This paper summarizes a game-changing technology using shape memory polymer (SMP) to provide downhole sand control in openhole environments. An openhole completion maximizes well productivity/injectivity and longevity without the concern of plugging and/or collapsing perforation tunnels that are frequent challenges in cased-hole completions. Conventional openhole sand control techniques include stand-alone-screen (SAS), expandable screens and openhole gravel packing (OHGP). In some cases, the uniformity, size and level of compressive strength of the formation dictate the use of an OHGP completion. This has proven to be a highly effective technique and eliminates the concerns of plugging and erosion associated with a SAS. However, an OHGP is not always feasible and/or practical for some reservoirs and geographic locations. Some of the challenges of OHGP include lack of deck space and equipment, incompatibility with annular zonal isolation tools, difficulty to gravel pack across shale zones, and unavailability of equipment or fluid design to effectively gravel pack extremely long laterals without exceeding reservoir fracture gradient. The SMP technology can fill the gaps that exist with current OHGP techniques. The performance of the SMP centers on its inherent glass transition property. It is run into the wellbore in its compacted state and then activated to expand to the openhole size at the target depth when exposed to a catalyst. Once expanded, the SMP conforms to the sandface including washouts and any irregularities within the SMP expansion limit. It is porous in both compacted and expanded states with permeability of over 30 Darcy after expansion. Its filtration capability is equivalent, if not superior, to that of an OHGP application. In this paper, the SMP’s "engineered" behavior and sand control mechanism will be introduced first, followed by the performance comparison between the SMP and conventional OHGP, activation fluid design and the operational procedures. The last section will be focused on the SMP operating envelopes.

This paper covers the novel application of combining shape memory polymer (SMP) conformable screen with inflow control devices (ICD) to provide operational efficiency, wellbore stability and production enhancement in unconsolidated reservoirs openhole completion. It is not uncommon to have unconsolidated reservoirs with permeability heterogeneity. It becomes more challenging when the formation sands are non-uniform and poorly sorted. The Conventional solution for these type of reservoirs encompasses the use of gravel pack techniques in combination with sand control screens that are equipped with inflow control devices (ICD). However, operational execution is complex and risky especially when openhole isolation packers are added to isolate and compartmentalize the multiple zones. An alternative solution to this challenge is the simplified combination of SMP conformable screen with ICD. An SMP conformable screen with ICD replaces the burdensome gravel pack operation, provides conformable sand control and maximizes the benefits of the already proven inflow control technology. This integrated application brings efficiency to well site operation by reducing the quantity of downhole accessories, reducing rig site operating hours, and saving overall capital expenditures (CAPEX) or operating expenditures (OPEX). The shape memory polymer provides improved wellbore stability and efficient sand control regardless of the uniformity of formation sands in the different reservoir layers. The combination with ICDs will ensure that production longevity and recovery are optimized by efficiently equalizing inflow profiles. Technical contributions which include filtration performances, inflow control modeling and completion fluid management are provided to expatiate on the performance analysis of this innovative approach in resolving a critical challenge in horizontal sand control completions.

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Typical wells in the Filanovskogo field are in a multi-zone reservoir with heterogeneous production flow profiles. The use of inflow control devices (ICD) in conjunction with zonal isolation packers, though successful, continues to evolve to improve overall ICD performance. However, in a contemporary cost-driven oil and gas market, persistent innovation has resulted in ICD performance improvement, and it has introduced changes that yield cost-effective deployment approaches, as evident in this case for Filanovskogo field. This paper details the inherent production challenges posed by the heterogeneity of Filanovskogo reservoir flow profiles. Analysis of the flow profiles facilitated an optimal inflow control modeling that efficiently balanced the production inflow across the various zones and provided means to restrict water inflow selectively. The ICD modeling yielded a solution that assured an improvement in oil recovery from the reservoir. In addition to the sought-after production benefit, the completion design incorporated equipment that collectively reduced operation sequence. The executed completion design features installation of nozzle-type ICDs fitted with premium screens and integral screen isolation valves. An in-depth look into the operational steps is provided, along with a comprehensive review of the technologies that facilitated this streamlined execution. This review includes a technical overview of the integral sliding choke sleeve of the ICD that can be actuated open/close in the future to manage water ingress. The outcome of this completion design is a solution that saves wellsite operating hours, allows execution of multiple steps simultaneously, depicts production flow balance, and ultimately delivers an enhanced oil production lifespan. This completion design has leveraged the successes from industry best practices, particularly in ICD applications, to devise a region-specific solution that is relevant in today's cash-conservative market.