SPE DISTINGUISHED LECTURER · PDF file2006-2007 SPE DISTINGUISHED LECTURER SERIES 3 OVER VIEW...

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SPE DISTINGUISHED LECTURER SERIESis funded principally through a grant of the

SPE FOUNDATION

The Society gratefully acknowledges those companies that support the program by allowing their professionals to

participate as Lecturers.

And special thanks to The American Institute of Mining, Metallurgical, and Petroleum Engineers (AIME) for their

contribution to the program.

Society of Petroleum EngineersDistinguished Lecturer 2006-07 Lecture Season

Challenges on Sand Control and Completions for Productivity in

Ultra-Deep Waters

Luis C. B. Bianco, Ph.D.Senior Petroleum Engineer

PETROBRAS

2006-2007 SPE DISTINGUISHED LECTURER SERIES 3

OVER VIEW

• Reservoir Conditions at Ultra-Deep Waters

• Challenges in Drilling & Completion

• Completion for Productivity

• Sand Control for Deepwater Viscous Oil

• Conclusion Remarks

0 20 40 60 km

Cabo Frio

Campos

Rio de Janeiro

Macaé

400 m400 m400 m

1.000 m1.000 m1.000 m

2.000 m2.000 m2.000 m

RoncadorRoncador

Albacora lesteAlbacora leste

MarlimMarlim SulSul

MarlimMarlim LesteLesteBarracudaBarracuda

CaratingaCaratinga

Ultra-Deep Waters - Campos Basin

Reservoir Conditions at Ultra-Deep Waters

• Deep and ultra-deep waters > 1500 m• Shallow burial sediments < 1000 m• Fracture gradient < 0,57 psi/ft• Temperatures 25 – 60 °C• Viscosities >20 cP

Source: SPE 98342

Reservoir Conditions at Ultra-Deep Waters

GASOILWater

• Turbidite reservoirs: internal sub-seismic complexity• Non-consolidated sands: non cemented sands• Median to Fine sands: non uniform, high fines content• High porosity and permeability

Economics X Technology

191 10 100 1,000

VOIP (Milhões de m3)

Non-economic

Technology Dependent

Feasible

Challenges in Drilling & Completion

• Geological uncertainties• Narrow operational window for drilling

Low absorption pressureElevated pore pressure

• Presence of reactive shalesNeeds high performance drilling & completion fluids

• Special wells requiredImproves reservoir drainageCompensates low oil mobility

Challenges in Drilling & Completion

• Mandatory sand control• Effective control on water injection and

productionNeeds zonal isolation

• Completion reliability and intervention requirements

Offshore submarine operations

• Cold sea bed waters → hydrates, thermal fractures for injectors, etc...

Collapsed ESP intake retrieved from the well

Completion for Productivity

• Project considerations for Productivity

Well Geometry Selection

Oil Production Influx Profile

Sand Control System Selection

Control on Water Production and Injection

Oil Lifting or Sand Control?

Source: SPE 87966

Fishbone multi-laterals

Horizontal multi-fractured wells

Source: Schlumberger

Source: SPE 26796

Single horizontal well with zonal isolation

Well Segmentation ConceptIn

Original influx profile

Optimized influx profile

Improved sand screens Annular Barrier

Influx control devices into the sand screens

Source: SPE 98342

Oil Production Influx Profile

Sand Control System Selection

• What are the limits for each sand control method?

Installationoperation

• What are the implications if some fine sand production is permitted?

Flow linesSurface equipmentsSand handling and disposal

Control on Water Production and Injection

• How can well productivity be jeopardized due to the early water breakthrough with fines migration?

• How can water injectivity be maximized?

Oil Lifting or Sand Control?

• Which system will set the rules for the well completion design: sand control or lifting?

Improvements on well construction

• Extensive use of geo-steering technology• Single-fluid well construction technology

Minimization of the fluid damage

• Sand control systemDelivering low pressure drop through the screen

• Water injection maximization Well segmentation concept

• Artificial lifting system tolerant to larger amount of fines (bellow 70 micrometers)

Fluid damage removal and return of permeability

• Drilling stability and completion efficiencyHighly inhibited drilling fluids Low invasion profileEfficient mud cake easy to remove

Well simulator

Damage removal and return of permeability

Radial Flow Test Cell Mud cake efficiencyDamage due to filtrationMud cake removalFines migrationPlugging effects

Formation sand

Gravel

Source: SPE 95025

Drill-in Fluid Invasion - bridging agent and polymers

Source: SPE 95025

DamageDamageZoneZone

UndamageUndamageZoneZone

ZoomZoom

Source: SPE 95025

,1 1818

,1 2727

0,00E+00

2,00E-04

4,00E-04

6,00E-04

8,00E-04

1,00E-03

1,20E-03

Depht of invasion (mm)

Drill-in Fluid (Marked polymer and CaCO3)Bottom

IodineCalcium

Invasion profileInvasion profile

2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 51 0 0

Z nC u

E n e rg y (k e V )

T y p ic a l s p e c tru m fo r T y p ic a l s p e c tru m fo r u n c o s o lid a te du n c o s o lid a te d s a n d s to n e s a n d s to n e

2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 51 0 0

Z nC u

E n e rg y (k e V )

T y p ic a l s p e c tru m fo r T y p ic a l s p e c tru m fo r u n c o s o lid a te du n c o s o lid a te d s a n d s to n e s a n d s to n e

Sand Control for Deepwater Viscous Oil

• Horizontal Open Hole Gravel PackMost used sand control method

• Stand Alone ScreensWire WrappedMeshed (single or multilayer) Expandable

• Frac & PackNot used above 60 degree

• Open Hole Gravel PackCarrier fluid compatible with the mud cakePressure at the casing shoe limited by the frac pressureLight propantGravel impairment

• Stand Alone and Expandable Screens Screen performance testso Coupon Testso Tangential testso Full scale tests

Packer

FlapperLocator

Blank pipeScreen

Perforated extension

Seal bore sub

Carrier Fluid Circulation

Work String

Completion Fluid

Packer

FlapperLocator

Blank pipeScreen

Perforated extension

Seal bore sub

Carrier Fluid Circulation

Work String

Completion Fluid

Horizontal Open Hole Gravel Pack

Gravel Pack Impairment Test

Some Results

0 1000 2000 3000 4000 5000t (min)

GS 7,2GS 8,0GS 9,6GS 10,1GS 5,82

0 500 1000 1500 2000 2500 3000 3500 4000t (min)

GS 6,6GS 7,3GS 8,7GS 9,2GS 5,31

Sand 12/20Ceramic 16/20

Screen Performance tests

Coupon Test

Source: SPE 98342

Selecting the weave apertures

• Slurry test• Conformance test

Results for the Coupon test

Pre-Expansion - Time vs PressureOld & New PFM125 Screen

KCl & Oil Conformance Tests - Sand put on top of screen with flow rate @100mls/min

0,01 0,1 1 10 100Time (mins)

Old, KCl ConformanceNew, KCl ConformanceOld, Oil Conformance (R)New, Oil ConformanceNew, Oil Conformance (R)

Pre-Expansion - Time vs PressureOld & New PFM125 Screen

Viscous Oil Slurry Test - Sand agitated in Oil

0,01 0,1 1 10 100Time (mins)

Old, 100mls Oil SlurryOld, 100mls Oil Slurry (R)Old, 200mls Oil SlurryNew, 100mls Oil SlurryNew, 100mls Oil Slurry (R)New, 200mls Oil Slurry

Source: SPE 98342

Transversal Flow Test

Outlet Flow&Transducer Port

Inlet Flow &Transducer Port

Source: SPE 98342

Results for the Tangential Flow Test

Source: SPE 98342

OLD PMF125 Filtration layer on top NEW PMF125

Baseline

Time vs Pressure

0 5 10 15 20 25 30

Time (min)

250cp Mineral Oil with 0.25% Min- U- Sil 30 (<30 µm Fine Silica) @ 10mls/minConductivity Cell & Load Press @1000psi

Full Scale Test

Viscosity Effect on Flow Pressure Drop through a Premium Screen

0,0 0,5 1,0 1,5 2,0 2,5 3,0 3,5Flow Rate (liters/min)

946100232270

VISCOSITIES (cP) Multilayer Premium Screennominal openning size: 175 µm3 ft long

Results for the Full Scale Test

Hydraulic Conductance and ConductivityOLD and NEW PMF125 expandable screen, 22% Expanded

0 50 100 150 200 250 300 350 400

Time (min)

Conductance OLDConductance NEWConductivity OLDConductivity NEWMass of solids OLDMass of solids NEW

initial bridging

plugging process

invasion process

1. Slurry test screen conductanceHow easily oil flows along a certain path through a porous material

2. Conformance test sand pack conductivity

How well a porous material accommodates the flux of oil

PQG∆

RsRacLn

lGK 34.15

Seepage forces due to flow leads to increase confining pressure at the sand pack reducing the permeability of the sand layer on the screen surface

from Johan Tronvall

Compaction Induced by fluid flow

Weave surface at the shroud side and internaly (10X)

Cell breakdown

Cut screen after test

Screen envelop

Basepipe

Screen Removed from Well

Shroud cut and openned

Conclusion Remarks

• Improvements on the performance of horizontal wells come from proper well design and completion practices. They also depend on understanding the influence and effects of each productivity factor.

• Where traditional completion solutions have not given good results, special or "designed for" solutions need to be conceived, tested and applied.

Conclusion Remarks

• Viscous Oil exploitation in offshore ultra-deep waters is a challenge that can change the way well construction is done.

• Well geometry, water production control and oil influx profile have high influence on productivity.

• Drilling fluid compatibility, mud cake removal and return of permeability can impact the efficiency of completion.

Conclusion Remarks

• Screen performance is highly affected by its construction, particles size distribution, amount of migrating fines produced and oil viscosity.

Thank you for your attention!

Questions?

SPE DISTINGUISHED LECTURER · PDF file2006-2007 SPE DISTINGUISHED LECTURER SERIES 3 OVER VIEW...

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