Abstract
Sand production remains one of the major challenges in managing mature fields in Malaysia. Wells that experience severe sand production due to primary sand control failure require remedial solutions to continue producing without jeopardizing asset integrity. In these cases, operators rely heavily on through-tubing metallic sandscreen (TTSS), however, the applications remain limited due to the short TTSS lifespan, especially in wells in a high erosive environment. With increased intervention risk, frequent replacement is both economically and operationally unfeasible. Therefore, most high gas-oil ratio (HGOR) wells remain closed-in today, in need of a durable sand screen that can withstand high erosional velocity. Various types of erosion resistant through-tubing sand screens (ER-TTSS) have been implemented to test their sustainability and longevity in highly erosive environments. Additional challenges can be associated with the actual deployment of these remedial solutions into mature wells.
This paper will discuss the performance of Malaysia's first installation of bonded bead sandscreen in HGOR well, Well #1 at offshore East Malaysia. Instead of using conventional mesh or wire wrapped type as filtration media, bonded bead sandscreen incorporates tightly bonded beads to filter sand and is expected to have superior performance over conventional metallic TTSS. Prior to installation, computational fluid dynamic (CFD) simulation and sand retention test (SRT) were conducted to determine sand erosion risk and optimize the screen design for Well #1. The information gathered from the CFD was then utilized to optimize the tubular components and minimize the effect of erosion on the complete bottom hole assembly (BHA). Additionally, well #1 was on an unmanned production platform; therefore, the deployment options for this intervention had to be considered during the early planning phase of the operation. A combination of slickline unit with suitable pressure control equipment was selected to minimize personnel on board and match deck load limitations while ensuring proper service delivery.
The outcome of pilot testing of bonded bead sandscreen in Well #1 will be discussed. Recommendations for future optimization will also be included to ensure that bonded bead sandscreen remains one of the competent through-tubing sand solutions, especially for HGOR wells. Furthermore, the operational techniques that were utilized to reduce the operational risk and costs will be discussed in order to demonstrate how such wells can be intervened in a cost-effective manner to extend the asset's life.
