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SPE Distinguished Lecturer Program
The SPE Distinguished Lecturer Program is funded principally through a grant from the SPE Foundation.
The society gratefully acknowledges the companies that support this program by allowing their professionals to participate as lecturers.
Special thanks to the American Institute of Mining, Metallurgical, Petroleum Engineers (AIME) and Offshore Europe for its contribution to the program.
Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl
Open Hole Gravel Packing: New Trends and What We are
Doing to Overcome the Challenges
Agostinho CalderonPetrobras
Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl
01
Outline
Main unconsolidated sandstone reservoirs in Brazil
Review of the current Horizontal Open Hole Gravel Pack Technology – evaluation
New trends and challenges in Open Hole Gravel Pack
Conclusions
02
Main unconsolidated sandstonereservoirs in Brazil – Campos Basin
03
ALBACORA LESTEALBACORA LESTE(1986)(1986)
MARLIM (1985)MARLIM (1985)
MARLIM LESTE (1987)
MARLIM SUL (1987)MARLIM SUL (1987)
RONCADOR (1996)RONCADOR (1996)
ALBACORA (1984)ALBACORA (1984)
BARRACUDA (1989)BARRACUDA (1989)
CARATINGA (1989)CARATINGA (1989)
ESPADARTE (1994)ESPADARTE (1994)
11--RJSRJS--539539 –– 19991999
Main unconsolidated sandstonereservoirs in Brazil – Espirito Santo Basin
04JUBARTE (2000)
CACHALOTE (2001)
GOLFINHO (2003)
PEROÁ/CANGOÁ (1996)PEROÁ/CANGOÁ (1996)
Offshore reservoirs:
Unconsolidated Sandstones
Ø K
OHGP Good solution
for sand control
Horizontal Wells:
High Productivities
Review of the current Open Hole Gravel Pack (OHGP) technology
5 ½” screen
05
Review OHGP Review OHGP
285 wells - No sand control failure (sand production)06
HORIZONTAL OHGP
3
9
19
39
2931
26
5
2825
21
2723
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
YEAR
NU
MB
ER O
F W
ELLS
285 WELLS285
WELLS
OHGP Operations: Water Depth x Horizontal Lenght
07
0
400
800
1200
1600
2000
0 200 400 600 800 1.000 1.200 1.400
Horizontal Lenght (m)
Wat
er D
epth
(m
)
1998 1999 2000 2001 2002 2003 2004 2005 2006 2007 2008 2009 2010
OHGP – Evaluation (141 wells – 50%)OHGP – Evaluation (141 wells – 50%)
10
Average completion efficiency: 86 %
C.E. (Completion Efficiency) = 1/DR x 100
skinwfe
wfe
PPPPP
DR
Review of the current Open Hole Gravel Pack
11
Alpha and Beta Wave Technology – Water Pack
Cross section well with Open Hole Gravel Pack
Oil flow throughcreated “filter”
PROPPANTh
SCREEN
OPEN HOLE
Reservoir
Screen
Wash Pipe
Selected Gravel
wave
β wave
Review of the current Open Hole Gravel Pack
12
The method “Alpha and Beta Wave Technology” – Water Pack
13
Alpha and Beta Wave Technology – Water Pack(High Leakoff or Formation Fracture – Result Incomplete Pack)
Deep Water Challenges for OHGP Operations
Deep Water Challenges for OHGP Operations
DeepDeep andand ultra ultra deepwatersdeepwaters HighHigh productivityproductivity
Short Short sedimentsediment layerslayers
HighHigh frictionfriction losseslosses duringduring GP op.GP op.
LongLong horizontal horizontal sectionssections
NarrowNarrow operationaloperational windowwindowfor OHGP for OHGP operationsoperations
Rocks w/ low fracture resistanceRocks w/ low fracture resistance
14
Hydraulic Limits DefinitionHydraulic Limits Definition
Upper Limit: High pump rates pay zone fracture premature screen out
Minimum pump rates premature screen out in the rat hole
Normal Normal AlphaAlpha wavewave propagationpropagation
PrematurePremature Beta Beta wavewave propagationpropagation
15
Simulator - Variable flow rate design
ALFA WAVE BETA WAVE
Max pump rate
Min pump rate
16
Alpha Wave Beta Wave
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Open BOP configurationOpen BOP configuration Reducing the fluid weightReducing the fluid weight Use of lightweight proppants Use of lightweight proppants Zero rat hole configuration Zero rat hole configuration Flow divergence valves Flow divergence valves Large diameter wellLarge diameter well Friction reducerFriction reducer
17
Narrow operational window Narrow operational window
Some strategies to overcome the limitsSome strategies to overcome the limits
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Closed BOP Closed BOP configurationconfiguration
BOP BOP –– Blow Out Blow Out PreventerPreventer
18
Packer Blank pipe Screen
RigTank
Work string (Water Pack)
Completion Fluid
Flowmeter(Choke Manifold)
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Open BOP Open BOP configurationconfiguration
19
RigTank
Work string (Water Pack)
Packer Blank pipe Screen
Flowmeter (Flowline)
BOP
Completion Fluid
Valve
To theShakers
Hydraulic limits extension - OHGP
Open BOP configuration Open BOP configuration –– FlowmeterFlowmeter in the in the FlowlineFlowline
20
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Open BOP configurationOpen BOP configuration
21
0
2
4
6
8
10
12
14
16
18
20
0 50 100 150 200 250
t, min.
Q, b
pm
BOP closedBOP openedmin. flow rate at Rat Hole
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Reducing the fluid weight Reducing the fluid weight (Gravel pack carrier fluid) (Gravel pack carrier fluid)
22
0
2
4
6
8
10
12
14
16
0 20 40 60 80 100 120 140 160 180
t, min.
Q, b
pm
Fluid Density = 10 ppaFluid Density = 9.5 ppamin. flow rate at Rat Hole
Fluid Density = 10 ppg Fluid Density = 9.5 ppg
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Use of lightweight proppants Use of lightweight proppants
23
0
2
4
6
8
10
12
14
16
18
20
0 20 40 60 80 100 120 140 160
t, min.
Q, b
pm
Sand (specific gravity=2.6)Lightweight proppant (spec. Gravity=1.25)min. flow rate at Rat Hole (sand)min. Flow rate at Rat Hole (LW)
Zero Rat Hole: Liner
13 3/8”
WD = 1.554m
Well 12 ¼”
LINER 9 5/8” or 10 ¾” Flush
Zero Rat Hole Configuration
Hydraulic limits extension - OHGP
24
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Zero rat hole configuration Zero rat hole configuration
25
Zero Rat Hole
0
2
4
6
8
10
12
14
16
18
20
0 20 40 60 80 100 120 140 160
t, min.
Q, b
pm
Zero rat hole
rat hole
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Flow divergence valves Flow divergence valves
27
Elapsed time (min)
Pres
sure
(psi
)
Formation Fracture PressureBottonhole PressureSurface Pressure
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Large diameter wellLarge diameter well
28
0
2
4
6
8
10
12
14
16
18
20
0 20 40 60 80 100 120 140 160
t, min.
Q, b
pm
Normal Bore (8.5 in)
Large Bore (9.8 in)
min. flow rate at Rat Hole
29
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Case Study usingCase Study using 3 Strategies: 3 Strategies: Open BOP Open BOP configuration / Duo density configuration / Duo density ProppantsProppants / Reducing the / Reducing the fluid weightfluid weight (Gravel pack carrier fluid) (Gravel pack carrier fluid)
Well data (Well data (GolfinhoGolfinho Field):Field):
Horizontal Extension: 1150mHorizontal Extension: 1150mWater Depth: 1581mWater Depth: 1581mFluid weight: 9.6 Fluid weight: 9.6 ppgppgGravel Pack Carrier fluid: 9.1 Gravel Pack Carrier fluid: 9.1 ppgppgFracFrac Gradient: 0.56 Gradient: 0.56 psipsi/ft/ftRat Hole: 14.75Rat Hole: 14.75””
30
Output of Simulator Output of Simulator
Ceramic d = 2.7 Lightweight Proppant d = 1.75
Hydraulic limits extension - OHGP
31
Hydraulic limits extension - OHGPHydraulic limits extension - OHGP
Output of Simulator Output of Simulator
32
Hydraulic limits extension - OHGPHydraulic limits extension - OHGPGolfinhoGolfinho Field: Field: Open BOP configuration / Duo density Open BOP configuration / Duo density ProppantsProppants / / Reducing the fluid weight (Gravel pack carrier fluid) Reducing the fluid weight (Gravel pack carrier fluid)
0
1000
2000
3000
4000
5000
Pres
são
1 (p
si)
0
5
10
15
20
Conc
Par
af (p
sa)
0
10
20
30
40
50Va
zão
Desc
(bpm
)
0
10
20
30
40
50
Vaz
ão R
etor
no (b
pm)
Alfa Beta
1 ppa de Carbolite 20/401 ppa LiteProp 175 - 20/25
Screenout = 2.606 psiBomb. Camai 9.1 ppg: Aj uste de v azão
Total Carbolite 20/40 bomb = 51.658 lbmTotal Liteprop 20/25 bomb = 12.411 lbmTotal de propante na FM = 56.351 lbmTotal propante na Coluna = 7.718 lbm
0 50 100 150 200Elapsed Time (min)
Gravel Pack 7-GLF-27HA-ESS / SS-61 (23/05/09)
Filter Cake Removal - The Producer WellFilter Cake Removal - The Producer Well
Screens FormationGravel F. C.
34
• No mechanical filter cake removal mechanism
• Injection impairment
• Costs: clean up (flow back) vs acidizing
• Poor results without treatments
• Always treated Mud acid Drill solids
• No mechanical filter cake removal mechanism
• Injection impairment
• Costs: clean up (flow back) vs acidizing
• Poor results without treatments
• Always treated Mud acid Drill solids
The Injector’s ProblemThe Injector’s Problem
35
Seal SubsSeal Subs
ScreensScreensScreensPolished
ExtensionPolished Polished
ExtensionExtensionWash PipesWash Wash PipesPipes
FluidsFluidsFluids
Field Application - Dedicated Acidizing ToolField Application - Dedicated Acidizing Tool
37
New Trends and Challenges in OHGP
Drilled horizontal section with
SBM and OHGP with non-
aqueous fluid (alpha and beta
wave mode)
In 2007
Non-aqueous fluid for OHGP - alfa and beta wave mode
Open Hole Gravel Pack“Infill Drilling Project”
8 ½” OH
9 5/8”CSG
38
New trends and challenges in OHGP
Focus
Make the formulation of inverted solids-free emulsionwith carrier fluid for horizontal gravel pack operationsfeasible
Evaluate if the alpha and beta waves occur
Keep the use of regular premium screens without anykind of extra paths
Non aqueous fluid for OHGP – Newtonian behavior
39
Physical testing simulation - results
40
After fluid development: Physical simulation (flow loop):3 kind of proppants (sand, ceramic and bauxite) and new gravel pack carrier fluid
Alpha and Beta wave was detected with all proppants
Excellent packing
SPE 102295
1st STEP – Field application – MarlimSPE 110440
Packer
Basic Data:
Water depth: 665m
Horizontal Section: 380m
8 ½” Well ; 5 ½” 250 µ screen
Proppant: 16/20 mesh(Ceramic)
Frac gradient = 0.60 psi/ft
Well Design
Non aqueous fluid for OHGP - alfa and beta wave
41
665 m
1944 m
Field application – OHGP design
16 bpm
4 bpm
6 bpm
Flow
rate
, bpm
Time, min
Maximum Flow rate -Fracture
Minimum Flow rate –Rat Hole
ALPHA BETA
OHGP – Operational window
42
Gravel pack execution – Marlim field
Packer
Time, h
Pres
sure
, psi
Flow
rate
, bpm
–C
onc,
lb/g
al
Flow rate (BPM)Surface conc (lb/gal)
Bottom ext P3 (psi)Bottom below the packer P2 (psi)Bottom above the packer P1 (psi)
Surface PressureSurface pressure (psi)
43
Gravel pack execution – Marlim field
Relevant observations – Marlim field application
Low contamination of GP carrier fluid with DIF
Effective mud cake DIF x GP carrier fluid – no losses
The measured and the simulated pressures were found similar
Excellent ceramic packing (> 100%)
Proper filter cake clean up with production flow
44
Packer
PI = 70.7 m3/day / kgf/cm2
DR = 1 (zero skin)
Contribution from the whole horizontal extension (Production Log Tool)
Ceramic
Results - Marlim field application
45
New trends and challenges in OHGPManati Field – Northeast of Brazil
Block - BCAM 40Water depth < 50m9 Km from the coastEnvironmental sensitivearea (zero discharge)
GAS STATION
BCAM 40 BLOCk
RING FENCEMANATI FIELD
47
Discovered - oct/2000, well 1-BAS-128
Gas Reservoir – Low vertical depth (1400m)
Thick reservoir - (100m to 350m)
High permeabilities (200 mD – 500 mD) and highporosities (21%)
High Productivity Index
High fluid density (up to 12.5 ppg)
Manati field – northeast of Brazil
48
Completion; no sandcontrol (7” liner)
Sergi Fm
Água Grande Form.
300 m
Manati field – Initial well project (no sand control)
49
7” casing
9 5/8” casing
8 ½” OH
Main restrictions observed during well completions:Liner top isolation (dry-test) – 52 hours / well
300m perforation (highcosts)
Initial well project (no sand control)
During well completions, new requirements (50% increase in flowrates)
R&D Center (CENPES) Sandproduction risks Sand controlrequirement
50
Sand control options for Manati fieldMain limitations for cased hole sand control (Fracpack) – Manati field:
‘
‘
‘
‘
‘
51
Liner top isolation (rig time and leak risks)
Long perforation intervals
Smaller screen diameter - 3 ½”
Injection of high fluid volumes - calibration testsand fracpack (minimum 10000 bbl estimated)
Longer rig time to flow back the well and environmentalrestrictions (zero discharge).
High water volumes injection in gas reservoirs are notrecommended
Fracpack require stimulation boat: high power, pressures, gel and higher costs
Sand control with OHGP for Manati field:
52
No liner, cement operations, logs for cementevaluation, dry-test.
No guns and rig time
No fluid injection and related problems with flow back,separation, environmental restrictions. The evaluationis fast;
OHGP with low pump rate and pressure, low power,no gel, lower costs and risks.
One operation for OHGP and up to 5 fracpackoperations, for 300m thickness
OHGP requires 5 ½” screen (8 1/2” OH) and fracpack3 ½” screen (7” CSG).
Fracpack OHGP Selected
‘
‘
‘
‘
‘
300 m
5 Fracpacks
1 OHGP
50 m
Options for sand control – Manati field
53
Main challenges for OHGP in Manati field
Higher pore pressure than the conventional OHGP;
Drill in fluid requirements:
Completion fluid Same weight D.I.F and compatible;
Usual D.I.F. (NaCl base) More than 10 ppg (CaCl2) is usual, but is incompatible with polymers
Drill in Fluid (sodium formate) and completion fluid(sodium formate and potassium formate)
54
Good results (All requirements): Mud cake thickness(< 1mm), Break out pressure (< 10 psi), K return (90 %)
OHGP in Manati field: wells number 5 and 6
55
These 2 wells were drilled with water base D.I.F(Sodium Formate base)
The D.I.F. was displaced by filteredcompletion Fluid (Sodium Formate andPotassium Formate).
The premium screens was RIH and the OHGPperformed
OHGP execution – Manati field (2 Wells)
OHGP Chart - Well 5 (100% packed)
Treating pressureSlurry ratePropant concentrationReturn rate
Time (min)
Pres
sure
(psi
)
Con
c(p
pg),
pum
pra
te (b
pm)
56
Well tests evaluation Manati field:
48219.7142YWell-0622015.8243YWell-0529511.5194NWell-04
30512.6191NWell-03
K (mD)AOF (milIionm3/day)
Net Pay(m)
SandControl(Y/N)
Wells
(OHGP) Higherproductivity thanwithout sandcontrol
The best productivity result in Manati field is OHGP (compared with wells without Sand Control)
57
PAPERIPTC 12364
Conclusions
OHGP: Productivity and reliability;
The oil base system as a gravel packcarrier fluid: sensitive reservoirs and mature fields;
For higher pore pressure reservoirs formates;
OHGP is a good option for high permeability reservoirs (gas or oil): simplicity, productivity and economic advantages
58
Society of Petroleum Engineers Distinguished Lecturer Programwww.spe.org/dl
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