Real Life Results from the Development Testing of a Novel, Non-Metallic High Temperature Remedial Conformable Sand Control Systems for Use in High Rate Gas Wells

Technological advances in remedial sand control and development of brand-new improved completion and downhole filter mechanisms have filled a gap in the industry regaining life in shut in wells. Whilst the use of polymer-based solution, typically rated 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, 100°C/212°F. Failed screens, failed gravel packs and sand consolidation treatments lead to shut-in wells. Development of a high temperature conformable remedial sand control systems solution will address such failures. Laboratory testing was conducted to cover 6 main goals. 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 the expected particle size distribution, including mix of proppant and formation sand. Further testing such as porosity, permeability was also required 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 filling all annular gaps. Erosion testing to determine max production rates for the filter was also conducted. Testing was conducted for over 80 materials which resulted in the selection of one material to take to qualification into full scale product. Whilst not directly comparable in all aspects to that of a conventional polymer the material was able to withstand high temperature testing and fulfil all the aims of the project including compression requirement. The proposed solution will be qualified in the coming year, with the aim to deploy the technology in Middle East within a gas well with failed sand screens. This development is completely unique to all other remedial sand control products and fills a gap within the market for high temperature conformable screen solutions. This product has the ability to regain life in shut in gas wells, successfully retaining a mixture of proppant and formation sand and offering flexibility for future stimulation activities.