Design, Testing and Field Deployment of an Online Sand Sampling and Particle Size Analysis Package

Abstract

Abstract Particle Size Analysis (PSA) of formation or produced sand is an important process in oil and gas exploration and production. This information is required to design downhole sand control, surface sand monitoring and removal systems, and to predict erosion in completion and production systems. A major operator in Malaysia required PSA data as well but found it a challenge as their wells, located offshore in Field Z, contain high amounts of contaminants such as TENORM, Mercury and Hydrogen Sulphide (H2S). Manually collecting produced sand samples was deemed too hazardous to people and the asset thus a closed loop Online Sand Sampling and PSA package was developed and deployed offshore. Samples were taken directly off flowline sample points, flowed through an online PSA system and continued its flow path to a closed loop drain line. The system therefore collected liquid, gas, and sand samples without any need for manual handling thereby eliminating exposure of harmful substances to personnel. A field laptop, running propriety software, connected via ethernet cable to the PSA system continuously measure and record the size of sand particles as they flow through the said system. This allowed the offshore execution team to view and record particle size data in real time. Data collated was available for further analysis onshore because the file format of the PSA software allows play back to refine particle images captured during the sampling operation. This was completed for 32 wells with the majority of the sampling providing good clear particle size information. Results were re-run and analysed again onshore by a sand management technical team from both the operator and service provider. The results were comparable to lab analysed samples of commonly used Laser Particle Size Analysis (LPSA). Therefore this first of its kind method provides a novel way for operaters to sample sand and solids in hazardous and also non hazardous environments.