Technology Innovation and Integration Enabling More Flexible, Adaptive, and Reliable Sand Control in Openhole Completions

AbstractLong, multi-zone openhole completions have the benefits of maximizing reservoir contact and reserve captures with fewer wells, particularly for deepwater or remote environments. When producing from loosely consolidated or unconsolidated reservoirs, openhole completions are challenged by well longevity, zonal isolation, and subsurface control. Conventional gravel packs and standalone screen applications, along with the selection and design guidelines are being pushed to the limit. A new generation of sand control technologies is needed to meet these challenges.This paper highlights ExxonMobil's technology integration and hardware innovation in bringing flexibility, adaptability, and reliability to openhole sand control. Technology integration reduces uncertainties in conventional sand control selection and design guidelines, which have been based on sand prediction, well design, and grain size from selected formation samples. An analytical, log-based grain size analysis was introduced to link a Rosin-Rammler formula to formation properties. A limit-based analysis links formation strength or sanding potential to operating conditions including production rate, influx, drawdown, and depletion. Integrating log-based grain size, limit-based analysis, and conventional guidelines to the entire completion interval enables a more flexible and reliable sand control design. Further integration with Well Operability Limits allows production throughout well life without geomechanical failure of the completion.A series of innovative, enabling hardware has been developed in collaboration with service suppliers. The internal shunt Alternate Path® technology with true zonal isolation enables gravel packing multi-zones and extended lengths in openholes. The self-mitigating MazeFlo® technology enhances sand screen reliability in standalone screen completions or workovers. Both hardware technologies adapt to downhole uncertainties to achieve more reliable sand control. Emerging technologies like inflow control devices and sliding sleeves can be incorporated to control production flow in selective zones.ExxonMobil's technology integration and innovation provide a distinguishing platform for openhole sand control. This platform positions openhole sand control completions for extended lengths, multiple zones, as well as production control.