Multi Zone Single Trip Gravel Pack System Deployed on Hydraulic Workover Unit: Holistic Approach to Optimize Drilling and Completion Cost in the Mahakam Delta

2020 ◽  
Author(s):  
M., I. Maharanoe
Keyword(s):  
Cost Saving ◽  
Safety Issue ◽  
Holistic Approach ◽  
Driving Factor ◽  
Sand Production ◽  
New Frontier ◽  
Mahakam Delta ◽  
Gravel Pack ◽  
Jack Up ◽  
Shallow Reservoirs

The Multi Zone Single Trip Gravel Pack (MZSTGP) system has been proven as the main solution for developing shallow reservoirs and overcoming sand production issues in marginal sand prone wells in the Mahakam Delta, Indonesia. Robust operating procedures and completion equipments have been developed to assure safe and efficient operations through conventional swamp or jack up rig operations since 2006. Due to marginal reserves being available and the high cost of conventional rig utilization to perform MZSTGP completion, Pertamina Hulu Mahakam initiated completion of the well using a rigless technique to install gravel pack completion with Hydraulic Workover Unit (HWU). This alternative solution is the main driving factor as a new frontier of MZSTGP rigless operation and enables the delivery of typical marginal wells economically at the Mahakam Delta swamp area. This has resulted in potential significant well cost saving up to 37% compared to conventional rig cost, or approximately equivalent to half a million USD along the completion phase. Post rigless gravel pack operation, production stabilized at expected rate and the well has no restrictions to keep producing at this rate or even higher. This new frontier solution of MZSTP rigless operation can be considered as the first successful rigless 7” MZSTGP installation at swamp areas worldwide with no NPT and safety issue.

Evaluation of Latest Technological Advances in Sand Control Completions: A Case Study

2021 ◽  
Author(s):  
Rishabh Bharadwaj ◽  
Manish Kumar ◽  
Shashwat Harsh ◽  
Deepak Mishra
Keyword(s):  
Oil And Gas ◽  
Control Method ◽  
Control Mechanisms ◽  
Sand Production ◽  
Production Rates ◽  
Reservoir Properties ◽  
Water Contact ◽  
Technological Advances ◽  
Sand Control ◽  
Gravel Pack

Abstract Sand control poses huge financial loses during production operations particularly in mature fields. It hinders economic oil production rates as well as damages downhole and surface equipment due to its abrasive action. Excessive sand production rates can plug the wellhead, flow lines, and separators which can result in detrimental well control situations. This paper will provide a comparative study on various sand control mechanisms by reviewing the latest advancements in sand management techniques. This study evaluates the performance of through-tubing sand screens, internal gravel pack, cased hole expandable sand screen, modular gravel pack system, openhole standalone screen, multi-zone single trip gravel pack, slim gravel pack, and chemical sand consolidation mechanisms. Various field examples from Niger-Delta, Mahakam oil and gas block, and offshore Malaysia are examined to gain an insight about the application of aforementioned sand control methods for different type of reservoirs. This study enables the operator to tackle the sand production problem according to the well construction changes during the life cycle of a well. The internal gravel pack completion system delivers a prolonged plateau production regime in shallow depths. In high drawdown conditions, chemical sand consolidation completion incurs early water breakthrough and elevated sand production. Chemical sand consolidation technique yields better results in deeper formations and its placement can be improvised by implementing coiled tubing and diversion techniques for multi-stage treatments. Depending on the well inclination, gas-water contact, producing zone type and thickness, well age, and economy, the completion types out of modular gravel pack, openhole standalone screen, slim gravel pack, and through tubing sand screen is recommended accordingly. Acquiring offset data, well log analysis, particle size distribution and performing pressure tests will improve the data quality of the obtained reservoir properties. This will further help in the selection of the most suitable sand control method for the target reservoir.

Imperatives for Implementing Gas-Lifting for Fields with Sand Control: OT Field Experience

2021 ◽  
Author(s):  
Kingsley Iheajemu ◽  
Erasmus Nnanna ◽  
Somtochukwu Odumodu
Keyword(s):  
Control Mechanism ◽  
The Other ◽  
Control Mechanisms ◽  
Sand Production ◽  
Stable Production ◽  
Sand Control ◽  
Open Hole ◽  
Gravel Pack ◽  
Production Problems ◽  
Gas Lift

Abstract Unconsolidated sandstone formations are normally completed with one form of sand control or the other. The aim is to manage sand production as low as reasonably practicable and protect well and surface equipment from possible loss of containment. There are about 8 broad types of sand control namely; internal gravel pack, external gravel pack, chemical sand consolidation (SCON), open-hole expandable sand screen, cased-hole expandable sand screen, stand-alone screen, pre-packed screen and frac & pack. Gas-lifting targets to increase pressure drawdown required for wells to produce by injecting gas at a pre-determined depth using gas-lift valves installed in the tubing. Whereas gas-lift design targets to optimize the gas-lift injection to ensure stable production, the associated drawdown may challenge the operating envelope of the sand control mechanism in place. The OT field has been in production for about 50 years and has been on gas-lift for about 20 years. There have also been occasional sand production problems in the field; some of which occur in gas-lifted wells. This paper will highlight the outcome of a study that investigated the performance of various sand control mechanisms under gas-lift production and present observed trends to serve as guide in maximizing the performance of such gas-lifted wells with sand control mechanism.

Extending Gravel Pack Carrier Fluid Performance in Highly Deviated Well for 7-Inch Gravel Pack Completion without Shunt Tube by Using High Grade Suspension Gravel Pack Fluid in Mahakam Offshore

2021 ◽  
Author(s):  
Putu Yudis ◽  
Doffie Cahyanto Santoso ◽  
Edo Tanujaya ◽  
Kristoforus Widyas Tokoh ◽  
Rahmat Sinaga ◽  
...  
Keyword(s):  
Control Method ◽  
Oil And Gas Industry ◽  
High Rate ◽  
Control Treatment ◽  
High Grade ◽  
Sand Production ◽  
Worst Case ◽  
Carrier Fluid ◽  
Sand Control ◽  
Gravel Pack

Abstract In unconsolidated sand reservoirs, proper sand control completion methods are necessary to help prevent reservoir sand production. Failure due to sand production from surface equipment damage to downhole equipment failures which can ultimately result in loss of well integrity and worst-case catastrophic failure. Gravel Packing is currently the most widely used sand control method for controlling sand production in the oil and gas industry to deliver a proppant filter in the annular space between an unconsolidated formation and a centralized integrated screen in front of target zones. Additional mechanical skin and proper proppant packing downhole are the most critical objective when implementing gravel packs as part of a completion operation. This paper presents a case history of Well SX that was designed as single-trip multi-zone completion 7-inch casing, S-shape well type, having 86 deg inclination along 1300 meters, 4 to 5-meter perforation range interval and 54 deg inclination in front of the reservoir with total depth of 3800 mMD. The well consists of 4 zones of interest which had previously been treated with a two-trip gravel pack system. While Well NX was designed as single-trip multi-zone completion in 7-inch casing, J-shape well type, 8-meter perforation interval and 84 deg inclination in front of the reservoir with total depth of 3300 mMD. The well consists of two zones of interest which had previously been treated with a single-trip gravel pack system. Both wells are in the Sisi-Nubi field offshore Mahakam on East Kalimantan Province of Borneo, Indonesia. This paper discusses the downhole completion design and operation as well as the changes to the gravel pack carrier which overcame challenges such as high friction in the 7" lower completion and the potential for an improper annular gravel pack due to the lack of shunt tubes in a highly deviated wellbore. In vertical wellbores, obtaining a complete annular pack is relatively easy to accomplish but in highly deviated wellbores, the annular gravel pack is more difficult to achieve and can contribute additional skin. Tibbles at al (2007) noted that installing a conventional gravel pack could result in skin values of 40 to 50, mostly due to poor proppant packing in perforation tunnels. Therefore, operator required to find a reliable gravel pack carrier fluid optimization for typical highly deviated wells to overcome the potential sand production issues by applying a single-trip multi-zone sand control system across both zones (without shunt tubes) along with the utilization of a high-grade xanthan biopolymer gravel pack carrier fluid. Laboratory testing was conducted to ensure that the gravel pack fluid could transport the sand to the sand control completion, large enough to allow for a complete annular pack and still allow the excess slurry to be circulated out of the hole. Electronic gravel pack simulations were performed to ensure that rate/pressure/sand concentration would allow for a complete gravel pack. All four zones in Both of Well SX and NX were successfully gravel packed with a high rate, relatively high sand concentration slurry. The well has not exhibited any sand production issues to date. The current production from both wells is above expectation and are comingled from the two primary zones. Multiple factors were considered during the design and operation of the sand control treatment. Those factors will be described in this paper, starting with candidate selection, completion strategy, operational challenges and treatment execution along with production monitoring of the well.

Unlocking the True Value of Permanent Acoustic Sensors via Integration in a Digital Field as a Proactive Method of Sand Monitoring in Gas Wells

2021 ◽  
Author(s):  
Qi Zheng Lee ◽  
Wei Jian Yeap ◽  
Sulaiman Sidek ◽  
Hazrina Abdul Rahman ◽  
Sarran Raj Kunasekaran ◽  
...  
Keyword(s):  
Real Time ◽  
Cost Benefit Analysis ◽  
Cost Benefit ◽  
Holistic Approach ◽  
Field Monitoring ◽  
Acoustic Sensors ◽  
Sand Production ◽  
Gas Wells ◽  
Cascading Effects ◽  
True Value

Abstract Sand production is one of the operators’ intimidating challenges as the cascading effects can cause significant damages to the surface equipment and often lead to costly clean-up effort. Its effects are further amplified in gas wells with higher gas velocities lead to more detrimental effects on the facilities. Consequently, the facilities will deteriorate, leading to uncontrolled hydrocarbon release which compromise the operation safety considerably. Hence, sand detection devices such as acoustic sensors are extremely crucial to detect sand production as early as possible prior to any undesirable damage. This paper highlights the selection reasoning and advantages of permanent acoustic sensors as well as the method in maximizing the data value through integration with digital field monitoring. Various sand monitoring equipment are available in the industry and its selection is mainly driven by operators’ purpose with cost-benefit analysis. The multi-disciplinary team collaboratively decided on a holistic approach of utilizing the permanent acoustic sensors to its maximum potential. Integration of permanent acoustic sensors with digital field monitoring further improves the investment return as the sensors can provide real-time sand production data. Effective real time sand monitoring can be performed by both offshore and onshore crews where immediate countermeasure can be deployed if abnormal readings detected. When handling sand prone wells, proactive measures have been proven to be more effective if compared to reactive measures. Each well production potential can be maximized by installing sand sensors to ensure safe operating envelope without sand production as well as to trigger alarm if sand detected. The key to unlocking the potential is to ensure data is effectively transmitted to the command center and to the office via our digital field system. The operators are also trained on the next course of action such as beaning down the wells to safe operational envelope in case of sand breakthrough. The value of the acoustic sensors outweighs the total cost involved as real-time sand monitoring system helps to safeguard surface facility integrity considerably.

Integrated Reservoir Management Strategy in Sisi Nubi Mature Gas Field to Unlock Reserves and Production Optimization

2020 ◽  
Author(s):  
R. M. P. Azhar
Keyword(s):  
Management Strategy ◽  
Reservoir Management ◽  
Production Optimization ◽  
Difficulty Level ◽  
Driving Mechanism ◽  
Gas Field ◽  
Technical Limitation ◽  
Well Completion ◽  
Mahakam Delta ◽  
Gravel Pack

Sisi and Nubi are two gas fields located in the Mahakam Delta, 25 km offshore the modern Mahakam Delta to the east, in 60-80m of water depth. Sisi was discovered in 1986 and Nubi in 1992. The fields have been in production since November 2007 from 5 wellhead platforms. Peak production reached 450 MMscfd in 2010, and by the end of 2019 the average production is 150 MMscfd with cumulative production around 1.28 Tcf of gas and 31.3 MMstb of condensate. Having gravel pack and tubingless as well completion in Sisi Nubi leads to several limitations such as some reservoirs were not perforated due to Gravel Pack (GP) technical limitation or are not accessible due to some restrictions such as bridge plug and sediment. Building a simple yet vivid and properly integrated reservoir management strategy was done to tackle the aforementioned issue. The work was to map the remaining potential as well as production risk of both perforated and unperforated reservoirs and to develop the integrated production and development strategy for Sisi Nubi’s optimum’s production and recovery. The works involved multi entities; geoscientists, reservoir engineers, well intervention, and also the well performance team. Up to 2000 meters of unperforated reservoirs within 664 intervals, have been thoroughly studied, covering detailed geological correlation at reservoir scale, initial and current fluid status, driving mechanism, current pressure estimation, and reservoir-level volumetric calculation. Well obstacle classification based on the difficulty level to re-access perforation targets as a well strategy to produce reservoirs were performed in joint coordination with the well intervention team. The final deliverables are selected candidates that qualified both technical criteria and stakes were proposed for execution. An increase of Fifty-five (55) Bcf of stated reserves from existing wells have been booked thanks to this work. In addition, having the systematic strategy allows optimum offshore intervention barge planning.

Hanging Screen Evaluation to Unlock Marginal Sandy Reservoir: Case Study of Peciko Gas Field, Indonesia

2021 ◽  
Author(s):  
Danny Hidayat ◽  
Rantoe Marindha ◽  
Triantoro Ade Nugroho ◽  
Reyhan Hidayat ◽  
Runi Kusumaning Rusdi
Keyword(s):  
Control Method ◽  
Low Cost ◽  
Sand Production ◽  
Liquid Loading ◽  
Control Cost ◽  
Gas Field ◽  
Production Phase ◽  
Sand Control ◽  
And Performance ◽  
Shallow Reservoirs

Abstract Peciko Field currently produces gas from multilayer sand-prone shallow reservoirs. Therefore, it needs sand control method to unlock these marginal reservoirs through low-cost intervention. Hanging screen has been reviewed as an alternative solution to minimize sand control cost while maintaining its robustness to maximize the recovery. This paper will present and evaluate the hanging screen installation and performance from subsurface to surface elements in Peciko field. Hanging screen implementation in Peciko will be evaluated in terms of ease of installation to its performance during production phase. Peciko wells are equipped with real-time monitoring system including Acoustic Sand Detector. Therefore, sand problems could be easily identified. Any indication of screen failure will be confirmed by checking the surface equipment like chokes and intrusive probes. Further intervention to retrieve the screen and perform visual check at surface can be executed to extend the verification. Filter size, placement method, clean-up, and sand sieve result will be gathered to identify the root cause and determine the best method to apply hanging screen as reliable sand control method. Nine installations in 2019 conclude that screen plugging, liquid loading, and combination of both are main issues in production phase. With three plugging cases from well Fx and E2x, it was found that excessive drawdown pressure triggers high gas velocity in perforation tunnel and causing excessive sand production that plugged the screen. These cases also prove that self-unloading by choke movement can lead to plugging if the drawdown pressure and gas rate are not monitored carefully. Commingle production in Ax becomes an issue in lifting performance when reservoir pressure declines and liquid was produced from several reservoirs. Limiting drawdown pressure gives smaller gas rate to lift the liquid and make the well died from liquid loading easily. Massive sand production in well E2x and E2y cause an increase in Top of Sediment (TOS) and lead to inaccessible screen even with multiple bailing attempts. A series of screen design, choke configuration, proper clean-up and continuous monitoring are critical steps to be performed prior and after screen installation to maintain production lifetime. With average stakes of 0.2 Bcf per well, hanging screen has proven to produce 67% of the well reserves in shallow reservoirs. This value creation led to the conclusion that hanging screen is an economically-feasible-sand control method to be implemented in Peciko.

Comprehensive Transient Modeling of Sand Production in Horizontal Wellbores

SPE Journal ◽  
2007 ◽  
Vol 12 (04) ◽  
pp. 468-474 ◽  
Author(s):  
Alireza Nouri ◽  
Hans H. Vaziri ◽  
Hadi Arbi Belhaj ◽  
M. Rafiqul Islam
Keyword(s):  
Numerical Model ◽  
Significant Proportion ◽  
Horizontal Wells ◽  
Gas Production ◽  
Operating Conditions ◽  
High Rate ◽  
Sand Production ◽  
Predictive Tool ◽  
Sand Control ◽  
Gravel Pack

Summary Installing sand control in long horizontal wells is difficult and particularly challenging in offshore fields. It is, therefore, imperative to make decisions with regard to the most optimum completion type objectively and based on reliable assessment of the sanding potential and its severity over the life of the well for the intended production target. This paper introduces a predictive tool that forecasts not only the initiation of sanding, but also its rate and severity in real time. A series of well-documented experiments on a large-size horizontal wellbore was simulated using a finite difference numerical model. The model accounts for the interaction between fluid flow and mechanical deformation of the medium, capturing various mechanisms of failure. The model allows capturing the episodic nature of sanding and the resulting changes in the geometry and formation consistency and behavior within the sand impacted regions. Sand detachment is simulated by removal of the elements that are deemed to have satisfied the criteria for sanding based on considerations of physics, material behaviour and laws of mechanics. The proposed numerical model is designed to account for many of the factors and mechanisms that are known to influence sanding in the field and as such can be used as a practical tool for predicting the frequency and severity of sand bursts and changes in operating conditions that can be considered for mitigating or managing such problems. The model shows reasonable agreement with the experimental results in terms of borehole deformation and sanding rates. The model correctly predicted initiation of shear failure from the sides of the borehole and its propagation to the boundaries of the sample. It was further seen that the propagation of the shear failed zone resulting from sand production agreed well with the numerical pattern of failure growth upon removal of elements satisfying the sanding criteria. The approach and concepts used are considered suitable for application to field problems involving horizontal wells. Introduction A significant proportion of the future oil and gas production is expected to come from sand-prone reservoirs, many of which are offshore. While these reservoirs are highly prolific they are complex to develop and manage. Typical cost of completing a major offshore well exceeds $100 million and these wells are expected to remain productive for 20 years and longer. The control of solids production in these high-rate wells over the life of the well is a challenge and requires a good understanding of the mechanical behavior of the formation under a variety of conditions. Various options are available, ranging from placing active sand control, such as gravel pack and frac pack, to natural completion, such as a cased and perforated hole. Objectivity is required in choosing the correct completion type, which must account for the production strategy and natural changes in the reservoir such as changes in the stress state, permeability, and multiphase flow, including water cut. Once the completion type is chosen, it must be operated optimally to maximize production while maintaining efficiency and longevity. For instance, in sand-control completions, operations must be tailored to mitigate generation and transport of fines that can cause plugging of the gravel pack and lead to screen erosion, whereas in natural completions, the emphasis would be in preventing formation sand production or keeping it under the tolerance that can be handled by the facility. Utilization of a reliable sand production prediction tool is essential in selecting the optimum completion technique and optimization of the operational conditions.

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