Extending the Performance of Standalone Sand Screens (SAS) with Flow Segmentizers in Gas Wells

Abstract

Sand control application in gas wells is very challenging, especially in the application of a standalone sand screen (SAS) due to the high erosional risks. Many failures have been observed in the industry over the years causing production deferments and additional OPEX to the operators for remedial sand control operations. This work presents the performance evaluation of a unique SAS in open hole completion concept piloted in a horizontal gas well and the replication in other new wells in a Malaysian gas field. In 2012, a pilot gas well was completed with SAS with optimally placed flow segmentizers along the horizontal completion to limit the screen erosional risks. The placement was determined using a tool developed through an R&D. It estimates the optimum locations of the flow segmentizers based on the targeted SAS life or erosional velocity limit imposed. At the heart of it is a proprietary erosion model specifically developed for SAS application. The well performance was compared to adjacent wells producing from the same reservoir but completed using the conventional open-hole gravel pack. The pilot well achieved higher Productivity Index in comparison to the adjacent wells. Over the 10-year observation period, the production performance was consistent with minimal skin values and no sand production issues. Multifinger Imaging Tool (MIT) was run to measure the erosion levels in the tubing and the result indicated very minimal erosion because of sand production even after several years of production. Recently, another one (1) new infill well was drilled and completed with the same concept as the pilot well. The segmentizer placements were supported by an optimization study based on the expected production scenario. Positive flow back results with no indication of sand production was detected from the intrusive sand monitoring equipment. With the application of SAS and flow segmentizers, a cost reduction of 25% as compared to more complex application of open-hole gravel pack was realized.