3M Ceramic Sand

Screen Systems
New Opportunities
With Ceramics

3M Advanced Materials Division

2016
 Global Industry Challenge: Screen Erosion Costs Millions

The petroleum Industry spends millions of dollars each year to prevent and
repair down-hole sand control failures which reduce hydrocarbon
production rates
Source, Halliburton

With a good quality completion in place, the analysis of screen failures

indicated that screen erosion was by far the most common screen failure
mechanism. Fluid that flowed through the screen with a small amount of
fine sand particles greatly accelerated the screen erosion. Sand control
completions using flux analysis
Oil and Gas Journal based on SPE 84495 -M.H. Stein, BP America; A.A. Chitale,
Quiline Software Inc.; G. Asher, APA; and H. Vaziri, Y. Sun, J.R. Colbert, and F.A.
Gonzalez, BP America -2005

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 3M Ceramic Sand Screens

BP Energy Outlook 2030 (2013) Oil/gas production challenges:

Ultradeep wells
HP/HT wells
Sand erosion, corrosion
Why requirement for new solutions
Long life time
Increased MTBF
3M development:
Ceramic sand screen solution
Stack of ceramic rings
Defined gap width for sand retention
and laminar flow

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 Stand Alone accredited laboratory test services
3M uses its 90 years experience of particle analysis
and its facilities to perform state of the art sand analysis
Particle Size Distribution (PSD) Analysis
Dry sieve analysis
Laser particle size analysis (LPSA)
Sand retention testing
Erosion testing
Corrosion testing
Scanning Electron Microscope (SEM)

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 Why ceramics in downhole sand screen?
The unique properties of technical ceramics made from silicon carbide

Over 10 times as hard as metallic screens

Exceptional wear and corrosion resistance

Suitable for use even under extreme

conditions

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 Erosion resistance
Test conditions: 20/40 mesh sand, high loaded in air, blasting with 30 50 m/s (90 150 ft/s)
Ceramic Longevity Test Duration: 4 hours with no erosion (no change in mass)

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 Erosion Testing
3rd Party Erosion Testing 1 Results

Test Results
Similar results were obtained using coupons mounted in test fixtures.
The fixture had a 40 mm (1.6) opening to test ceramic screens and wire-
wrap screens respectively and compare erosion performance.

The wire-wrap screens failed in every single test at slight different timings,
After 240 min whereas the ceramic screens did not show any visible wear or material
loss.

After 60 min

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 Erosion Testing
3rd Party Erosion Testing 2 Test Results

High Speed Erosion Testing Results

Sintered silicon carbide has an excellent potential to mitigate wash-out erosion.
In contrast to all steels, polymer and hard coated steels, 3M Ceramic sand screens did not show any visible wear
or material loss.

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 Ceramic integration into a sand control system

Screen design assembly based on stack of rings hold together

with end caps on a perforated base pipe
Sand screens are protected always with an external metallic
shroud.

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 Accelerated technology adoption from 2011
A proven track record of circa 25 installations since 2010 attribute to the success of this
innovation
Several SPE papers document its high relevance to operators
3M earned the CEO innovation award from BG Group in 2013 for deploying ceramic sand
screens in a gas well in Bolivia

Successfully installed

Installation pending

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 3M Ceramic Sand Screens
Engineering and design
Standard screens made to order:
Ceramic screens size are available from 1.67 to
7.154 OD screen, used for both through tubing and
stand alone applications.

6, 8, 10 and 12 gauge standard slot openings.

11
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 3M Ceramic Sand Screens
Features and applications
Designed to deliver high performance sand control in
erosion-corrosion risk posed wells.
Potential alternative to Gravel Pack applications
Protect well jewelry from proppant flow back
Easy deployment via wireline/slickline, coiled tubing or
conventional rig system
Light intervention through existing production tubing
minimizes HS&E and operational risk whilst maximizing
rapid return on investment

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 CTT Installation Success
Low CAPEX, Fast ROI, Longer well life cycle
Challenge:
Gas Producer in the North Sea (Maersk Oil):
Old gas well, started in 1983
Several well treatments and work-overs
2009: well was shut in. Unmanageable at 1,250 psi flowing pressure

Enabling Technology:
3M Ceramic Thru Tubing Sand Screen

Success:
Well on production since 2011 Re-gain sand free production with new tubing head pressure of 650 psi
Intervention payback: 1 week
Source: ATCE Presentation 2011
Production rate leveled in at 2 MMscf/d
65 Months incremental gas production
No further Intervention required
3900MMscf to date and still producing
Approximately $15 MM ROI

* Based on US avg gas import price (Sept 14) $3.95 per 1000 cubic feet

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 3M Ceramic Stand Alone Screen alternative to IGP
Summary of installation success at BG Bolivia
Challenge:
Gas producer in Bolivia (onshore):
Metallic screens failed after 2 months
Remote location
Complex work over

Enabling Technology:
3M Ceramic Sand Screen without IGP

Success: Approval of Ceramic Sand Screens as the recommended standard sand

control method within the whole BG group
Reduced work over complexity
Lower CAPEX
Lower OPEX

X15 Longevity increase to date 25% Higher Production Rate

compared to conventional - from expected 6MMscf/d to 8MMscf/d 64MMscf/Month extra to present
premium metallic screen life - ($237K EXTRA per Month*)
Continuous Production from November 2012 to present
* Based on US avg gas import price (Sept 14) $3.95 per 1000 cubic feet

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 3M Ceramic sand screens for proppant flow back for sub sea well completions
Technology enabler allowing optimized well production
Customer Challenge:
After under expectation production rates from non stimulated wells, client wants to
fracture the new drilled wells in order to achieve better production rates

Problems:
Equipment at surface cant cope with proppant flow back.
No Sand management facilities on the platform.
Estimated velocity in perforations: 100ft/s. Standard screens can withstand ca. 3ft/s.
Need for erosion resistant screens.

Solution:
3M ceramic sand screen has been considered because of their high erosion resistance
properties
Set the screens across and above the stimulated perforations

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 3M Ceramic sand screens for proppant flow back for sub sea well completions
Technology enabler allowing optimized well production
9,802 7
Completion details:
9,808 7
Set of 3 screens 2 3/8 NUE L80Cr13 3 modules each 61 9,810 7
/ OD 3.540

Slot opening 300m for proppant 20/40 Mesh. Ca.

100T proppant used per well

SRT in laboratory confirmed the good permeability of

the sand and the relevance of the 300m slot opening

Screens to be deployed on E-Line and hanged on a E-

Packer 11,026 7

11,033 7
11,062 7
61 11,302 7

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 3M Ceramic sand screens for proppant flow back for sub sea well completions
Technology enabler allowing optimized well production

Technical results:
Delivered reliability in an highly erosive environment
Well A production ~25 MMSCFD
Well B production ~35 MMSCFD
Proppant flow back after the installation of the screens: none
Longevity of the CCS compared to client expectations: X8, and still performing

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 Learn more about the ceramic sand screens

References
SPE 146721: an Innovative Milestone in Sand Control Maersk Oil
SPE 160327: Ceramic Sand Screens for Sand Control in Unconsolidated reservoirs: Application and Sand Retention
Capabilities in the Maturing Oil Field, Gaiselberg, Austria - RAG
SPE 166092-MS: Ceramic Sand Screen : Ceramic Sand Screen An innovative Downhole Sand Control Solutions for
Old & Challenging Cased Holes
OTC-25106-MS: An Innovative Approach of Revival for Damaged Wells in High Erosive Environment Using Ceramic
Sand Screens BG Group
SPE-176225-MS: Cased Hole Ceramic Screen Cutting Completion Cost for Marginal Reservoir : Application in Tunu
Field
MOC-Egypt- April 2016: Ceramic Sand Screen Systems - a unique down-hole solution for sand control
S. Wildhack, S. Mssig, F. Strahammer and M. Leitner: Sand Control with Ceramic Screens in Unconsolidated
Reservoirs demonstrated in the mature Gaiselberg Oilfield. OIL GAS European Magazine, 2/2012, p. 7478.

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