New Approach in Gas-Condensate Fields Results in Smart Sand Management

_ This article, written by JPT Technology Editor Chris Carpenter, contains highlights of paper URTeC 4044415, “New Approach for Well-Cleanup and Well-Testing Operations in High-Rate Gas-Condensate Fields Resulting in Smart Sand-Management System,” by Luis Perez, Chris Denton, and Mackenzie Ferrin, SOS Sand Technology, et al. The paper has not been peer reviewed. _ The authors’ objective is to provide robust completion strategies for the Middle East’s high-pressure/high-temperature (HP/HT) gas wells, focusing on well-testing operations that require extreme solutions for solids separation, fluid recovery, sour service, and efficient well cleanup. This study evaluates flowback operations across various well-cleanup scenarios. It introduces a cleanup and flowback-testing approach incorporating advanced solids separation technology, portability, equipment automation, improved metallurgy, and enhanced operational safety standards. Description of Current System Emergency Shutdown Valve (ESD). The fluid mixture from both the wellbore and reservoir flows into the production tubing, proceeding through the production wellhead’s flow wing valve and subsequently through a 10,000-psig ESD valve. Mounted atop the flow wing valve, the ESD valve is hydraulically actuated and protects the downstream facility infrastructure. Sand Management System (SMS). The SMS effectively segregates solid particles from the production fluids and consists of two primary modules: the desander vessel (primary stage) and the wellhead filter (secondary stage) (Fig. 1). The functionalities of the two components are detailed in the complete paper. Desander Vessel. Engineered with a single cyclonic device coupled with a solids accumulator at the bottom, the desander vessel facilitates the separation of gas, oil, water, and solids. Production fluids are introduced tangentially at high pressure, leading to centrifugal separation. Gaseous components are extracted through the top vortex finder, while denser liquid phases progress to the cyclone’s narrowing section. Here, velocity increases because of centrifugal forces that segregate solids from liquids. The solids adhere to the vessel wall and fall into the accumulator. Simultaneously, gas and liquid components converge centrally and ascend through the overflow. The accumulator uses a flushing mechanism, executed every 2 hours, to mobilize and evacuate solids from the system. Wellhead Filter. Strategically positioned downstream of the desander, the wellhead filter captures residual solids to prevent choke erosion. It uses a dual-pod arrangement, with each pod containing a pair of wedge wire filter elements capable of eliminating 95% of well-produced solids. These 100-μm mesh filters process flows from the inside out, allowing the filtered sand to accumulate at the vessel’s base. Maintenance involves periodic isolation, depressurization, and purging of sand. The filter system features a dual capacity, allowing for independent flushing and manual operation of all connecting valves.