Maximizing Well Integrity and Production: ICD Erosion Management in High GOR Environments (SPE 210762)

Challenge:

In the Laverda Field, well LAV02ST2 faced significant operational challenges due to elevated Gas Oil Ratios (GORs) during start-up. The well, completed with sand screens and Inflow Control Devices (ICDs), experienced gas inflow, raising concerns about erosion in the ICDs under multi-phase flow. The risk of well failure due to erosion, particularly in high-velocity regions, created uncertainty around safe production rates and long-term well integrity.

Key concerns included:

  • High gas velocities concentrating at ICDs, increasing erosion risk.
  • Potential housing erosion that could compromise the well’s integrity.
  • Solids production adding to erosion uncertainty.
  • Production was halted pending a detailed study to quantify the erosion risk and establish a safe operating envelope.

Solution:

An integrated technical approach was employed, including:

  1. Near-Wellbore Modelling:
    Tools like NETool® and GAP were used to model gas inflow and peak velocities at ICDs, identifying critical erosion risks.
  2. CFD Analysis:
    Computational Fluid Dynamics (CFD) simulated multi-phase flow conditions, assessing erosion at ICD slots and housing. The analysis identified housing erosion as the critical risk and established erosion limits.
  3. Revised Production Strategy:
    Based on the CFD results, production rates were safely increased from 10,000 bopd to 20,000 bopd, doubling output while maintaining well integrity.
  4. Erosion Monitoring:
    A real-time production monitoring system was implemented, tracking erosion rates and adjusting production based on GOR and flow conditions.

Value Added:

  1. Doubling Production: The safe operating envelope allowed production to increase from 10,000 to 20,000 bopd.
  2. Longevity: The well’s integrity was preserved, with an allowable erosion rate of 0.32-0.4 mm/year, ensuring safe operation over its 8-10 year lifespan.
  3. Cost Efficiency: Preventing premature well failure and interventions saved millions in deferred production and repair costs.
  4. Enhanced Reservoir Management: The study led to a 50% reduction in GOR, allowing sustained higher production and improved reservoir pressure management.

This integrated approach enabled the operator to achieve a significant production uplift while ensuring long-term well integrity, demonstrating the importance of managing ICD erosion risks in high GOR environments.