Completion Sand Control PDF

Sand Control
Copyright 2007, , All rights reserved

Completions Type
Barefoot
(Openhole)
Slotted Cemented
Liner Casing/liner
Completion Screen/
Fracpack
Type open hole
External Internal
Gravelpack Gravelpack
Chemical
Consolidation

SAND PRODUCTION PROBLEMS
AND
PRODUCTIVITY EFFECTS

Sandstone Reservoir
mineral grain
Quartz, SiO2
natural cementing
CaCO3
Copyright 2007, , All rights reserved 4

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.

Sand Production
 Once the destabilizing forces overcome the formation

strength, the rock will fail.
 Sand production will follow if sand can be transported.

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.

PRODUCTIVITY EFFECTS
• Erosion damage of surface and subsurface

production equipment (eg.Casing/liner failures)
• Plugging of well and surface production

facilities
• Sand Disposal

Sand production during a four-rate test
SAND RATE
CRITICAL OIL RATE
OIL
OIL RATE
SAND
“TOLERABLE”
FINES
0 1 2 3 4 5 6 7
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

Causes of Sand Production (II)
 Geological Factors
– tertiary age reservoirs, usually shallow depths
Þunconsolidated
 Impairment on Natural Consolidation
– high compressive strength
– internal pore pressure supports the overburden
'   - P

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.

Prediction of Sand Production
Experience
Analogy
Special Well Test
Core Inspection and Testing
Measurements
Log Interpretation
Correlations

MEASURES TO CONTROL SAND PRODUCTION
1. Reduce producing oil and gas rates below the

critical rate for sand production.
2. Prevent sand production mechanically by screen or gravel pack.
3. Chemically consolidate the formation sand near the wellbore using

resinous material.
4. Inject resin-coated gravel into the perforations to pack and

stabilize the perforations.

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

0
0
FLOW RATE, Q

Methods for Sand Control
 Screnless
 With Screen

Screenless Methods for Sand Control
In-situ consolidation
 Use of resins to consolidate formations.
Resin-Coated Gravel
 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*)
* - mark of Schlumberger

(GRAVEL PACK)
MECHANISMS OF MECHANICAL RETENTION
BRIDGING FILTER-SIZE RETENTION
SAND SAND
GRAVEL
GRAVEL
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

MECHANICAL SAND RETENTION
UNDERREAMED UNDERREAMED
INSIDE CASING CASING SCREEN LINER OPEN HOLE OPEN HOLE
GRAVEL PACK GRAVEL PACK IN OPEN HOLE GRAVEL PACK GRAVEL PACK

PERMEABILITY REDUCTION AS A FUNCTION OF RATIO OF GRAVEL SIZE
TO FORMATION GRAIN SIZE (After Saucier)
1.0
0.8
dG50(optimum) = 5 or 6dR50
0.6 RULE OF THUMB
K/Ki
0.4
0.2
0
0 2 4 6 8 10 12 14 16 18 20
dG50/dR50

Gravel Pack
Sand - Gravel - Screen

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

OPTIMUM GRAVEL SIZE DIAMETER AND OPTIMUM SCREEN SIZE
(*) DG50(optimum) = 5DR50 DLINER SLOT = 0.5DGmin
100
CUMULATIVE PERCENTAGE BY WEIGHT
90
COMMERCIAL
80 RESERVOIR
GRAVEL
70
60
50
40
DGmin
30
DR50
20 DG50
10
0 1.0 0.1 0.01 0.001 0.0001
GRAIN DIAMETER, INCHES
(*) FOR SCREEN LINER IN OPEN HOLE DLINER SLOT = 2xDR10 FOR NONUNIFORM SAND
AND = DR10 FOR UNIFORM SAND
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. βG=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 17x105- 1.24 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

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

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

Sample collection
% cumulative
%
size
size (log)
bail sample (high end)

core sample
bail sample (low end)

GRAVEL PACK PLACEMENT
(Washpipe raised)

GRAVEL PACK EVALUATION

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 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

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

Internal gravel pack
Cased Hole Considerations

Reliable drilling and Isolate production from
completion undesirable zones
methodologies
Requires efficient
perforation system
Poor perforation pack
may lead to low
productivity
Easier workover
compared to EGP

External gravel pack
Open Hole Considerations

Can be Underreamed, No damage due to poor
increasing wellbore area perforation pack efficiency
Hole stability is a concern Water production control

while drilling and completion may become impractical

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 casing-
screen.

Circulation system - EGP
 Fluid may leak to the formation,

may be circulate back to the
surface or both.
will be placed in the annular
formation-screen.
 Accessories : Lower and Upper
Telltale.

Squeeze system - IGP
 Fluid may leak only to the

formation.
 Fluid may travel through inside
the screen.
will be placed inside perforation
tunnels and annular casing-
screen.

Formation Analysis
 Lithology, definition of fluids

 Granulometry, selection of gravel size

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

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

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.

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

Filtration
 All fluids must be filtered

– preferably at well site; avoid contamination in tanks and
transports
 Brines must be filtered at 2 μ
 Gels must be filtered at 10 μ
– 15/64 in to 3/8 in choke at 500 psi
– estimate 10% reduction in viscosity

Damage caused by solids
500
A (2.5 ppm)
(A) Bay Water Filtered
Permeability (md)
Through 2um Cotton Filer

100
(B) Bay Water
B (26 ppm) Through 5um Cotton Filter
(C) Produced Water Untreated

50
C (94 ppm)
(D) Bay Water Untreated
D (436 ppm)
10
0 0.02 0.04 0.06 0.08 0.10
Volume Injected (gal/perf)

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

Screen, blank pipe & wash pipe
Screen length: 5 ft above and 5 ft below perforations

Screen OD: gap of 1-in per side screen minimum gap wash-pipe
Wash pipe OD: very close to screen ID  1-in
Blank pipe OD: slightly less than screen

Blank pipe ID: same as screen
blank pipe
screen

Liners or Screens ?
Slotted Liners Wire Wrapped

Screens
low cost enhanced control
robust large flow area
un-restricted flow
small fluid area cost can be high

pressure loss across welding might corrode
slots
slots erosion
primary control only

The ideal gravel pack
Complete packing with a properly sized high-

permeability 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 fluid-
loss pills.

Poor gravel pack placement
Perforation
Potential for
production loss
Open Hole
Potential for
production loss and/or screen
failure (erosion)

Poor interface Gravel / Sand
Reduced pack permeability

Potential for production
loss

Matrix damage
Invasion of the matrix by

treatment/completion fluids
loss

Damage zone
Perforation Crushed Zone

Potential for
production loss
Open Hole Filter Cake
Potential for
production loss

Gravel pack damage
Residuals from the treatment fluid

loss

Multi-zone treatment
10000 16
0 5 10 15 20 1 10 1 00 1 000
9000
Rate or Conc. (bpm or ppa)

12840 12840 14
8000
SP ILD 12
Surface Pressure
Pressure (psi)
7000
12860 6000 10
12860
Rate
5000 8
4000 6
12880 12880
3000
4
2000
Conc. 2
12900 1 2 9 00
1000
0 0
0 10 20 30 40 50 60
12920 12920
Time (minutes)
12940 12940
8000 190
7500 180
Temperature (Deg F)
12960 12960
Pressure (psi)
7000
170
6500
12980 12980
160
6000
Temp. Lower Gauge
150
5500
13000 1 3 000
BHP Upper and Lower 140

5000
Temp. Upper Gauge
13020 1 3 02 0
4500 130
0 10 20 30 40 50 60
Time (minutes)

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)

Two zones (lower wet)
0 50 1 00 1 50 0. 1 1 10 1 00
1 0360 10360 6000 30
Rate (bpm) Co nc (p pa)

1 0380 10380 5000 25
Well Pressure (p si)

1 0400 10400
4000 20
1 0420
10420
3000 15
1 0440
10440
2000 10
1 0460
10460
1000 5
1 0480
10480
0 0
1 0500
10500
Wet Sand 0 20 40 60
1 0520
10520
Time (min)
1 0540
10540

Multi-zones results
 Complete Packs of All Zones

 Significant Completion Cost
Savings
 Elimination of Kill Pills
 Better Production

Completion Sand Control PDF

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Sand Control

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SAND PRODUCTION MECHANISM

As fluids flow through a porous material, drag forces are

Copyright 2007, , All rights reserved

 Once the destabilizing forces overcome the formation

Copyright 2007, , All rights reserved 6

 Fines – solids with  44 microns

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• Erosion damage of surface and subsurface

• Plugging of well and surface production

Copyright 2007, , All rights reserved

Sand production during a four-rate test

CRITICAL OIL RATE

PRODUCTION TIME, MONTHS

• Decline of reservoir presssure (increase of

• Cementing Material, Degree of Consolidation

• Fluid Viscosity, Production Velocity, Drag Forces

• Increasing water production (destroys

• Formation damage (increases drawdown)

Copyright 2007, , All rights reserved

Copyright 2007, , All rights reserved 11

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1. Reduce producing oil and gas rates below the

2. Prevent sand production mechanically by screen or gravel pack.

3. Chemically consolidate the formation sand near the wellbore using

4. Inject resin-coated gravel into the perforations to pack and

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CRITICAL SAND FREE OIL RATE

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Sand - Gravel - Screen

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RETAINED WEIGHT, PERCENTAGE

0 0.01 0.001 0.0001

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(*) DG50(optimum) = 5DR50 DLINER SLOT = 0.5DGmin

1. PROPERLY SIZED GRAVEL AND SCREEN LINER.

2. SHOOTING LARGE DIAMETER PERFORATIONS TO

3. CLEANING AND WASHING THE PERFORATIONS TO

4. EFFECTIVE TRANSPORT AND PLACEMENT OF THE

5. PRESSURIZING AND SQUEEZING GRAVEL IN THE

6. MAINTAINING CLEAN WELLBORE FLUIDS

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4. PRODUCED SAND FROM THE SEPARATOR OR SAND TRAP

Not recommended 5. SAND BAILERS

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bail sample (high end)

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