Open Cell Matrix Polymer Filter as ‘Fit for Purpose’ Alternative of Thru Tubing Sand Consolidation

Abstract

There are three main challenges on sand control with mechanical screen namely erosion, pass-through, and plugging. Pass-through and plugging are common issues related to the particle size distribution (PSD); meanwhile, erosion is caused by the high production rate. So far, there is no established screen that could tackle sand issues related to the PSD dependencies. This paper is aimed to present an OCMP filter as an alternative screen to tackle pass-through and plugging challenges due to improper screen slot opening size and high uniformity coefficient (UC).

Conventional sand screen requires natural sand packing (NSP) to create an effective sand filter and optimal flow. Thus, it depends on the screen slot opening size to provide a good NSP. On the other hand, the data for defining slot opening size is not readily available for every reservoir. NSP is limited to the PSD of sand with a high UC and high fines. An open cell matrix polymer (OCMP) filter was introduced to solve this problem. OCMP filter was designed to allow combinations of multiple distinct layers with a range of pore sizes ranging from 180 – 565 microns. Hence, it could be an answer to the PSD-dependent screen selection. OCMP filter was conveyed by slickline and run compressed within the sleeve to allow passage through tight restrictions which then decompressed to be conformant with a significantly large inner diameter (ID) of the area requiring sand control when the sleeve is removed.

OCMP filters had been successfully installed in three (3) Mahakam wells using slickline and an LCT barge. It can produce up to 600 bopd and 2.6 mmscfd of gas. In terms of production parameters, an OCMP can compete with the established Sand Consolidation in its first installations, and has a high potential to outperform most of the developed sand control technologies in Mahakam Field.