bpm

Introduction of Gravel Pack with Inflow Control
Completion in Brazil
6th European Sand Management Forum
© 2014 Baker Hughes Incorporated. All Rights Reserved.
Abrahão Jardim / Alberto Costa / Tobias Rocha / Hang Nguyen / Peter Kidd – Baker Hughes
Daniela Leite / Arcindo Santos – Statoil Brasil
1
© 2014 BAKER HUGHES I NCORPORATED. ALL RI GHTS RESERVED. TERM S AND CONDI TI ONS OF USE: BY ACCEPTI NG THI S DOCUM ENT, THE RECI PI ENT AGREES THAT THE DOCUM ENT TOGETHER W I TH ALL I NFORM ATI ON I NCLUDED THEREI N I S THE
CONFI DENTI AL AND PROPRI ETARY PROPERTY OF BAKER HUGHES I NCORPORATED AND I NCLUDES VALUABLE TRADE SECRETS AND/ OR PROPRI ETARY I NF OR M ATI ON OF BAKER HUGHES (COLLECTI VELY "I NFORM ATI ON"). BAKER HUGHES RETAI NS ALL RI GHTS
UNDER COPYRI GHT LAW S AND TRADE SECRET LAW S OF THE UNI TED STATES OF AM ERI CA AND OTHER COUNTRI ES. THE RECI PI ENT FURTHER AGREES TH AT THE DOCUM ENT M AY NOT BE DI STRI BUTED, TRANSM I TTED, COPI ED OR REPRODUCED I N W HOLE OR
I N PART BY ANY M EANS, ELECTRONI C, M ECHANI CAL, OR OTHERW I SE, W I THOUT THE EXPRESS PRI OR W RI TTEN CONSENT OF BAKER HUGHES, AND M A Y NOT BE USED DI RECTLY OR I NDI RECTLY I N ANY W AY DETRI M ENTAL TO BAKER HUGHES’ I NTEREST.
Agenda
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2
Objectives
Reservoir Information
Conventional Gravel Pack ICD Gravel Pack – Well Design
Challenges
Case History #1
Case History # 2
Conclusions
Objectives
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▪ Provide sand control
▪ Provide uniform inflow along long horizontal well
▪ Provide additional oil production compared with standard screens
3
Reservoir Information
▪ Peregrino field is located 85 km offshore Brazil (Campos Basin)
▪ 24 km of extension
▪ Water depth around 100 m
▪ API: 140
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▪ Unconsolidated sands and thin heavy oil-bearing sections
▪ Wells require sand control techniques
▪ Producer wells: 30
4
Reservoir Simulation Studies
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▪ Evaluate the well completion effect on the reservoir behavior of horizontal well in
Peregrino field, considering:
– OHGP with Standard Screen vs. OHGP with ICD screen completion
– Water injection effect
– Determine ICD type and rating, joint quantity and optimum flow resistance rating
– Determine additional pressure drop requirements with ICD completion
– Estimate the oil and water cumulative production with and without ICD Technology
– Estimate the oil and water influx (bpd/ft) behavior
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Reservoir Simulation Observations
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▪ ICD completions add value in the long term when it is compared with standard
completion.
▪ ICD completion promote an evenly fluid influx along the horizontal section and delay
in the water breakthrough
▪ It is recommendable to install sliding sleeve (mechanical water shut off) in order to
control the water production (after 5 years); reservoir simulations (based on ICD with
6.4FRR flow resistance rating) show that water will come mainly from reservoir
areas with less flow resistance in the porous media (more permeability)
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Conventional Gravel Pack vs. ICD Gravel Pack – Well Design
 Typical Architecture for Horizontal Open Hole Gravel Pack Wells with standard
screens
5-1/2” Standard Screens
2.71 SG Proppant
Bull Plug
GP Packer
 Typical Architecture for Horizontal Open Hole Gravel Pack Wells with ICD screens
Bull Plug
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GP Packer
5-1/2” ICD Screens
LWP 1.75 SG Proppant
5-1/2” Standard Screen
Sliding Sleeve
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Challenges
 ICD screens restrict fluid from entering the screens/washpipe annulus resulting in a
lower alpha dune height
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 Pumping rate during beta wave placement must be slowly reduced to stay below
fracture pressure
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Hookup for Gravel Packing with ICD Screen
OHGP
Crossover
Tool
AntiSwabbing
LBHP Tool
Shifting
Tool
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Indicator
Couplings
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Indicating
Collet
Fluid Loss
Control
Valve
Perforated
Tubing
EQUALIZER
Screen
2-Way
Shifting
Tool
Sliding
Sleeve
Configuration During Gravel Packing
Washpipe
EQUALIZER Screen
Crossover Sub
Double Pin Sub
Perforated Tube
Sliding Sleeve
Premium Screen
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Shifting Tool
Bull Plug
10
Bull Plug
Configuration During Production
EQUALIZER Screen
Double Pin Sub
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Sliding Sleeve
Bull Plug
11
Premium Screen
Bull Plug
Challenges - The Proppant Selection
 Select the correct proppant to be transported at low rates without settling
Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 20/40 LiteProp175, 5500 psi FP)
Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 16/20 Carbolite, 5500 psi FP)
2000
2000
Q, BPM =
Q, BPM =
5.49
1800
1800
1600
1600
Stop Proppant feeding when beta wave is about 600ft of heel
1400
1400
1200
1200
STP-alpha
1000
STP-beta
STP-frac
STP, psi
STP, psi
Stop Proppant feeding when beta wave is about 800ft of heel
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5.00
ICD Screen: TRUE
ICD Screen: TRUE
12
Ver 06-12-2012
Lateral
Length
STP x Lateral lengthSTP
(ft)vs.for
1.75
SG proppant
Ver 06-12-2012
STP vs. (ft)
Lateral
STP x Lateral length
forLength
2.71 SG proppant
STP-alpha
1000
STP-beta
STP-frac
800
800
600
600
400
400
200
200
0
0
0
500
1000
1500
2000
Lateral Length, ft
2500
3000
3500
0
500
1000
1500
2000
Lateral Length, ft
2500
3000
3500
Challenges - The Proppant Selection
▪ Regular shape – good roundness and sphericity;
ULW-175
ULW-125
 SG = range from 1.75 to 1.90
 Bulk density = range from 70 to 72 lb/ft3
 Stress environments as high as 8,000 psi
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 Yields 35% less weight than regular ceramic
13
ULW-108
Challenges – The
HorizontalSimulation
Gravel Packing Design Criteria
Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 20/40 LiteProp175, 5500 psi FP)
4500
Ver 06-12-2012
0.95
ICD Screen: TRUE
0.90
Centralized: FALSE
Fluid Return Ratio = 0.95
Hole Angle, deg. = 90
Hole Dia., in = 8.9
Screen OD/ID, in = 6.3, 5.082
Wash Pipe OD, in = 4
Roughness, in = 0.01
Fluid Vis., cps = 1.2
Fluid Dens., ppg = 9.7
Mix Ratio, ppga = 1
Gravel Dia., in = 0.027
3500
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Pump Pressure, psi
3000
0.80
2500
0.75
2000
0.70
1500
0.65
1000
0.60
500
0.55
0
0.0
2.0
4.0
Ppump-alpha at bottom
14
0.85
6.0
Pump Rate, BPM
Ppump-beta at TOS
Ppump-Frac
8.0
10.0
Dune/Hole Ratio
0.50
12.0
Dune Height/Hole Diameter Ratio
4000
 Gravel pack
design software
which takes in to
account the large
increase in
pressure drop
during beta wave
placement
Challenges – The Simulation
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Open Hole Horizontal Gravel Packing
Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 20/40 LiteProp175, 5500 psi FP)
ICD Screen: TRUE
Estimate Pump Time and Amount of Proppant Pumped
Tubular Volume above Packer, ft³
1286.62
Dune/Hole Ratio
Pump Rate, BPM
Return Rate, BPM
0.74
5.00
4.75
0.65
7.68
7.30
0.70
6.37
6.05
0.74
5.00
4.75
0.80
3.16
3.00
Alpha Pressure, psi
Beta Pressure, psi
Frac Pressure, psi
369
182547
1706
929
431141
2028
623
296282
1854
369
182547
1706
132
72669
1563
Alpha Time
Beta Time
163.72
110.14
74.57
101.53
108.48
105.20
163.72
110.14
317.06
120.16
Time for proppant to reach Packer, min
Time at end of Alpha, min
Time at end of Beta, min
45.81
209.53
319.67
29.82
104.40
205.93
35.97
144.45
249.66
45.81
209.53
319.67
72.53
389.58
509.75
Proppant amount below Packer, lbs
Proppant amount at Screen-out, lbs
54201
63268
53535
62601
53861
62928
54201
63268
54659
63726
Minimum Rate to prevent duning in Worstring
Workstring Number
1
Workstring ID, in
4.778
Transport Rate in WS (Horizontal), BPM
7.12
Maximum deviation angle, degree
75
Correction Factor (for angle > 45°)
0.6707
Transport Rate in WS, BPM
4.78
Minimum Rate to prevent duning, BPM
4.78
2
4.778
7.12
75
0.6707
4.78
3
4.778
7.12
75
0.6707
4.78
4
4.778
7.12
75
0.6707
4.78
5
4.778
7.12
75
0.6707
4.78
Minimum Rate to prevent premature sandout
Pump Rate to yield 0.83 Dune/Hole ratio, BPM 2.81
Recommended Minimum Rate during Alpha-wave Placement:
15
4.78
Challenges – The Simulation
STP vs. Time
2000
7.0
1800
6.0
1600
STP, psi
1200
4.0
1000
3.0
800
600
2.0
400
1.0
200
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0
0.0
0
50
100
150
200
250
300
Time, min
STP
16
STP_Frac
PR
RetRate
350
400
Rate, BPM
5.0
1400
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Case History # 1 – General Data
17
Field
Peregrino
Water Depth
400ft
Last Casing
9-5/8” @ 10,397/7,600ft MD/TVD
Open Hole
8-1/2” @ 15,101 ft MD
Horizontal Pay Zone
10,394ft – 15,101ft MD
Formation
Unconsolidated Sandstone
Reservoir Permeability
5,800 mD
Reservoir Porosity
28%
Fracture Gradient
0.66 psi/ft
Gravel Pack Fluid
9.7 ppg NaCl Brine
Workstring
5-1/2” OD, 4.778” ID, 21.90lb/ft
Blank Pipe
5-1/2” OD, 4.89” ID, 13%Cr, 17lb/ft
Screen
5-1/2” EQUALIZER SELECT 6.4FRR
Washpipe
4” Hydril 511, P-110, 11.6lb/ft, 3.380” ID
Average Caliper Simulated
8.9” (simulated)
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Case History # 1 – Circulation Test, GP Design and Simulation
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Pump Rate
(bpm)
Return Rate
(bpm)
Pressure
(psi)
% Return
2.0
2.0
204
100.0
4.0
4.0
530
100.0
5.0
5.0
736
100.0
6.0
6.0
1030
100.0
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Case History # 1 – Gravel Pack Pumping Job Parameters
19
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Case History # 2 – General Data
20
Field
Peregrino
Water Depth
400ft
Last Casing
9-5/8” @ 10,141/7,692ft MD/TVD
Open Hole
8-1/2” @ 13,422ft MD
Horizontal Pay Zone
10,141ft – 13,422ft (3,281ft MD)
Formation
Unconsolidated Sandstone
Reservoir Permeability
5,800 mD
Reservoir Porosity
28%
Fracture Gradient
0.71psi/ft
Gravel Pack Fluid
9.7 ppg NaCl Brine
Workstring
5-1/2” OD, 4.778” ID, 21.90lb/ft
Blank Pipe
5-1/2” OD, 4.89” ID, 13%Cr, 17lb/ft
Screen
5-1/2” EQUALIZER SELECT 6.4FRR
Washpipe
4” Hydril 511, P-110, 11.6lb/ft, 3.380” ID
Average Caliper Simulated
8.9” (simulated)
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Case History # 2 – Circulation Test, GP Design and Simulation
21
Pump Rate
(bpm)
Return Rate
(bpm)
Pressure
(psi)
% Return
2.0
2.0
204
100.0
4.0
4.0
530
100.0
5.0
5.0
736
100.0
6.0
6.0
1030
100.0
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Case History # 2 – Gravel Pack Pumping Job Parameters
22
Case History #2 (Field Data vs. Post-Job Simulation Data)
Average OH Diameter in Post-Job Simulation was based on the Amount of Proppant in Pumping Data
Field Pumping Data
Post-Job Simulation Data
B-24 OHGP Pumping Data 12 Feb 2013
1800
STP vs. Time
9
Statoil Brazil, Well B-24 (9.6OH, EQ Select 6.4 FRR, 20/40 LP175, ProppantCF = 1.25, FG=0.715)
2000
10.0
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7
1200
6
1000
5
Start of Beta Wave
800
4
Start of Alpha Wave
600
3
400
2
200
1
1800
9.0
1600
8.0
1400
7.0
1200
6.0
1000
5.0
800
4.0
600
3.0
400
2.0
200
1.0
0
0.0
0
0
50
100
0
0
50
100
150
200
250
300
350
150
200
250
300
350
Time, min
400
Elapsed Time, min
STP
23
Pump Rate
RetRate
MR
DH_MR
STP
STP_Frac
PR
RetRate
400
Rate, BPM
1400
STP, psi
8
Flow Rate, BPM | MR, ppa
Pressure, psi
1600
Case History #2 (Post-job Simulation and Actual
Pumping Data)
SUMMARY
Average Open Hole Diameter, in
ProppantCF in Simulation
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Pump Rate during Alpha, BPM
Pump Rate at end of Beta, BPM
Average Mix Ratio, ppa
DHR
STP Beginning, psi
STP_Slurry at Packer, psi
STP_ Alpha at Bottom, psi
STP_Beta @ TOS, psi
Start Time, minutes
Time for proppant to reach Packer, minutes
Alpha Time, minutes
Beta Time, minutes
Total GP Time (min)
Proppant amount in Alpha dune, lbs
Proppant amount in Beta wave, lbs
Proppant amount below Packer, lbs
Proppant amount at Screen-out, lbs
Proppant amount above Packer, lbs
Annulus Filled_Alpha
Annulus Filled_Beta
Clean Fluid Volume, bbls
Comment
24
9.6
1.25
Simulation
6.10
2.5
1
0.743
618
536
638
1823*
0
36.95
191.96
139.07
367.98
46304
24575
70879
79792
8913
65.33%
34.67%
1900
Simulation at constant
Mix Ratio. Est STP =
1823 psi if shut dow n
after pumping 78641
lbs proppant (98.6%
of total proppant
amount and Beta
w ave w as at ~ 150 ft
of top of screen)
Actual
6.1
2.5
1
0.7
603
564
560
1610
0
36.5
164.18
161.18
361.86
40300
29403
69703
77299
7596
57.82%
42.18%
1870
Cut proppant w hen
pump rate is at and
below 3 BPM. No
proppant during the
last 10 minutes of
pumping.
Conclusion
▪ Peregrino Field – unconsolidated sandstone reservoir demanding sand
control techniques
▪ Two GP jobs successful performed using ICD completion – pioneer
introduction of this technology in offshore Brazil
 Typical completion architecture include ICD screens and a single joint of
standard premium screen at the toe enabling fluid return
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▪ Special strategy to address the challenges: special software to job design,
Lightweight proppant and experience of GOM operations
25
© 2014 Baker Hughes Incorporated. All Rights Reserved.
Thank you Very Much!
Questions?
Don’t forget Techno Day 3rd April, AECC, Aberdeen
26

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