Performance of Bonded Bead Sand Screen as Remedial Sand Control in Highly Erosive Environment

Abstract

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 and are uneconomical for workovers require a remedial solution to continue producing without compromising asset integrity. In these cases, operators rely heavily on Through-Tubing Sand Screen (TTSS), however the applications remain limited due to short TTSS lifespan especially in highly erosive environment. Frequent changeout is economically and operationally not feasible with increased intervention risk. Therefore, most high Gas-Oil Ratio (GOR) 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 durability and longevity in these wells. This paper will discuss the performance of Malaysia's first installation of bonded bead sand screen in Well A. In contrast to conventional wire wrap or mesh filtration media, bonded bead sand screen incorporates tightly fused beads in cartridge form that act as depth filter to exclude sand, installed on a flushed perforated base pipe. The design is expected to provide superior erosion resistance performance as compared to conventional metallic sand screen. Prior to installation, Computational Fluid Dynamic (CFD) simulation and Sand Retention Test (SRT) were conducted to determine potential erosion rate at the targeted flow rate and optimum bead size, respectively. During the 3 months pilot installation period, vigilant surface sand monitoring was in place, aided by real-time Acoustic Sand Monitoring (ASM) and Ultrasonic Flowline Thickness measurement (RT-UT). Well flowing parameters were also monitored closely to ensure that well is flown within the target parameters. Bonded bead sand screen was then retrieved post 3 months effective flowing period for detailed inspection, teardown and evaluation. Second screen were then installed for a period of > 6 months as part of the replication. Several criteria were identified as key performance indicators to evaluate the effectiveness of this technology. The outcome of pilot installation, teardown findings and subsequent replacement of bonded bead sand screen in Well A will be discussed. Recommendations for future optimization will also be included to ensure that bonded bead sand screen remains as one of the competent through-tubing sand solutions, especially for high GOR wells.