As part of well cost reduction initiative, screenless fracpack has been successfully applied in Field D in which gravelpack or fracpack have been the prevalent sand control completion methods. This paper discusses the first application of screenless fracpack in Malaysia with description on design process, implementation method, challenges in design and execution, production performance, and the recommended way forward.

Typical gravel pack or fracpack would require installation of downhole screen and packer assemblies, followed by gravel pack or fracpack pumping. The associated cost ranges from USD 1 million to USD 2 million for a multi-zone well. However, screenless fracpack application eliminates the high-cost screen and packer assemblies. Perforations are made with vertically oriented 0-180 degree phasing (up and down) to maximize fracture alignment with perforations as well as to minimize potential sand production from the perforations without fracture. Subsequently, perforations and near wellbore matrix are treated with resin injection to consolidate near wellbore formation in ensuring good sand/fines control in formation that is not fractured. Hydraulic fracturing utilizes tip screen out method to create short fracture length and wide fracture width to maximize dimensionless fracture conductivity. Proppant can be resin coated or treated with network of fibers to control proppant flowback in absence of downhole screen assemblies.

All planned procedures have been successfully conducted. Perforations were made in a short interval i.e. about 2m in length with limited entry 4 SPF/ 0-180 degree phasing. Dynamic underbalance technique was incorporated to maximize open perforations effectively. Resin injection plan was dropped due to low permeability and low injectivity. Resin squeeze into a tight formation can end with either incomplete resin and overflush injection, or fracturing with the viscous resin, either of which would damage the formation. A highly conductive fracture has been created with tip screen out. Nolte Smith log-log plot showed a unit slope, an indication of tip screen out. Proppant flowback control was obtained with resin coated proppant. Post screenless fracturing, the well was carefully unloaded and cleaned. Well production showed good productivity and effective sand control. Currently, other fields are being studied and considered for the same application.

Screenless fracpack is applied for the first time in a field offshore Malaysia. It is a bold step change whereby gravelpack or fracpack are commonly used as sand control. The application was driven by well cost reduction effort and the application is currently considered for replication in other fields. The benefit of the new method is not only the well cost savings by elimination of screen and packer assemblies, but it also provides full bore access and simpler well interventions. This application helps in brownfield and marginal field development whereby small reserves may negatively project economics due to high cost for gravelpack or fracpack installation.

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