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Sand, or fines as some may call it, entering currently producing wells is one of the earliest problems faced by the Oil and Gas Industry in hydrocarbon recovery [Rogers, 1954; Carlson et al. 1992; McLeod 1994; JPT Staff 1995; Barrilleaux et al. 1996], and one of the toughest to solve in general [McLeod 1997]. Every year the petroleum industry spends significant capitol in cleaning and disposal costs, repair problems related to sand production, and lost revenues due to lower production rates due to mitigation efforts [Mathis 2003; Palmer et al. 2003]. Thus, sand control is, and should be, an integral part of well planning [Guerrero 2014] in unconsolidated reservoirs [Willson et al 2002; Chang 2006; Jaimes 2012], i.e., reservoirs where the rock has little or no natural inter-grain cementation. Sand production [Veeken et al. 1991; Subbiah et al. 2021] is caused by structural failure of the borehole wall rock due to drilling, degree of consolidation (very low compressive strength), the interaction between the rock and flowing fluids (production creates pressure differential and frictional drag forces that can combine to exceed the formation compressive strength), excessive drawdown causing fines and sand grain movement to the wellbore, or reduction of reservoir pressure. Sand production leads to adverse effects on various components in the wellbore and near wellbore area [Zamberi et al. 2014], such as tubing, casing, flowlines, and pumps, as well as surface equipment [Peden et al. 1984; Lidwin et al. 2013]. In addition, sand production may allow for the creation of downhole cavities [Peden et al. 1985] resulting in loss of structural integrity of the reservoir around the wellbore and ultimately possible collapse of the wellbore. Along with these possible issues, there is an additional economic impact in that sand must be separated out and disposed of at the surface and can be a few liters to several hundred cubic meters [Lidwin et al. 2013]. Decisions around sand production are not purely economic these days because regulatory and environmental restrictions have come to play a significant role in the decisions of how sand production will be handled. In general, what constitutes an acceptable level of sand production depends on operational constraints such as the ability to use erosion resistant materials, fluid separator capacity, sand disposal capability, and artificial lift equipment's capability to remove slurry from the well, but with that said, sand control methods that allow unconsolidated reservoirs to be exploited often reduce production efficiency. Thus, an effective design is always a balance between keeping formation sand in place without unduly restricting current and future productivity [Saucier 1974; Mathis 2003; Palmer et al. 2003; Lastre et al. 2013]. There are two primary methods of sand control these days, namely passive and active, where passive sand control uses perforation orientation and placement to try and mitigate sand production, while active sand control uses a more intrusive approach utilizing downhole filters [Tibbles et al. 2020]. Currently, the most popular and successful method of negating sand production is gravel packing around a downhole filter. In this method, gravel is deposited downhole by pure beta wave deposition in slightly deviated wellbores, i.e., wellbores having a deviation angle in the screen section less than about 50 degrees, or by what is normally referred to as alpha/beta wave deposition in highly deviated wellbores, i.e., wellbores where the screen section maximum deviation is greater than 50 degrees.
Sand, or fines as some may call it, entering currently producing wells is one of the earliest problems faced by the Oil and Gas Industry in hydrocarbon recovery [Rogers, 1954; Carlson et al. 1992; McLeod 1994; JPT Staff 1995; Barrilleaux et al. 1996], and one of the toughest to solve in general [McLeod 1997]. Every year the petroleum industry spends significant capitol in cleaning and disposal costs, repair problems related to sand production, and lost revenues due to lower production rates due to mitigation efforts [Mathis 2003; Palmer et al. 2003]. Thus, sand control is, and should be, an integral part of well planning [Guerrero 2014] in unconsolidated reservoirs [Willson et al 2002; Chang 2006; Jaimes 2012], i.e., reservoirs where the rock has little or no natural inter-grain cementation. Sand production [Veeken et al. 1991; Subbiah et al. 2021] is caused by structural failure of the borehole wall rock due to drilling, degree of consolidation (very low compressive strength), the interaction between the rock and flowing fluids (production creates pressure differential and frictional drag forces that can combine to exceed the formation compressive strength), excessive drawdown causing fines and sand grain movement to the wellbore, or reduction of reservoir pressure. Sand production leads to adverse effects on various components in the wellbore and near wellbore area [Zamberi et al. 2014], such as tubing, casing, flowlines, and pumps, as well as surface equipment [Peden et al. 1984; Lidwin et al. 2013]. In addition, sand production may allow for the creation of downhole cavities [Peden et al. 1985] resulting in loss of structural integrity of the reservoir around the wellbore and ultimately possible collapse of the wellbore. Along with these possible issues, there is an additional economic impact in that sand must be separated out and disposed of at the surface and can be a few liters to several hundred cubic meters [Lidwin et al. 2013]. Decisions around sand production are not purely economic these days because regulatory and environmental restrictions have come to play a significant role in the decisions of how sand production will be handled. In general, what constitutes an acceptable level of sand production depends on operational constraints such as the ability to use erosion resistant materials, fluid separator capacity, sand disposal capability, and artificial lift equipment's capability to remove slurry from the well, but with that said, sand control methods that allow unconsolidated reservoirs to be exploited often reduce production efficiency. Thus, an effective design is always a balance between keeping formation sand in place without unduly restricting current and future productivity [Saucier 1974; Mathis 2003; Palmer et al. 2003; Lastre et al. 2013]. There are two primary methods of sand control these days, namely passive and active, where passive sand control uses perforation orientation and placement to try and mitigate sand production, while active sand control uses a more intrusive approach utilizing downhole filters [Tibbles et al. 2020]. Currently, the most popular and successful method of negating sand production is gravel packing around a downhole filter. In this method, gravel is deposited downhole by pure beta wave deposition in slightly deviated wellbores, i.e., wellbores having a deviation angle in the screen section less than about 50 degrees, or by what is normally referred to as alpha/beta wave deposition in highly deviated wellbores, i.e., wellbores where the screen section maximum deviation is greater than 50 degrees.
For the first time in China, shunted gravel-pack screens have been used for two long, fishbone type, multilateral openhole sand control wells in 2022. Shunt-tube systems have been widely used in cased hole and openhole gravel-packing operations in the past few decades as the most reliable sand control solution. However, this is the first shunted gravel-pack screen application in an openhole main bore with fishbones. This successful drilling and completion methodology can be used in this field and other locations to increase the well production rate by enlarging the reservoir contact area with fishbones without adding much capex to drilling and completion operations. Challenges and solutions for two wells included running the completion tool string to total depth in complicated well configurations, optimized operating procedures, gravel-pack pumping design for complicated scenarios resulting from fishbones, and onsite operations. The work included a detailed analysis of post-job data. The uncertainties of fluid loss and wellbore stability around the fishbones and the potentially unstable shale streaks in the 600-m-long openhole sections became challenging during gravel packing. Bridging was observed when slurry arrived at the openhole, and shunt tubes were activated much earlier than expected for both wells. Most (85%) of the packing was pumped through shunt tubes for the first well. High wellhead pressure caused by shunt friction was well managed to make sure as much gravel as possible was pumped. For the second well, 67% of the packing was pumped through shunt tubes. As there were no bottomhole gauges ran on wash pipes, post-job analysis was mainly based on volumetric data to analyze the potential packing sequence for the two wells. Post-job data analysis indicated that early gravel bridging might be attributed to potential hole collapses around the lateral and shale sections. Without the use of alternate shunt-tube screens and proper carrier fluid, the job would likely have resulted in an incomplete packing and failed sand control operation. Packing efficiency was 123% and 146%, respectively for the two wells, and the oil production rate was two times higher than that expected.
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