Appratus for, and Method of, Controlling Sand Production from an Oil Well

Abstract

An apparatus and a method for controlling sand production from an oil well. A sand rate comparison value determined at a given oil production rate is used to control the oil production rate by controlling the choke to set the oil production rate to a set production rate corresponding to the oil production rate. The sand rate comparison value is used to confirm that the measured reduced sand flow rate, at that given oil production rate, is below the allowable sand rate (ASR). Since the oil production rate is associated with the sand rate, the sand rate comparison value is used to control the sand rate, by being used to control the oil production rate, and so the sand rate comparison value functions as, and therefore typically comprises, or is, a sand rate control parameter.

Claims

1. A method of controlling sand production from an oil well, the method comprising the steps of: (a) providing a continuous output production flow from a wellhead of an oil well connected to an oil-containing reservoir, the output production flow comprising hydrocarbon-containing oil at an oil production rate and sand at a sand production rate, and the output production flow being conveyed by a pipeline from the wellhead to a facility for processing, transporting by pipeline, or storing the oil; (b) at a sand management station along the pipeline between the wellhead and the facility, passing the output production flow through a sand management system installed in the pipeline, wherein the sand management system comprises a solids separator configured to separate sand from the oil of the output production flow, wherein the sand management system has an input which receives the output production flow from the wellhead along an upstream part of the pipeline, the upstream part being upstream of the sand management system, and an oil output which outputs the oil, having sand separated therefrom, along a downstream part of the pipeline, the downstream part being downstream of the sand management system; (c) opening a choke of the wellhead to increase the oil production rate and sand production rate, whereby the sand production rate is increased to a level higher than an allowable sand rate (ASR) which is a predetermined maximum threshold sand production rate of the pipeline, and, at least during a time period when the sand production rate is higher than the allowable sand rate (ASR), continuously or continually separating sand in the output production flow from the oil of the output production flow using the solids separator of the sand management system to provide a zero or non-zero reduced sand flow in the downstream part of the pipeline; (d) after or during step c), measuring sand flow in at least one of the sand management system and the downstream part of the pipeline to provide a reduced sand flow rate, which is a flow rate of the reduced sand flow, in the downstream part of the pipeline; (e) comparing the reduced sand flow rate with the allowable sand rate (ASR) to provide a sand rate comparison value; and (f) controlling the oil production rate using the sand rate comparison value to maintain the reduced sand flow rate in the downstream part of the pipeline below the allowable sand rate (ASR).

2. A method according to claim 1 wherein the sand rate comparison value comprises, or is, a sand rate control parameter which is used to control the sand rate in the controlling step (f)..

3. A method according to claim 1 wherein in step (e) the reduced sand flow rate and the allowable sand rate (ASR) are compared to determine the sand rate comparison value and to confirm that the measured reduced sand flow rate is below the allowable sand rate (ASR), and in step (f) the oil production rate is controlled using the sand rate comparison value by controlling the choke to set the oil production rate to a set production rate corresponding to the oil production rate in step (c).

4. A method according to claim 1 wherein in step c) the oil production rate is increased to a value so that the associated sand flow rate from the reservoir is no greater than a predetermined maximum threshold, which maximum threshold has been determined or estimated to avoid damage to the wellbore and/or wellhead upstream of the sand management system and/or damage to the reservoir.

5. A method according to claim 1 further comprising the steps, before step c), of (i) measuring the sand production rate in the pipeline to provide a measured sand production rate from the reservoir, (ii) determining or estimating a maximum accumulated sand flow rate of sand at least partially resulting from the removal of accumulated sand from the wellbore, and (iii) calculating from the measured sand production rate and the maximum accumulated sand flow rate, and from a maximum sand separation rate of the sand management system, a first maximum oil production rate that can be conveyed to the sand management system to maintain a reduced sand flow rate below the allowable sand rate (ASR) at the output of the sand management system, whereby excess sand above the allowable sand rate (ASR) is separated from the oil by the solids separator, and wherein in step c) the oil production rate is increased to a level no greater than the calculated first maximum oil production rate.

6. A method according to claims 1 wherein after the commencement of step c), the oil production rate and the sand production rate are permitted, after an initial increase in sand flow rate at least partially resulting from the removal of accumulated sand from the wellbore, to stabilise to respective stabilised values of the oil and sand production rates exiting the reservoir of the oil well.

7. A method according to claim 1 wherein the sand management system is temporarily installed in the pipeline for a series of intermittent time periods, each intermittent time period comprising a test period during which the sand management system is operational to separate sand from the oil production, and the sequence of the combination of steps b), c), d), e) and f) is carried out during the test period.

8. A method according to claim 7, wherein the method further comprises the steps, after step c) and during the test period, of (1) closing the choke of the wellhead to decrease the oil production rate and sand production rate; (II) measuring the decreased reduced sand flow rate in the pipeline to provide a measured decreased reduced sand flow rate, (III) comparing the measured decreased reduced sand flow rate and the allowable sand rate (ASR) to determine the sand rate comparison value to confirm that the measured decreased reduced sand flow rate is no greater than the allowable sand rate (ASR); (IV) setting the oil production rate to a set production rate corresponding to the decreased oil production rate; and (V) terminating the test period.

9. A method according to claim 8 wherein the choke is closed in step (1) after the oil production rate and the sand production rate have stabilised, subsequent to an initial increase in sand flow rate at the commencement of step c) at least partially resulting from the removal of accumulated sand from the wellbore, to respective stabilised values of the oil and sand production rates exiting the reservoir of the oil well.

10. A method according to claim 8 further comprising the step, after terminating the test period in step (V), of step (VI) which comprises uninstalling the sand management system from the pipeline at the end of the test period.

11. A method according to claim 10 wherein, subsequent to step (VI), after a production time period during which continuous output production flow is conveyed by the pipeline from the wellhead to the facility for processing, transporting by pipeline, or storing the oil, the sand management system is re-installed on the pipeline and steps b) to f) are repeated.

12. A method according to claim 11 wherein the production time period is at least one week or at least one month.

13. A method according to claim 1 wherein the sand management system is installed in the pipeline for a continuous oil production time period, and the sequence of the combination of steps d), e) and f) is carried out once at a beginning of the continuous oil production time period, or repeatedly at a plurality of times during the continuous oil production time period.

14. A method according to claim 13, wherein after step c), and after the oil production rate and the sand production rate have stabilised, subsequent to an initial increase in sand flow rate at the commencement of step c) at least partially resulting from the removal of accumulated sand from the wellbore, to respective stabilised values of the oil and sand production rates exiting the reservoir of the oil well, the method further comprises the steps of (i′) measuring the stabilised reduced sand flow rate in the pipeline, and (ii′) calculating, from the measured stabilised reduced sand flow rate and from a maximum sand separation rate of the sand management system, a second maximum oil production rate that can be conveyed to the sand management system to maintain a reduced sand flow rate below the allowable sand rate (ASR) at the output of the sand management system, whereby excess sand above the allowable sand rate (ASR) is separated from the oil by the solids separator, and wherein the method further comprises step c′), after step c), in which the oil production rate is further increased to a level below the calculated second maximum oil production rate.

15. A method according to claim 14 wherein in step c′) the oil production rate is increased to a value so that the associated sand flow rate from the reservoir is no greater than a predetermined maximum threshold, which maximum threshold has been determined or estimated to avoid damage to the wellbore and wellhead upstream of the sand management system and/or damage to the reservoir or a formation above the reservoir.

16. A method according to claim 1 the input of the sand management system continuously receives the output production flow from the wellhead and the oil output of the sand management system continuously or continually outputs the oil, having sand separated therefrom, along the downstream part of the pipeline.

17. A method according to claim 1 the sand management system carries out the following steps: A. separating sand from the hydrocarbon-containing oil using the solids separator and independently outputting from the solids separator the sand and a remaining hydrocarbon-containing oil; and B. cleaning residual oil deposits from the sand separated by the solids separator in a solids cleaning system connected to a solids output of the solids separator, the solids cleaning system having a first output outputting the cleaned sand and a second output outputting first residual oil.

18. A method according to claim 17 wherein the hydrocarbon-containing oil and the sand are present in a multiphase hydrocarbon-containing fluid comprising an oil phase, a sand phase, a water phase and a gas phase, and wherein the sand management system carries out the following further steps: C. after separating sand from the hydrocarbon-containing oil using the solids separator, separating the remaining multiphase hydrocarbon-containing oil into an oil phase, a water phase and a gas phase in a fluid separator in fluid communication with the solids separator; D. independently removing the oil phase, the gas phase and the water phase from the fluid separator, wherein the oil phase is removed from the separation system through an oil outlet, the gas phase is removed from the separation system through a gas outlet; and the water phase is removed from the separation system through a water outlet; and E. cleaning residual oil from the water phase separated by the fluid separator by a water cleaning and recycling system connected to the water outlet of the fluid separator, wherein the water cleaning and recycling system comprises an oil separator separating oil from the water phase to provide cleaned water and second residual oil, the oil separator outputting the cleaned water, and outputting the second residual oil.

19. A method according to claim 18 wherein the first and/or second residual oil are recycled to the sand management system or to the pipeline, or wherein the first residual oil is recycled to the fluid separator and/or the second residual oil is recycled to the fluid separator.

20. A method according to claim 19 wherein the oil separator separates oil from the water phase whereby the oil content of the cleaned water is lower than 20 ppm by weight, or within the range of from 5 to 20 ppm by weight, based on the total weight of the cleaned water.

21. A method according to claim 19 wherein the fluid separator removes oil from the water phase whereby the oil content of the water phase exiting the fluid separator is lower than 500 ppm by weight, or within the range of from 300 to 500 ppm by weight, based on the total weight of the water phase.

22. A method according to claims 18 (1) the solids separator removes sand from the multiphase hydrocarbon-containing fluid whereby the sand content of the remaining multiphase hydrocarbon-containing fluid entering the fluid separator is lower than 1 weight%, or within the range of from 0.5 to 1 weight%, based on the total weight of the remaining multiphase hydrocarbon-containing fluid, and/or (II) the fluid separator removes water from the oil phase whereby the water content of the oil phase exiting the oil outlet is lower than 2 weight%, or within the range of from 1 to 2 weight%, based on the total weight of the oil phase, and/or (III) the solids separator removes sand from the multiphase hydrocarbon-containing fluid whereby the hydrocarbon content of the sand exiting the solids outlet is lower than 10 weight%, or within the range of from 5 to 10 weight%, based on the total weight of the separated sand, and/or (IV) the solids cleaning system removes hydrocarbons from the sand whereby the hydrocarbon content of the cleaned sand is lower than 1 weight%, based on the total weight of the cleaned sand.

23. An apparatus for controlling sand production from an oil well, the apparatus comprising a sand management system comprising: a solids separator configured to separate sand from a continuous output production flow from a wellhead of an oil well having an oil-containing reservoir, the output production flow comprising hydrocarbon-containing oil and sand, the solids separator having an input for receiving the output production flow from the wellhead along an upstream part of a pipeline, the upstream part being upstream of the sand management system, and an oil output for outputting the oil, having sand separated therefrom, along a downstream part of the pipeline, the downstream part being downstream of the sand management system, a control system for controlling the choke of the wellhead thereby to vary the oil production rate and sand production rate from the oil well, and a measurement device for directly or indirectly measuring a flow rate of a zero or non-zero reduced sand flow in the downstream part of the pipeline to provide a measured reduced sand flow rate, which is a flow rate of the reduced sand flow in the downstream part of the pipeline, wherein the control system comprises: a data storage module configured to store an allowable sand rate (ASR) which is a predetermined maximum threshold sand production rate of the pipeline, a comparator module for comparing the measured reduced sand flow rate, received from the measurement device, with the allowable sand rate (ASR) to provide a sand rate comparison value; and an oil flow rate control module for outputting a control signal to the choke for controlling the oil production rate, wherein the oil flow rate control module processes the sand rate comparison value to maintain the reduced sand flow rate downstream of the sand management system below the allowable sand rate (ASR).

24. An apparatus according to claim 23 wherein the sand rate comparison value comprises, or is, a sand rate control parameter which is used to control the sand rate during the controlling of the oil production rate by the choke.

25. An apparatus according to claim 23 wherein the comparator module is arranged to compare the measured reduced sand flow rate and the allowable sand rate (ASR) to determine the sand rate comparison value, and to confirm that the measured reduced sand flow rate is below the allowable sand rate (ASR), and the oil flow rate control module is arranged, by processing the sand rate comparison value to control the choke to set the oil production rate to a set production rate corresponding to the oil production rate which produced the measured reduced sand flow rate measured by the measurement device.

26. An apparatus according to claim 23 wherein the sand management system further comprises a solids outlet connected to the solids separator such that the sand separated by the solids separator from the hydrocarbon-containing oil can be removed from the solids separator through the solids outlet, and a solids cleaning system connected to the solids outlet, wherein the solids cleaning system is configured to clean deposits of residual oil from the sand separated by the solids separator to provide cleaned sand and first residual oil, the solids cleaning system having a first output for outputting the cleaned sand and a second output configured for outputting the first residual oil.

27. An apparatus according to claim 26 wherein the sand management system further comprises a fluid separator in fluid communication with the solids separator and arranged to receive a remaining multiphase hydrocarbon-containing oil from the solids separator, the fluid separator being configured to separate the remaining multiphase hydrocarbon-containing fluid into an oil phase, a water phase and a gas phase; a water outlet connected to the fluid separator such that the water phase can be removed from the sand management system through the water outlet; and a water cleaning and recycling system connected to the water outlet, wherein the water cleaning and recycling system is configured to clean residual oil from the water phase separated by the fluid separator, the water cleaning and recycling system comprising an oil separator for separating the residual oil from the water phase to provide cleaned water and second residual oil, the oil separator having a third output for outputting the cleaned water, and a fourth output for outputting the second residual oil.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0054] Embodiments of the present invention will now be described in more detail by way of example only with reference to the accompanying drawings, in which:

[0055] FIG. 1 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a typical known well test on a given oil well, or group or field of oil wells;

[0056] FIG. 2 schematically illustrates a known wellhead and pipeline arrangement which is used for carrying out the typical known well test illustrated in FIG. 1;

[0057] FIG. 3 schematically illustrates an apparatus for controlling sand, and comprising a sand management system, in accordance with an embodiment of an apparatus of the present invention;

[0058] FIG. 4 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a periodic well test, using a sand management system as illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a first embodiment of the method of the present invention, the method being carried out on a given oil well, or group or field of oil wells;

[0059] FIG. 5 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a continuous well test, using a sand management system as illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a second embodiment of the method of the present invention, the method being carried out on a given oil well, or group or field of oil wells; and

[0060] FIG. 6 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a continuous well test, using a sand management system as illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a third embodiment of the method of the present invention, the method being carried out on a given oil well, or group or field of oil wells.

DETAILED DESCRIPTION

[0061] Referring to FIG. 3 there is schematically illustrated an apparatus for controlling sand production from an oil well, the apparatus comprising a sand management system 240, in accordance with an embodiment of the present invention.

[0062] The sand management system 240 is connected to a given oil well 250 shown in FIG. 3, which may alternatively comprise a group or field of oil wells, as described above. The oil well 250, which may be onshore or offshore, has a wellhead 252 connected by a wellbore 230 to a natural underground oil-containing reservoir (not shown), and a pipeline 254 extending from the wellhead 252 to a processing, transporting by pipeline, or storage facility 256. There is a continuous output production flow from the wellhead 252 comprising hydrocarbon-containing oil and sand. A choke 258 is provided at the wellhead 252 to control the oil flow rate along the pipeline 254, or terminate the oil flow. The downstream part 268 of the pipeline 254, downstream of the sand management system 240, is provided with a diverting line 260 for diverting a portion of the oil flow in order to measure the sand content of the oil flow either online or offline by a sand content measurement device 262. At a sand management station 282 along the pipeline 254 between the wellhead 252 and the facility 256, the sand management system 240 is installed in the pipeline 254.

[0063] The input of the sand management system 240 continuously receives the output production flow from the wellhead 252 and the oil output of the sand management system 240 continuously or continually outputs the oil, having sand separated therefrom, along the downstream part 268 of the pipeline 254.

[0064] The sand management system 240 comprises a solids separator 270 configured to separate sand from the oil of the output production flow. The solids separator 270 is typically a centrifugal separator, but any suitable separator known in the oil production industry as being suitable for use in separating sand particles from oil may be used. The sand management system 240 has an input 248 which receives the output production flow from the wellhead 252 along an upstream part 266 of the pipeline 254 and an oil output 274 which outputs the oil, having sand separated therefrom, along the downstream part 268 of the pipeline 254. The sand management system 240 also has a sand outlet 272, a water outlet 271 and a gas outlet 278.

[0065] A control system 280 is coupled either by a wireless or wired connection to the sand management system 240 for controlling the choke 258 of the wellhead 252 thereby to vary the oil production rate and sand production rate from the oil well 250.

[0066] The sand content measurement device 262 measures the reduced sand flow rate in the downstream part 268 of the pipeline 254 to provide a measured reduced sand flow rate.

[0067] In an alternative embodiment of the present invention, the sand content measurement device 262 may be incorporated into the sand management system 240 to measure the sand flow rate of the oil outputted from the sand management system 240.

[0068] In a further alternative embodiment of the present invention, the sand content measurement device 262 is not provided; instead, a first measurement device for measuring the sand flow rate entering the sand management system 240 and a second measurement device for measuring the rate of sand separated by the solids separator 270 may be provided, either as independent devices or in a common measurement system. The measurements of the first and second measurement devices can be used to calculate the reduced sand flow rate in the downstream part 268 of the pipeline 254, for example by deducting the rate of sand separated by the solids separator 270 from the sand flow rate entering the sand management system 240. The sand management system 240 further comprises a solids outlet 288 connected to the solids separator 270 such that the sand separated by the solids separator 270 from the hydrocarbon-containing oil can be removed from the solids separator 270 through the solids outlet 288.

[0069] In accordance with the broadest aspect of the present invention, the sand management system 240 may simply comprise the solids separator 270 to separate sand from the hydrocarbon-containing oil. The solids separator 270 may comprise any device suitable for separating sand from the hydrocarbon-containing oil; in the preferred embodiment a centrifugal separator is employed, although other devices may alternatively be used. The sand exits the solids outlet 288 connected to the solids separator 270. As described hereinbelow, in accordance with a preferred embodiment of the present invention, the separated sand is subsequently processed on-site, in particular cleaned. However, in alternative embodiments of the present invention the sand separated from the hydrocarbon-containing oil is not subsequently processed. Furthermore, in accordance with a preferred embodiment of the present invention, water present in the multiphase fluid from the oil production, is used to clean the sand, and the water is also subsequently cleaned, and gas present in the multiphase fluid from the oil production is also separated. These water and gas treatments are also only preferred aspects of the present invention.

[0070] In accordance with the preferred embodiment as illustrated in FIG. 3, a solids cleaning system 286 is connected to the solids outlet 288. The solids cleaning system 286 is configured to clean deposits of residual oil from the sand separated by the solids separator 270 to provide cleaned sand and first residual oil. The solids cleaning system 286 has a first output 272 for outputting the cleaned sand and a second output 276 configured for outputting the first residual oil.

[0071] The sand management system 240 further comprises a fluid separator 284 in fluid communication with the solids separator 270 and arranged to receive a remaining multiphase hydrocarbon-containing oil from the solids separator 270. The fluid separator 284 is configured to separate the remaining multiphase hydrocarbon-containing fluid into an oil phase, a water phase and a gas phase. The water outlet 271 is connected to the fluid separator 284 such that the water phase can be removed from the sand management system 240 through the water outlet 271.

[0072] A water cleaning and recycling system 273 is connected to the water outlet 271. The water cleaning and recycling system 273 is configured to clean residual oil from the water phase separated by the fluid separator 284. The water cleaning and recycling system 273 comprises an oil separator 279 for separating the residual oil from the water phase to provide cleaned water and second residual oil The oil separator 279 has a third output 275 for outputting the cleaned water, and a fourth output 277 for outputting the second residual oil.

[0073] As described further hereinbelow, in use the oil production flow in the pipeline 254 is passed through the sand management system 240 which functions to remove sand, i.e. solids particles, from the hydrocarbon-containing oil.

[0074] The sand management system 240 carries out the following steps: first, the sand is separated from the hydrocarbon-containing oil using the solids separator 270. The separated sand and the remaining hydrocarbon-containing oil are independently outputted from the solids separator 270.

[0075] Typically, the solids separator 270 removes sand from the multiphase hydrocarbon-containing fluid whereby the sand content of the remaining multiphase hydrocarbon-containing fluid entering the fluid separator 284 is lower than 1 weight%, optionally within the range of from 0.5 to 1 weight%, based on the total weight of the remaining multiphase hydrocarbon-containing fluid. Typically, the solids separator 270 removes sand from the multiphase hydrocarbon-containing fluid whereby the hydrocarbon content of the sand exiting the solids outlet 288 is lower than 10 weight%, optionally within the range of from 5 to 10 weight%, based on the total weight of the separated sand.

[0076] Then, the sand is cleaned by cleaning residual oil deposits from the sand separated by the solids separator 270 in the solids cleaning system 286 connected to the solids output 288 of the solids separator 270. The solids cleaning system 286 may function by cleaning the sand centrifugally or by washing with high pressure water, although other techniques may be employed. The cleaned sand is outputted from the solids cleaning system 286. Such cleaned solid particles, such as sand, are sufficiently free of residual hydrocarbons that in most, if not all, oil producing countries it is legally and environmentally acceptable to dispose of the cleaned sand locally in the vicinity of the oil well.

[0077] Also, residual oil is outputted from the solids cleaning system 286, which may be recycled to the fluid separator 284.

[0078] Typically, the hydrocarbon-containing oil and the sand are present in a multiphase hydrocarbon-containing fluid of the oil production flow which comprises an oil phase, a sand phase, a water phase and a gas phase. When such a multiphase hydrocarbon-containing fluid, preferably the sand management system 240 carries out the following further steps: after separating sand from the hydrocarbon-containing oil using the solids separator 270, the remaining multiphase hydrocarbon-containing oil is separated into an oil phase, a water phase and a gas phase in the fluid separator 284 which is in fluid communication with the solids separator 270. The oil phase, the gas phase and the water phase are independently removed from the fluid separator 284. The oil phase is removed from the separation system through the oil output 274, the gas phase is removed through the gas outlet 278 and the water phase is removed through the water outlet 271.

[0079] Any residual oil in the water phase which is separated by the fluid separator 284 is cleaned from the water phase by the water cleaning and recycling system 273 connected to the water outlet 271 of the fluid separator 284. The oil separator 279 separates oil from the water phase to provide cleaned water and second residual oil. The oil separator 279 outputs the cleaned water, and outputting the residual oil. The residual oil may be recycled to the sand management system 240, to the pipeline 254, to the fluid separator 284 or to the solids separator 270.

[0080] Typically, the fluid separator 284 removes water from the oil phase whereby the water content of the oil phase exiting the oil output 274 is lower than 2 weight%, optionally within the range of from 1 to 2 weight%, based on the total weight of the oil phase.

[0081] Typically, the fluid separator 284 removes oil from the water phase whereby the oil content of the water phase exiting the fluid separator 284 is lower than 500 ppm by weight, optionally within the range of from 300 to 500 ppm by weight, based on the total weight of the water phase.

[0082] Subsequently, preferably the oil separator 279 separates oil from the water phase whereby the oil content of the cleaned water is lower than 20 ppm by weight, optionally within the range of from 5 to 20 ppm by weight, based on the total weight of the cleaned water.

[0083] Typically, the sand management system 240 removes hydrocarbons from the sand whereby the hydrocarbon content of the cleaned sand is lower than 1 weight%, based on the total weight of the cleaned sand.

[0084] Referring now to FIG. 4, there is shown a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a well test using a sand management system, for example the sand management system illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a first embodiment of the present invention, the method being carried out on a given oil well, or group or field of oil wells. The oil well(s) may be onshore or offshore. It should be noted that although the method described herein is a well test performed on one well, it is possible that the test could be performed on a group of wells or on an oil field, that is, oil production from many wells is combined into a single pipeline and the test is performed on this combined flow.

[0085] As described above, in accordance with the broadest aspect of the present invention, the sand management system may simply comprise a solids separator to separate sand from the hydrocarbon-containing oil. The solids separator may comprise any device suitable for separating sand from the hydrocarbon-containing oil. Optionally, but not essentially, the separated sand may be processed on-site, for example by cleaning, and water and gas phases in a multiphase fluid of the oil production may also be processed.

[0086] In accordance with this aspect of the present invention, a sand management system, which can separate sand from the oil production, is used during a well test to determine the sand production characteristics as a function of the oil production rate, and to use the determined characteristics to increase, preferably optimise, oil production from the well without excessive sand production in the downstream pipeline or processing, transporting by pipeline, or storage facility.

[0087] The wellhead 252 of the oil well 250 is connected by the wellbore 230 to an oil-containing reservoir (not shown). During the test, a continuous output production flow is provided from the wellhead 252. The output production flow comprises hydrocarbon-containing oil at an oil production rate and sand at a sand production rate, and the output production flow is conveyed by the pipeline 254 from the wellhead 252 to the facility 256 for processing, transporting by pipeline, or storing the oil.

[0088] At the sand management station 282 along the pipeline 254 between the wellhead 252 and the facility 256, the output production flow is passed through the sand management system 240 installed in the pipeline 254, as described above. The sand management system 240 comprises the solids separator 270 configured to separate sand from the oil of the output production flow. The input 248 of the sand management system 240 receives the output production flow from the wellhead 252 along the upstream part 266 of the pipeline 254, upstream of the sand management system 240, and the oil output 274 outputs the oil, having sand separated therefrom, along the downstream part 268 of the pipeline 254.

[0089] The well test is illustrated in FIG. 4. In FIG. 4, the y axis 201 and the x-axis 202 respectively represent production rates and time, as described above for FIG. 1. The allowable sand rate (ASR) is represented by dotted line 203, the oil production rate is shown by line 204 and the sand production rate by line 205. In FIG. 4, the test sequence is broken into 4 distinct time periods 220, 221, 222 and 223 that are described hereinbelow.

[0090] Similar to FIG. 1, FIG. 4 schematically illustrates a monthly (or some other period, for example at least one week or at least one month) well test but in this case a compact sand separation, collection and also potentially sand washing unit is temporarily installed during the well test, for example the sand management system 240 as shown in FIG. 3. Alternatively, the unit may be a solids separator, for example as disclosed in WO-A-2016/075317. Other solids separators, such as hydrocyclone separators, for separating solid particles, such as sand, from multiphase hydrocarbon-containing fluids in the oil and gas production industry are known to those skilled in the art of oil and gas production.

[0091] At the start of well test during time period 220, the sand management system 240 is connected to receive the production flow from the well 250 undergoing the well test. This allows produced sand to be continuously or continually separated from the oil production. The sand management system 240 collects the sand so the sand content of the oil production can be managed as required. For example, the sand management system 240 could simply store the sand for removal after the test or, as illustrated in FIG. 3, the sand management system 240 may incorporate a sand washing arrangement to clean the hydrocarbons from the sand particles so that sand can be disposed of at the wellsite in an environmentally safe manner.

[0092] Returning to FIG. 4, at the beginning of time period 220, the sand production, as measured by the sand measurement device 262, or another measurement device, prior to installation of the sand management system 240 and therefore prior to separation of sand from the oil production flow, or as described above as measured by the sand management system 240 after installation of the sand management system 240, is below the ASR. This sand content level indicates to the operator that oil production can be increased without necessarily exceeding the ASR. In other words, at the beginning of the test the operator determines that there is some possibility to carry out the test to generate data on the sand content which can then be used to increase the oil production without generating excess sand in the oil production flow, which would otherwise compromise the flow capacity of the pipeline or downstream operations.

[0093] As shown by upward ramp 206, as the test is commenced the choke 258 on the wellhead 252 which is installed on the production pipeline 254 is opened to increase oil production to a higher level 207. The increased oil production rate correspondingly results in the sand production rate increasing to a higher level 208.

[0094] The oil production rate is increased to a value so that the associated sand flow rate from the reservoir is no greater than a predetermined maximum threshold, which maximum threshold has been determined or estimated to avoid damage to the wellbore 230 and wellhead 252 upstream of the sand management system 240 and/or damage to the reservoir or a formation above the reservoir.

[0095] In this example, the operator has selected an increased oil production rate that has resulted in a sand production rate at the higher level 208 which is nevertheless still below the ASR.

[0096] Therefore, again the operator determines that there is still some further possibility to try to increase the oil production, and the choke 258 is opened further so that the oil production increases, by upward ramp 209, to the even higher level 210.

[0097] Accordingly, in the method of the present invention, the choke 258 of the wellhead 252 is opened to increase the oil production rate and sand production rate, whereby the sand production rate is increased to a level higher than an allowable sand rate (ASR) which is a predetermined maximum threshold sand production rate of the pipeline 254. At least during a time period, for example time period 221, when the sand production rate is higher than the allowable sand rate (ASR), sand in the output production flow is continuously or continually separated from the oil of the output production flow using the solids separator 270 of the sand management system 240.

[0098] The removal of sand by the solids separator 270 provides a zero or non-zero reduced sand flow in the downstream part 268 of the pipeline 254.

[0099] In this example test of FIG. 4, the sand management system 240 is connected to the well 250, and therefore sand is removed from the oil production flow by the solids separator 270. Unlike the known well test described in FIG. 1, with the sand management system 240 connected to the well 250 as shown in FIG. 3, it is not necessary to reduce the oil production rate even if the sand production rate in the upstream part 266 of the pipeline 254 prior to the sand management system 240 is above the ASR: this is because the sand is separated from the oil production flow by the sand management system 240. The resultant reduced sand flow in the downstream part 268 of the pipeline 254 can be maintained below the ASR.

[0100] Therefore, the higher oil production rate is maintained at level 210 during a wellbore cleanout time period 221.

[0101] In the wellbore cleanout time period 221, the increased oil production rate removes the sand that has become inadvertently accumulated, or stored, in the wellbore 230, and this removal of accumulated sand causes a significant increase in the sand production rate in the upstream part 266 of the pipeline 254. As this accumulated/stored sand is removed from the wellbore 230, the sand production decreases to level 212, which represents the sand production from the reservoir due to the increased oil production. In other words, the increased oil flow rate from the reservoir, which also increases the sand production rate from the reservoir, additionally causes a temporary increase, or “spike”, in the sand production rate from the wellbore 230 as a result of the higher oil flow causing dislodging and removal of accumulated or stored sand in the wellbore 230. This sand removal constitutes a “wellbore cleanout”. Accordingly, in the typical method of the present invention, after the commencement of the step of opening the choke, the oil production rate and the sand production rate are permitted, after an initial increase in sand flow rate at least partially resulting from the removal of accumulated sand from the wellbore 230, to stabilise to respective stabilised values of the oil and sand production rates exiting the reservoir of the oil well. The stabilised oil level is level 210 and the stabilised sand level is level 212.

[0102] The test method then proceeds to the next time period 222, during which the sand rate is lowered to a value below the ASR as a result of sand being produced from the reservoir alone. This lower sand production rate is achieved by the operator closing the choke 258 on the oil production line 254 to reduce the oil production rate by a downward ramp 213 to a lower level 214. In this example, this lowering of the oil production rate results in the reduced sand flow rate reducing to a lower level 215 that is still above the ASR. The new reduced sand flow rate, as a result of sand removal by the solids separator 270, is determined in this embodiment by using the sand measurement device 262.

[0103] Therefore, the choke is closed further by the operator, to reduce the oil production rate by a downward ramp 216 to a lower level 217. This correspondingly results in a lower reduced sand flow rate, at level 218, which is below the ASR. This still lower reduced sand flow rate is determined in this embodiment by using the sand measurement device 262.

[0104] Accordingly, the oil production rate can be set at the level 217 as the new oil production rate for the subsequent oil production time period 223, for example for following month, or for the time period prior to the next well test. Therefore, at the commencement of time period 223 the operator has, during the well test, set the oil production rate to a higher “steady state” value until the next well test, which has correspondingly set the reduced sand flow rate to a “steady state” value below the ASR.

[0105] It may be seen that the well test of this embodiment of the present invention has achieved a significantly higher increase in the oil production rate, at level 217, as compared to the initial rate prior to the test, at level 204, than is achievable using the known well test as described above, and has also performed a wellbore cleanout to remove all sand accumulated or stored in the wellbore 230, and has reset the sand production rate at a level, i.e. level 218, which continues to be lower than the ASR. The oil production rate has been increased without exceeding the ASR in the downstream part 268 of the pipeline 254 either during the test or after the test.

[0106] The cross-hatch area shown during time periods 221 and 222 in FIG. 4 represents the volume of sand captured by the sand management system 240 during the well test. As a result of this test method of this embodiment of the present invention, an additional oil production rate ΔR, indicated by arrowed line 219, is achieved in addition to the oil production rate achieved during the known, present-day practice shown in FIG. 1. After the commencement of time period 223, the sand management system 240 can be removed from the well 250 and moved onto another well in order carry out the monthly well test on that next well.

[0107] Therefore, in accordance with the method of the present invention, after the choke 258 has initially been opened to increase the oil production rate, the reduced sand flow rate in the downstream part 268 of the pipeline 254 is measured to provide a measured reduced sand flow rate. The measured reduced sand flow rate is compared with the allowable sand rate (ASR) to provide a sand rate comparison value, which typically comprises, or is, a sand control parameter. Then the oil production rate is controlled using the sand rate comparison value, which is used as a sand control parameter, to maintain the sand production rate in the downstream part 268 of the pipeline 254 below the allowable sand rate (ASR).

[0108] In this embodiment, the sand management system 240 is temporarily installed in the pipeline 254 for a series of intermittent time periods, each intermittent time period comprising a test period during which the sand management system 240 is operational to separate sand from the oil production, and the sequence of the combination of the sand measuring step, the comparison step and the control step as described above is carried out during the test period.

[0109] In each test period, during which the sand management system 240 is temporarily installed in the pipeline 254, the sand management system 240 is employed to separate excess sand, in particular increased flow of sand that was accumulated or stored in the wellbore 230, so that the ASR is not exceeded in the downstream part 268 of the pipeline 254. The oil production rate is reset to an increased value which maintains the flow of sand in the downstream part 268 of the pipeline 254 below the ASR, even after the sand management system 240 has been uninstalled following the intermittent test period. The reset oil production rate has a sand production rate, i.e. the rate of sand flow from the reservoir, which is below the ASR. Therefore the sand management system 240 can be uninstalled, and excess sand separation is no longer required, until the subsequent sand test is conducted after a production period of at least one week or at least one month.

[0110] In this embodiment of the method of the present invention, after the choke 258 has been opened, as described above, during the test period the choke 258 of the wellhead 252 is subsequently closed to decrease the oil production rate and sand production rate. In this embodiment of the method of the present invention, the choke 258 is closed after the oil production rate and the sand production rate have stabilised, subsequent to an initial increase in sand flow rate at the commencement of the opening of the choke 258 at least partially resulting from the removal of accumulated sand from the wellbore 230, to respective stabilised values of the oil and sand production rates exiting the reservoir of the oil well.

[0111] Then the decreased reduced sand flow rate in the pipeline 254 is measured to provide a measured decreased reduced sand flow rate. The measured decreased reduced sand flow rate and the allowable sand rate (ASR) are compared to determine the sand rate comparison value, which typically comprises or is a sand control parameter, which is used to control the sand rate by controlling the oil production rate, to confirm that the measured decreased reduced sand flow rate is below the allowable sand rate (ASR). Thereafter, the oil production rate is set to a set production rate corresponding to the decreased oil production rate, which sets the sand rate as a result of using the sand rate comparison value, as a sand control parameter, to control the oil production rate. Finally, the test period is terminated. After terminating the test period, the sand management system 240 is uninstalled from the pipeline 254 at the end of the test period.

[0112] Subsequently, after a production time period during which continuous output production flow is conveyed by the pipeline 254 from the wellhead 252 to the facility 256 for processing, transporting by pipeline, or storing the oil, the sand management system 240 is re-installed on the pipeline 254 and the steps of the well test as described above are repeated. Typically, the production time period is at least one week or at least one month.

[0113] FIG. 5 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a continuous well test, using a sand management system as illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a second embodiment of the method of the present invention, the method being carried out on a given oil well, or group or field of oil wells.

[0114] In the embodiment illustrated in FIG. 5, the sand management system 240 is permanently installed on the well 250 rather than just for the well test period. Accordingly, the sand management system 240 is installed in the pipeline 254 for a continuous oil production time period, and the sequence of the combination of the sand measuring step, the step of comparing against the ASR, and the step of controlling the oil flow based on a sand rate comparison value, which is used as a sand control parameter, is carried out once at a beginning of the continuous oil production time period, or repeatedly at a plurality of times during the continuous oil production time period.

[0115] The initial steps are the same as those shown in FIG. 4. In other words, also in this embodiment, after opening the choke 258 so that the sand production flow is greater than the ASR, the following steps are carried out: measuring the reduced sand flow rate in the downstream part 268 of the pipeline 254 to provide a measured reduced sand flow rate; comparing the measured reduced sand flow rate with the allowable sand rate (ASR) to provide a sand rate comparison value; and controlling the oil production rate using the sand rate comparison value to maintain the reduced sand flow rate downstream of the sand management system below the allowable sand rate (ASR).

[0116] In this embodiment however, the increased oil production rate 310 is now determined such that the sand management system 240 is capable of handling both the sand accumulated/stored in the wellbore 230 plus the sand continuously produced from the reservoir as a result of the increased oil production rate, i.e. sand production rate 311. The sand produced from the reservoir as a result of the increased oil production rate on an ongoing basis is shown as sand production rate 312.

[0117] In this embodiment therefore, a maximum sand separation rate of the sand management system 240 is determined, or provided. This parameter effectively defines the capacity of the given sand management system 240 to be able to separate sand from the incoming oil flow at a given separation rate. Preferably in this embodiment, before the oil production rate is increased at upward ramp 209, the sand production rate in the pipeline 254 is measured by sand measurement device 262 or another device to provide a measured sand production rate from the reservoir. Thereafter, a maximum accumulated sand flow rate of sand at least partially resulting from the removal of accumulated sand from the wellbore 230 is determined or estimated. Then, there is a step of calculating from the measured sand production rate and the maximum accumulated sand flow rate, and from a maximum sand separation rate of the sand management system 240, a first maximum oil production rate that can be conveyed to the sand management system 240 to maintain a reduced sand flow rate below the allowable sand rate (ASR) at the output of the sand management system 240, whereby excess sand above the allowable sand rate (ASR) is separated from the oil by the solids separator 270. As described above, in this embodiment the oil production rate is increased by upward ramp 209 to a level 310, and level 310 is no greater that the calculated first maximum oil production rate.

[0118] The new increased oil production rate 310 is maintained as a “steady-state” oil production rate during a continuous oil production period. The cross-hatch area in FIG. 5 represents the sand volume captured by the sand management system 240 during the well test period and the continuous oil production period. Since the sand management system 240 is installed permanently on the well 250, the reduced sand flow rate can be continuously or continually checked by the sand measurement device 262.

[0119] This new method results in an increase, ΔR, in the oil production, as shown by arrowed line 319, as compared to the initial oil production rate, 204, before the installation of the sand management system 240 and the carrying out of the well test.

[0120] However, if the increased sand rate is now such that it does not cause erosion/damage concerns for the wellhead 252 and/or other equipment upstream of the sand management system 240, and does not damage the reservoir or the formation above the reservoir, then a further increase in oil production can be established as shown in the embodiment of FIG. 6.

[0121] FIG. 6 is a graph schematically illustrating the relationship between the production rate of oil, and the production rate of sand, with respect to time during a continuous well test, using a sand management system as illustrated in FIG. 3, in a method of controlling sand production from an oil well in accordance with a third embodiment of the method of the present invention, which is a modification of the second embodiment, the method being carried out on a given oil well, or group or field of oil wells.

[0122] As shown in FIG. 6, and as previously described with reference to FIG. 5, after the sand production rate has stabilised at level 312 and this rate has been measured, by use of the sand measurement device 262 or another device, and confirmed to be below a level that would potentially cause damage to the wellhead 252 and other equipment, then the choke 258 on the wellhead 252 is opened further, as shown by upward ramp 313, to increase the production to level 314. This increase in the oil production rate results in an increase in the sand production rate to a level 315. If this is level 315 is below a sand production rate that can cause damage to the wellhead 252, then the new production rate, at level 314, can be held at this level until the next monthly well test. It will be apparent to those skilled in the art that this further additional oil production rate at level 314 can be achieved through further increases and/or decreases in the oil production rate until a manageable long-term sand production rate is achieved. This method thus provides a significantly increase ΔR, which is typically optimised, in the oil production rate 320 as compared to the initial oil production rate 204 as shown in FIG. 4.

[0123] Referring to FIG. 6, in this embodiment, after the increase in the oil production rate by upward ramp 209, and after the stabilised values of the oil and sand production rates exiting the reservoir of the oil well have been achieved, typically the stabilised sand production rate in the pipeline is measured to provide a measured stabilised sand production rate. Then there is a step of calculating from the measured stabilised sand production rate and the maximum sand separation rate a second maximum oil production rate that can be conveyed to the sand management system to maintain a reduced sand flow rate below the allowable sand rate (ASR) at the output of the sand management system, whereby excess sand above the allowable sand rate (ASR) is separated from the oil by the solids separator. Thereafter, the oil production rate is further increased to a level 314 which is below the calculated second maximum oil production rate.

[0124] It is possible that for any given oil well the sand output of the reservoir may generally vary over time, and in particular may increase over time. If the measured reduced sand flow rate varies relative to the allowable sand rate (ASR) a well test can be repeated in order to try maximise the oil production rate while maintaining the sand flow rate below the ASR, and the sequence of the combination of the sand measuring, comparing and controlling steps is repeated after the step of increasing the oil production rate has been repeated.

[0125] The methods of the embodiments of FIGS. 4 to 6 may be carried out by an on-site operator by taking measurements from the sand measurement device 262 and using independent, e.g. manual, control of the choke 258 in order locally to control the oil production. However, in these embodiments the sand management system 240 may be configured as further illustrated in FIG. 3 to permit automatic, and optionally remote, control of the sand management system 240 and the choke 258, and thereby the oil production to maintain the reduced sand flow rate below the ASR. Such automatic, and optionally remote, control of the sand management system 240 and the choke 258 is particularly beneficial in the embodiments of FIGS. 5 and 6 in which the sand management system 240 is installed in the pipeline 254 either permanently or for an extended production period of, for example, more than 3 months.

[0126] In order to provide such automatic and/or remote control, as shown in FIG. 3, in the illustrated embodiment the control system 280 comprises a data storage module 281 configured to store an allowable sand rate (ASR) which is a predetermined maximum threshold sand flow rate of the pipeline 254. This value can be determined by the operator, set by local regulations, or calculated for any given pipeline, as is known to those skilled in the art. The control system 280 also comprises a comparator module 283 for comparing the measured reduced sand flow rate, received from the measurement device 262 or another device, with the allowable sand rate (ASR) to provide a sand rate comparison value. The control system 280 further comprises an oil flow rate control module 285 for outputting a control signal to the choke 258 for controlling the oil production rate. The oil flow rate control module 285 processes the sand rate comparison value, which is used as a sand control parameter, to maintain the reduced sand flow rate downstream of the sand management system below the allowable sand rate (ASR).

[0127] As described above, the control system 280 may thereby enable automatic and remote control of the sand management system 240 and the choke 258, particularly when the sand management system 240 is permanently installed in the pipeline 254.

[0128] Various modifications to the present invention may be made by the person skilled in the art of oil production without departing from the scope of the present invention as defined in the appended claims.