Thane Russell is CEO of Absolute Energy Solutions, based in Calgary. Founded in 2001, the company provides a wide range of sand control products, including MeshRITE and FacsRITE  sand control screens, as well as a variety of specialist drilling, well construction and completion services.

MeshRITE stainless steel (SS) screens address sand control challenges in thermal wells and are widely used around the world, notably in Venezuela, to assist the production of heavy oil. The screen is made of compressed SS fibers, which generate unique and beneficial characteristics including angular pore spaces, greater than 80% porosity and very high permeability. Unlike traditional sand-control methods that rely on fixed pore sizes and bridging, MeshRITE screens effectively handle sands with poor grain-size sorting and resist failure and plugging, even with extended use. This is achieved thanks to the very wide pore-size distribution of the MeshRITE media: 15 to 650 microns. In addition, the pores are angular, making them extremely difficult to plug-off. The screen acts as a depth filter, avoiding sorting of grains at the well/formation interface. The sand layer around the screen quickly becomes stabilized, delivering high productivity and low decline rates over the long term.

Slotted liners do not handle torque well—they tend to twist and the slots can open or close, resulting in highly variable flow. Closed slots lead to higher velocity flow at adjacent open slots, causing further sanding and/or plugging. Conventional wire-wrap screens are better, but can change or lose their sand retention capabilities over time. Velocity is the key—MeshRITE screens spread flow over a very large area, providing high flow rates while mimizing friction losses.

MeshRITE was originally developed in a project funded by Texaco and the Alberta Development Council to overcome problems with some in situ combustion (ISC) production wells. Well design was based on gravel-packing around wire-wrap screens but the gravel was proving difficult to place and failed at high temperatures. A variety of screen and pack technologies were tested. None matched the performance of compressed steel fiber.

MeshRITE screens are mechanically tough—able to cope with high stress levels during running-in and operation. They can handle drawdowns up to 800 psi and temperatures up to 350 degC (660 degF). They can also handle expansion and contraction due to variations in temperature. 

MeshRITE screens are compatible with all types of sand-control techniques, including openhole and cased-hole gravel packs, horizontal gravel packs, stand-alone screen deployment, and through-tubing sand-control in oil and gas reservoirs.

Absolute Energy Solutions also manufactures FacsRITE— seamless pipe in which filter cartridges are flush-installed within drilled holes. FacsRITE is cheaper than premium screens and is more resistant to plugging and erosion than slotted liner. The density of filter cartridges can be varied depending upon the specific downhole production environment and can incorporate inflow control devices (ICDs) to balance flow along the wellbore.

Thorough planning and modeling are key to the success of sandface completions strategies. This requires geomechanical data and a good understanding of sand mobility, fluid composition and PVT behavior. 

Like many other experts involved with technological development for heavy oil, Russell observes that industry take-up of new technology is often very slow. Completions engineers are particularly conservative—reluctant to risk untested sand control systems after all the expense of exploration and drilling. In addition, many operators are reluctant to invest additional capital expenditure for advanced sand control systems, despite the fact that, with proper planning, this investment can soon be recovered through improved productivity.

Absolute Energy Solutions is continuing to develop new completions solutions and address the need for cost-effective equipment able to withstand very high temperatures and extreme changes in temperature. The company is also looking at ways to improve efficiency, such as making workovers in SAGD wells easier and faster.

MeshRITE and FacsRITE are trademarks of Absolute Energy Solutions.