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design, topside installation of wear monitors on all chokes, the
Kapok Parang
implementation of two independent types of sand detection 0 10 20 30 40
Miles
producing at a maximum gas rate of 30 Mmcfd with an production on all wells. Sand production is a major
associated 100 psi drawdown at the sand face. consideration in establishing the production potential for
Kapok. In addition, the plan of development called for Kapok
to produce into a multiphase pipeline to a central processing
hub3. As a result, sand production problems at Kapok could
have severe effects not only for Kapok deliverability but for a
larger portion of Trinidad deliverability if the operation of the
central processing hub is negatively impacted. Therefore, a
completion plan was adopted that included mechanical sand
control, at the sand face, in every well.
The first line of defense is the correct application of sand
face completion technologies that are aimed at keeping the
sand downhole. Special core testing was carried out on the
full-bore core that was taken at a depth of 7000 feet in the
Kapok field. Sand size distribution seen in Figure 3 that Laser
Particle Size (LPS) indicates massive amount of fines in the
range of 25-35% of reservoir sand was found to be sub-325
mesh (<44 microns). These fines migrated during both fluid
sensitivity and fines migration testing as evidenced by changes
in permeability. The amount of fines produced was small
indicating that there is slight grain movement and not massive
release of fines. As a result the distribution suggested an open
gravel pack to minimize drawdown of the formation and
inflow of fines.
Cake
P1 Buildup
P2
"Hot Spot"
Erosion Path CL
∆P = P1 - P2
Topsides Design Consideration The major advantage of installing this detector is for the
Non-Intrusive Sand Monitors. A non-intrusive, acoustic early detection of a sand control failure but is highly
sand monitoring device is placed on all wells on Kapok. The influenced by multiphase production. As a result, the increase
device is strapped on the outer wall of the flowline, in signal which results from sand impacts will vary hugely
downstream of the second 90o bend from the tree (see Figure from well to well, and will even vary within a well as the flow
5). conditions change. During the calibration for each well it was
found that the detector was able to distinguish water from sand
and sand production less than 0.1 pound per Mmcf of gas.
Whenever sand was injected the response time was very fast
and essentially instantaneous. The installation of the detector
is simple, reliable and needs some intervention and
maintenance. The device can not be installed close to the
choke, since noise from the choke generates an unacceptably
high background signal which sometimes masks any sand
signal.
4 SPE 94896
Intrusive Sand Monitors. An intrusive sand erosion probe is Test Separator with Automatic Sand Flushing System.
located on all wells on Kapok. The probe is inserted into the The test separator on Kapok is equipped with a vortex sand
flowline and almost spans the ID of the flowline. The probe trap and solids collection accumulator. A test separator with
continuously monitors the thickness of the element and reports an induced vortex desander is located at the bottom of the
any changes to the DCS display. This probe uses Electric vessel for periodic removing of sand. The desanding operation
Resistivity (ER) to calculate the thickness. As the metal loss is done offline. A portable sand trap can be installed from the
increases, the Electric Resistivity also increases (see Figure desander. The sand collected and be inspected and again
7). determine sand production rate, grain size and type of
produced solids debris. The system is used during the ramp
up of wells, unloading of new wells and where a peak in the
acoustic detector is observed. The initial returns on all wells
S A N D /E R are normally flowed back into the test separator in the event of
FLOW capturing any unexpected high volume of proppant from the
PROBE
gravel pack. This solid will be collected in the separator and
not end up in the single multiphase export pipeline thereby
interrupting production from leaving Kapok platform. Samples
can then be retrieved and can be visually inspected.
Choke Wear Monitor. The majority of wear in choke occurs
in the vena contracta and in the adjacent downstream area as a
A C CESS result of high velocity, cavitation or flashing created by the
F IT T IN G pressure drop. The seat body of the cage design is extended
into the outlet bore of the choke. This extended section
contains an annular cavity that is sealed from the flow line
pressure. By monitoring the cavity for any significant pressure
increase, the operator can detect a failure of the seals or
washout of the seat liner (see Figure 8).
SA N D L O G #1
are:
1. A continuous sand monitoring system on the flowline of
each well where specific alarms are set for each individual (1)
Reading above
alarm limits for a
NO Continue producing as per
well priorities/constraints
wells and short term tending can be facilitated on the DCS. sustained 15 mins schedule.
scanning electron microscope (SEM). (1) Alarm set after calibration of acoustic
4. A test separator with an indued vortex desander at the YES detectors. This setting is equivalent 0.1
lb/MMscf nominal sand production.
bottom of the vessel for periodic removing of sand. The Choke back well in 10 MMscf/d
increments every 15 mins until acoustic
(2) Using a PI of 0.5 MMscf/d/psi for
particular well, the control on the choke
sand collected can be inspected and can determine sand detector reading is below alarm setting.
DO NOT repeat bean up exercise. DO
is limited to 20 psi drawdown. This
equates to 10 MMscf/d increments.
NOT use well as ‘swing’ production (3) Routing to test separator allows for the
production rate, grain size and type of produced solids and schedule sand injection testing. UT solids to be contained in a vessel verses
flowline and take shakeouts off carrying through the sand into the
debris. flowline. Contact PE to analyse well multiphase pipeline and jeopardizing
data and make further deliverability to the area processing
5. Monthly manual ultrasonic (UT) non-destructive testing recommendations. hub.
The control items in the flow chart are the size of the justification. The value of surveillance will be measured by
drawdown step and the stabilization time. The former is a the future ability to ensure that the promised production is met
function of the in situ sand strength (degree of cementation, and create options to grow production and reserves.
particle size and shape, reservoir pressure, formation depth) Full-bore Cores. The first strategic data in understanding
and the completion type. The latter is a function of fluid sanding tendencies in wells begins during the appraisal phase
viscosity, formation permeability and well deviation. of the field. A full suite of Electric-line logs were taken in
As a result to minimize the "shock effect" on the formation Kapok in conjunction with full-bore cores. The acquisition of
sand, it is best to use the smallest possible drawdown step that whole cores was used to help in reservoir characterization and
is practical. In general, it is more efective to use a large to ensure proper gravel pack sizing. Rock mechanical data was
number of small drawdown steps with shorter stabilization measured for borehole stability and for the design of optimum
time in between steps than a few large steps and long sand free completions.
stabilization. Any fragile bonding (cementation) as well as the Production Logs. To date none has been run on Kapok
packing of sand grains will be adversely affected both the however it is part of the surveillance plan to ensure that there
frequency of shut-downs and the rate of downhole pressure is an even distribution of flow along the open-hole
increase. completion. This minimizes any concern of concentrated flow,
The type of choke used (level of control on choke size plugging or damage of the pack, or partial flow from the
opening) governs the minimum achievable drawdown. reservoir. The production log also confirms that the flux rate
Regardless of the magnitude of drawdown, there is an upper through the pack and across the screens is evenly distributed.
limit on stabilization time for reaching the maximum effective Permanent Downhole Pressure Gauges. Once stable, all
stress possible which governs the sand strength. Increasing Kapok wells were shut-in for an initial Pressure Build-Up
stabilization time beyond that provides no additional benefit. (PBU). The PBU confirmed the high reservoir quality (kH,
Once the pore pressure within the near vicinity of the wellbore permeability-height) and the completion efficiency (skin).
and around the outer extremes of the gravel pack reaches a With the high quality reservoir sands and efficient completion,
near steady state condition (so called stabilization state), that drawdown constraints were not an issue for Kapok wells.
is considered to be the optimum stabilization time4. Gravel Pack Memory Log. Most of the completions in the
To materialise the true benefit of the sand monitoring and Kapok development are of a horizontal design. Information on
operating guidelines the training of the platform operators is the gravel pack quality was of significant importance as it
critical to its success. As the operators are at the forefront of affected the well’s production. To this end a cost effective
the operations and will be handling any sanding event they gravel pack evaluation solution was created. The gravel pack
should understand and be comfortable with the procedure. logging tool was integrated into the well completion work
They should be allowed to make recommendations and string that was conveyed at the bottom of the gravel pack wash
thereby own the procedure as this document ensures their pipe. The tool was operated in memory mode providing gravel
safety and maintain the reputation of BPTT LLC as a pack data across the entire gravel pack interval. By correlating
responsible operator. the density difference to the gamma ray count rates made it
possible to identify voids along the lateral length that
Well Conditioning. The concept of well conditioning is based ultimately determined the percentage of pack. This technology
upon the phenomenon of “post failure stabilisation’ where confirmed a 50 feet void on one of the Kapok wells resulting
stable cavities are formed behind the completion2. The in a remedial completion sleeve over the void thereby
technique only applies to transient sand producers and can be restricting the flow across the unpacked area and successfully
achieved by beaning up the well in steps to a maximum flow producing the well sand free.
rate (drawdown) that exceeds the required final flow rate. Saturation Logs. Water breakthrough is a key risk at Kapok
After every bean-up step, the well is kept at a constant rate since most of the reservoirs are thin and are underlain by
until the sand production rate declines to a steady-state value water. The presence of water will be monitored through
(often zero). Following the highest flow rate, the well is detecting gas-water contact (GWC) movements and saturation
beaned back to its required flow rate, at which the well now changes using saturation logs in offset surveillance wells.
will be producing sand-free. Real-time Production Monitoring. A surface gas meter is
Flow line samples. Shakeouts are taken from each well at present on all wells to monitor real-time gas rates. Production
least once per platform visit: well test will be carried out to confirm or adjust these rates. At
1. Obtain flowing sample from flowline least once per month a production well test is done on all th
downstream of the wellhead choke. wells to obtain flow rates of gas, condensate and water using
2. Heat sample if it contains an emulsion. the test separator. Production is allocated back to each well at
3. Centrifuge sample (for 2 to 3 minutes if the end of each month’s when all the production from Kapok
necessary). is counted.
4. Record results for transfer to Production Report.
If a well shows abnormal amounts of sand, condensate, or Conclusion
water, notify the Production Engineer. The tendency to produce incipient sand during the Kapok
Field development was confirmed from core testing and
Down-hole Surveillance Plan
experience with analog fields within Trinidad. As a result any
Formulation of a detailed surveillance plan is seen as a critical
major sand production will not only pose a risk to Kapok gas
step in outlining the types of data required, the frequency and
delivery but also be detrimental to bpTT gas supply to
SPE 94896 7
Acknowledgements
The author wishs to acknowledge the management of the BP
Trinidad and Tobago LLC, the Kapok project team, Greater
Cassia Operations Team, the many contactors and BP
Exploration and Technology Group namely Hans Vaziri for
his work on bean-up schedule for sandy wells and John Glenn
for his work on recommending alarm settings for sand
detectors who all made Kapok outstanding production delivery
a reality for permission to publish and present this paper.
References
1. Penberthy, W.L. Jr.; Shaughnessy, C.M “Sand Control,”
SPE Textbook Series Vol. 1, page 1-8.
2. Teng, D.; Nettleship, G.; Hicking, S. and Hindmarsh, K.
“High rate Gas Well Design: Issues and Solutions –
Goodwyn Gas Condensate, NWS, Australia” SPE paper:
50081 presented at the 1998 SPE Asia Pacific Oil and Gas
Conference and Exhibition, Perth, Australia, 12-14
October 1998.
3. Balgobin, C.J et al “The Kapok Field – A Step Change for
Trinidad Gas Developments” SPE paper: 75670 presented
at SPE Gas Technology Symposium, Calgary, Alberta,
Canada, 30 April - 2 May, 2002.
4. Vaziri, Hans – Technical study on bean-up schedule for
sandy wells.