SPE-183329-MS

Downhole Sand Ingress Detection Using Fibre-Optic Distributed Acoustic

Sensors

Pradyumna Thiruvenkatanathan, Tommy Langnes, Paul Beaumont, Daniel White, and Michael Webster, BP

Copyright 2016, Society of Petroleum Engineers

This paper was prepared for presentation at the Abu Dhabi International Petroleum Exhibition & Conference held in Abu Dhabi, UAE, 7-10 November 2016.

This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
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Abstract
Sand production remains a key technical challenge in many reservoirs where formations comprise of
weakly consolidated sandstone. Sand control completion equipment is typically installed to prevent sand
from entering the well. However, in cases where the sand control is ineffective due to installation flaws/
defects, high sand production may occur often requiring choking back of wells and resulting in significant
hydrocarbon production losses. An effective remediation requires identification of locations of sand entry.
However, there is currently no proven technology available in the market that accurately identifies downhole
sand ingress locations in real-time. In this paper, we present results from a new technology solution
that addresses this challenge by using in-well conveyed fibre optic distributed acoustic sensors (DAS)
for the detection of sand ingress zones across the reservoir section throughout the production period in
real time. The technology employs a novel signal processing technique that isolates and extracts acoustic
signals resulting from sand ingress from background flow and instrumentation noise in real time. The new
processing architecture also addresses the "big-data problem" that currently hinders DAS technology uptake
through use of intelligent feature-extraction techniques that reduce data volumes at source (by several orders
of magnitude). The technology feasibility has now been verified both through flow loop experiments and
through multiple field trials and has been successfully used to inform the first targeted sand remediation
in a BP production well.

Introduction
Sand production remains one of the key technical challenges in many hydrocarbon producing wells in sand
prone reservoirs. Sand production can cause damage to downhole completion, subsea equipment and surface
facilities through erosion, increasing the risk to maintaining mechanical well integrity. Sand accumulation
can also cause instability in production facilities reducing production and costing significant amounts of
time and cost to clean out.
Where sand production is considered a risk, sand control completion systems are installed to help prevent
sand from entering the well. However, the mechanical sand control systems are not always fully effective and
the end result may be high sand production which results in choking back the well and reducing hydrocarbon
production significantly. In most cases, the precise sanding interval is unknown making sand remediation
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operations (such as remedial plug placements) often ineffective. This results in continued sand production
and consequent production losses. A successful remediation requires identification of locations of sand entry
to inform ‘targeted sand shut-off’ operations. However, there is currently no proven technology available
in the market that accurately identifies the sand ingress locations during well production in real time.
This paper presents a new technology solution that addresses this key challenge using fibre-optic
Distributed Acoustic Sensors (DAS) to detect and visualize sand ingress points along with the relative sand
concentration in real-time across the reservoir throughout the production period as illustrated in Fig. 1.

Figure 1—Schematic illustrating an example DAS ‘sand log’

computed across the reservoir interval to identify sand entry points

The technology employs a novel digital signal processing scheme that distinguishes sand ingress ‘signals’
from fluid flow and other background ‘noise’ in real time and presents the results as ‘sand ingress logs’ (or
‘sand logs’) to provide a relative measure of sand ingress across the reservoir section during production.
The technology has now been successfully used:

• To monitor the sand ingress during production (in real time) to inform and optmise oil production.

• To inform and implement a targeted sand ‘shut-off’ operation to increase hydrocarbon production
rates
• To assess the reliability of the sand control equipment reliability during production to improve
future designs
The key results from two consecutive field trials of the technology conducted in an oil producing well are
presented in this paper. Results from correlation studies to validate DAS observations with other peripheral
surface and sub-surface data are also presented.

Sand detection
Traditionally, sand detection is achieved using acoustic ‘point’ sensors that are clamped on to the production
flowline at surface. Produced sand particles that get carried to surface with the produced fluids strike the
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walls of the pipe and create stress waves that are captured as sound signals by the acoustic sensors mounted
on the pipe wall (Brown, 2000). The acoustic signals generated by the impacting sand particles are extracted
from flow noise in liquid systems and other mechanical noise by monitoring and filtering the frequencies of
the sound signal generated. This is based on the assumption that the frequency distribution of the acoustics
generated by the sand striking the pipe wall is different to that of fluid flow and other mechanical noise.
While such surface acoustic sand detectors provide a delayed indication of onset of downhole sanding
events, they do not provide information about the zones in the reservoir that are producing sand. A successful
sand shut-off operation, however, requires knowledge and definitive identification of the zones (or depth
sections) in the reservoir contributing to sanding and their relative concentrations.
DAS (also referred to as fibre optic Distributed Vibration Sensors (DVS)) has been looked upon as a
potential candidate technology for downhole sand detection in recent years (Mullens, Lees, & Duvivier,
2010). DAS are intrinsic optical fiber based acoustic sensing systems that use the backscatter component
of the light injected into an optical fiber for detecting acoustic (i.e. dynamic strain) perturbations along the
length of the fiber. Unlike traditional ‘point’ sensors, the fiber itself acts as the sensing element with no
additional transducers in the optical path and measurements are taken along the length of the entire fibre,
allowing for a true, distributed, measurement using a single fiber. The DAS provides sensitivity to strain
variations by monitoring changes in the length and index of refraction of the fibre induced by impinging
acoustic pressure waves. The fiber, in effect, functions akin to a distributed array of microphones spread
over the entire length of the well ‘listening’ to down-hole acoustics.
Fibre optic DAS technology is now being increasingly applied for a number of downhole surveillance
applications. The technology has been applied for monitoring hydraulic fracturing (Cox & Molenaar, 2013),
vertical seismic profiling (Mateeva, et al., 2013) and for single phase flow profiling applications (In 't
Panhuis, et al., 2014). DAS has also been trialled for downhole sand detection in recent years (Mullens,
Lees, & Duvivier, 2010). Whilst these trials yielded encouraging results by providing data indicative of in-
well sanding, they also highlighted some of the current limitations of the technology, as summarized below:

• Firstly, fiber-optic DAS systems capture not just the acoustic signals resulting from sand ingress
into the well bore, but all the other background "noise" as well – including that of fluid flow,
instrumentation noise etc. This mandates the need for a robust signal processing procedure that
clearly identifies and distinguishes sand ingress signals from other noise sources. This, however,
requires a clearer understanding of the "acoustic fingerprint" of in-well sand ingress in order to
be able to segregate sand ingress sounds from other ambient acoustic background noise although
this is not known in the industry.
• DAS systems produce substantially large data volumes (which under certain acquisition settings
may result in data as large as 1 TB/hour). Such data volumes create complexities in data handling as
they impose challenges in real-time data transmission from the Wellsite and also in data integration
with existing IT platforms (due to data bandwidth limitations) often requiring the acquired data to
be stored in hard drives on site that are later shipped back to shore post acquisition for interpretation
and analysis. This increases the analysis and interpretation turnaround time (typically by a few
weeks to months) before an interpreted set of results to inform sand remediation can be delivered.
This consequently results in continued production losses during this period. There is currently no
method in the market for processing the raw DAS data in real time to reduce data volumes at source
and aid real-time decision support for sand monitoring.
• Effective remediation requires not just a binary ‘Yes’ or ‘No’ output for detection of in-well sanding
events but also a measure of relative concentrations of sand entering the wellbore at different
sections along the reservoir interval at the different production rates. Such a quantitative (or semi-
quantitative) measurement would enable detection of the zones contributing the most sand which
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may then be evaluated and prioritised for shut off operations in order to optimise hydrocarbon
production in the entire well.
The following sections present a new technology solution that was developed within BP to address these
key challenges. The proposed solution uses DAS as the primary input data feed and employs a novel and
propietary real-time signal processing algorithm that automatically processes the raw data to isolate and
extract the sand ingress signals from background noise in real time. The system outputs ‘sand logs’ that
provide a relative measure of sand ingress across the reservoir section in real time, consequently converting
TeraBytes of raw acoustic information into easily interpretable and decision-friendly logs that indicate
locations of sand entry and relative concentration in real time.

Technology development
Flow loop experimentation
The first step in developing the real-time sand detection system was to develop a physical understanding
of the ‘acoustic fingerprint’ of sand ingress in to hydrocarbon producing wells i.e., to have a description
of what sand ingress into a production tubing ‘sounded’ like on fiber-optic DAS. This acoustic fingerprint
of sand ingress was derived empirically with the help of experimental data from a multi-phase flow loop
experiment conducted by BP. The results have now also been modelled through first principles to obtain a
clearer understanding of the underlying physics. The flow loop comprised of a test section with multiple
fluid and sand ingress ports. The fibre was attached on the outside of the test pipe to simulate the case
where the fibre is installed as part of the downhole completion (Corbett, Fagervik, Stewart, Smith, & Falcon,
2002). Known concentrations of sand were then injected along with known quantities of other multi-phase
fluids to best simulate reservoir conditions. The DAS data was then gatherered across the entire test section
to analyse the characteristics of the acoustic data specifically at the sand entry points (during times when
sand was injected along with other multi-phase fluids) and compare these with zones where there were no
sand injection but only multi-phase fluids (at similar rates and phase compositions). These experiments
formed the basis for uniquely identifying and extracting the sand ingress fingerprint. This was followed by
experiments to quantify the performance limits of the DAS (more specifically, the sensitivity and spatial
resolution) by varying the concentrations of injected sand at different spatial locations across the test section.
An image of the flow loop test setup is shown in nFig. 2.

Figure 2—Photo illustrating the experimental setup during flow loop trial
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Specific tests were also conducted to examine the variability of the sand ingress fingerprint to variations
typically observed during production to best simulate reservoir conditions (e.g. varying fluid flow rates,
fluid phase composition etc.). The data was also analysed to distinguish sand transporation acoustics from
that of sand ingress.
The results of the experiments whilst providing a good basis for the study of the acoustic fingerprint
of sand ingress (and sand transport) as measured on the DAS, also enabled the construction of a new
digital signal processing algorithm that would uniquely identify and extract the sand ingress signals from
background noise in real-time.

Field trials
Following the flow loop trials, the performance of the DAS and the real-time sand detection algorithm were
tested with field data acquired on a well with a history of sand production. The candidate well had an open
hole gravel pack completions and had a fibre optic cable preinstalled across the reservoir interval. Three
consecutive field trials were conducted at 6 month intervals.
Results – Field trial 1. The acquired data was first depth calibrated to ensure data alignment with the
wellbore measured depth (MD) before commencement of data acquisition for sand monitoring purposes.
The DAS data was acquired from the entire length of the fibre that was permanently installed within the
downhole completion assembly. The well was initially operated at a steady production rate and then ramped
up to higher drawdown pressure before being brought back to initial production conditions. This was done
to understand the temporal behavior of sand ingress under different production conditions. The acquired
raw data was stored in hard drives and later shipped from platform to shore for data interpretation. The
data was then manually processed to check and analyse the data gathered across the reservoir section to
identify zones with acoustic signals of similar characteristics to the sand ingress fingerprint as modelled
and experimentally observed during the flow loop trials. This indicated multiple depth zones with acoustics
of similar characteristics to that of the ‘sand ingress fingerprint’ and these ‘zones of interest’ were then
investigated further to verify conformance with the sand ingress fingerprint. The data was later reprocessed
to filter out the background flow and instrumentation noise and retain just the acoustic signals of sand
ingress. The filtered sand acoustic signals were then averaged through time to construct a "sand log" across
the entire reservoir section. A representative example of the sand log hence constructed is shown in Fig. 3.

Figure 3—Representative example of DAS sand log computed from data acquired in field trial 1

The DAS sand log presents the acoustic amplitude (filtered for sand ingress) as a function of depth across
the reservoir interval. Reviewing the log indicates five distinct zones of sand ingress with relatively higher
sand ingress noise observed in zones 3 and 4.
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The DAS data was then further analysed to study the transportation of the sand from the point of entry all
the way up to the surface. Fig. 4 displays a DAS ‘sound field’ filtered to monitor sand transportation over
the entire well depth acquired for a period of several hours during well ramp up. The sound field displays
the calibrated measured depth along the y axis and the time stamp along the x-axis and the acoustic intensity
as a colour scale (with red being high acoustic intensity and blue being low). The plot also overlays the
surface flowline acoustic sensor data (red data trace at the bottom of the illustration) aligned in time with
the DAS sound field.

Figure 4—DAS sound field filtered to monitor sand transport.

A few observations can be made from the soundfield shown in Fig. 4:

• Filtering the DAS soundfields to pick up sand transport acoustics indicated sand slugs (shown
by ‘streaks’ of increased acoustic power) originating from around 3000 mMD and reaching the
surface with velocities increasing at shallower depths. Correlating the DAS measurements at times
when the sand slugs reach the surface with the data captured on the surface acoustic sensors at the
production flow lines indicate a good match between the filtered DAS data and the surface sensor
data. Lab samples taken, at the time, further confirmed the presence of sand in the produced fluid
verifying the feasibility of the technology and the signal processing technique used to filter and
capture sand transportation on the DAS.
• We also observe a ‘red carpet’ of high intensity acoustics acoustics near the surface. This is because
of contamination of surface noise (caused by mechanical equipment on surface) that may be filtered
and removed through further processing.
Field trial 2. In order to check the repeatability of the measurement, a second field trial was conducted
in the candidate well, six months after the first field trial. This time, the well was initially shut-in and then
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ramped up in steps, holding the production rates stable for several hours at each choke setting. As part of
the field trial, data processing and real time data handling infrastructure was developed to enable real time
streaming of processed acoustic data through the BP network. Back end visualization systems were also
bult to visualize and manipulate the processed acoustic data in real time.
Sand logs were computed at each of the production rates (under stable drawdown conditions) and the
computed logs were then integrated through time to construct ‘drawdown-lapsed sand logs’ as shown in
the representative example illustrated in Fig. 5.

Figure 5—Representative example of cumulative sand logs constructed from data acquired in the second field trial
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The drawdown-lapsed sand logs allow for a better representation of the temporal behavior of sand ingress
across the sanding intervals identified downhole enabling a clearer insight into the chokes/drawdowns at
which each of the sand producing intervals begin contributing sand. This knowledge not only aids better
evaluation of the extent of sanding in each of the sand ingress zones, but also provides valuable information
to help identify the well drawdown envelope for optimum oil production.
The first data trace (shown as a solid blue curve on the left in Fig. 5) shows the sand log computed at
a relatively low drawdown (of nearly 160 psi). When comparing these results with those of field trial 1, it
may be observed that many of the sand producing intervals identified in field trial 1 remain consistent in
field trial 2. As the drawdown is increased progressively, more zones are seen to produce sand.
Field trial 3. The results from field trials 1 and 2 were then used to execute the first ‘DAS-informed’
targeted sand remediation operation in BP. Selected sand ingress zones as identified in field trials 1 and 2
were isolated using mechanical patch technology and the well was brought back into production. The DAS
was then connected up again to the optical fibre and the data acquisition commenced. The complete end-
to-end technology solution incorporating BP’s real time sand detection algorithm was installed and tested
as part of the field trial. Sand logs were also computed in real time to evaluate and compare the sanding
behavior observed downhole post remediation. A representative example of Normalized sand ‘profiles’
both pre and post remediation at similar well drawdowns are presented in Fig. 6 with the remediated zones
highlighted in pink.

Figure 6—Representative example of Normalised DAS sand profiles computed pre and post remediation

The results show a substantial reduction in the overall sand production (by over 70%) post sand shut off
indicating a successful remediation. This was also confirmed through physical samples taken on surface.
The lower sanding rates have also enabled further ramp up of the well and this has consequently led to a
significant increase in oil production by more than 2,000 barrels per day.

Summary and Conclusion

The results presented in this paper, prove the technical feasibility of using DAS for the construction of
‘sand ingress logs’ that provide a measure of relative concentrations of sand entry at each of the producing
intervals through time.
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The ability to detect sand ingress using DAS across the reservoir section now provides a unique capability
to monitor and control the sand at the ‘source’. Furthermore, the ability to use the new sand detection
technology on a preinstalled fibre optic cable also allows for sand monitoring throughout the life of well
and not just a snapshot measurement. This capability enables:

• Targeted remediation to increase hydrocarbon production

• Optimal drawdown control to manage sand related risks during well ramp up and production
operations
• Sand control equipment reliability monitoring that helps inform future sand control completion
and equipment designs
Together, these benefits allow for maximising reservoir recovery and minimising operational risk and
cost.
The technology has now been embedded into the business through data handling and signal processing
infrastructure to facilitate generation and visualisation of sand logs in real-time. This new real time sand
monitoring solution is now being routinely used to identify sanding zones for targeted remediation and also
production optimization both on wells with fibres permanently installed and using wireline conveyed DAS
on wells without preinstalled fibres.

Acknowledgement
The authors would like to thank and acknowledge Adrian Zett, Hans Vaziri, Valery Gasanov, Dana
Aytkozhina and C.S. Natarajan for their support and guidance through out the research and development
cycle. We would also like to thank the management of BP for their support in preparation of this paper and
for providing the opportunity to present it.

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