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Copyright 2005, SPE/IADC Middle East Drilling Technology Conference & Exhibition
This paper was prepared for presentation at the SPE/IADC Middle East Drilling Technology
Conference & Exhibition held in Dubai, U.A.E., 1214 September 2005.
This paper was selected for presentation by an SPE/IADC Program Committee following
review of information contained in an abstract submitted by the author(s). Contents of the
paper, as presented, have not been reviewed by the Society of Petroleum Engineers or the
International Association of Drilling Contractors and are subject to correction by the author(s).
The material, as presented, does not necessarily reflect any position of the SPE, IADC, their
officers, or members. Electronic reproduction, distribution, or storage of any part of this paper
for commercial purposes without the written consent of the Society of Petroleum Engineers or
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Abstract
Expandable sand screens (ESS.) are a relatively new sand
control system, which combines many of the properties of
gravel packs with the ease of installation of a stand-alone
screen. Although they have been used in a wide variety of
applications, they are not considered a panacea and have an
operational envelope, which is becoming clearer with time.
Weatherfords ESS system currently (June 2005) has 340
installations and over 700 years of combined production. A
recent survey of the installations was analyzed in terms of
performance and reliability.
The productivity performance of the ESS has been shown
to be very good, with an average skin of 0.3 being achieved in
recent openhole applications. ESS completions generally
perform better than the baseline models. Where field
comparisons were possible, they also performed better than
alternative sand control completions.
Over the 340 ESS wells, ESS has a reliability comparable
with other sand control systems, with initial failures less than
5% and a production failure rate of 0.021 failures/well.year.
This gives a projected survival rate at 20 years of greater than
90%. This rate is expected to get better with improving
operations, designs, systems and application selection.
Introduction
When the first ESS was launched in 1999 it was a radical
departure from convention, it introduced the concept of direct
screen contact with the formation as a means of increasing
productivity, sand control and reliability.
ESS was designed and aimed specifically at openhole
applications, despite the subsequent use of it in cased-hole
applications. Features such as large exposed filter area and
variable ESS borehole contact (becoming known as compliant
.
SPE/IADC 97282
40
# Cone OH Skin
# Compliant OH Skin
35
# of skins
30
25
20
15
10
5
>9
>8
>7
>6
>5
>4
>3
>2
>1
>0
>-1
0
Skin Value (Range)
15.00
40
Data Wells
All OH Skins
10.00
30
5.00
20
0.00
10
-5.00
# Data Wells
Skin Value
Cone
Horizontal
Compliant
Horizontal
All Horizontal
(>85)
Cone Deviated
Compliant
Deviated
Cone Straight
All OH Deviated
(<85)
Compliant
Straight
All OH
straight(<15)
SPE/IADC 97282
No.of
Wells
Well.
Years
Design
failures
(%)
183
175
194
369
844
783
507
255
1514
3369
0.6
0
1
0
1.69
Applica
tion
Failures
(%)
0
9.7
3
2.2
2.4
Infant
failures
(%)
Production
Failures/
well/yr
0.6
0.57
1
0.8
0.24
0.056
0.020
0.016
0.011
0.004
Loss of Well 1
340 wells
727 well.years
5 wells
9 wells
2 wells
15 wells
0.021 failures/well.year
18
Remedial Action
19
Unplanned
Downtime
36
Operationally
straightforward
266
0
100
200
300
SPE/IADC 97282
Design+application+infant
10.0%
8.0%
6.0%
4.0%
2.0%
0.0%
1999
2001
2003
2005
Y ear
6%
Initial Failure
Producing at or above
expectation
73%
2%
Not Connected
5%
Depleted
9%
Producing non-optimally
6%
20%
40%
60%
80%
100%
SPE/IADC 97282
Hydraulic Collapse
Formation Collapse
3
2
No ESS Issue
0
10
1.05
1
Fraction Still Producing
0.95
0.9
0.85
0.8
0.10
1.00
time (Years)
10.00
SPE/IADC 97282
Hole quality
Well trajectory for deployment and expansion
Weave selection
Mud selection
Borehole/ESS stability
Metallurgy
Erosion
Final clean up and bean up
4.0
3.5
sand passed through (g)
Hole Quality
Hole quality is important in all types of sand control
completions. It includes several aspects such as how in-gauge,
and free from tight spots is the hole. Also cleanliness, with the
removal of cuttings beds and thick filter cake recommended.
The production and sand control performance of the ESS
tends to be higher in a gauge hole where compliant expansion
is possible or where a fixed cone can be sized to minimize the
annulus18. Drilling a gauge hole for a given application is
down to a combination of proper BHA equipment selection
and configuration, Drill In Fluid [DIF] selection and adoption
of good drilling practices. Once the hole has been drilled then
running a caliper, either LWD or wireline, can quantify hole
quality.
Hole cleanliness can be managed with proper attention to
detail with the drilling fluid to ensure proper cuttings removal.
Also prior to running the ESS the drilling fluid must be
conditioned at high circulating rates to allow it to pass the
filter weave and to leave the reservoir section with a thin filter
cake.
Final hole quality can be checked by a slide trip from the
previous shoe to TD. This will also give an up to date
measure of the friction factors for input into the torque and
drag simulations which are updated immediately prior to
running in hole and real time to verify a problem free ESS
deployment and expansion process as below.
3.0
2.5
2.0
1.5
1.0
0.5
0.0
0
50
100
150
200
250
300
350
400
450
500
550
600
d10 of sand
Where the d10 of the sand is greater than the weave aperture
(150 micron in this case) very little sand passes through the
weave. As the sand gets smaller with d10s less than the weave
aperture the amount of sand passing through the weave
increases gradually at first then more dramatically and there
comes a point where the sand is too small to form a stable
filtercake on the screen. Defining the cut off point for
acceptable solids production is difficult, but Hodge et al22
proposed a limit of 0.12 lbs/ft2, which correlates to 0.4g sand
in these plots. Using 0.4g as the limit for sand production, it
can be seen from the graph that a 150 micron weave would
give adequate sand retention for sands with d10s as low as 130
micron. The plot of the d5 of the sands against sand passing
through the 150 micron weave shows that a d5 of 150 micron
is just within the maximum area of retention (Figure 9).
SPE/IADC 97282
3
2.5
2
1.5
1
0.5
0
0
50
100
150
200
250
300
350
400
450
500
550
600
d5 of sand
Borehole/ESS Stability
New operators are sometimes concerned that the relatively
modest ESS strength will cause problems with hole collapse.
A simple geomechanical model was developed to better
understand the processes leading to excessive deformation and
to be used as a screening tool.
The model is based on concepts developed for
tunnelling23,24 and tunnel support. It calculates the depth of a
failed or yielded zone around a wellbore as a function of
wellbore support from a mud overbalance or an expandable
sand screen. The yielded zone grows as the mud support is
removed and the well is drawndown and depleted. Volume
changes in the yielded zone compress the ESS.
The EWBS model predictions have been calibrated against
experimental and field measurements of ESS deformation.
Figure 10 shows the input/output sheet for the model. The
model uses various inputs, depth, formations stresses,
reservoir pressure, well trajectory, rock properties, and
depletion/drawdown. The model calculates the maximum ESS
deformation during field life. A detailed description of the
model is available.18
Well Details
Client
Well
Field
Region
Comments:
6.0
2.5
5.5
2.0
Well Properties
Depth
Overburden
Max Horizontal Stress
Min Horizontal Stress
Initial Pore Pressure
Final Pore Pressure
Azimuth (SHmax)
Inclination
Hole size
ESS OD
7214
5100
3800
3800
3440
2000
0
90
6
6.00
ft
psi
psi
psi
psi
psi
degs
degs
inch
inch
5.0
1.5
Skin
3.5
these tests the drilling mud is flowed through the ESS weave
at a constant rate and the pressure drop across the weave is
monitored with time. If 500 mls of mud can pass the weave
without significant rise in pressure the test is deemed
successful. The drill in fluid is conditioned through
increasingly fine sieves until the test is successful, and the
mesh rating required is recommended for use in the rig
shakers. Before the screens are run in the field rigsite mud
tests should be performed to ensure the mud is properly
conditioned.
ESS has been successfully run with both water and oil
based muds in open hole. The only problems have occurred
with sized salt systems, the particle size of which can be
difficult to control. As a result Weatherford do not generally
recommend the use of sized salt systems with ESS.
ESS ID (inches)
4.5
1.0
4.0
Formation Properties
Unconfined Compressive Strength
Triaxial Stress Factor
Friction angle
Cohesion
Young's modulus
Poisson's ratio
Expansion
Yielded Material Cohesion
Initial Reservoir Permeability
Yielded Reservoir Permeability
Mud Calculations
Over Balance
Wellbore Pressure
200
2.15
21.4
68.2
493000
0.43
0.1
15
3000
1500
psi
mD
mD
250
3690
psi
psi
psi
psi/psi
degs
psi
psi
0.5
3.5
3.0
0
500
1000
1500
2000
2500
Wellbore Pressure (psi)
250psi Overbalanced
20% Deformation Limit
ESS ID
3000
3500
Reservoir Pressure
Expected Final Reservoir Pressure
Yield Zone Diameter
0.0
4000
Metallurgy
The selection of materials for the constituent components of
ESS encompasses an evaluation of four main attributes;
suitability for expansion without tearing at achievable loads,
mechanical strength, fabricability and resistance to corrosion
& environmental cracking.
A material with a high strain-hardening exponent will
promote uniform plastic deformation to high strain levels and
will be suitable for slotted expandable applications. Fracture
toughness is important to prevent tearing at stress
concentration features, i.e. the slot ends. Solution annealed
UNS S31603 (316L) austenitic stainless steel is utilised for the
standard ESS basepipe, weave and shroud and offers high
ductility, strain-hardening rate and fracture toughness. Other
higher specification materials such as UNS S32760 (25 Cr),
and UNS N08825 are also suitable from an expansion
perspective.
A secondary aspect of suitability for expansion influenced
by material characteristics is the force necessary to generate
expansion. To enhance the strength of the system, it is
possible to increase the basic cross-sectional area, the system
design or the yield strength of the material. However, as a
consequence of improvements in mechanical performance,
e.g. tensile load bearing capacity or collapse resistance, there
is a concomitant increase in expansion force requirements.
This must be assessed against expansion tool loading
constraints for the length of a specific installation or the
generic tool design life.
The two main mechanical service requirements of the ESS
system are 1) the capacity to support both the string weight
and the axial force component of expansion and 2) to resist
collapse from formation stresses. The weight of the string is
carried by the basepipe through the connections. The
connection, being more restricted on cross-section by design,
has a higher strength requirement than the basepipe.
Therefore, solution annealed UNS S32760 or S32750 super
duplex stainless steels, possessing a specified minimum yield
strength more than double that of the austenitic basepipe, has
been adopted in the standard ESS product. This material
maintains good ductility and high fracture toughness at this
strength level.
The original selection of stainless alloys for standard ESS
stemmed from a requirement to provide resistance to
moderately-corrosive CO2-bearing reservoirs. Use of a 316L
filtration medium is common in traditional screen
construction.
An assessment of well corrosivity and a specific material
recommendation is typically conducted for all ESS
applications. For production wells the fluid, temperature and
pressure data is firstly assessed to determine the partial
pressures of acid gases and estimate the potential in-situ pH of
produced waters. The in-situ pH, pH2S, chloride content and
temperature levels are then assessed to evaluate the risk of
localized corrosion or environmental cracking. Particular
attention is paid to the weave material, given the nature of the
critical dimensions in a filter component, and stricter selection
criteria applied.
In cases where well conditions are deemed to present too
great a risk of weave corrosion failure, an upgrade from
UNS S31603 to UNS N08825 is recommended to enhance the
SPE/IADC 97282
SPE/IADC 97282
Erosion
Erosion is usually only a problem is cased hole applications.
In a cased hole ESS application, a high flux from the
perforations can lead to erosion and a loss of sand control.
The ESS has been extensively tested to understand the
controlling factors and limits on erosion.
Over thirty erosion tests have been performed at the South
West Research Institute in San Antonio. These tests have
enabled the development of a model which can predict the
specific mass loss as a function of particle size, concentration,
type and rate. The specific mass loss is loss in grams from the
ESS per gram of solids impinging on the weave. The sand
integrity of ESS weave with various percentages of weight
removed was also measured. This allows the approximate
time to failure to be calculated for a given application.
For a given production rate the failure times are most
sensitive to the area open to flow. This is due to the specific
erosion being proportional to velocity to the power of between
two and four. The sand loading and the weight loss at loss of
sand control have a much lesser effect on the time to failure.
If in a given application erosion is becoming a concern,
then perforating with more shots per foot or with bigger entry
holes can dramatically extended the time to failure.
Bean up
It is of crucial importance to the productivity, reliability and
functionality of the ESS that it is brought on to initial
production in a controlled manner. After installation if the
well is rapidly opened then the filter cake will quickly fall off,
possibly mix with failed formation material and plug the ESS.
A high-pressure drop could then be applied across the ESS,
which could lead to severe deformation or collapse failure of
the screen. Deformation due to mud plugging takes the screen
out of compliance with the formation.
Once the ESS begins to deform, it can start to restrict
access. To mitigate against this, generic bean up procedures
have been developed25. These recommend that nodal analysis
be used to determine the FTHP and FBHP as a function of
choke setting and rate. If a downhole pressure gauge is used
then the FBHP can be directly measured. If not or if the gauge
fails then choke settings and FTHP must be relied upon.
The first choke setting must be small enough (e.g. 8 to 16
64ths) so that the total drawdown expected is less than 150psi.
This means that a drawdown larger than 150psi is unlikely to
be applied to the ESS. The first choke setting should be held
for fours hours to allow the filter cake to clean up. The 2nd
choke setting is designed such that the increment in drawdown
is less than 150psi and so on up to the maximum rate desired.
The total drawdown can exceed 150psi after the 1st choke
setting, only the increment in drawdown must be kept below
150psi.
After the well has been cleaned up, normal bean-up
procedures can be used.
Hole Quality
Well Trajectory
Weave Selection
Mud Selection
Borehole/ESS Stab.
Metallurgy
Erosion
Beanup
No Issue
Slight Issue
Major Issue
10
SPE/IADC 97282