Introduction of Gravel Pack with Inflow Control Completion in Brazil

Transcription

1 Introduction of Gravel Pack with Inflow Control Completion in Brazil 6 th European Sand Management Forum Abrahão Jardim / Alberto Costa / Tobias Rocha / Hang Nguyen / Peter Kidd Baker Hughes Daniela Leite / Arcindo Santos Statoil Brasil B A K E R H U G H E S I N C O R P O R A TED. A LL R I G H TS R E S E R V E D. TERMS A N D C O N D I TI O N S O F U S E : B Y A C C E P TI N G THIS DOCUMENT, THE RECIPIENT A G R E E S THAT THE DOCUMENT TOGETHER W I TH A LL I N FORMATI O N I N C LUDED THEREIN I S THE C O N FI D E N TI A L A N D P R O P R I E TARY PROPERTY OF B A K E R H U G H E S I N C O R P O R A TED AND INCLUDES VALUABLE TRADE SECRETS AND/OR PROPRIETARY INF ORMA TI O N O F B A K E R H U G H E S (C O LLECTI V E LY "I N FORMATI O N "). B A K E R H U G H E S R E TAINS A LL R I G H TS U N D E R C O P Y R I G H T LAW S A N D TRADE SECRET LAW S O F THE U N I TED STATES OF A M E R I C A A N D O THER COUNTRIES. THE RECIPIENT FURTHER A G R E E S TH A T THE D O C U M E N T M A Y N O T B E D I S TRIBUTED, TRANSMITTED, C O P I E D O R R E P R O D U C E D I N W H O LE O R I N P A R T B Y A N Y M E A N S, E LECTRONIC, MECHANICAL, O R O THERWISE, W I THOUT THE EXPRESS PRIOR WRITTEN C O N S E N T O F B A K E R H U G H E S, A N D M A Y N O T B E U S E D D I R E C TLY O R I N D I R E C TLY IN A N Y W A Y D E TRIMENTAL TO BAKER HUGHES INTEREST.

2 Agenda Objectives Reservoir Information Conventional Gravel Pack ICD Gravel Pack Well Design Challenges Case History #1 Case History # 2 Conclusions 2

3 Objectives Provide sand control Provide uniform inflow along long horizontal well Provide additional oil production compared with standard screens 3

4 Reservoir Information Peregrino field is located 85 km offshore Brazil (Campos Basin) 24 km of extension Water depth around 100 m API: 14 0 Unconsolidated sands and thin heavy oil-bearing sections Wells require sand control techniques Producer wells: 30 4

5 Reservoir Simulation Studies 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 5

6 Reservoir Simulation Observations 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) 6

7 Conventional Gravel Pack vs. ICD Gravel Pack Well Design Typical Architecture for Horizontal Open Hole Gravel Pack Wells with standard screens GP Packer 5-1/2 Standard Screens 2.71 SG Proppant Bull Plug Typical Architecture for Horizontal Open Hole Gravel Pack Wells with ICD screens GP Packer 5-1/2 ICD Screens LWP 1.75 SG Proppant 5-1/2 Standard Screen Bull Plug 7 Sliding Sleeve

8 Challenges ICD screens restrict fluid from entering the screens/washpipe annulus resulting in a lower alpha dune height Pumping rate during beta wave placement must be slowly reduced to stay below fracture pressure 8

9 Hookup for Gravel Packing with ICD Screen OHGP Crossover Tool Anti- Swabbing LBHP Tool Shifting Tool Indicating Collet Perforated Tubing 2-Way Shifting Tool Indicator Couplings Fluid Loss Control Valve EQUALIZER Screen Sliding Sleeve 9

10 Configuration During Gravel Packing Washpipe EQUALIZER Screen Crossover Sub Double Pin Sub Perforated Tube Sliding Sleeve Premium Screen Shifting Tool Bull Plug Bull Plug 10

11 Configuration During Production EQUALIZER Screen Double Pin Sub Sliding Sleeve Premium Screen Bull Plug Bull Plug 11

12 STP, psi STP, psi Challenges - The Proppant Selection Select the correct proppant to be transported at low rates without settling STP x Lateral length STP vs. (ft) Lateral for Length 2.71 SG proppant Ver STP x Lateral length STP (ft) vs. for Lateral 1.75 Length SG proppant Ver ICD Screen: TRUE Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 16/20 Carbolite, 5500 psi FP) Q, BPM = ICD Screen: TRUE Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 20/40 LiteProp175, 5500 psi FP) Q, BPM = Stop Proppant feeding when beta wave is about 800ft of heel 1600 Stop Proppant feeding when beta wave is about 600ft of heel STP-alpha STP-beta 1000 STP-alpha STP-beta STP-frac STP-frac Lateral Length, ft Lateral Length, ft

13 Challenges - The Proppant Selection Regular shape good roundness and sphericity; SG = range from 1.75 to 1.90 ULW-175 ULW-125 ULW-108 Bulk density = range from 70 to 72 lb/ft3 Stress environments as high as 8,000 psi Yields 35% less weight than regular ceramic 13

14 Pump Pressure, psi Dune Height/Hole Diameter Ratio Challenges The Simulation ICD Screen: TRUE Horizontal Gravel Packing Design Criteria Statoil Brazil, Well B-24 (EQ Select 6.4 FRR, 20/40 LiteProp175, 5500 psi FP) Centralized: FALSE Fluid Return Ratio = 0.95 Hole Angle, deg. = 90 Hole Dia., in = 8.9 Screen OD/ID, in = 6.3, 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 = Ver Gravel pack design software which takes in to account the large increase in pressure drop during beta wave placement Pump Rate, BPM Ppump-alpha at bottom Ppump-beta at TOS Ppump-Frac Dune/Hole Ratio 14

15 Challenges The Simulation 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 Dune/Hole Ratio Pump Rate, BPM Return Rate, BPM Alpha Pressure, psi Beta Pressure, psi Frac Pressure, psi Alpha Time Beta Time Time for proppant to reach Packer, min Time at end of Alpha, min Time at end of Beta, min Proppant amount below Packer, lbs Proppant amount at Screen-out, lbs Minimum Rate to prevent duning in Worstring Workstring Number Workstring ID, in Transport Rate in WS (Horizontal), BPM Maximum deviation angle, degree Correction Factor (for angle > 45 ) Transport Rate in WS, BPM Minimum Rate to prevent duning, BPM 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:

16 STP, psi Rate, BPM Challenges The Simulation STP vs. Time Time, min STP STP_Frac PR RetRate 16

17 Case History # 1 General Data Field Peregrino Water Depth 400ft Last Casing 10,397/7,600ft MD/TVD Open Hole Horizontal Pay Zone 15,101 ft MD 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, ID, 21.90lb/ft Blank Pipe 5-1/2 OD, 4.89 ID, 13%Cr, 17lb/ft 17 Screen Washpipe Average Caliper Simulated 5-1/2 EQUALIZER SELECT 6.4FRR 4 Hydril 511, P-110, 11.6lb/ft, ID 8.9 (simulated)

18 Case History # 1 Circulation Test, GP Design and Simulation Pump Rate (bpm) Return Rate (bpm) Pressure (psi) % Return

19 Case History # 1 Gravel Pack Pumping Job Parameters 19

20 Case History # 2 General Data Field Peregrino Water Depth 400ft Last Casing 10,141/7,692ft MD/TVD Open Hole Horizontal Pay Zone 13,422ft MD 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, ID, 21.90lb/ft Blank Pipe 5-1/2 OD, 4.89 ID, 13%Cr, 17lb/ft 20 Screen Washpipe Average Caliper Simulated 5-1/2 EQUALIZER SELECT 6.4FRR 4 Hydril 511, P-110, 11.6lb/ft, ID 8.9 (simulated)

21 Case History # 2 Circulation Test, GP Design and Simulation Pump Rate (bpm) Return Rate (bpm) Pressure (psi) % Return

22 Case History # 2 Gravel Pack Pumping Job Parameters 22

23 Pressure, psi Flow Rate, BPM MR, ppa STP, psi Rate, BPM 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 B-24 OHGP Pumping Data 12 Feb Start of Beta Wave 800 Start of Alpha Wave Elapsed Time, min STP Pump Rate RetRate MR DH_MR Post-Job Simulation Data STP vs. Time Statoil Brazil, Well B-24 (9.6OH, EQ Select 6.4 FRR, 20/40 LP175, ProppantCF = 1.25, FG=0.715) Time, min STP STP_Frac PR RetRate 23

24 Case History #2 (Post-job Simulation and Actual Pumping Data) 24 SUMMARY Average Open Hole Diameter, in 9.6 ProppantCF in Simulation 1.25 Simulation Actual Pump Rate during Alpha, BPM Pump Rate at end of Beta, BPM Average Mix Ratio, ppa 1 1 DHR STP Beginning, psi STP_Slurry at Packer, psi STP_ Alpha at Bottom, psi TOS, psi 1823* 1610 Start Time, minutes 0 0 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 65.33% 57.82% Annulus Filled_Beta 34.67% 42.18% Clean Fluid Volume, bbls Comment Simulation at constant Cut proppant w hen Mix Ratio. Est STP = pump rate is at and 1823 psi if shut dow n below 3 BPM. No after pumping lbs proppant (98.6% of total proppant proppant during the last 10 minutes of pumping. amount and Beta w ave w as at ~ 150 ft of top of screen)

25 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 Special strategy to address the challenges: special software to job design, Lightweight proppant and experience of GOM operations 25

26 Thank you Very Much! Questions? Don t forget Techno Day 3 rd April, AECC, Aberdeen 26