Turning $3.5m of coiled tubing campaign cost into $58m profit using a FourPhase DualFlow desander.
A major Norwegian oil and gas producer experienced a screen collapse in one of their highest producing wells. This caused a significant volume of sand to be produced into the wellbore and furthermore reaching the production facility. The well was immediately shut-in due to sand handling limitations topside. A wireline operation was performed but was held up at a shallow depth of 1 575m. It was then assumed that the well was almost completely filled with sand. The well was scheduled for a plug and abandonment (P&A) followed by drilling of a side-track well to regain production. Prior to the execution of a P&A operation, the wellbore must be cleaned down to the appropriate depth to allow for setting of barrier plugs, etc. A Coiled Tubing (CT) operation is a typical solution for this type of cleanout.Solution
After evaluation of using Coiled Tubing to clean out the wellbore, it was decided to make an attempt to kick-start the well using a 5K psi DualFlow desander to remove the sand at surface. The DualFlow unit was already installed and in operation, as part of continuous production solution on other solids producing wells. The DualFlow unit is connected to 40+ wells via the test manifold in the production system. No downsides were identified during the evaluation of a kick-start attempt on the well, and if successful, the cost of the CT package, additional personnel on board (POB) and logistical impact would also be eliminated.


The DualFlow desander delivered enhanced production. The well was able to be kick-started and the majority of the sand causing a blockage was lifted out. There was an assumption that the well was flowing with a water cut of 99%. It turned out that during the initial recovery period the actual water cut was only 71%. The P&A operation was cancelled. The well was returned to production with a high oil production potential.

  • Significant reduction in personnel and equipment compared to CT operation
  • Expected cost of $3.5m performing a CT cleanout as preparation for P&A and drilling of side-track
  • There was a total production earning due to recovered oil during the Initial Production Recovery stage of $1.4m equaling a total planned operation difference of $4.9m


The well is being produced through the 5K DualFlow production enhancement system, providing an average oil
production of ~560Sm³/day. The wellbore is maintained at surface with a separation efficiency of >99%. Total solids removed (YTD) of 7 817kg.

  • All sand is continuously transported out of the wellbore ensuring an always clean wellbore
  • During the operation, achieving a higher sand-free oil production rate at the production facility, giving a direct profit of $0.23m/day
  • An estimate of a conservative 250 production days for a full year, gives a total earning due to the 5K DualFlow
    production enhancement system of $58m



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