Ceramic Sand Screens: Qualification Strategy for a High Rate Gas Application

Cadogan, Paul; Hall, S. R.; Jackson, Richard; Meschke, Frank; Read, Trent; Gundemoni, Bhargava Ram; Barth, Peter

doi:10.2118/191931-ms

Cited by 4 publications

(2 citation statements)

References 10 publications

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“…The fluid control continuity equation (eq ) and the momentum equation (eq ) are presented below: 1 ∂ ρ ∂ t + ρ ∂ u j ∂ x j = 0 ∂ u i ∂ t + u j ∂ u i ∂ x j = prefix− 1 ρ ∂ p ∂ x i + v ∂ 2 u i ∂ x j 2 + f i where ρ is the fluid density, kg/m 3 . u i and u j are fluid velocity, m/s.…”

Section: Numerical Simulation Of Erosion In Metal Mesh Screen Pipe Un...mentioning

confidence: 99%

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Erosion Life Prediction of Metal Mesh Screen Pipes in Oil Wells Based on Numerical Simulation of Discrete Particle Flow

Cao,

Wen,

Qiu

et al. 2023

ACS Omega

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High-speed fluid-carried sand particles pose a significant challenge to oil well screen pipes, leading to sand control failure and adversely affecting the well’s production and recovery rates. This research targets the commonly used metal mesh screen pipe in oil well sand production and establishes a full-sized three-dimensional structure model. A fluid–solid coupling of discrete particle flow numerical simulation algorithm is incorporated to formulate a novel method for predicting the screen pipe’s erosion life. This method provides a solution to the complex task of predicting the pipe’s lifespan under oil sand fluid erosion. The analysis elucidates the impact of sand particles on the velocity distribution and erosion rate of the metal mesh at varying velocities, facilitating the prediction of the mesh screen pipe’s erosion life. Key findings reveal that the velocity and erosion rate vary across the different layers. The first layer screen experiences velocity and erosion rates that are 3.6–3.76 times and 2.45–2.50 times, respectively, higher than those at the inlet. The second layer screen undergoes velocity and erosion rates 2.32–2.43 times and 1.04–1.06 times, respectively, higher than those at the inlet. Erosion failure primarily occurs in the first layer screen due to velocity expansion instigated by the screen tube’s structure. The discrete flow numerical simulation method proves valuable in predicting the mesh screen’s erosion life at different flow rates, with a maximum error of 6.38% when compared with field monitoring life values. This method introduces a new technical approach to predicting the life span of metal mesh screens in oil wells. The study concludes by suggesting measures to extend the screen pipe’s lifespan, thereby enhancing oil recovery.

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Section: Numerical Simulation Of Erosion In Metal Mesh Screen Pipe Un...mentioning

confidence: 99%

“…The fluid control continuity equation ( eq 1 ) and the momentum equation ( eq 2 ) are presented below: 10 where ρ is the fluid density, kg/m 3 . u i and u j are fluid velocity, m/s.…”

Section: Numerical Simulation Of Erosion In Metal Mesh Screen Pipe Un...mentioning

confidence: 99%

Erosion Life Prediction of Metal Mesh Screen Pipes in Oil Wells Based on Numerical Simulation of Discrete Particle Flow

Cao,

Wen,

Qiu

et al. 2023

ACS Omega

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Development of Plasma Sprayed Coatings to Improve the Erosion Resistance of Wire Wrapped Screens

Ochmann

Amro

Gronde

et al. 2021

Day 1 Tue, March 23, 2021

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The installation of sand screens in wells can fail in one of two ways: by causing an unacceptable high pressure drop in the near wellbore area or by losing the ability to retain particles. Four mechanisms can lead to a failure: plugging, corrosion, erosion and mechanical deformation. To increase the lifetime under erosive conditions, a coating for wire wrapped screens was developed and tested. Erosion occurs, when formation particles hit the screen surface with high velocities or by continuous production of fines through the screen openings. The screen openings must keep a specified size in order to control the formation sand or gravel pack. If the opening size increases due to erosion, more particles are produced and erosion increases. A newly developed coating is put on the outside (i.e. facing the formation) of standard wire wrapped screens to make the slots resistant against erosion. The coating consists of ceramic or hard metal and is applied by plasma spraying. An extensive development and verification program was conducted to guarantee defined slot widths, corrosion resistance and mechanical strength of coating and screen. A test facility was built to investigate the erosion resistance of sand screens. It consists of a flow loop to circulate a slurry of water and particles through 2″ coupons. Samples of standard wire wrapped, metal mesh and coated screens were tested. The tests were conducted with flow velocities of up to 18.5 m/s and particles of up to 100 micrometer for up to 60 h. The screens where compared under consideration of optical criteria, mass loss and functionality. The coated screens showed no sign of wear on the outside and kept their initial slot size. The slots of uncoated wire wrapped screens more than doubled in some places, when eroded under the same conditions. To test the functionality of the samples, sand retention tests were conducted before and after erosion. Since there were no changes in slot width, the coated screens show the same retention capabilities before and after erosion, while metal mesh screens that were eroded under the same conditions lost their ability to retain sand. The newly developed coating improves the resistance against erosion, is able to withstand corrosive well environments and has mechanical properties suitable to be safely installed in any well. Therefore the coating has the ability to improve the lifetime of screens under erosive conditions.

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First Successful Installation of Through-Tubing Ceramic Sand Screen in Seligi Oil Field, Offshore Peninsular Malaysia

Kadir

Rusli

Samsudin

et al. 2021

Day 1 Tue, March 23, 2021

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The Seligi field, located 240 kilometers offshore peninsular Malaysia in the Malay basin was discovered in May 1971 and is one of the largest oil fields in Malaysia. Sand production in the Seligi field has been observed, especially from the J reservoirs group. Within the Seligi field, Well G was identified as one of the wells with sand production to surface that could lead to sand accumulation at surface facilities and erosion of equipment. Historically, there had been no in-situ sand control measures in the well. The default practice for sand control was to choke back the well, to prevent triggering of the surface sand probe (production with maximum sand-free rate). This approach however is a compromise, while it limits sand production, it also limits the production potential of the well (well technical potential). As part of the production enhancement assessment program, remedial sand-control methods were considered to increase the oil production while minimising sand production. Among the options considered was ceramic downhole sand screen installation. Ceramics have been used in many extreme erosion and corrosion applications, with ceramic sintered silicon carbide being 50 times harder than steel. Ceramic sand screens made with sintered silicon carbide offer much higher erosional resistance at speeds of 300ft/s sand impingement velocity. Due to the aggressive nature of the sands and high velocities of greater than 50ft/s in Well G, a through-tubing ceramic sand screen was selected. The ceramic sand screen served as a fit for purpose solution that allowed the well potential to be fully maximised, enabling a continuous production with minimal sand production at surface. This paper reviews the first successful pilot installation of through-tubing ceramic sand screen in Well G in the Seligi Oil Field, Offshore Peninsular Malaysia. Discussed are careful analysis and planning, i.e. velocity calculations, tool deployment simulations, tool inspections and detailed job procedure leading to a successful installation. With the ceramic sand screen installed, the well was able to produce at 100% production choke opening with lower tubing head pressure and has not produced sand at surface despite multiple shutdowns and well bean ups. The installation has also removed the need to have sand handling facilities at topside and has generated an implicated cost saving from expensive intervention programs. Given the success of this pilot installation, a baseline in sand control has been set for this field, with new well candidates being considered for future replication.

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Ceramic Sand Screens: Qualification Strategy for a High Rate Gas Application

Cited by 4 publications

References 10 publications

Erosion Life Prediction of Metal Mesh Screen Pipes in Oil Wells Based on Numerical Simulation of Discrete Particle Flow

Erosion Life Prediction of Metal Mesh Screen Pipes in Oil Wells Based on Numerical Simulation of Discrete Particle Flow

Development of Plasma Sprayed Coatings to Improve the Erosion Resistance of Wire Wrapped Screens

First Successful Installation of Through-Tubing Ceramic Sand Screen in Seligi Oil Field, Offshore Peninsular Malaysia

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