Best Practice for Stand-alone Screens · Best Practice for Stand-alone Screens Ian Wattie...
Transcript of Best Practice for Stand-alone Screens · Best Practice for Stand-alone Screens Ian Wattie...
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Best Practice forStand-alone Screens
Ian WattieCompletion Engineering Consultant
Yala Peak Limited
Sand Management Forum26th – 27th March 2014
Aberdeen
Stand-alone ScreensBest Practices
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Industry Completion Failure DataData for OH Completions with Stand-Alone Screens
Highest Failure Rate for Major Operator: 15 Failures/19 Wells
Average Failure Rate from Industry Database: 39 Failures/110 Wells
Lowest Failure Rate of Major Operators: 4 Failures/71 Wells
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1. Sand control best practices for selection, design, manufacturing,installation & start-up mostly not followed
2. First wells had no sand control based on log-derived UCS3. Short length screens and large annular gap have much bigger
effect than other bad practices4. Very short screens will plug or erode sooner due to higher
rates/metre5. Very short (e.g. < 10 metres) screen mesh intervals are extremely
sensitive to anything less than ideal practice at every stage6. Screen mesh size too small; very large D10 sand size7. Screens run in brine > 250 NTU picking up debris8. Screens needed to be worked past shale picking up swelling shale9. Lower post-acid loss rate 0.5 bpm - did not clean off all filter cake10. Production declines are fines plugging formation or screen11. Sudden changes in production are wellbore collapse onto screen,
plugging the screen and reducing annulus permeability with re-sorted sand, shale and residual mud-cake
Field Case Causes of ProductionDecline/Disappointment
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Sand Control Best PracticesOutline
• Sand failure risk assessment• Sand control strategy selection• Sand screen selection method• Sand screen manufacturing QA & QC• Completion installation practices• Production start-up
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Sand Control Best Practice
• Sand failure risk assessment - risk of sandproduction– Strength characterisation– Stress characterisation– Formation failure modelling
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Comparison of Log Predicted UCS with Core Measured UCS
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Core Measured UCS, psi
Log
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CS
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Field-1 SamplesField-2 SamplesField-3 SamplesField-4 SamplesUnit Slope Line
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Formation Strength CharacterizationUse of Core Data to Establish UCS Range
Example Formation Strength CharacterizationCore Measured Unconfined Compressive Strength vs. Depth
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Formation Stress Characterization
Principle Stresses = Vertical, Hz-max, Hz-minAbsolute Stress = Total Stress Acting at DepthNet Stress = Absolute Stress - Pore PressureDepletion Forecast, so Net Stress increases over field
life
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History Matching with Field Data
Comparison of Field Sand Production Data with Model PredictionConventional Wells with Standard, Non-Stress Oriented, Perforations
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Sand Control Best Practice
• Select strategy for sand management– Produce sand to facilities, collect and dispose– Prevent formation failure (wellbore orientation,
fracture and perforation tactics, resin stabilisation,increase pressure, choke back well, shut-in well,redrill well)
– Screen out at sand face (stand-alone screen,gravel pack, frac-pack)
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Sand Control Best Practices• Select and design stand-alone sand control screen
– Select most likely screen type• mesh sizes around D10 from PSD• select maximum od screen size to minimise annulus (max 1”
less than nominal hole size drilled)– Sand screen mesh sizing by proven lab testing methods
• Plugging resistance test flow and return perms (screen & sandpack)
• Sand retention– RDIF selection by testing
• Drillability (inc. shale stability, loss control, rheology)• Completability (inc. formation damage, screen plugging)
– Clean-up treatment by testing• Screen coupon from production line mesh• Sand as per PSD• RDIF with drill solids (including shale)• Clean-up fluid at representative volume
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Formation Sand VariationSample Selection
Particle Size Distribution of Formation Sand Samples
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High Perm Sand Low Perm Sand Worse Case
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Test Procedures forScreen Qualification
Gradual FormationFailure
• Flow at constant dP• Produced solids conc. and
particle size• Initial / final sand pack,
gravel and screen perms
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Reservoir Drill-In Fluid Selection
Fluid Loss Control
Bridging Agent PSDBridging Agent ConcPolymer/Starch Conc
RheologyPolymer Conc
ReactivityShale stability
Formation Damage
Filtrate / Solids InvasionFiltercake RestrictionDrill Solids Conc / Reactivity
Screen PluggingFiltercake Plugging
Performance Test Criteria
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• Integrated test of:– RDIF (with drill solids inc shales)– Clean-up fluid volume, circulation, pressure
and temperature, soak time– Flowback onto screen
• Screen plugging measurements:– flow initiation pressure– retained flow capacity– peak pressure
Clean-up System Testing
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Screen Plugging Tests
12.2 ppg OBMw/ Super Pickle + Mark II
12.2 ppg OBMw/ 7.5% HCL +25% EGMBE
12.2 ppg NaCL/KCL/NaBrWB DIF w/ EDTA
Filtercake
Formation Sand
12.2 ppg NaBr/KCL WB DIF #3w/ EDTA
Formation Sand
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Integrated System Testing
• Results graph of retained productivityCallanish & Brodgar Screen Plugging Test Results
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12.2 ppgEnviromul OBMSuperPickle +HDC MarkII
Fordacal/MilBarOBM # 2328
SuperPickle +HDC MarkII
KCOOH Fordacal# 2326 WBM
EDTA
Callanish(Halliburton) Brodgar(Baker)
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12.2 ppg NaCL/KCL/NaBr WBM
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DIF/Screen/Clean-up Test Results
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Sand Control Best Practices• Procurement
– Qualification testing (for specific screendesign & manufacturing location supplyingproject)• Corrosion testing weave (completion &
production fluids)• Bead testing mesh size• Burst & collapse full size joint• Assess assembly, inspection, repair and quality
control procedures– Manufacturing quality control
• Inspect records for satisfactory performance• Inspect screens for correct assembly and signs
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Sand Control Best Practices• Field installation
– Drill reservoir with RDIF MBT < 5ppg (pit, not returns),drilled solids < 50% and < 30ppb
– Avoid too much steering which leaves ledges– Clean boats, rig piping, pumps, shakers and pits– Pickle running string and washpipe– Minimise time between TD and screens on bottom for shale
clock (3-4 days to do all the stiff wiper trip, casing clean-upand RIH practices)
– Circulate open hole to RDIF with zero solids (i.e. same shalestabilisers, same viscosity, same weight to keep holediameter)
– Clean casing to < 0.01% solids in brine returns (not justNTU)
– Make-up all screen using dope-free ideally, or 1” paint brushdoping pin-end only (screen, wash-pipe, work-string)
– Hold acid treatment against sand face to soak filter-cake byholding wellbore static with seals in sealbores 24
Solids Conc in Active System(Initial CaCO3 = 52 ppb; Dilution Rate = 0 bbl/ft)
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DIF Quality Control
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Impact of DIF Quality on Filtercake Cleanup
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Sand Control Best Practices• Production Start-up
– Limit drawdown– Gradual choke opening– Production or reservoir engineer witness
offshore to influence, observe, record andreact
– Repeat for re-starts following first fewproduction trips
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1. Sand control selection practices followed – 2. Sand control design practices followed – 3. Sand control manufacturing quality practices followed – 4. Sand control installation practices followed in procedure, and in
practice – 5. 60 - 80 metre screens will avoid plugging and erosion due to
lower rates/metre – 6. 60 - 80 metre screen mesh intervals are less sensitive than last
wells to anything less than ideal practice at every stage – 7. Annular gap minimised, which has much bigger effect than good
/ bad practices – 8. Screen mesh sized for very large D10 sand size – 9. Run screens in clean brine < 0.01% solids – 10.Avoid plugging screens by keeping shales from swelling – 11.Ensure acid treatment effective by testing, uncontaminated
filter-cake, good placement & exposure time to filter-cake –
Lessons Applied New Field
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Sand Control Best PracticesKey Points Summary
• Core samples for sand strength• Long screens, large OD screens• D10 particle size screen pre-selection & test• Soluble filter cake by lab testing & QC
during drilling & completion operations• Prevent shales swelling (RDIF shale
inhibitors, shale avoidance, exposure time)• Clean pits, pumps, pipes, shakers, brine
and pickle running string & wash-pipe29
Sand Control Best Practices
SPE 73772 An Evaluation for Screen-Only and Gravel-Pack CompletionsSPE 110082 Current State of the Premium Screen Industry: Buyer Beware ….SPE 135294 Comparison of Inflow Performance and Reliability OHGP and OHSAS Completions
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Industry Completion Failure DataData for OH Completions with Stand-Alone Screens
Highest Failure Rate for Major Operator: 15 Failures/19 Wells
Average Failure Rate from Industry Database: 39 Failures/110 Wells
Lowest Failure Rate of Major Operators: 4 Failures/71 Wells
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