Case Study: WARP Advanced Fluid Technology Meets Critical Requirements Offshore Malaysia

Challenge: In this deepwater application, the formation of the reservoir dictated that the expandable sand screens (ESS) be 150 microns to achieve optimum production while controlling formation solids production. A conventional reservoir drill‐in fluid would plug the screens and severely restrict wellbore productivity and water‐base systems would cause emulsification problems with produced hydrocarbons.

Solution: A VERSAPRO system using WARP Fluid Technology, utilizing specially treated microparticles as the weighting agent was identified as the best candidate fluid for drilling the 8½‐in. section and for completing the well. Extensive laboratory testing was carried to optimize fluid formulation against formation damage and production screen plugging.

Result: Two 8½‐in. sections were drilled to total depth (TD), the hole was in gauge and the 150‐micron expandable screens were run and expanded without problems. There were no indications of damage to the formation or plugging of the screens downhole; the production flowback from both intervals was as predicted and a skin factor of +1 was calculated.

Well Information
Location Offshore Malaysia
Well type Deepwater production
Completion type 150‐micron openhole expandable sand screens
Water depth 4285 ft (1306 m)
Well depth Measured depth: 10,443 and 14,337 ft (3183 and 4370 m)
Well depth True vertical depth: 8727 and 10,026 ft (2660 and 3056 m)
Sections drilled 1,218 and 778 ft (371 and 237 m)
Hole size 2 x 8½ in.
Maximum hole angle 65 and 71 degrees
Maximum bottomhole temperature 140°F (60°C)
Mud weight 10.4 and 11.1 lb/gal (1,246 and 1,330 kg/m3)

The Details

The low rheology, specifically formulated VERSAPRO system using WARP Fluid Technology was used as a reservoir drill‐in fluid in this deepwater application. The properties of the fluid are found in the table.

Before running the ESS it was required that the fluid pass a Production Screen Test (PST) using a 150‐micron screen while optimizing the bridging agents to prevent invasion and subsequent damage to the formation. This requirement was met by selection of bridging agents using OPTIBRIDGE software, careful monitoring of the particle size distribution, and the optimized use of the solids control equipment.

While drilling, the shakers were dressed with 210‐mesh screens (API140; d100 range 98 < 100.1 ≤ 116.5), and at TD, one shaker was dressed with 325 mesh (49 < 54.0 ≤ 58) with the other four shakers retaining the 210‐mesh screens. The vast majority of the PSTs which were conducted while drilling passed the test. After drilling, a wiper trip was performed and the well was displaced to a fluid which passed the PST.

Reservoir Drill‐in Fluid Properties
Mud weight (lb/gal) 11.0 – 11.4 11.1 11.1
6 rpm (Fann 35@122°F [50°C]) 3 - 4 3 3
10‐min gel - 5 6
PV (cP) ALAP 19 23
YP (Pa) 7 - 10 7 7
HTHP FL@250°F [121°C] (mL) < 4 < 4 < 4
OWR 70:30 – 75:25 71:29 71:29
Salt (mg/L Br2) 160,000 166,500 162,000
ES (v) - 258 410

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“WARP Advanced Fluid Technology enabledthe first application of 150‐micron expandable sand screens for 2 well completions in Malaysia.”
Scott Verrett
Fluids Operations Manager Malaysia