the mud even after an extended suspension time between drill-in and clean-up of the wells, a novel static aging test under downhole temperature and high pressure was conducted. Experiments have shown that the downhole stability is commonly underestimated when the surrounding pressure is lower than in the field. Thus, a high-pressure cylinder was used in vertical orientation in a heating oven with a pressure pump regulating the pressure up to 200 bar. The reservoir section was drilled with the optimized organo-clay-free oil-based drilling fluid (OCFOBDF) specified in the qualification phase. Tracers in the lower completion were used to identify clean-up from the upper high-permeability streak and the deeper (relatively lower) high-permeability streak. Due to extended wait on weather after drilling and completion of the first of the four wells, the lag time until clean-up was almost 11 weeks (74 days). It could be experimentally shown that the qualified OCFOBDF system weighted with micron sized barite remains mobile without phase separation even after static aging at 160 °C and 200 bar for the maximum estimated lag time between drilling and clean-up of 3 months. The absence of a gas cap in the set-up also better represents downhole conditions in the reservoir section and has shown that it improves the fluid´s stability. The clean-up of the well was successful with a maximum flowrate of 3.0 MM Sm3/d. Analysis of the tracers has proven that clean-up was successful for the entire reservoir section, including the deeper part. It could be concluded that in alignment with the lab tests that the mud fulfilled its requirement to be mobile even up to three months. Because of the superior properties, settling of solids (bridging and weighting material) could be avoided, resulting in no blockage of the (lower part of the) reservoir. The use HPHT aging has been the key to proving the long-term stability and mobility of the combined Drill-In and Completion Fluid. This technique falls outside of current API RP testing practices but is believed to be highly beneficial for qualification of fluids that will be left in the lower completion for long periods, especially in open hole completions under high temperature and pressure.
The Seligi field, located 240 kilometers offshore peninsular Malaysia in the Malay basin was discovered in May 1971 and is one of the largest oil fields in Malaysia. Sand production in the Seligi field has been observed, especially from the J reservoirs group. Within the Seligi field, Well G was identified as one of the wells with sand production to surface that could lead to sand accumulation at surface facilities and erosion of equipment. Historically, there had been no in-situ sand control measures in the well. The default practice for sand control was to choke back the well, to prevent triggering of the surface sand probe (production with maximum sand-free rate). This approach however is a compromise, while it limits sand production, it also limits the production potential of the well (well technical potential). As part of the production enhancement assessment program, remedial sand-control methods were considered to increase the oil production while minimising sand production. Among the options considered was ceramic downhole sand screen installation. Ceramics have been used in many extreme erosion and corrosion applications, with ceramic sintered silicon carbide being 50 times harder than steel. Ceramic sand screens made with sintered silicon carbide offer much higher erosional resistance at speeds of 300ft/s sand impingement velocity. Due to the aggressive nature of the sands and high velocities of greater than 50ft/s in Well G, a through-tubing ceramic sand screen was selected. The ceramic sand screen served as a fit for purpose solution that allowed the well potential to be fully maximised, enabling a continuous production with minimal sand production at surface. This paper reviews the first successful pilot installation of through-tubing ceramic sand screen in Well G in the Seligi Oil Field, Offshore Peninsular Malaysia. Discussed are careful analysis and planning, i.e. velocity calculations, tool deployment simulations, tool inspections and detailed job procedure leading to a successful installation. With the ceramic sand screen installed, the well was able to produce at 100% production choke opening with lower tubing head pressure and has not produced sand at surface despite multiple shutdowns and well bean ups. The installation has also removed the need to have sand handling facilities at topside and has generated an implicated cost saving from expensive intervention programs. Given the success of this pilot installation, a baseline in sand control has been set for this field, with new well candidates being considered for future replication.
Mahakam block has supported Indonesia's Oil and Gas production with over 40 years of deliverability. Presently, along with its maturity cycle, comes the challenge of a steeply declining matured field with indicators of marginal reserves, included unconsolidated sand reservoirs as one of the main contributors which required sand control. In addition, future offshore platform development emerged the urgency of light deployment and robust sand control. Deep dive into the methodology, it was mandatorily to revisit what techniques available on the shelves and what is the current technology has to offer. Mahakam subsurface sand controls were classified into gravel pack, open hole stand-alone screen, chemical sand consolidation (SCON), and thru-tubing metal screen. These also respectively account for the highest to the lowest of operational investment, associated production contribution, and its reliability. Thru tubing screen methodology in cased-hole application showed weakness by plugging and erosion issue resulting on minimum utilization as lowest end subsurface sand control means. Several normative elements factored into it, with the root cause of screen placement. It was avoided to install metallic screen in front perforation due to direct jetting during the natural sand packing (NSP) process, causing an installation at slightly above perforation with the absence of stable NSP and screen size selection complexity. Thru-tubing screen with higher strata of material, silicon carbide or ceramic, was selected as a pioneer on new installation philosophy to tackle erosion issue. It was combined with the developed Mahakam sand grain size map as a screen size selection guideline. A confidence pseudo-straddle thru-tubing ceramic screen (TTCS) installation campaign in front of perforation interval was explored on swamp (Tunu) and offshore (Peciko) gas wells. This technique adopts open hole SAS with retrievable concept optimizing slickline intervention. Perfection of the techniques is a process that continues. However, based on the current study and trial results on wells installation throughout 2020 to 2021, positive results were achieved: Operation simplicity with minimum operation HSE risk, Sand free production delivery addressing highly unconsolidated reservoir with widely distributed sand grain by mitigating the risk of screen erosion, The average cost savings were 66% in delta and 76% in offshore compared to allocated SCON budget, Cummulative gas deliverability increased by more than 200% compared to previous thru-tubing metal screen performance, Performance exceeded average SCON production rate and in-situ gas velocity limit at several installations, The installation method had a 100% retrievability success ratio from all retrieval attempts on inactive wells installation, It had no damaging effect to the reservoir when remedial by SCON was required, The installation concept adoption has been proven on highly deviated and unique completion configurations. This enlightenment boosted confidence in both the assessment technique and installation philosophy. This initiative would enable the production of Mahakam marginal sandy reservoir while sparking to a wider application as an alternative robust and light sand control solution.
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