Managing Sand Production Risks to Maximise Well Uptime
- Based on an interview with FourPhase Operations Manager Marianne Mikalsen -
Sand production remains one of the most persistent challenges in oil and gas operations. Around 70% of the world’s hydrocarbon reservoirs are in unconsolidated or weakly consolidated sandstone formations, environments where the risk of sand migration and erosion is inherently [1]. When not managed effectively, produced sand can lead to erosion, equipment damage and unplanned shutdowns, reducing both safety and production efficiency.
Our goal is not just to remove sand, but to predict and prevent its impact. By combining rigorous planning, field experience and data-driven insight, FourPhase enables operators to maintain continuous production with confidence.
Sand production remains one of the most persistent challenges in oil and gas operations. Around 70% of the world’s hydrocarbon reservoirs are in unconsolidated or weakly consolidated sandstone formations, environments where the risk of sand migration and erosion is inherently [1]. When not managed effectively, produced sand can lead to erosion, equipment damage and unplanned shutdowns, reducing both safety and production efficiency.
Our goal is not just to remove sand, but to predict and prevent its impact. By combining rigorous planning, field experience and data-driven insight, FourPhase enables operators to maintain continuous production with confidence.
From Experience to Predictive Performance in Sand-Producing Wells
Our operations over the years have provided extensive experience across a range of wells producing solids, and we save the data from all our operations. The database provides us with the ability to perform detailed scenario modelling and risk assessment. This means every campaign begins long before the equipment reaches the platform, and ensures that processes run seamlessly once operations begin.
Our accumulated experience provides the foundation for predictability. By analysing parameters such as PVT properties, fluid- and sand rate, solids characteristics and flow velocity, we can forecast operational efficiency and erosion risk before a job even starts. This approach allows us to make informed decisions about which jobs to accept, and which ones will need further clarifications on expected results. These conversations ensure expectations are clear from the outset, whether the target is 100% uptime or a more measured performance goal based on well conditions.
Our accumulated experience provides the foundation for predictability. By analysing parameters such as PVT properties, fluid- and sand rate, solids characteristics and flow velocity, we can forecast operational efficiency and erosion risk before a job even starts. This approach allows us to make informed decisions about which jobs to accept, and which ones will need further clarifications on expected results. These conversations ensure expectations are clear from the outset, whether the target is 100% uptime or a more measured performance goal based on well conditions.
Data-Led Workflows that Minimise Erosion and Downtime
Across the industry, the financial impact of poor sand management is well documented. Erosion from entrained solids is now recognised as a major contributor to equipment failures in production systems, pipelines and valves. Effective mitigation, therefore, is central to maintaining production integrity and cost control.
Each FourPhase operation follows a structured, data-driven workflow. Before mobilisation, the team carries out a full operational assessment, covering every detail from well characteristics, optimal tie-ins, interfaces, site considerations, calculations and risk analysis to identify the optimal operational configuration. During operation, non-destructive testing (NDT) is used to confirm equipment integrity and wall thickness.
Where necessary, 3rd-party-certified measurements are also included to further confirm predictions and measurements. By owning these services, all the data gathered contributes to even stronger data-sets and future predictive models. Maintenance programmes are adjusted in real time based on both live data and cumulative field knowledge, ensuring that erosion remains within acceptable limits throughout the campaign.
Production optimisation is a core part of our sand-management workflow. When FourPhase specialists are offshore, they can focus on a single well and tune it in close collaboration with the operator’s well owner (often “PETEK”/production technology). Together, we align production parameters, logging data and well programmes, and test against live solids data from the FourPhase system.
The objective is not simply to “balance” velocity, sand rate and erosion, but to establish the highest stable operating window for that well — where the rate is as high as the well can sustain, the sand volume is manageable for the system, and separation efficiency remains high. If erosion cannot be avoided to reach the production goal, it is monitored and kept within agreed limits to be aligned with a suitable maintenance program. On several long-term production assets LINK, this way of working has enabled operators to sustain production increases of around 30% over more than three years, giving significant cumulative gains.
The benefits of this proactive approach are evident from recent operations. In a Norwegian North Sea field, FourPhase deployed a DualFlow desander upstream of the produced-water reinjection pumps after repeated pump failures were causing field-wide shutdowns. By implementing a remotely monitored and largely unmanned solution, the operator eliminated pump failures and achieved zero NPT across more than 11,000 hours of unmanned operation. The system continuously removed solids from the production separator, preventing erosion and enabling an additional 1 MSm³/day of continuous flow without downtime. Real-time solids measurement also allowed improved calibration of sand sensors, further optimising production and enhancing reservoir understanding.
These results underline what FourPhase consistently demonstrates in practice: that integrated, data-led solids management directly translates into measurable uptime and production gains. And the gains continue after we leave. In this case the operator could go back to standard maintenance procedures for critical equipment previously prone to excessive wear, which meant the risk of downtime going forward is significantly reduced.
Each FourPhase operation follows a structured, data-driven workflow. Before mobilisation, the team carries out a full operational assessment, covering every detail from well characteristics, optimal tie-ins, interfaces, site considerations, calculations and risk analysis to identify the optimal operational configuration. During operation, non-destructive testing (NDT) is used to confirm equipment integrity and wall thickness.
Where necessary, 3rd-party-certified measurements are also included to further confirm predictions and measurements. By owning these services, all the data gathered contributes to even stronger data-sets and future predictive models. Maintenance programmes are adjusted in real time based on both live data and cumulative field knowledge, ensuring that erosion remains within acceptable limits throughout the campaign.
Production optimisation is a core part of our sand-management workflow. When FourPhase specialists are offshore, they can focus on a single well and tune it in close collaboration with the operator’s well owner (often “PETEK”/production technology). Together, we align production parameters, logging data and well programmes, and test against live solids data from the FourPhase system.
The objective is not simply to “balance” velocity, sand rate and erosion, but to establish the highest stable operating window for that well — where the rate is as high as the well can sustain, the sand volume is manageable for the system, and separation efficiency remains high. If erosion cannot be avoided to reach the production goal, it is monitored and kept within agreed limits to be aligned with a suitable maintenance program. On several long-term production assets LINK, this way of working has enabled operators to sustain production increases of around 30% over more than three years, giving significant cumulative gains.
The benefits of this proactive approach are evident from recent operations. In a Norwegian North Sea field, FourPhase deployed a DualFlow desander upstream of the produced-water reinjection pumps after repeated pump failures were causing field-wide shutdowns. By implementing a remotely monitored and largely unmanned solution, the operator eliminated pump failures and achieved zero NPT across more than 11,000 hours of unmanned operation. The system continuously removed solids from the production separator, preventing erosion and enabling an additional 1 MSm³/day of continuous flow without downtime. Real-time solids measurement also allowed improved calibration of sand sensors, further optimising production and enhancing reservoir understanding.
These results underline what FourPhase consistently demonstrates in practice: that integrated, data-led solids management directly translates into measurable uptime and production gains. And the gains continue after we leave. In this case the operator could go back to standard maintenance procedures for critical equipment previously prone to excessive wear, which meant the risk of downtime going forward is significantly reduced.
Continuous Improvement through Inspection and Learning
Once the operation concludes, the process of learning and improving keeps going. Equipment is inspected, erosion is measured, and all data is captured for review. Dedicated post-job meetings bring together the FourPhase team and client representatives to discuss performance outcomes, identify successes and potential improvements. Insights from each operation feed into future projects, ensuring that each campaign strengthens the next.
This structured feedback loop supports not only internal improvement but also industry transparency. Frequent inspection and verification under DNV-certified procedures allow both operator and service provider to maintain a clear view of equipment performance and expected wear rates.
This structured feedback loop supports not only internal improvement but also industry transparency. Frequent inspection and verification under DNV-certified procedures allow both operator and service provider to maintain a clear view of equipment performance and expected wear rates.
Sand Management as a Driver of Reliability
Delivering near-100% uptime in sand-producing wells is not about eliminating risk, but managing it with precision. Our approach is grounded in data, experience and engineering integrity. By combining discipline in planning, operational experience and technology designed for continuous operation, we help operators turn uncertainty into predictability. As wells become more complex and production environments more demanding, efficient solids management will remain a defining factor in operational success.
“Our commitment to continuous improvement is what builds trust with our clients. They know we’re always using data insights to continuously refine our approach,”
- says Marianne Mikalsen, Operations Manager at FourPhase.
References:
[1] - https://link.springer.com/article/10.1007/s13202-024-01860-1?
“Our commitment to continuous improvement is what builds trust with our clients. They know we’re always using data insights to continuously refine our approach,”
- says Marianne Mikalsen, Operations Manager at FourPhase.
References:
[1] - https://link.springer.com/article/10.1007/s13202-024-01860-1?
Get in touch