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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
© 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 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
© 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
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
© 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
Installation and Performance
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%
© 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
Installation and Performance
• 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
© 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
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”)
© 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
Current System & Application
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
© 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
Current System & Application
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
© 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
ESS Field Incidents
Slide 11
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© 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
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
© 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
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
© 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
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
© 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
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
© 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
Reliability Analysis
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
© 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
Reliability Analysis
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
© 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
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
© 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
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
© 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
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.).
© 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
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
© 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
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.
© 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