An Advancing Sand Control Chemistry to Increase Maximum Sand ...
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Presented by Martin Grainger
Authors: Nataliya Ludanova, Pratyush Singh, Kern Smith
Weatherford International Inc.
An Advancing Sand Control Chemistry to Increase Maximum Sand Free Rate in Failed Gravel Pack Wells
SPE Sand Management Forum March 2014
© 2009 - 2012 Weatherford. All rights reserved.
Sand Control
1
Sand Control
Re-Active Passive
Mechanical Methods
• Frac packs
• HRWP/HRWF
• Horizontal GP
• Open hole GP
• Expandable screens
• Stand alone screens
Chemical Methods
• Sand consolidation
• Sand conglomeration
– ZPAS
• Other
Mechanical Methods
• Oriented perforating
• Selective perforating
• Controlled drawdown
Pro-Active
© 2009 - 2012 Weatherford. All rights reserved.
What is ZPAS
• Unique and advanced patented chemical solution
• A proactive sand control method
• Alters zeta potential of solid surfaces to the optimum
range of agglomeration
• Disperses and coats sand grains and formation fines
when added to aqueous solutions
• Provides a strengthened attraction between the particles
without causing substantial damage to permeability
2
© 2009 - 2012 Weatherford. All rights reserved.
Zeta Potential – Where do we need to be
Zeta Potential [mV] Stability behavior of the colloid
+3 to -5 Maximum agglomeration
-5 to -10 Strong agglomeration
-10 to -15 Medium to weak agglomeration
-16 to -30 Threshold
-31 to -100 Low to excellent dispersion
-47.85
-1.58
-28.37
1.194
-50
-40
-30
-20
-10
0
10
UntreatedSilica
TreatedSilica
UntreatedCoal
TreatedCoal
Ze
ta P
ote
ntia
l (m
V)
Zeta Potential (mean) before and after SandAid™ treatment
© 2009 - 2012 Weatherford. All rights reserved.
Sand Conglomeration
• Untreated
4
• Treated
© 2009 - 2012 Weatherford. All rights reserved. 5
Blank 40X
Treated 40X
Treated 150X
Sand Conglomeration
© 2009 - 2012 Weatherford. All rights reserved.
Agglomeration Test Result
6
Untreated Sand
Treated Sand
Murky: Sand/ fines dispersed Clear: Sand/Fines settled
• On Inverting Sand will move as plug
• Turbulence will disrupt plug but will
settle again in few minutes
© 2009 - 2012 Weatherford. All rights reserved.
Formation Damage Test Actual field core 3rd Party Lab (Single phase @ 95 0F)
Sand A Sand B K (mD)
Initial 131
K (mD)
returned 143
K (mD)
Initial 442
K (mD)
returned 505
© 2009 - 2012 Weatherford. All rights reserved.
Formation Damage Test Results (Actual Field Core @ 65 deg F)
8
2500.00
2600.00
2700.00
2800.00
2900.00
3000.00
0 100 200 300 400 500 600 700 800
P
e
r
m
e
a
b
i
l
i
t
y
m
D
Flow rate ml/hrs
Permeability of 3% KCl before and after Treatment with 7% ZPAS in 3% KCl (w/ 0.5 % Surfactant) (Sample ID 4)
Initial Permeability Regain Permeability
Initial Permeability = 2657 mD (average)
Final Permeability = 2754 mD (average)
Percent Regain Permeability = 103% (average)
© 2009 - 2012 Weatherford. All rights reserved.
Sand Retention Test
9
• Blank or Untreated Sand Sample were tested – leads to
catastrophic failure.
• Treated Sand sample with ZPAS shows almost negligible
sand production
© 2009 - 2012 Weatherford. All rights reserved.
Application
In existing wells, SandAid technology can be pumped through
current tubular, flow line or coiled tubing.
Service
packer
Well
screens
Zone treated
with ZPAS Perforations
Optional
additional
zones
Production
tubing or
workstring
Zone treated
with ZPAS
Production
tubular or
workstring
Service
packer
Optional
additional
zones
Gravel or Frac
pack treated
with ZPAS
Remedial New Wells and Workovers
© 2009 - 2012 Weatherford. All rights reserved.
Benefits
• No significant reduction in permeability
• Pumped downhole as a matrix treatment – relatively
simple to apply
– Can be mixed in fresh water, brines and seawater
• Compatibility testing may be required
– Fairly long zones can be treated
– Bull head down production tubing, CT and flow lines
• Remains ductile – Adapt to changing reservoir conditions
• Re-agglomerates – Allows to explore MSFR
© 2009 - 2012 Weatherford. All rights reserved.
Current Update
• Around 280+ wells treated to date
• Success ratio: more than 90%
• Maximum Sand Free Rate (MSFR) increased in all
successful wells
• Treatment life > 3 years for some wells
– Longevity varies from few weeks to several years
12
© 2009 - 2012 Weatherford. All rights reserved.
Case History - West Africa
13
FIELD NAME ZATCHI MARINE
WELL NAME ZAM 104 ST (SLOT2)
DATE: Account
SINGLE COMPLETION VERTICAL DEVIATED HORIZONTAL SELECTIVE
ICGP OHGP GRAVEL SIZE: 20/40 40/60
String w eight up [t] Casing Size: [in] Type of packer f luid:
String w eight dow n [t] Top: [m] Bottom: [m] Density: [kg/l]
Make up report yes [y/n]
DRILLING PERIOD
RIG USED
RT/TIE DOWN
WELL HEAD RATING
TOTAL DEPTH SHEAR RELEASE VALUE: -lbs.
TOP CMT PLUG SHEAR RELEASE VALUE: lbs.
BRIDGE PLUG
ANNULUS FLUID
BTM CHECKED ON
GEOG COORD LAT
GEOG COORD LONG Nom. O.D. Thread lb/ft Steel Gr. %
X-MAS TREE
BONNET MAKE UP TORQUE : GREASE :
BACK PRES, VALVE REF Tools
15.40
X/O370m
Thd S. Grade Top (m)
CSG/LIN OD
TOP AT mt
SHOE AT mt
CEM UP mt
LINER HANGER :
LINER HANGER :
LINER HANGER :
CASINGS CHARACTERISTICS
OD NOM
531.23
531.61
Top (mMD) Bottom (mMD)
TYPE OF GUNS :
TYPE OF CHARGE :
SHOOT DENSITY :
Top (m) Bottom (m)
Top (mMD) Bottom (mMD)
TELL TALE SCREEN 4"NU SLOT 8
M-18 COLLET SEAL LOCATOR NOTES : 589.50
Perforated Intervals
586.00 C
Level
Level
583.50
565.50 568.10 C
570.50
F. Pounga.
J. Uwatse / A. Savioli
Superintendant
Rig SupervisorsJOB PURPOSE
542.25
TOP CENTRALIZER. W/ 2-7/8" CS BOX x EUE PIN 2.441 6.496
X-O. SIZE 2-7/8" EUE BOX x 2-3/8" EUE PIN. 1.900 3.362
25
Level
26
4.25
EXTENSION HOUSING
M-21 DOWELL PACKER 7 5/8" 26,4-33#
COLLAR
SEAL HOUSING
5.00
6.53 537.73
538.91
540.27
563.02
544.47
589.32
X-O 4 1/2" NU BOX- 4 NU PIN
SCREENS SLOT 8 W/CENTRALIZERS N° 4 587.50
4.50
2.47
4.50
4.72
LOCATING COLLAR
M-18 SUMP PACKER 3.26 6.31WORKOVER
37
4.44
2.52
2.875
4.50
4.69
2.875
2.312
2.875
4.500
N/A
2.441
2.441
2.441
N/A
3.75
3.7524
17.34
2.875
530.8
154.98
498.68
523.71
516.82
504.62
520.49
516.09
7-5/8"
3708-5/8"
11.000
3.700
2.875
4.000
BTC
ISOLATED INTERVAL
16"
10-3/4" BTC
BTC 195.6
173.8
89
161
396 40.5
Welded
BTC
NA
379.4
1" thick
75
26"
1.900
2.441
17
13
N/A
21
Dow n to
516,09mL-80
1 TBG HGR DP4-H5 2-7/8" EUE TOP x HYD-CS BOTT.
6.5hyd.cs
SIZE
API 5A-2
ID OD
14.00
ESP
I.D. Depth
1.03
Manufact. Model type
0
Eni Congo
24/05/88 - 09/07/88 Nom. O.D.
GENERAL INFORMATIONS
2.400
2
11º25'28",495 - E
4º31'42",704 - S
ADJUSTABLE UNION W/ 2-7/8" HYD-CS PIN x PIN
2,875"
2200 ftlb
WELL HEAD DESCRIPTION
11" x 2-9/16" 3,000-psi Clamped
Size 2½" Type TSB2
2-9/16" x 2-9/16" x 11" 3,000-psi Composed
11" DP4-H5-MS EU UP * VAM DOWN
PRODUCTION CASING
8-5/8"
16 ¾" * 3K Breda Unitized
TUBING HANGER
WHD
Bottom (m)
370
BTC 26.47-5/8"
WELL HEAD
Nom OD lb/ft
BTC 36
TO m
WHD
695
16" 10"3/4
WHD
STEEL
161
24/02/2000
NAVIFOR-2
14
1.03-Kg/lt f iltered Sea-Water
840 - mMDORKB
NA
3,000 - psi w orking pressure
Tubing
COMPLETION STRING
Packer
Filtered Sea-Water
Well deviation [max.]:mMDorkb Well deviation @ BPL depth: -mMDORKB
ARPO 20 / C
695
370
8-5/8" 7-5/8"
WHD
370
lbf/ft
Sea Bed
370
THRD
396
ID mm
15
20
251.3
19
16
26.4
695 14
PKR M 18 DOWELL 773.5
DISCHARGE HEAD W/ 2-3/8" EUE BOX UP.
12 TBG 2 7/8" EU 6,5# L-80 N° 1
9
11
36
4.94
34
33
581.00 C
36
540.67
540.83
5.00
3.81
14.19
151.815.000
2.441
2.441
2.875
2.875
2.441
2.875
148.94
2.441
516.47
506.53
PUP JOINT 2 7/8" HYD.CS 153.03
501.63
2.875
18
6.496
2.362
7
PUP JOINT 2 7/8" HYD.CS
DPGTA - DB. CARRIER MANDREL.10
8 TBG 2 7/8" HYD. CS 6,5# L-80 N° 36
PUP JOINT 2 7/8" HYD.CS
GAS SEPARATOR: FRSTZ H6 FER B AR.
516.974.000
587.69
521.85
542.52
GRAVEL PACK ASSEMBLY
23
22
562.86
542.05
543.94
542.72
4.000
4.000
4.50
4.88
4.60
3.50
31
32
5.00
SAFETY SHEAR COLLAR
30
LOCATING COLLAR
4.00
3.50 5.0029
EXTENSION HOUSING 3.81
35 O-RING SEAL SUB 4" NU
3.50
3.18
4.72
27
28
2.441
PUMP: 400PMSND H6 STD PNT. TYPE 104 P12. N/A
3
4.00
SEAL SECTION: FSB3DB FER HL AB/AB H6PF N/A
2.441
3.50
MOTOR: FMH-A 85HP/ 1078V/ 54A/ 50HZ.
PORTED HOUSING W/CLOSING SLEEVE
3.56
N/A
COMPLETION STRING BOTTOM.
LOCATOR EXTENSION
BLANK PIPES W/CENTALIZERS
3.81
29 July 2008
BOTTOM CENTRALIZER
LK-5 INJECTION VALVE
PUP JOINT 2 7/8" HYD.CS
4 TBG 2 7/8" HYD. CS 6,5# L-80 N°14
5 PUP JOINT 2 7/8" HYD.CS
SAFETY VALVE. BAKER TME-5.6
COMPLETION SKETCH
Offshore CHGP ESP completion
• K = 2000 md
• Φ = 30%
• BHT = 104°F
• Workover in July 2008, increasing
levels of sand
• Well shut in Oct 2008
Worked over Dec 2010
• Sand cleanout and ZPAS job
• Positive response ~120 days prod
• Post Production reached 950 BOPD
(compared to 63 BOPD)
• ZERO Sand
• 3 failed GP wells treated with 100%
successful results
© 2009 - 2012 Weatherford. All rights reserved.
Case History - GOM
14
Offshore CHGP completion
• K = 1000 md
• Φ = 30%
• BHT = 157°F
• Net perfs = 25 ft
• Initial completion in 2004
• Well shut in due to sand
production
• Two GP zones are shut in
Worked over in March 2011
• 1st trial well for this customer
• Was tested to fail
• After success is proved, the
customer used ZPAS in other
wells in different regions
© 2009 - 2012 Weatherford. All rights reserved.
Case History - GOM
15
Offshore CHGP completion
• K = 200 md
• Φ = 27%
• BHT = 170°F
• Net perfs = 70 ft
• Early 2012 initial GP completion
• Well shut in due to excessive
sand production within few
weeks of initial completion
Worked over in May 2013
• Sand cleanout and ZPAS job
• Post Production reached 300
BPD
• ZERO Sand Presence
• Eliminating the need of
expensive re-completion
© 2009 - 2012 Weatherford. All rights reserved.
Case History - South America
16
CHGP + ZPAS completion
• K = 1060 md
• Φ = 24%
• BHT = 191 F
• Perforation = 6 ft
• Oil Well
• Fines Production was
observed
• Sand cleanout and ZPAS
treatment
• 2 wells were treated after GP
failure (fines production)
• 20 wells treated in 2013 using
ZPAS + GP as a preventative
measure
• All jobs are producing at
increased MSFR
© 2009 - 2012 Weatherford. All rights reserved.
Case History – Egypt
• Offshore Completion – Cased &
Perforated
• Gas Well
• PLT run and Isolated water
producing zone
• Kliquid = 45 md
• Φ = 18%
• BHT = 275 F
• Net Perforations = 90 ft
(Gross Interval = 174 ft)
• Worked over April 2013
• Sand cleanout and Tagged TOS
• SRT & Placement analysis
conducted
• SandAid treatment (followed by 16
hrs shut-in)
• Positive well response ~ 8 months
production
• Increased MSFR by almost 70%
17
© 2009 - 2012 Weatherford. All rights reserved.
Conclusions
• Zeta Potential Altering Technology, provides an advanced chemical
method that reliably increases the Maximum Sand Free Rate
– MSFR is increased in (almost) all wells
– Fines production is eliminated or significantly reduced
• Internal and external laboratory testing confirmed:
– No significant reduction in permeability
– Increase in Sand Free rate
• Easy to apply
– Most jobs can simply be bullheaded down the production tubing or work
string
– Allows for long intervals to be treated.
– Can be used to repair existing and/or failed mechanical sand control
methods, such as gravel pack, sand screens, etc.
19
© 2009 - 2012 Weatherford. All rights reserved. 20
Thank you - Any questions?
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