OTC 16051

Wash Pipe Or No Wash Pipe? That is The Question

Francisco Pineda, SPE, Bryce Traweek, and James Curtis, SPE, BJ Services Company
Copyright 2004, Offshore Technology Conference
This paper was prepared for presentation at the Offshore Technology Conference held in
Houston, Texas, U.S.A., 36 May 2004.
This paper was selected for presentation by an OTC Program Committee following review of
information contained in an abstract submitted by the author(s). Contents of the paper, as
presented, have not been reviewed by the Offshore Technology Conference and are subject to
correction by the author(s). The material, as presented, does not necessarily reflect any
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presented.

Abstract
Conventional gravel pack or frac pack completions typically
require the use of wash pipe to act as a conduit for fluid
returns as well to carry a shifting mechanism to open or close
a return port. Using properly sized wash pipe can enhance the
placement of the gravel across the entire annular space and the
formation. It can be used in conjunction with a shifting
mechanism and a sliding sleeve to force the fluid returns to
pass through the bottom of the screen. It can allow a washdown capability while running the assembly into hole. In
specialty systems, it can even act as a pumping conduit for
post-gravel pack stimulation.
However, the use of wash pipe, especially in long
horizontal wells, means the loss of valuable rig time due to
make up and break up of the wash pipe, or recovery if the
wash pipe is stuck. Economic considerations, along with
completion efficiencies, are especially important on deepwater
completions.
Not using wash pipe reduces rig time,
generating significant cost savings, and also eliminates the risk
of sticking it.
This paper reviews conventional wash pipe applications
and describes new systems that accomplish the same goal with
a minimum amount of wash pipe or no wash pipe at all.
Uses of Wash Pipe
The production of formation sand into a well is one of the
oldest problems plaguing the oil and gas industry because its
adverse effects on well productivity and equipment.1
Gravel packing and frac packing are the methods of choice
for sand control. In combination with sand screens they
provide downhole filters to prevent production of formation
sand. During the execution of these methods, a properly sized
sand or proppant has to be placed in the formation as well as
the annulus of the screen-casing or screen-open hole using a
gravel pack packer assembly with a gravel pack service tool
and wash pipe inside the sand screen, with its bottom hanging
as close as possible to the end of the screen. This

configuration aids the placement of the sand or proppant by

allowing the gravel pack fluids to travel down the tubing,
through and out the ports of the gravel pack service tool and
assembly, down the blank/screen-casing or open hole annulus,
into the perforations or open hole, through the screen, up the
wash pipe and gravel pack service tool, and into the gravel
pack packer-casing annulus.
Wash pipe can also be use as a conduit to allow washdown capabilities when installing screens or liners. In
isolation systems, wash pipe is used to run shifting tools to
activate sliding sleeves in order to achieve returns during
gravel packing.
There are also other economic factors to consider when
using wash pipe, such as the valuable rig time necessary for
making up, running in and breaking up, especially in
horizontal wells, and also in the unfortunate case of fishing if
the wash pipe becomes stuck.
Wash Pipe Selection Criteria
Proper selection criteria include strength, material, connection
type, and diameter. Strength must exceed the maximum
expected tensile load, however the internal diameter should
also be maximized in order to minimize flow friction and
facilitate fluid returns. The preferred connection type is a
flush joint to prevent sticking and to allow downward flow in
the wash pipe screen annulus near the end of the treatment.
Properly sized wash pipe is as important as properly sized
sand screen. The generally accepted optimum ratio of the ID
of the screen to the OD of the wash pipe is 0.8 or greater, in
order to facilitate return flow up the wash pipe.2 This also
results in a narrow wash pipe screen annulus, which favors
fluid flow on the outside rather than the inside of the screen,
due to the higher friction pressure in the inner annulus.
Premature bridging and a possible screen out is discouraged.
This could occur when the fluid enters the screen/wash pipe
annulus, depositing gravel in the outer annulus and possibly
causing premature bridging. The most common screen/wash
pipe configurations are shown in Table 1.
RATIO
Washpipe (FJ)
Nom.
lb/ft
OD (in)
*
Size (in)
1.995
1
2.25
1.315
0.7
2.441
1 1/4
5.18
1.660
0.7
2.992
2 3/8
5.95
2.375
0.8
3.548
2 7/8
6.40
2.875
0.8
3.875
2 7/8
6.40
2.875
0.7
4.276
3 1/2
9.20
3.500
0.8
4.892
0.8
4
11.60
4.000
4.670
0.7
3 1/2
9.20
3.500
5.675
4
11.60
4.000
0.7
* Washpipe screen OD - ID ratio - 0.8 Optimum

BLANK & SCREEN

Size (in)

lb/ft

2 3/8
2 7/8
3 1/2
4
4 1/2
5

4.70
6.50
9.30
9.50
11.60
18.00
17.00
23.00
32.00

5 1/2
6 5/8

ID (in)

Table 1 Wash Pipe Selection Table

OTC 16051

Gravel Pack Systems with Wash Pipe

Hydraulic setting tool

Standard Gravel Pack Assembly

In this conventional system the wash pipe serves as a conduit
to aid circulation of the gravel pack fluids to the bottom of the
annulus of the screen/casing or screen/open hole, as shown in
Fig. 1. Wash pipe OD - screen ID ratio should optimally be
0.8. This basic system has been in use in the industry for
decades.

GP Packer

Multi-Service Closing
Sleeve
Service tool with shifting and
circulating valve
Safety Joint

Hydraulic setting tool

Blank
Isolation Tubing

GP Packer

Sliding Sleeves
(Production)
Screen

Multi-Service
Closing Sleeve
Service tool with shifting
and circulating valve

Sliding Sleeves
(GP & Prod.)

Sump Seals
(Polished ID)

Wash pipe with multi-service

shifting tool (spaced out below
lower sliding sleeve)

Sump Packer

Isolation Seals

Safety Joint

Fig. 2 Standard Gravel Pack Assembly w/ Isolation Assembly

Blank
Screen

Wash pipe with mule shoe

(spaced out close to end of
screen)

Sump Packer
Sump Seals

Fig. 1 Standard Gravel Pack Assembly

Standard Gravel Pack Assembly w/ Retrievable Isolation

Assembly
In this system the isolation assembly serves as a conduit to aid
circulation of the gravel pack fluids to the bottom of the
annulus of the screen/casing or screen/open hole, obtaining
fluid returns through the screen and lower sliding sleeve. The
wash pipe serves as shifting tool carrier to open or close lower
sliding sleeve, as shown in Fig. 2. Isolation tubing OD - screen
ID ratio should optimally be 0.8.
This system has shown to be effective for controlling fluid
losses and for zonal isolation in stacked multi-zonal
completions, yet still requires rig time for wash pipe handling,
especially in longer intervals.
At the time of writing, for standard offshore as well as
deep-water applications, 636 systems with 431 sliding sleeves
had been run since 1995 in the United States. For deep-water
application in South America, 55 systems with 134 sliding
sleeves had been run since 2000.

Single Trip Horizontal Gravel Pack And Selective

Stimulation (SHGPSS) System
This system, shown in Fig. 3, allows the gravel pack assembly
to be installed, the gravel pack to be pumped, and a selective
stimulation of the entire packed interval to be performed all
in a single trip.
The fluid path during gravel packing mode is the normal
crossover type configuration. Slurry is pumped down the
workstring and out the closing sleeve and down into the open
hole section while returns are achieved through the ported
subs in the washpipe assembly to the annulus above the
packer. Once a sand-out is achieved the service tool is
positioned in the reverse position changing the fluid path
direction. After excess slurry is reversed from the workstring,
a secondary ball is dropped and converts the tool from gravel
packing mode to stimulation mode.
The stimulation mode relies on the bullplugged washpipe
incorporating polished stingers and ported subs that seal
between screen sections to allow for selective stimulation
placement. The fluid path is thus changed to exit the
workstring through the service tool and directly enter the
inside of the washpipe.
The service tool is then picked up in order to position the
straddled polished stingers across the inverted molded seals
placed between screen joints. Between the polished stingers,
at the end of the washpipe, the ported subs that were
previously used to take returns during the gravel pack now
create flow path for the stimulation treatment to be squeezed
into selected intervals. Once the first screen joint/open hole
section has been stimulated, the service tool and washpipe are
picked up to straddle the next screen section and pumping
resumes. This can be repeated as many times as necessary to
selectively stimulate the entire open hole section.
After the stimulation treatment is complete, the service
tool is pulled from the wellbore until the polished stinger trips
the double flapper valve isolating the formation from fluid
losses.3

OTC 16051

activation tool. This actuation string is removed from the well

after completion of the treatment.
At the time of writing, for standard offshore as well as
deep-water applications, 81 systems with 94 sliding sleeves
had been run since 1999 in the United States. For deep-water
application in South America, 5 systems with 5 sliding sleeves
had been run since 2001.
.

POOH, Isolate
Well

Stimulate
Well

Convert

Tool

Hydraulic setting tool

Set Packer
Gravel Pack

GP Packer
RIH
Washdown

Fig. 3 SHGPSS System

At the time of writing, this relatively new system had been

installed in twelve wells, as shown in Table 2, with good
results.
Item

Region

Environment

Year
Installed

1
2
3
4
5
6
7
8
9
10
11
12

South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.
South Am.

Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water
Deep-Water

2001
2002
2002
2002
2002
2002
2003
2003
2003
2003
2003
2003

Type
Injector
Injector
Injector
Injector
Injector
Injector
Injector
Injector
Injector
Producer
Producer
Injector

Casing Open Hole Open Hole

Size
Size
Length
(in)
(in)
(ft)
9 5/8"
8 1/2"
1696
9 5/8"
8 1/2"
2116
9 5/8"
8 1/2"
2297
9 5/8"
8 1/2"
2106
9 5/8"
8 1/2"
2110
9 5/8"
8 1/2"
1818
9 5/8"
8 1/2"
3435
9 5/8"
8 1/2"
2625
9 5/8"
8 1/2"
2133
9 5/8"
8 1/2"
2103
9 5/8"
8 1/2"
1923
9 5/8"
8 1/2"
2031

Table 2 Horizontal Single Trip GP/ Stimulation Completions

Gravel Pack Systems with out Wash Pipe

In areas of the world where transportation, access, availability,
and maintenance of equipment are difficult, utilizing a gravel
pack system that requires no wash pipe is advantageous.
The need for such washpipeless systems has been
increasing due to high rig rates in the event of fishing
operations. In a frac pack operation, one of the most common
problems is stuck wash pipe, soon after screen out or reverse
out is accomplished. Utilizing a gravel pack system that
requires no wash pipe eliminates that unforeseen event in
addition to reducing costs.
The following systems incorporate the previously
mentioned isolation assemblies to obtain zonal isolation and to
control fluid losses.
Standard Gravel Pack Assembly w/ High Pressure
Retrievable Isolation Assembly
This system is mechanically actuated and hydraulically
powered, and is shown in Fig. 4. The isolation assembly
serves as a conduit to aid circulation of the gravel pack fluids
to the bottom of the screen/casing annulus, where fluid returns
are obtained through the screen. The fluid enters the isolation
tubing through a screen-wrapped port on the bottom of the
assembly, which later becomes isolated after system actuation.
The isolation tubing OD screen ID ratio should optimally be
0.8.
The system uses a short actuation string section, less than
20 feet, which is composed of flush joint tubing and an

Multi-Service
Closing Sleeve

Safety Joint

Service tool with shifting

and circulating valve
Actuation String

Blank
Isolation tubing
Sliding Sleeves
(Production)
Screen
Sump Seals
(Polished ID)

Ported Isolation Seals

(Spaced out in polished
ID seals) (fluid returns)

Sump Packer
Fig. 4 Standard Gravel Pack Assembly w/ High Pressure
Retrievable Isolation Assembly

Standard Gravel Pack Assembly w/ Ball Drop Retrievable

Isolation Assembly
This system is hydraulically actuated and powered, and is
shown in Fig. 5. The isolation assembly serves as a conduit to
aid circulation of the gravel pack fluids to the bottom of the
screen/casing annulus. Fluid returns are obtained through the
screen and a multi-service valve (MSV) on the bottom of the
isolation tubing. The MSV is closed after system actuation.
The isolation tubing OD screen ID optimum ratio should be
0.8. This system does not use any wash pipe or actuation
string.
This system has been developed and tested and at the time
of writing, was ready to go in the field. This kind of system
has particular application in deep-water, sand control
environments, where minimization of rig time and risk
mitigation are of paramount importance.

OTC 16051

References
Hydraulic setting tool
GP Packer

1.
2.
3.

Multi-Service Closing
Sleeve
Service tool with shifting and
circulating valve
Hydraulic drop sub and valve
actuator

Safety Joint
Blank

Isolation tubing
Sliding Sleeve
(Production)

Screen

Sliding Sleeve
(GP & Production)

Isolation Seals

Sump Packer
Sump Seals
(Polished ID)

Fig. 5 Standard Gravel Pack Assembly w/ Ball Drop Retrievable

Isolation Assembly

Conclusions
1. In gravel packing, a conduit is needed to ensure
circulation to the bottom of the screen. The conduit
may be retrievable (wash pipe) or permanent/
retrievable (isolation assembly).
2. In frac packing, taking returns through the bottom of
the screen is not as important, but having a conduit is
necessary in the event that gravel packing the
screen/casing annulus is required afterwards.
3. Especially in deep-water environments, and wells with
long intervals, the trend is to reduce or eliminate the
usage of washpipe.
4. Washpipeless systems can save rig time and prevent
fishing operations.
5. When possible, choose a washpipeless gravel pack
or frac pack system that accomplishes the same
functions as systems that use washpipe.
Acknowledgments
The authors of this paper would like to express the
appreciation of the members of their respective engineering
and operations staff. Without their combined efforts, this
accomplishment would not be possible. We also thank BJ
Services for the permission to publish this paper.
Nomenclature
GP
ID
MSV
OD
SHGPSS system

=
=
=
=
=

Gravel pack
Internal diameter
Multi-service valve
Outside diameter
Single trip horizontal gravel pack and
selective stimulation system

Sand Control SPE Series on Special Topics Volume 1,

Penberthy, W.L. Jr. and Shaughnessy, C.M., Society of
Petroleum Engineers, Richardson, TX (1992) 1.
Gravel Pack Manual Version 2, BJ Services Company,
Houston, TX (1999) 20.
Vilela, A., et al., Novel Single Trip Horizontal Gravel Pack and
Selective Stimulation System Improves Injectivity in Deepwater
Wells, paper SPE 84260 presented at the 2003 Annual
Technical Conference and Exhibition, Denver, Oct. 5 8.

SI Metric Conversion Factors

ft 3.048*
E 01 = m
in 2.54*
E + 01 = mm
lbm 4.535 924
E 01 = kg
* Conversion factor is exact.