Sand Control

Sand Control
Copyright 2007,
, All rights reserved
Completions Type
Barefoot (Openhole) Slotted Liner

Cemented Casing/liner
Fracpack
Completion Type
Screen/ open hole
External Gravelpack
Chemical Consolidation
Internal Gravelpack
Copyright 2007,
SAND PRODUCTION PROBLEMS AND PRODUCTIVITY EFFECTS
Copyright 2007,
Sandstone Reservoir
mineral grain
Quartz, SiO2
natural cementing
CaCO3
Copyright 2007,
SAND PRODUCTION CONTROL AND PRODUCTIVITY EFFECTS
SAND PRODUCTION MECHANISM
As fluids flow through a porous material, drag forces are created along the path of flow. Depending on the degree of natural intergranular cementation, compaction, intergranular friction, and cohesion of particles making up the porous material, flowing fluid may carry with it considerable quantities of loose and friable sand grains.
Copyright 2007,
Sand Production
Once the destabilizing forces overcome the formation strength, the rock will fail.
Sand production will follow if sand can be transported.
Copyright 2007,
Sand and Fines

Fines solids with 44 microns Fines are most probably produced in every well.
Fines are not controlled. They can be dissolved.

Sand can not be dissolved. Needs to be controlled.
Copyright 2007,
PRODUCTIVITY EFFECTS
Erosion damage of surface and subsurface production equipment (eg.Casing/liner failures) Plugging of well and surface production facilities
Sand Disposal
Copyright 2007,

Sand production during a four-rate test
SAND RATE CRITICAL OIL RATE
OIL
OIL RATE
SAND
TOLERABLE FINES
0
Copyright 2007, , All rights reserved
PRODUCTION TIME, MONTHS
FACTORS INCREASING SAND PRODUCTION
Decline of reservoir presssure (increase of overburden pressure) Cementing Material, Degree of Consolidation Fluid Viscosity, Production Velocity, Drag Forces Increasing water production (destroys intergranular cementing material) Formation damage (increases drawdown)
Causes of Sand Production (I)
Time Dependence
decreasing reservoir pressure increases the effective stress on the grains (overburden is constant)
Fluid Flow
fluid velocity and viscosity contributes to the pressure drop near the wellbore (drag force) production induces stress on the formation sand induced stress > formation stress sand production
Copyright 2007,
11
Causes of Sand Production (II)
Geological Factors
tertiary age reservoirs, usually shallow depths unconsolidated
Impairment on Natural Consolidation

high compressive strength internal pore pressure supports the overburden
' - P
12
Causes of Sand Production (III)

Mutiphase Flow

Water production may dissolve natural cementing materials weakening the intergranular bonds; Water production may mobilize fines resulting in plugging of the pore structure.
Copyright 2007,
13
Prediction of Sand Production
Experience Analogy Special Well Test Core Inspection and Testing
Measurements Log Interpretation Correlations
Copyright 2007,
14
MEASURES TO CONTROL SAND PRODUCTION
1. 2.
Reduce producing oil and gas rates below the critical rate for sand production. Prevent sand production mechanically by screen or gravel pack.
3.
4.
Chemically consolidate the formation sand near the wellbore using resinous material.
Inject resin-coated gravel into the perforations to pack and stabilize the perforations.
Copyright 2007,

CONTROLLING PRODUCTION RATES
Pr
INFLOW BOTTOM HOLE FLOWING PRESSURE, Pwf
OUTFLOW (CONTROLLED)
CRITICAL DRAW-DOWN
CRITICAL SAND FREE OIL RATE

0 0
FLOW RATE, Q
Copyright 2007,
Methods for Sand Control
Screnless
With Screen
Copyright 2007,
17
Screenless Methods for Sand Control

In-situ consolidation
Use of resins to consolidate formations.
Resin-Coated Gravel
Injection of pre-coated gravel.

Copyright 2007,
18
Methods for Sand Control using Screen

Gravel Pack Natural Sand Pack (NSP)
Frac & Pack (Frac-n-Pack, Frac-Pack, StimPAC*)
* - mark of Schlumberger
19
MEASURES TO CONTROL SAND PRODUCTION (GRAVEL PACK)

MECHANISMS OF MECHANICAL RETENTION
BRIDGING FILTER-SIZE RETENTION
SAND
GRAVEL GRAVEL
SAND
THE WHOLE IDEA BEHIND GRAVEL PACKING IS THAT THE GRAVEL MAY BE SIZED TO EFFECTIVELY RETAIN THE FORMATION SAND AND THE SCREEN MAY BE SIZED TO RETAIN THE GRAVEL
Copyright 2007,

MECHANICAL SAND RETENTION INSIDE CASING GRAVEL PACK UNDERREAMED CASING GRAVEL PACK SCREEN LINER IN OPEN HOLE OPEN HOLE GRAVEL PACK UNDERREAMED OPEN HOLE GRAVEL PACK
Copyright 2007,
PERMEABILITY REDUCTION AS A FUNCTION OF RATIO OF GRAVEL SIZE TO FORMATION GRAIN SIZE (After Saucier)
1.0
RULE OF THUMB
0.8 K/Ki 0.6 0.4 0.2 0 0 2 4
dG50(optimum) = 5 or 6dR50
10
12
14
16
18
20
dG50/dR50
Gravel Pack
Sand - Gravel - Screen
Copyright 2007,
23
FORMATION GRAIN SIZE STATISTICAL DISTRIBUTION (Sieve Analysis)
RETAINED WEIGHT, PERCENTAGE
40
30
20
10
0 0.01
0.001 0.0001
PARTICLE SIZE, INCHES

FORMATION GRAIN SIZE DISTRIBUTION (Sieve Analysis Results)

100 90 80 70 60 50 40 30 20 10 0 1.0
CUMULATIVE PERCENTAGE BY WEIGHT
DG50(optimum) = 5DR50
DR50 0.1 0.01 0.001 0.0001
GRAIN DIAMETER, INCHES

OPTIMUM GRAVEL SIZE DIAMETER AND OPTIMUM SCREEN SIZE
(*) 100 90 80 70 60 50 40 30 20 10 0 1.0 (*)

CUMULATIVE PERCENTAGE BY WEIGHT
DG50(optimum) = 5DR50
DLINER SLOT = 0.5DGmin
COMMERCIAL GRAVEL RESERVOIR
DGmin
DR50 DG50
0.1
0.01
0.001
0.0001
Copyright 2007,
FOR SCREEN LINER IN OPEN HOLE DLINER SLOT = 2xDR10 FOR NONUNIFORM SAND AND = DR10 FOR UNIFORM SAND
GRAIN DIAMETER, INCHES
MEASURES TO ACHIEVE PROPER INSIDE CASING GRAVEL PACK
1. PROPERLY SIZED GRAVEL AND SCREEN LINER.

2. SHOOTING LARGE DIAMETER PERFORATIONS TO ALLOW EFFECTIVE PLACEMENT OF GRAVEL.
3. CLEANING AND WASHING THE PERFORATIONS TO REMOVE DEBRIS FROM THE PERFORATIONS.
4. EFFECTIVE TRANSPORT AND PLACEMENT OF THE GRAVEL IN THE PERFORATIONS. 5. PRESSURIZING AND SQUEEZING GRAVEL IN THE PERFORATIONS. 6. MAINTAINING CLEAN WELLBORE FLUIDS THROUGHOUT THE GRAVEL PACKING OPERATION.
COMMERCIAL GRAVEL DATA

____________________________________________________________________________________________________ Aprox. G=bkG-a Sand/Gravel US Mesh Median Porosity Permeability ________________________ Size(in.) Size Dia.(in.) (%) (mD) a b ____________________________________________________________________________________________________ 0.006 ----- 0.017 40/100 0.012 0.008 0.017 40/70 0.013 0.010 0.017 40/60 0.014 32-39 1.2x105-1.7x105 1.6 2.12x1012 0.017 0.033 20/40 0.025 35-40 1.54 2.12x1012 0.023 0.047 16/30 0.035 0.033 0.066 12/20 0.050 0.039 0.066 12/18 0.053 0.043 0.079 10/20 0.056 32-40 5x105-6.5x105 1.34 8.4x1011 0.047 0.079 10/16 0.063 35-40 17x105-20x105 0.066 0.094 8/12 0.080 36-40 17x1051.24 5.31x1011 0.079 0.132 6/16 0.106 -42 ____________________________________________________________________________________________________
By convention, 20-40 mesh commercial gravel passes through a 20 mesh sieve and is retained by a 40 mesh sieve
Copyright 2007,
PROCEDURES TO COLLECT SAMPLES OF FORMATION SAND
1. RUBBER-SLEEVES CORES 2. CONVENTIONAL CORES 3. SIDEWALL CORES 4. PRODUCED SAND FROM THE SEPARATOR OR SAND TRAP
Not recommended
5. SAND BAILERS
Copyright 2007,
Sampling

per layer
critical for gravel size determination
full core samples are best

bail samples are not representative because of loss of high and low ends of particle distribution
sidewall cores are acceptable

frequent sampling
heterogeneous formation - 1 ft uniform formations - 5, 10, 20 ft spacing
shale-shaker
representative, if collection is accurate
Copyright 2007,
30
Sample collection
size
% cumulative
size (log)
bail sample (high end) core sample bail sample (low end)
Copyright 2007,
31
GRAVEL PACK PLACEMENT
(Washpipe raised)
Copyright 2007,
GRAVEL PACK EVALUATION
Copyright 2007,
EXERCISE
Well X4 is to be gravel packed. A sidewall sample was available and a sieve analysis was made. Results of the analysis are shown in the following table:
_________________________________________________________________ U.S.sieve Grain Weight Cumulative Number diameter retained Weight weight (mesh) (in.) (gm) percent percent _________________________________________________________________ 8 0.0930 12 0.0661 16 0.0469 20 0.0331 30 0.0232 0.25 1.4 1.4 40 0.0165 50 0.0117 0.79 4.3 5.7 100 0.0059 2.81 15.4 21.1 140 0.0041 3.25 17.8 38.9 200 0.0029 4.10 22.5 61.4 270 0.0021 325 0.0017 4.52 24.8 86.2 Pan 2.52 13.8 100.0 Totals 18.24 _________________________________________________________________
solution
Copyright 2007,
Suggest gravel and screen for gravel pack design for the well.
First Selections

1st: select fluid system

least damaging, economical, efficient
2nd: select gravel and screen or slotted liner

size and type
3rd: NODAL analysis:

evaluate effect on well productivity
4th: Re-select fluids and gravel

if necessary
Copyright 2007,
35
Gravel Pack Preparation

Always
In OH, clean mud cake prior running screen
In CH, ensure that all perforations are open and clean

Clean tubing prior to any pumping
Copyright 2007,
36
Internal gravel pack

Cased Hole Considerations
Reliable drilling and completion methodologies Requires efficient perforation system Isolate production from undesirable zones
Poor perforation pack may lead to low productivity
Easier workover compared to EGP
Copyright 2007,
37
External gravel pack

Open Hole Considerations
Can be Underreamed, increasing wellbore area No damage due to poor perforation pack efficiency
Hole stability is a concern while drilling and completion
Water production control may become impractical
Copyright 2007,
38
Circulation system - IGP
Fluid may leak to the formation, may be circulate back to the surface or both.
When pumping slurry, gravel will be placed inside perforation tunnels and annular casingscreen.
Copyright 2007,
39
Circulation system - EGP
Fluid may leak to the formation, may be circulate back to the surface or both.
When pumping slurry, gravel will be placed in the annular formation-screen.

Accessories : Lower and Upper Telltale.
Copyright 2007,
40
Squeeze system - IGP

Fluid may leak only to the formation. Fluid may travel through inside the screen. When pumping slurry, gravel will be placed inside perforation tunnels and annular casingscreen.
Copyright 2007,
41
Formation Analysis

Lithology, definition of fluids Granulometry, selection of gravel size
Copyright 2007,
42
Fluids Compatibility

potential damage by fines migration (clays) formation cores are often unavailable
inference from lab studies on similar formations

requires comprehensive clays analysis of the samples
Copyright 2007,
43
Clay Chemistry
Montmorillonite
swelling clays sensitive to fluids with low NaCl content
Kaolinite, illite and chlorite

dispersed by fluid movement NaCl increases the sensitivity of the clays CaCl2 is normally used instead of NaCl
Copyright 2007,
44
Clays

In Gravel Packing, potential clay problems merits serious consideration when clay content equals or exceeds 5%. As a prevention, a clay stabilizer should be add to the carrier fluid.
Copyright 2007,
45
Acid clean-up prior to gravel pack

HCl dissolves calcium scale and improves injectivity Fluoboric Acid - controls swelling and movement of clays and fines (dissolves most and stabilizes the remain) Maximum operational flexibility Increased leak-off rate during GP
Do not overflow the well after treatment
Copyright 2007,
46
Filtration
All fluids must be filtered

preferably at well site; avoid contamination in tanks and transports
Brines must be filtered at 2 Gels must be filtered at 10

15/64 in to 3/8 in choke at 500 psi estimate 10% reduction in viscosity
Copyright 2007,
47
Damage caused by solids
500 A (2.5 ppm) (A) Bay Water Filtered Through 2um Cotton Filer (B) Bay Water Through 5um Cotton Filter (C) Produced Water Untreated C (94 ppm) D (436 ppm) 10 (D) Bay Water Untreated
Permeability (md)
100
B (26 ppm)
50
0.02
0.04
0.06
0.08
0.10
Volume Injected (gal/perf)
Copyright 2007,
48
Sizing Criteria
Saucier Method: median grain for gravel is 5 or 6 times median grain size for sand formation (D50)g = 5 or 6 x (D50)f Coberly Method: uniform sands. Gravel too large to prevent fines.
Stein Method: uniform sand.

Schwartz Method: reduces probability of fines
Copyright 2007,
49
Screen, blank pipe & wash pipe

Screen length: 5 ft above and 5 ft below perforations minimum gap Screen OD: gap of 1-in per side screen 1-in Wash pipe OD: very close to screen ID Blank pipe OD: slightly less than screen Blank pipe ID: same as screen
blank pipe
wash-pipe
screen
Copyright 2007,
50
Liners or Screens ?
Slotted Liners
low cost robust
Wire Wrapped Screens

enhanced control large flow area un-restricted flow
small fluid area pressure loss across slots slots erosion primary control only
cost can be high welding might corrode
51
The ideal gravel pack

Complete packing with a properly sized highpermeability gravel. Clear interface between the formation sand and gravel. No invasion of the matrix with damaging material. No reduced-permeability section between the formation sand and the gravel pack. No residuals from the carrier fluid and/or fluidloss pills.
52
Poor gravel pack placement

Perforation Potential for production loss Open Hole Potential for production loss and/or screen failure (erosion)
Copyright 2007,
53
Poor interface Gravel / Sand

Reduced pack permeability Potential for production loss
Copyright 2007,
54
Matrix damage
Invasion of the matrix by treatment/completion fluids Potential for production loss
Copyright 2007,
55
Damage zone
Perforation Crushed Zone Potential for production loss Open Hole Filter Cake Potential for production loss
Copyright 2007,
56
Gravel pack damage

Residuals from the treatment fluid Potential for production loss
Copyright 2007,
57
Multi-zone treatment
0 5 10 15 20
12840
10
1 00
1 000
12840
Pressure (psi)
SP
12860
12860
ILD
12880
12880
12900
1 2 9 00
10000 9000 8000 7000 6000 5000 4000 3000 2000 1000 0 0
16
Rate or Conc. (bpm or ppa)
14
Surface Pressure Rate
12 10 8 6 4
Conc.
10 20 30 40 50 60
2 0
12920
12920
Time (minutes)
12940
12940
8000 7500
190 180 170 160
Temperature (Deg F)
Pressure (psi)
12960
12960
7000 6500 6000 5500 5000
12980
12980
Temp. Lower Gauge BHP Upper and Lower Temp. Upper Gauge
150 140 130
13000
1 3 000
13020
1 3 02 0
4500 0 10 20 30 40 50 60 Time (minutes)
Copyright 2007,
58
Multi-zone treatment
Benefits
Interval between zones 6 feet Single trip in hole Single pump stage Simple
Completions
Gravel Pack-Frac / Pack
15 jobs to date for PRISA 1 job with 3 zones (2 x MZ)
Copyright 2007,
59
Two zones (lower wet)
0 1 0360
50
1 00
1 50
0. 1
10
1 00
10360
Well Pressure (p si)
6000 5000 4000 3000 2000 1000 0
30
Rate (bpm) Co nc (p pa)
1 0380
10380 10400 10420 10440 10460 10480 10500 10520 10540
25 20 15 10 5 0 20 40 Time (min) 60
1 0400
1 0420
1 0440
1 0460
1 0480
1 0500
1 0520
Wet Sand 0
1 0540
Copyright 2007,
60
Multi-zones results

Complete Packs of All Zones Significant Completion Cost Savings Elimination of Kill Pills Better Production
Copyright 2007,
61

Sand Control

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Sand Control

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Sand Control

, All rights reserved

Barefoot (Openhole) Slotted Liner

Screen/ open hole

, All rights reserved

SAND PRODUCTION PROBLEMS AND PRODUCTIVITY EFFECTS

, All rights reserved

, All rights reserved

SAND PRODUCTION CONTROL AND PRODUCTIVITY EFFECTS

SAND PRODUCTION MECHANISM

, All rights reserved

, All rights reserved

Sand and Fines

Fines are not controlled. They can be dissolved.

, All rights reserved

SAND PRODUCTION CONTROL AND PRODUCTIVITY EFFECTS

, All rights reserved

SAND PRODUCTION CONTROL AND PRODUCTIVITY EFFECTS

PRODUCTION TIME, MONTHS

FACTORS INCREASING SAND PRODUCTION

Causes of Sand Production (I)

, All rights reserved

Causes of Sand Production (II)

Impairment on Natural Consolidation

Causes of Sand Production (III)

, All rights reserved

Prediction of Sand Production

Experience Analogy Special Well Test Core Inspection and Testing

Measurements Log Interpretation Correlations

, All rights reserved

MEASURES TO CONTROL SAND PRODUCTION

, All rights reserved

MEASURES TO CONTROL SAND PRODUCTION

CRITICAL SAND FREE OIL RATE

, All rights reserved

Methods for Sand Control

, All rights reserved

Screenless Methods for Sand Control

Use of resins to consolidate formations.

Injection of pre-coated gravel.

Methods for Sand Control using Screen

Gravel Pack Natural Sand Pack (NSP)

Frac & Pack (Frac-n-Pack, Frac-Pack, StimPAC*)

MEASURES TO CONTROL SAND PRODUCTION (GRAVEL PACK)

, All rights reserved

MEASURES TO CONTROL SAND PRODUCTION

, All rights reserved

0.8 K/Ki 0.6 0.4 0.2 0 0 2 4

, All rights reserved

FORMATION GRAIN SIZE STATISTICAL DISTRIBUTION (Sieve Analysis)

RETAINED WEIGHT, PERCENTAGE

PARTICLE SIZE, INCHES

FORMATION GRAIN SIZE DISTRIBUTION (Sieve Analysis Results)

CUMULATIVE PERCENTAGE BY WEIGHT

DR50 0.1 0.01 0.001 0.0001

GRAIN DIAMETER, INCHES

OPTIMUM GRAVEL SIZE DIAMETER AND OPTIMUM SCREEN SIZE

(*) 100 90 80 70 60 50 40 30 20 10 0 1.0 (*)

DLINER SLOT = 0.5DGmin

COMMERCIAL GRAVEL RESERVOIR

, All rights reserved

GRAIN DIAMETER, INCHES

MEASURES TO ACHIEVE PROPER INSIDE CASING GRAVEL PACK

1. PROPERLY SIZED GRAVEL AND SCREEN LINER.

() 100 90 80 70 60 50 40 30 20 10 0 1.0 ()