fifteen years of expandable sand screen (ess … · introduction slide 3 •expandable sand screen...

Ref : SPE 166425 / Authors: Martin Geddes & Isma Mohd Ismail

6th European Sand Management Forum (26th & 27th March 2014)

Presenter: Martin Geddes

Fifteen Years of Expandable Sand Screen (ESS®)

Performance and Reliability

Contents

• Introduction

• Installations and Performance

• Current Systems & Applications

• ESS Field Incidents

• Reliability Analysis

• Reliability by Application

• Failure Mitigation

• Conclusions

Slide 2

© 2014 Weatherford. All rights reserved. Fifteen Years of Expandable Sand Screen Performance and Reliability. Presented by Martin Geddes at the 6 th European Sand Management Forum (Aberdeen), 27th March 2014

Introduction

Slide 3

• Expandable Sand Screen (ESS®) 1st trialled is in 1997

• ESS, sand control used in weak, poorly consolidated or unconsolidated formations

• Oil and gas production wells

• Water injection wells

• Gas storage

• ESS features & benefits:

• Compliant sand control

• Eliminating annulus between sand screen and wellbore

• Wellbore support

• Larger flow area & increased ID

• Benefit well productivity & reservoir drainage

• Installation and operational simplicity

• Multi-zone capability


Introduction

Slide 4

• Comprises three sandwiched layers

Base Pipe Slots Open

During Expansion Maximizing Inflow Area

Outer Shroud

Protects Filter

Media

Filter Media

Dutch Twill Weave Weave Layers Slide Over

Each Other During Expansion

Unexpanded Expanded No Change In Weave

Aperture Size


Installation and Performance

Slide 5

Data collected & classified for each ESS installation:

• Safety statistics (man-hours, rig days, LTI, etc)

• Well geometry data (depth, DLS, casings, TD, etc)

• Rig data (type, water depth, etc)

• Mud & fluid data (type, weight, shaker screens, etc)

• Well type (producer or injector, cased or open hole, etc.)

• Completion details (perf details, fluid loss device, hangers, isolation etc)

• ESS equipment info (type, length)

• Operational details

• Formation details (sand, strength, perm, as available)

• Productivity (well test info, skins, drawdowns, sand, etc)

• Status: (1) Success; (2) Installation (infant) failure; (3) Production failure



Slide 6

677 installations – until end of 2012

• Installations in open hole – 451 (67% of 677 total)

• Installed footage in open hole – 355,877ft (85% of 418,185 ft total)

Completion Type

Footage

OPEN HOLE ESS(451) 67%

CASED HOLE ESS

(193) 28%

OTHER(CHESS/PP & CHESS/FP)

(33) 5%

OPEN HOLE ESS(355,877ft) 85% CASED HOLE

ESS(52,230ft) 13%

OTHER(CHESS/PP &

CHESS FP)(10,077ft) 2%



• Mainly in oil producers, gas producers and water injectors

• Wells producing for more than 13 years

• Max. production rate 30,000 stb/day

• Max. gas rate 370 MMscf/day

• Max. water injection rate 65,000 bwpd

• Deep water application

• Single & multi-zone

• Deviated & horizontal wells

Slide 7


Current System & Application

Slide 8

• Product evolution

1997 : 1st Field trial (4”) & cone expansion

1999 : Commercial application

2000 - 2002 : MK I connection (4.5” & 5.5”) failure – removed from market

2002 (End) : MK II connection (4.5” & 5.5”) redesign

2000 : Compliant expansion - CRES (Rotary) – replaced by ACE (Axial)

2001 : Compliant expansion - ACE (Axial)

2005 : 7” ESS + 7” EZI system (compliant rotary expansion)

2006 : 120 micron weave

2006 : Single trip deployment (4”, 4.5” & 5.5”)

2006 : Single trip uni-direction fluid loss control (5.5”)

2009 : Single trip deployment & uni-directional fluid loss control (7”)



Slide 9

Current ESS Systems

Size Hole Size Run OD Max.

Compliant Expansion Type Filter Media

4.0” ~ 5.88” 4.40” 6.06” Axial compliant

expansion Expandable

connections Dutch Twill 120μm 150μm 230μm 270μm

4.5” ~ 6.00” 5.00” 6.75”

5.5” ~ 8.50” 6.10” 8.83”

7.0” ~ 8.50” 7.60” 9.25”

Rotary compliant expansion

Premium connections



Slide 10

• ESS installed in oil and gas producers, water injectors and gas storage wells

• ESS installed in wide range of well conditions

Current OH ESS Systems – 351 installations (52% of 677 total)

• Compliant expansion of 4” MKI, 4” MKII, 4.5” & 5.5” and 7” ESS® (from Q1 2001)

• Content from here focuses on Current Open Hole ESS Systems

215 (61%)

81 (23%)

48 (14%)

7 (2%)

0

50

100

150

200

250

Oil Producer Gas Producer Water Injector Other(Water producer, Gas connector

& Gas storage)

Inst

alla

tio

n


ESS Field Incidents

Slide 11

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ESS Field Incidents

Slide 12

Failure Type

Infant Failure

• During Installation

• First 180 days after installation

• Capture all type of completion

• Including batch completion and subsea wells

Production Failure

• After 180 days from installation

• Solids egress into the well

• Produce sand greater than the weave size is considered a failure

• ESS product failure

• ALL failures must completed WFT RCA investigation


ESS Field Incidents

Slide 13

Controllable factor Description Formation / Hole Condition

Unstable formation; washouts, swelling shale, OH deployment interface; tight spot, hang-ups etc.

Wellbore / Hole Trajectory Wellpath issues; high dogleg severity, deployment / expansion weight transfer issues etc

Improper Bean-up High initial drawdown, not following bean-up procedure

Improper Weave Size Poor weave retention, weave selected on PSA not fully representative of the reservoir sands

Design / Installation

Product and tool design, material selection, rig operational related problem, non-standard completion design

MUD / Wellbore Clean-up Fluids selection, mud conditioning / fluids change-out, filter cake clean up / mud flow back and other mud related issue, solids deposit, casing scrapper etc.

Un-controllable factor Description

Reservoir Faults / Tectonics Un-appraised geo-mechanical issue; abnormally stressed reservoir (overburden stress is smaller than maximum horizontal stress / reservoir faulting / tectonic activity)

3rd Party Swell Packer / OH Interface Client specified 3rd party equipment issue; elastomer design issue, early swelling, unpredicted reaction with openhole caused sandface completion to hang-up

• Controllable primary contributing factor

• Lessons learned captured and fed back selection

• Un-controllable primary contributing factor

• Issues experienced due to unknown factor


ESS Field Incidents Slide 14

To improve ESS reliability

• Identify and manage controllable factors impacting performance

• Uncontrollable factors affect all sand control systems – improve application screening

• 38 failure are controllable and 17 failure are uncontrollable

Current OH ESS Systems – 351 installations (52% of 677 total)

* Total encompass both infant and production failures

ESS failures (both infant and production)

Primary Contributing Factor Infant Production Total

Formation/Hole Condition 2 7 9

Wellbore/hole trajectory 1 0 1

Mud/Wellbore Clean up 4 4 8

Improper weave size 3 7 10

Improper bean-up 2 1 3

Design & installation 4 3 7

Reservoir Faults/Tectonics 4 8 12

3rd Party Swell Packer/OH Interface 5 0 5

Total 25 30 55


Reliability Analysis

Slide 15

• Understanding ESS performance is critical to improving future performance

• Weibull reliability software

• Weibull 2p distribution

• Maximum likelihood techniques

• All ESS failure within 180 days after installation were classed as infant failures

• Production time set to “0”

• All ESS failure after 180 days after installation were classed as production failures

• Production time recorded

• Wells still producing were treated as suspension at the end of 2012



Slide 16

58

176

299 351

70

342

915

1729

5.2%

(13) 7.4%

(25) 8.4%

(25) 7.1%

(0) 0.0%

(16) 9.1%

(24) 8.0%

(30) 8.5%

(3) 5.2%

(29) 16.5% (49) 16.4% (55) 15.7%

0%

5%

10%

15%

20%

25%

30%

0

200

400

600

800

1000

1200

1400

1600

1800

2000

2003 2006 2009 2012

Failu

re R

ate

%

Inst

alla

tio

n o

r W

ell-

Ye

ars

Installation

Well Years

Infant Failure

ProductionFailure

• Cumulative installation and cumulative online well-years

• Wells producing for more than 13 years

• On average open hole ESS producing for 5 years

• No infant failure further to 2009



Slide 17

• 2003 results not plotted due to small dataset and no production failure

• Significant reliability improvement at each time interval

• MTTF trend improving as cumulative well years increase

• MTTF value assumes constant well environment & most ESS wells have not reached end of their useful life

ReliaSoft Weibull++ 7 - www.ReliaSoft.com

Reliability vs Time Plot

2012\2012: 2009\2009: 2006\2006:

Time, ( t)

Re

lia

bil

ity

, R

(t)

=1

-F(

t)

0.000 30.0006.000 12.000 18.000 24.0000.000

1.000

0.200

0.400

0.600

0.800

2012

2009

2006

Production Failure Trending

Infant Failure Trending


Reliability by Application

Slide 18

• Oil Producer failures – 49 wells (22.8%)

• Gas Producer failures – 5 wells (6.2%)

• Water Injection failure – 1 well (2.1%)

27 (12.1%) 2 (2.5%) 1 (2.1%)

22 (10.7%) 3 (3.7%)

Total = 215

Total = 81

Total = 48

Total = 7

1085

371

225

48 0

200

400

600

800

1000

1200

0

50

100

150

200

250

300

Oil Producer Gas Producer Water Injector Other(Water producer, Gas

connector & Gas storage)

Wel

l-Ye

ars

Inst

alla

tio

n

Installation

Infant Failure

Production Failure

Well-Years


Reliability by Application

Slide 19

• Reliability plot excludes “water injectors” & “others” due to minimal failure rate

• Good performance in gas wells

• Oil producer well performance below overall reliability performance

• Attributed to early well failures (improvements via Lessons Learned)

ReliaSoft Weibull++ 7 - www.ReliaSoft.com

Reliability vs Time Plot

2012 Oil\2012: 2012 Gas\2012: 2012\2012:

Time, ( t)

Re

lia

bil

ity

, R

(t)

=1

-F(

t)

0.000 30.0006.000 12.000 18.000 24.0000.000

1.000

0.200

0.400

0.600

0.800

2012 Reliability

Gas Wells

Oil Wells


Failure Mitigation

Slide 20

10 step due-diligence process

Step Evaluation Description

1 Sand properties Aperture size selection from sand size data against retention testing database or actual retention testing.

2 Wellbore fluids Flow-through and filtercake flow-back testing performed during planning phase. QC checks performed at rigsite.

3 Geomechanics Consider borehole stability (sands/shales/fractures/depletion etc.).

4 Erosion Evaluate level of risk (velocity, particle size/type etc.).

5 Well geometry Consider trajectories, build angles, dogleg severities and review string design deploy ability via Torque & Drag.

6 Well condition Good drilling practices (hole gauge/washouts/shale instability/effective mud filter cake etc.).

7 FDS Integral/inner inflow control, zonal isolation requirements, fluid loss control, instrumentation interfacing, etc.

8 Corrosion Design for chemical environment (corrosion, acid stimulation, scale treatments etc.).

9 Well unloading Define appropriate procedure/parameters (staged slow rates etc.).

10 Process integrity Ensure right-first-time installation (robust procedures, HAZID, HAZOP and CWOP etc.).


Failure Mitigation

Slide 21

• Controllable factor - 10 step sand control selection

• Un-controllable factor – guidelines & operating window

• Lessons learned fed into Operations Process Management System (OPMS),

• Assisting future failure mitigation

Infant = 3

Infant = 10

Infant = 12

Infant = 0

Production = 0

Production = 16

Production = 8

Production = 6

FH, 1

FH, 4 FH, 4

WT, 1

MC, 3 MC, 5

WS, 2

WS, 7

WS, 1

BU, 3

DI, 4

DI, 2

DI, 1

FT, 6

FT, 1

FT, 5

SP, 1

SP, 4

Total = 3

Total = 26

Total = 20

Total 6

0

5

10

15

20

25

30

0

5

10

15

20

25

30

2003 2006 2009 2012

Failu

re W

ell

Year

SP

FT

DI

BU

WS

MC

WT

FH

3rd Party Swell PackerFaults/TectonicsWFT Design & Installation

Improper Bean-UPImproper WeaveMud/Wellbore Clean-UpWellbore/Hole Trajectory

Formation/Hole Condition


Conclusion

Slide 22

• ESS has matured as a viable sand control technology

• +15 Years of field application

• Maximum ESS benefit achieved

• Compliantly expanded

• Openhole environment

• Root cause analysis improving product understanding

• Lessons learned fed into an Operational Process Management System (OPMS)

• Assisting future failure mitigation

• Trends of improvement in performance and reliability

• Infant and production failure modes.

• Implementation of “10 Step Sand Control Selection” process

• Improving candidate well selection.


Fifteen Years of Expandable Sand Screen (ESS®)

Performance and Reliability

Ref : SPE 166425 / Authors: Martin Geddes & Isma Mohd Ismail

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fifteen years of expandable sand screen (ess … · introduction slide 3 •expandable sand screen...

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