AN ASSESSMENT OF GRAVEL PACKING METHODS USED IN THE PETROLEUM INDUSTRY

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AN ASSESSMENT OF GRAVEL PACKING METHODS USED IN THE PETROLEUM INDUSTRY

CHAPTER ONE

INTRODUCTION

1.1 EXTENT OF SAND PRODUCTION

Sand production from oil and gas reservoir will occur when the stresses in the formation rock exceed the mechanical strength of the rock material. This can happen in both unconsolidated and, apparently competent classic reservoirs due to a combination of: – high draw down, depletion, changes in near wellbore composition and cyclic loading of the wellbore.

This section briefly reviews the overall extent of the sand control problem and outlines the need for sand exclusion and the loss in productivity resulting from sand control methods. it further stresses the economic implication of sand control in terms of increased capital and operating cost and the need for a multi-disciplinary approach.

1.1.1 THE NEED FOR SAND CONTROL

Sand production can cause a variety of problems with numerous technical, operational and economic implications .for example, sand exclusion, be it remedial or preventive may be required to

(a) Ensure the integrity of the production system and minimize facility downtime-resulting from equipment failure (e.g. artificial lift)

(b) Avoid sand failure which may lead to formation impairment, downhole communication, buckling or collapses of production casing

1.2 COST OF SAND CONTROL

In functional terms the magnitude of the problem is best illustrated by considering that the average reported completion efficiency from gravel packed wells is seldom greater than 40% and is often significantly lower. This however, is only part of the problem. Severe zone impairment can lead to the requirement to drill more wells and build more process and oil gathering systems with obvious effect on unit technical cost, project cash flow and HSE aspect (health safety environment). Less tangible potentially equally important factors should be considered. For example, improved completion practices may lead to higher system pressure and deferment of lift facilities hence reduced capex and lower abandonment pressures giving higher recovery factors; all with a clear impact on development costs.

1.3 INSTALLATION OF SAND CONTROL SYSTEMS

Following the final decision on whether or not to install sand control is made; relatively detailed completion designs will be complied based on field development plan. These will then form the basis for:

(a) Completion services tender exercises

(b) Material and equipment procurement

1.4 ASSESSMENT CYCLE

1.4.1 PROBLEM IDENTIFICATION

The risk of future sand production through data gathering during exploration well testing and appraisal can be established. This early opportunity should be used to firm up a strategy for the next phase of appraisal well drilling and testing.

1.4.2 PROBLEM QUANTIFICATION

In combination with other major sub-surface uncertainties, rock mechanical modeling should be used to quantify potential sand production problem with respect to the various sub-surface development model. The incremental cost of sand control should be assessed early to allow plans. The main question requiring assessment being: when and where will sand failure occur and further, when applicable: the effect of installation of sand control on well performance highlighting (if any) the incentive for delaying or omitting sand control equipment/ facilities.

The effect of sand control/production on reservoir performance and economic offtake models, for instance the effect of an additional pressure drop on UR and the ability to monitor and manage reservoir offtake.

The effect of sand production on process engineering design and the operations philosophy

1.4.3 INTEGRATION APPROACH

Sand control has in the recent past been divided into three distinct activities

sand influx prediction
sand production detection and monitoring
sand influx prevention

Historically, sand control was seen as a sub-surface to be solved downhole. as a result, sand exclusion was routinely installed where a sand production problem was anticipated.

however, the practical problem facing most oil and gas sectors is how to keep the sand management process active and involved in all relevant engineering functions throughout the life cycle. in order to maintain full integrity of the production system, the group (oil and gas industry) requires the assurance that sand control gets the full attention through appropriate responsibilities and regular review of the sand management process

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