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Sand ControlFluid System and Down Hole Tools
June 2 nd , 2006Bogot, Colombia
Presenter: Sandra Garcia- Luis Velandia
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2
What are the consequences ofsand production?
Wellbore fill Equipment problems due to
sand fill Sand erosion of downhole
equipment Sand accumulation on surface Erosion of surface equipment Production Loss
Casing / Liner Collapse Sand Disposal
Environmental Concerns
Facility downtime
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3
What causes sand production?
Totally or weakly unconsolidated formations Argillaceous (containing clay) cementing materials Interaction of inter-granular friction and in situ
stresses Capillary forces Viscosity of the fluids in place
Improper well completionAcid stimulation / Completion fluids / Cement
Changing stresses in the near wellbore area High Production Rates Depletion of the Reservoir Pressure Production of High Viscosity Fluids
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4
What causes sand production?
Water Production Dissolves the cementing materials holding the sand
grains togetherinjection waterwater not from the immediate vicinity
Increased drag forces due to increasing total fluidrates
Increased drag forces due to two phase fluid flow Disturb the cohesive forces holding the grains
together Disturb the capillary forces holding the grains
together
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5
What can be done aboutsand production?
Production Restriction or Lower FlowVelocity
Choke back productionRe-perforate, etc.
Mechanical Methods Downhole Filter Gravel Pack Screen in Open hole - Expandable
Horizontal Gravel Pack FracPack
Chemical consolidation of the formation
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10 September 2014
Design
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7
Information required for designing asand control completion
Mineralogy and Water-Sensitivity of theFormation
Formation Sizing Sieve Analysis Particle Size Analysis
Gravel Sizing Gravel Pack vs. FracPac
Slot Sizing Gravel Pack vs. FracPac Slotted Liners Screen only Prepack Screens
etc.
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8
Information required for designing asand control completion
Completion method based on the formationinformation Clay Instability Rating (CIR) Acid Soluble Clays Formation Heterogeneity Formation Height Deviation
Reservoir Drive Type (water, gas, compac t ion ,etc.)
BHT BHP
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Information required for designing asand control completion
Swelling or migrating clay content Completion fluid selection and compatibility Sieve Analysis Particle Size Analysis
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10
Sizing the Gravel
Formation Sand Sample is run through a series of
sieves Amount remaining on each sieve
is plotted as a function ofcumulative weight % versusgrain diameter
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11
Sieve Analysis Plot
Various pointsare determined
D50 , D 10 , D 40 ,D90
These points canthen be used todetermine thegravel sized
needed to retaina formationsand .
100
90
80
70
60
50
40
30
20
10
0
VeryCoarse Coarse Medium Fine
VeryFine
Silt andFiner
U.S. Sieve No.
Sieve Opening mm
3250040000000000
.03040608.1.2.4.6.8.0.0
muav
P
c
a
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Gravel Sizing
Gravel Sizing - Gravel Pack Coberly Tausch & Corley Saucier 5-6 x D 50
Screen Only Completions Coberly Sparlin - D 10
FracPack 7-10 x D 50 One size larger than Sauciers Criteria
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Sizing the Screen Opening Gravel Pack
The screen opening is typically between 50-70% of the smallest gravel diameter
For 20/40 mesh sand the smallest gravel is the 40mesh which has a D 50 of 0.0165 0.0165 x 70% = 0.01155 or 0.012 opening (12
gauge) Screen Only
Screen Opening is approximately equal to theD10
Slotted Liner Slotted Liner Opening is approximately equal
to the D 10
Prepack Screen
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10 September 2014
Recent Gravel Pack Techniques
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Recent Gravel Pack Techniques
Slurry Pack - (1970s - 1990s) Can be used for cased and perforated or openhole completions
Typically used for vertical wells with shorter
intervals The carrier fluid is viscosifed
Originally viscous oilViscosified Water (80 lb m /1000 gallons HEC, 36-48lb m /1000 Xanthan, etc.)
Sand concentrations can range from 3 to 15ppg
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17
Recent Gravel Pack Techniques
Staged Acid - Prepack followed byAnnular Water Pack (1980s - ) Typically used on cased and perforated
completions
Staged Acid Prepack used to packperforationsCarrier Fluid is viscosified (typically 60 lb m /1000gal HEC)Sand Concentration is typically 3-4 ppg
Annular Pack (typically water pack) used tofill screen-casing annulus
Carrier Fluid is water or slightly viscosifed waterSand concentration is typically 0.5 - 2 ppg
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Recent Gravel Pack Techniques
Water Pack Only - typically used for openhole completions Water or slightly viscosified water Higher rates required
Lower sand concentrations required Very good annular packing technique
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19
Recent Gravel Pack Techniques
High Rate Water Pack Water or slightly viscosified water Higher rates required to fill perforations and
create numerous mini-fracs into the formation inhigh permeability wells
Typically 5-10 bpm or 1 bpm per 10 ft of perforations Sand concentrations
3-4 ppg Additional Surface Equipment is required
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Recent Gravel Pack Techniques
Ex-tension PacSM
Service Liquid Sand SM SC 2OOP TM SandWedge TM
Xtra_nalysis.xls SoftwareTip screenouttechniqueSand placement to
200-250-lbs/ft ofperforationsSkin values betweenHRWP and FracPac
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Ex-tension Pac SM Design
Candidates: Typical HRWP Area where fines are problematic
Pump at rates up to 15 bpm Use slick water (10 - 20 lb m gel /1000 gallons) Proppant concentrations up to 4 ppg Use Step-Rate test, Mini-frac, and Pad
equation to determine pad size.
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Recent Gravel Pack Techniques Horizontal Gravel Packing
Pump Rate and Fluid Velocity2-4 BPM(1-3 ft/sec)
Alpha and Beta Wave Progression Through Pack
Sand Concentration0.5 - 2 ppg
Placement Procedure and Tool Configurations Liner / Tailpipe Ratio
> 0.80 ratio Screen / Casing Clearance Screen / Open Hole Clearance Perforation Phasing
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10 September 2014
Ex-tension Pac
Gravel Pack Job, SqueezePosition
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Design:Correlation Well A:
* Sand Placement Increasing to at least 200-250 lb/ft.Placing as much sand bas possible behind pipe is critical togood well production. Actual packing factor in well A(sand in place) was 5600 lb/ft.
* System fluid - Using SandWedge allowed the sand size to beincreased from 20/40 to 16/20 for further conductivityenhancement.
* Down hole tools Using MPA and gravel pack assy. testedaccording to pressure requirements (7000 psi) permit performpickling, injection and reverse operations required.
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Design:
Well B:* Sand Placement Increasing to at least 200-250 lb/ft.
Placing not too much sand as possible behind pipe in order toprevent an early high water production (6224, 6230, 6240).
* System fluid - Using SandWedge allowed the sand size to beincreased from 20/40 to 16/20 for further conductivityenhancement.
* Down hole tools Using MPA and gravel pack assy. testedaccording to pressure requirements (7000 psi) permit performpickling, injection and reverse operations required.
* Proppant Size - 16-20 Using SandWedge / Slot GaugeScreen Size 0.012
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Log Well B.
Design:Log Well A.
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Design:Sieve Analysis
D50 = .0174
0
10
20
30
40
50
60
70
80
90
100
0.0010.010.1Size (inches)
P e r c e n t
U. S. MESH10 10060403020 325140 200
SIZE
2500 305010015025050075010001500
AveragesMedian: .0174Mean: 0.022Mode: 0.0199
Proj. No. Careto-1Sample No.
Uniformity Coefficient. D40/D90 = 2.7667
D10 = 0.0460D40 = 0.0209 D50 = 0.0174 D90 = 0.0076
%Fines = 0.0
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Running Sump Packer & BHA Assy
Permanent Packer RIH BHA:
- Seal Assy for permanent packer.- Screen 0.012 slot gauge AWWW, 4NU - Blank pipe 4NU - Shear Joint- Ex-tension Pack Assy
Landing nipple and Test Tool. Running tubing (test pressure 7000 psi). Spacing out tubing.
Final Test. Pulling Test Tool w/ slickline. Rig-up surface lines and set PRVs.
AWD @ 6222 top
VTA @ 6147 top
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Setting VTA Packer / Expend ball
Set Packer and Expelling the Ball
4/14/200617:40 17:50 18:00 18:10 18:20
4/14/200618:30
Time
0
500
1000
1500
2000
2500
3000
3500
4000 Backside Pressure (psi) Treating Pressure (psi)321
Local Event Log
1
2
3
IntersectionSet Packer
Annulus Test
Expelling the ball
BP-28.83
1034
-25.75
TP2076
-20.04
3609
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 13:08
VTA @ 6147 top
AWD @ 6222 top
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VTA @ 6147 top
AWD @ 6222 top
Assuring MPA PositionsMulti Positional Test
4/14/200618:35 18:40 18:45 18:50 18:55 19:00 4/14/200619:05Time
0
250
500
750
1000
1250A
0
1
2
3
4
5BBackside Pressure (psi) Treating Pressure (psi) Slurry Rate (bpm)A A B
76543
Local Event Log3
4
5
6
7
Squeeze Position
Circulation Position
Reverse Position Pump by Tubing
Reverse Position Pump by Annulus
Reverse Position Pump by Annulus
18:36:04
18:40:08
18:46:55
18:56:54
19:05:12
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 13:58
67200
4.33700 7
2500Reverse pump by
annulus
72090Reverse pu mp by tubing
220600Circulation
1.00.201000
1.00.50800Squeeze
Volume (bbl)Rate (bpm)Annulus Press (psi)Tubing Press (psi)MPA position
67200
4.33700 7
2500Reverse pump by
annulus
72090Reverse pu mp by tubing
220600Circulation
1.00.201000
1.00.50800Squeeze
Volume (bbl)Rate (bpm)Annulus Press (psi)Tubing Press (psi)MPA position
31
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VTA @ 6147 top
AWD @ 6222 top
Pickline
4/14/200619:10 19:20 19:30 19:40 19:50 20:00 20:10 20:20
4/14/200620:30
Time
0
20
40
60
80
100
A
0
3
6
9
12
15
B
0
10
20
30
40
50
60
70
CBackside Pressure (psi) Treating Pressure (psi)Slurry Rate (bpm) Stage Slurry Vol (bbl)
A AB C
987
Local Event Log
7
8
9
IntersectionAcid
Displacement
Reverse
SSV14.02
37.25
61.11
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 14:04
Pickling Acid
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Step Rate Test
Step Rate Test
4/14/200621:50 22:00 22:10
4/14/200622:20
Time
0
1000
2000
3000
4000
5000
A
0
5
10
15
20
25
30B
0
2000
4000
6000
8000
10000E
0
20
40
60
80
100
120
140G
Treating Pressure (psi) Slurry Rate (bpm)Backside Pressure (psi) Stage Slurry Vol (bbl)
A BE G
321
Local Event Log1
2
3
Load Well (Brine + Clasta FS)
Fluid Efficiency Test
Shut-In for FET Analysis
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 18:46
33
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Ex-Tension Pac TreatmentJob Summary
4/15/200602:46 02:48 02:50 02:52 02:54 02:56
4/15/200602:58
Time
0
2000
4000
6000
8000A
0
2
4
6
8
10
12
14
16
18B
0
2
4
6C
0
2000
4000
6000
8000
10000
12000
14000
16000
18000
20000E
Treating Pressure (psi)Slurry Rate (bpm)Slurry Proppant Conc (lb/gal)Bottomhole Proppant Conc (lb/gal)Backside Pressure (psi)
ABCCE
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 20:56
MaxTreatingPressure
AvgTreatingPressure
MaxSlurryRate
AvgSlurryRate
SlurryVolume
ProppantMass
Pumped
AvgProppant
Conc
Stage Number
psi psi bp m bpm bbl 100*lb lb/galPad 3952 3227 15.5 14.9 83 0 0
Proppant Laden Fluid 3143 3118 15 14.7 37 8.5 0.55
Proppant Laden Fluid 3096 3057 15 14.9 26 13.7 1.27
Proppant Laden Fluid 3771 3428 14.9 14.8 33 27.7 2.01
Proppant Laden Fluid 3910 3850 14.6 14.6 7 7.1 2.42
Screen Out 6000 -- -- -- -- -- --
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Reversing
4/15/200603:10 03:15 03:20
4/15/200603:25
Time
0
100
200
300
400
500
600
700
800
900A
0
1
2
3
4
5
6
7B
0
20
40
60
80
100
120D
Backside Pressure (psi) Annulus Rate (bpm)Returns Total (bbl)
A BD
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 21:02
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Re-stress Test
Re-Stress
4/15/200603:35 03:40 03:45 03:50 03:55
4/15/200604:00
Time
0
1000
2000
3000
4000
5000A
0
1
2
3
4
5
6
7B
0
10
20
30
40
50
60D
Treating Pressure (psi) Backside Pressure (psi)Tubing Rate (bpm) Tubing Total (bbl)
A AB D
21
Local Event Log
1
2
IntersectionFilling Tubing (Brine + Surfac tant)
Re-Stress
TP603.6
4417
Customer: MONTECZ S.A. Job Date: 14-Apr-2006 Sales Order #: 43215001Well Description: CARETO 1 UWI:
H A L L IB U R T O NINSITE for Stimulation v2.4.0p1
16-Apr-06 21:16
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Running Completion
RIH Completion:
- Seal Assy for VTA Packer (not additional packer).- No-Go Locator.- Tubing Joint 3 (spacing)- Landing Nipp le XN 2.635No -Go (in order to test the
string and set memories gauges).- Tubing Joint 3 (spacing) - Sliding Side Door X 2.750 (inside will set a Jet
pump).- Tubing to surface.
RIH jet pump and start the well test.
VTA @ 6147 top
AWD @ 6222 top
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Conclusions:
The objective of sand control was achieved, by putting Carbolite 16/20into formation (effective Sand Control technique).
C7 formation receives a total sand in formation of 262.5* lb/ft inaccording to the target.
C7 formation in Careto 01 has a ISIP gradient of 0.662psi/ft and Formation Stress Gradient of 0.568 psi / ft.
Using linear gel during PAD in most of the sand control operation willminimize the fluid friction in the tubing, the turbulence effect and theproppant transport into the formation in the sand laden stages.
According to pumped schedule, returned sand and re-stress test, thequantity of proppant into formation is good for this Sand Pack service.
According to pressure behavior and bottom hole proppantconcentration the small fracture generated in formation reached a tipscreen out condition.
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Historical Cases Colombia
Halliburton 2002
Production Rate Trend Sand Controled Wells 2003-2004-2005
0
1,000
2,000
3,000
4,000
5,000
6,000
7,000
8,000
20-Mar-03 28-Jun-03 6-Oct-03 14-Jan-04 23-Apr-04 1-Aug-04 9-Nov-04 17-Feb-05 28-May-05 5-Sep-05
B F P D
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Historical Cases Colombia
Halliburton 2002
Production Tendency Well A
0
1000
2000
3000
4000
5000
6000
7000
8000
9000
18-Jan-06 23-Jan-06 28-Jan-06 2-Feb-06 7-Feb-06 12-Feb-06 17-Feb-06Date
B B L
0
150
300
450
600
750
900
1050
1200
1350
B P D
Vt (BBL) Vw (BBL) Vo (BBL) Qt (BPD) Qw (BPD) Qo (BPD)
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10 September 2014
PoroFlex
Exp and ab le ScreenCom plet ion Sys tems
Tech no log y Overview
Halliburton 2002
41
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Why Expandable Screens? Borehole collapse damages completions
Eliminate or reduce borehole/screen annulus
Minimize plugging of non-uniform sands
Minimize pressure drops in horizontal intervals
Eliminate gravel pack failures
Installation of intelligent sand control equipment
Well Completions
PoroFlex
Halliburton 2002
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Why Expandable Screens?Borehole collapse during production
PluggedScreen
Erosion Sites
Solution: Stabilize borehole by expanding screen OD to or near
borehole ID .
Creates hot-spots on both sides of non-producingarea that plug sooner or erode, causing screen
failure.
PoroFlex
Halliburton 2002
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Eliminate AnnulusMinimize Plugging Effects of Non-Uniform Sand
Solution: Eliminate annulus by expanding screen OD to or near
borehole ID .
Fines move down the borehole annulus to findthe nearest unplugged section and plug it;increasing velocity in the unplugged sectionsuntil erosion occurs.
PoroFlex
Halliburton 2002
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Why Expandable Screens?Minimize pressure drop along horizontal section Caused by undesirable well screen OD/ID ratios. Can lead to early water coning, breakthrough or
blocking of oil production, and early start of sandproduction.
Solution: Install sand screens with larger ID for same OD.
Larger ID facilitates workovers and/or zonalisolation techniques
Allows installation of intelligent well completion
PoroFlex
Halliburton 2002
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Why Expandable Screens?
Gravel pack failures can be eliminated Caused by undesirable borehole geometries
in combination with carrier fluids and nature
Solution: Where possible, eliminate gravel packing
from well completion operations
Well Completions
PoroFlex
Halliburton 2002
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Additional Benefits Formation support lowers skin values
Large ID for easier well intervention access
Isolation of trouble zones with expandable solids(cladding)
High resistance to erosion and plugging
Well Completions
PoroFlex
Halliburton 2002
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Key Features Perforated solid base pipe
Stronger Remedial options
Premium one-piece sintered laminate screen Filtration integrity under a variety of load conditions Integral joint expandable threaded connection
Allows rotation during run-in
Makes up faster on the rig floor Mechanical or hydraulic expansion options
Hydraulic expansion more reliable in extended reachhorizontal wellbores
PoroFlex
Halliburton 2002
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System Components
S imple con f igura tion Uncom pl ica ted equipm ent Reliable ins tal lat io n
Open hole
Spacer
Standardconnection
ExpansionConeLauncher
ExpandableSandScreen
Down-JetFloat Shoewith SealBore
Production casing
or liner
Expandableconnections
ScreenSuspensionTool
PoroFlex
Halliburton 2002
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Installation Issues Hole geometry
Sperry- Sun Slickbore service to maintain hole size
Getting screen to bottom and wellbore clean-up Baroid for fluids selection and filter cake treatment
Completion placement Acoustic or caliper logging for hole size verification
Restriction effects Formation deformability Expansion tool stress
PoroFlex
Halliburton 2002
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Premium Screen
316L screen material One-piece construction
Plain Dutch weave Each layer sintered 360 coverage
Micron rating unchanged post-expansion Dual drainage layers Perforated outer shroud for stiffness and reliable
installation
PoroFlex
Halliburton 2002
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Screen Construction
Base pipe
Lower drainagemesh layer
Filter mesh layer
Upper drainagemesh layer
Outer shroud
Top fo ur layers s in teredto fo rm a one-piece f i l ter
PoroFlex
Halliburton 2002
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Screen Construction
Well Completions
Top View
Oblique View
Warp wire
Weave wire
Micron ra t ing d eterm ined by diam eter of warp w ire
Expansionalong radial axis
(no pores seen) Plain Dutchweave
Warp w ires no t expanded Weave w ires no t y ie lded
MICRON RATING UNCHA NGED
PoroFlex
Halliburton 2002
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Screen Joint ConstructionReceive mill-rolled blank base pipePerforate
Apply ID coatingThread box x pinInstall screen jacketsWeld screen jackets to base pipeInsert desiccant and install thread protectors
PoroFlex
Halliburton 2002
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Operating StepsHanger
ExpandedRun
ExpanderExpanding
ScreenExpansionCompleteRun Liner
PoroFlex
Halliburton 2002
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Expansion Process Mechanical
Set weight down Hydraulic
Expansion cone deployed to upper mandrelsection Slips set to anchor expansion tool Mandrel hydraulically extended to expand screen
Slips released and pipe run in hole to meetexpansion cone
At end of expansion, nose lands in seal bore,cone sheared, and expansion tool retrieved
(Click to run animation)
PoroFlex
Halliburton 2002
58
http://localhost/var/www/apps/h021041.HALAMERICA/Local%20Settings/My%20Documents/PD&C%20Stuff/PoroFlex/Animations/100101exsRoughCutdivx.avihttp://localhost/var/www/apps/h021041.HALAMERICA/Local%20Settings/My%20Documents/PD&C%20Stuff/PoroFlex/Animations/100101exsRoughCutdivx.avi8/11/2019 Presentacin Metodos Mecnicos Control Arena Junio 2-06
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SpecificationsPoroFlex Screen 6.125 8.500
Run-in OD (125/250) 5.375/5.460 7.370/TBD Run-in ID 4.500 6.390 Expanded OD 6.125 8.500 Expanded ID 5.440 7.730 Screen rating 125 & 250 125Screen material 316L 316LService rating Std. & H 2S Std. & H 2S
Expansion Tool
Run-in & retrieval OD 5.000 7.000 Expanded OD 5.440 7.730 Operating pressure (approx.) 3,500 psi TBDExpansion method Mechanical or HydraulicStroke length 10 15
PoroFlex
Halliburton 2002
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Job Histories
Amerada Hess GoM March, 2002 7 29# cased hole
Max hole angle 53
Dual zone completion (top of zones 8,558 and11,440 MD)
Upper zone 1 jt screen + 1 ea 10 annular barrier
Lower zone 1 jt screen + seal bore/float shoe Expansion to maximum OD (6.125) System performed per plan and procedure No production data available at this time
PoroFlex
Halliburton 2002
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Job Histories Repsol Indonesia March, 2002
6.125 open hole side track completion Maximum hole angle 57
Dual zone (top of screen at 3,312 MD) out of 7 casing
Upper zone 1 jt screen + 1 ea 10 annular barriers Lower zone 1 jt screen + seal bore/float shoe
Repsol Indonesia April, 2002 6.125 open hole side track completion
Maximum hole angle 90 Top of zone at 6,200 MD 288 feet of screen expanded
PoroFlex
Halliburton 2002
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Future Work
Petrobras 6.125 open hole completion
S shaped well Maximum hole angle 90
Dual zone completion out of 9- 5/8 casing Possible deployment below expandable liner hanger
Upper zone 750 screen + 225 blank (annularbarriers at either end) Lower zone 750 screen + seal bore/float shoe
PoroFlex