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Abstract MazeFlo™ technology enables a sand control screen to self-mitigate mechanical damage and improve reliability in sand-prone well production. A self-mitigating screen uses redundant sand control screens and compartment baffles to restrict the effects of any mechanical screen failure to a local compartment. The hydrocarbon flow continues intact through the remaining undamaged screen compartments. This innovative, patented technology is being commercialized in collaboration with a selected service company. This paper reviews the initial design and development of the self-mitigating screen prototype. The screen design balances flow hydraulics, well performance, mechanical integrity, and manufacturing complexity all while maintaining practical screen dimensions. Successful self-mitigation, after failure of an outer screen, requires that the incoming sand packs a compartment to shut off the flow path before any significant erosion occurs along the flow path to the redundant inner screen. The baffles are configured to both redirect fluid momentum from any "hot spot" inflow at the outer screen and impose a minimal friction loss during production through undamaged compartments. Each component in a compartment is designed to sustain erosion from the incoming sand of a failed outer screen. The offset outer and redundant inner screens are sized to minimize the impact on productivity when compared to conventional screens. The mechanical strength of the self-mitigating sand screen is also targeted to be equivalent to conventional screens. Development of the self-mitigating screen prototype is proceeding and includes extensive qualification by multiple modeling techniques and physical testing. The innovative, self-mitigating capability expands the current operating limits of screens in sand control completions. In a broader view, the self-mitigating screen enhances overall reliability and longevity and can be integrated with other emerging technologies such as openhole zonal isolation, inflow control, and intelligent wells for enhanced production flexibility. MazeFlo sand screens will expand ExxonMobil's suite of innovative sand control solutions that include Alternate Path® technology, NAFPacSM process, openhole gravel packing with zonal isolation, and customizable sand control for extreme length completions and injection conformance. |
