Development of High Temperature Remedial Conformable Sand Control Systems for Use in High-Rate Gas Wells

Technological advances in remedial sand control and development of improved completion and downhole filter mechanisms have filled a crucial industry gap, regaining life from shut in wells. Whilst the use of a polymer-based solution, typically rated at 100°C/212°F, have proved widely popular in recent years with significant results, a challenge still exists to deploy this technology in high temperature applications, 150°C /302°F. This paper will evaluate the development process of a high temperature conformable remedial sand control system tailored to fit a high flow-rate gas well application. Laboratory testing was conducted to cover 6 main aims. To confirm temperature and fluid compatibility at 150°C /302°F to replicate field life. Acid resistance testing was also conducted to confirm short term longevity in 15% HCl to replicate acid stimulation treatments. Sand retention testing was conducted in a range of particle size distributions which is representative of the field in question, this included a mix of proppant and formation sand. Further testing such as porosity and permeability was also conducted to compare to the current polymer-based offering. Compression testing was completed to confirm the filter would be able to be compressed during deployment and return to its natural size and shape without intervention and thus able to fill all the annular gaps. Erosion testing to determine the max production rates for the filter was also conducted. Testing conducted on over 80 materials resulted in the selection of one preferred material to progress from qualification to full scale product development. Whilst not directly comparable in all aspects to that of a conventional polymer, the material was able to withstand high temperature testing (150°C /302°F) and fulfil all the aims of the project including the compression requirement. This development is completely unique to all other current remedial or primary sand control products and fills a gap within the market for high temperature conformable screen solutions. This product can regain production from shut in gas wells, it successfully retains a mixture of proppant and formation sand, offering flexibility for future stimulation activities and reductions in flaring activities. The paper will provide an important reference for testing and design considerations of a high temperature conformable remedial sand control system tailored to fit a high flow-rate gas well application. The proposed solution will be further qualified with the aim to be deployed in a gas well that has sand production rate constraints.