Sand Control Technology for Extended-Reach Wells: Best Practices from the Longest Gravel Packs Performed Offshore Brazil

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Abstract The Campos basin is a sedimentary basin located in offshore Brazil, between the north coast of Rio de Janeiro State and the south coast of Espírito Santo State, encompassing many oilfields. Most of the reservoirs in the basin are high-permeability sandstones containing low API gravity oil but are without strong water drives. Long horizontal producer wells are the best economic option for field development but require water injection to maintain reservoir pressure. Horizontal sections generally range from 1000 to 2000m, which demands gravel pack as a sand control method. Gravel packing such long wells is a challenge and requires thoughtful engineering to optimize pumping techniques and technology. Presented here are best practices to overcome several challenges faced in this field to achieve overall success. The challenge for extended-reach gravel packing is that the long horizontal section develops high friction during the alpha and beta wave propagation. Increasing the pumping pressure to overcome this friction increases the risk of fracturing the formation, consequently reducing the equivalent circulation rate downhole impairing the proppant transportation. In contrast, a reduced pump rate during alpha wave propagation can lead to a premature screenout due to the increase in dune height of over 85%. To overcome these issues and place gravel packs in these wells, careful engineering and simulation, lightweight proppants, friction reducers, and thorough job planning were used to successfully perform gravel packs in more than 40 horizontal wells completed in the Campos basin from 2011 up to 2017. The experience of pumping the longest gravel pack jobs in offshore Brazil (horizontal length more than 2,000m) offer insights into best practices for gravel packs in extended-reach horizontal wells: Design considerations, specific well challenges faced, technologies deployed, and operational planning requirements. Specifically, highlighting the benefits of using lightweight proppants and optimized fluid systems to minimize screen out risks and maximize pack efficiency.