Successful Field Application of Aqueous-Based Formation Consolidation Treatment Implemented in Nile Delta, Egypt

Abstract

Sand production can be challenging for many operators in unconsolidated formations. The production of formation sand and fines can cause erosion damage to both surface and downhole equipment, resulting in major well intervention and sand disposal costs. Conventional resin consolidation systems have been successfully used to prevent solids production in short, homogenous intervals. However, resin consolidation attempts in longer intervals have resulted in erratic success rates, which could be attributed to a lack of complete and uniform treatment of the entire interval length. A recently developed aqueous-based resin (ABR) system has helped provide effective and efficient treatment of significantly longer intervals, has improved health, safety, security, environmental (HSSE) compatibility, and can help improve various operational considerations. This paper discusses results of laboratory testing and the subsequent successful treatment using the ABR system within a well located in Nile Delta, which was the first attempt of its kind in Egypt. Sieve analysis revealed unsorted formation sand, which usually requires a gravel pack completion, rather than a standalone screen; however, because of limitations with respect to wellbore diameter (5 in.), it was difficult to complete the well using conventional gravel pack completion methods. Additionally, the well had a history of unsuccessful treatment using a non-resin product, which modifies the surface potential charges of the sand grains and reduces the repelling forces between them. The well was still producing sand after that treatment; thus, the decision was made to treat the interval using the ABR system. Thereafter, hydrocarbon production, at a rate of 5.5 MMscf/D, was monitored and sand production from the well decreased by more than 95%, with no impairment to hydrocarbon production.

Chemical Sand Consolidation: From Polymers to Nanoparticles

“…Some researchers used water-based and saline-based chemical materials to consolidate loose sand formation. Bhasker et al [114] and Songire et al [115] applied an aqueous-based epoxy resin to consolidate the sand formation. Othman et al 2017 [116] utilized a solvent-based epoxy resin to control the sand formation in Peninsular Malaysia, Table 23.…”