COPYRIGHTcloud1.activelearner.com/contentcloud/portals/...Sand Control Completion Options and Design Sand Control Core Learning Objectives Identify both non-mechanical and mechanical

Introduction

Sand Control Core

Learning Objectives

This section will cover the following learning objectives:

Identify the need for sand control

Recognize the causes of sand movement

Define what consolidated sand is, and what it is not

Sand Control Core═════════════════════════════════════════════════════════════════════════

© PetroSkills, LLC. All rights reserved._____________________________________________________________________________________________

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Oilfield Sand Production is a Worldwide Problem

Why does sand production create such a problem?

Examples of Potential Sand Control Problems

Sand Control Core ═════════════════════════════════════════════════════════════════════════


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Apply API 14E standards to limit

allowable produced gas well rates to effectively minimize erosive

conditions



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Production Rate




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$

Sand Control Practices

Completion and operations engineers carefully monitorformations prone to sand production

Decisions are made early in a field development or re-development project regarding the need for sand controlpractices

These practices include:• Doing nothing and tolerating an expected very small or insignificant

sand volume production• Imposing rate restrictions to limit sand production potential• Using complex gravel pack and frac pack mechanical well

completions• Using other well completion methods such as slotted or pre-

perorated liners, screen mesh designs, expandable sand screens,resin consolidation techniques, proprietary mechanical sand controlcompletions, and other approaches



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Sand Control – A Safety Issue

Before being a productivity issue, it is a safety issue

Thk: 2.9 mm

Thk: 1.9 mm

Thk: 1.6 mm

Thk: 1.9 mm

Flow Direction

* Note the degree of erosion / wall thickness thinning due to sand production.

Thk = Wall thickness

Tubing Blast Joint Failure from Sand Erosion



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Causes of Sand Production

The formation components move when:• The forces induced by the flow or other factors are stronger than

the forces that hold the grain in place• This can result from:

– Compaction squeeze– Radial differential pressure

• Fluid inertia

• Fluid drag

– Relative permeability effects

– Reduction of bonding strength

– Change in choke setting– Other

AcidizingAcidizing

WaterfloodingWaterfloodingChange in choke settingChange in choke setting

Changes Due to:

Spike Sand Production

Sand Production Spike: Temporary – likely a reaction to a change in well operations

# o

f sa

nd

per

bb

l

Time or Volume Flowed

– Flowrate

– Drawdown

– Slight ∆saturation



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Catastrophic Failure

# o

f sa

nd

per

bb

l

Time or Volume Flowed

• Large scale ∆saturation• Depletion

Sand Production Failure: Major event which fills the wellbore and possibly surface facilities; requires a well workover

Temporary Condition

Catastrophic Failure

Sand production causes damage to facilities and resultant curtailment or production shut-down

Surface separator filled with produced sand, requiring cleanout

Consequences of Sand Production



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• Highly consolidated sandstone

• Consolidated sandstones

• Weakly consolidated sandstones

• Very weakly consolidated sandstones

• Very, very weakly consolidated sandstones

• Unconsolidated sand

Which Reservoirs Produce Sand?

Normally no sand control problemsNormally no sand control problems

Many ways of classifying sandstone strengths

One method:

Will produce sand at some

point

Will produce sand at some

point

Sand Classification

Zero strengthDry sand

Strength fromCapillary forcesDamp sand

Source: Schlumberger

Varying sand strengths and their classifications from very, very weak, to very weak, to weak, to

degrees of consolidation involve capillary pressure, cementing, sand compressive strength and related compaction for each sand sampled



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Potential Causes of Sand Movement

Fluid saturation changes

Surfactants in drilling fluids, completion fluids, etc.

Acid stimulation treatments

Solvents

Reservoir fluid flowrate / velocity changes and increased drag forces

Changes in the overburden stress, increased as fluids are withdrawn

Additional phases causing relative permeability problems

Shut-in and start-up changes which alter the sand packing arrangement near perforations

Other

Why?

Late Eocene sandstone is much shallower and would have a greater chance of being more unconsolidated.

Exercise – Sand Production

Two formations are under evaluation by a major production company. One is a Late Eocene sandstone

(about 60 million years old) and the other a Permian sandstone (about 350 million years old).

Two formations are under evaluation by a major production company. One is a Late Eocene sandstone

(about 60 million years old) and the other a Permian sandstone (about 350 million years old).

Which formation would likely have a greater chance of having sand production problems?



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Summary

It is mandatory that an asset team tasked with field development and operations consider a formation’s lithological properties to assess the potential to both:

a) Produce formation sandb) To plan accordingly to design the most effective approach to

managing sand production problems

This module addresses:• The conditions surrounding sand production• The approaches taken to choose the most effective remedial

techniques applicable for a wide variety of cases• The API 14E standard addressing erosional velocity limits • The engineering procedures to design a modern gravel pack

completion • The various empirical design steps for understanding effective sand

control techniques

Learning Objectives

This section has covered the following learning objectives:

Identify the need for sand control

Recognize the causes of sand movement

Define what consolidated sand is, and what it is not



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Sand Control Completion Options and Design

Sand Control Core

Learning Objectives

Identify both non-mechanical and mechanical methods of sandcontrol

Recognize that rate restriction is a valid practice to managesand production

Recognize that minor sand volume produced may be tolerated




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Sand Control Methods – Various Options

No Direct Mechanical Control

Mechanical Methods

Sand Control Methods – Various Options

No Direct Mechanical Control

• Living with / dealing with limited sand production

• Surface sand separation

• Rate reduction

• Cavity formation, wormhole formation

• Selective completion practices

• High-density and/or phase-oriented perforating

• Wellbore trajectory designs – horizontal, laterals, etc.

Small volume of sand

Small volume of sand

Safe operation with no threats to

erosion

Safe operation with no threats to

erosion

Difficult to sell to management

Difficult to sell to management

Avoid areas that produce high sand volumes

Avoid areas that produce high sand volumes

Access only sections free

of sand problems

Wellstream desandersWellstream desanders

Wellhead desandersWellhead desanders



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Sand Control – Live With It

SANDPRODUCTION

DRAWDOWN

FIELD PROVEN LIMIT

RESER

VOIR PRESSU

RE SAND

FREE+

‐

+

150 psi (134 kPa) drawdown may induce sand production on unconsolidated turbiditic sandstones

No Control / Cavity Formation / Rate Restriction

Will sand stop moving, after cavity formation, when velocity drops below threshold necessary to tear sand loose from formation?

Will sand move continuously? Is it tolerable?



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No Sand Control

• Wellbore fill accumulation• Sand disposal• Subsidence• Casing collapse or damage• Surface erosion or blockages• High well maintenance• High facilities maintenance including shut down

“Do nothing” and let sand be produced

Risks

• Not unrealistic as an approach

Cavity Formation

Enlarging the wellbore, whether by perforating (tunnel extension),underreaming, wormhole formation or cavity creation, increasesthe area of contact with the formation and decreases the flowingfluid velocity at any set flowrate

Original hole Becomes



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No Sand Control

May require no more than:• Periodically removing a

small amount ofproduced sand fromsurface facilities andbailing the well; and,

• Regularly pigging surfaceflowlines

The overall cost of doingnothing may be small

Minimal sand productionmay have little negative effectupon operations

In this case, note minimal sand in

separator

No Sand Control – But, Limit Velocity

Larger / more perforations

Larger wellbore

Reduce the rate

Underream

Cavity completion

Slow down fluid movement rate at the sand face



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Sand Production Strategy

Provide Clean Perforations

First… Reduce the Frictional Forces (Flow Rate per Unit Area)

1

Open Increased Section2

Create a Conductive Path into Formation3

• Increase the number and/or size of the perforations• Consider horizontal well completion

• Gravel pack the well• Frac pack the well

Mechanical Methods of Sand Control

Chemical Consolidation

Resin-Coated Sand

Slotted Liners or Screens without a gravel pack• Open Hole or Cased Hole (not recommended)

Slotted Liners or Screens with a gravel pack• Open Hole or Cased Hole

Frac packing or Fracturing

Expandable Screens

Vent Screens



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Perforating May De-Stabilize the Formation

Perforating Creates Perforation Tunnel Damage



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Perforating Creates Perforation Tunnel Damage

Two well completion perforating designs are under evaluation bya major production company. Both are weakly consolidatedsands.

Which completion would likely have a greater chance of havingsand production problems?

Why?

• One is beingcompleted using 4shots per foot(13 shots per meter) of zone thickness

• The other at 12shots per foot(39 shots per meter)

Careful additional study is necessary to size diameter and determine pressure drop through each perforation. Well

drawdown would need to be carefully managed to restrict rate to constrain tendency of sand to flow.

Exercise – Sand Production

InchesEntrance Hole Dia. 0.91CFE 0.73

4.483.36

TTPTCPECP 2.47 (62.7 mm)

(85.3 mm)

(113.8 mm)

(18.5 mm)

(23.1 mm)



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Resin Consolidation

Creates stronger matrix by cementing grains together withsynthetic plastics / chemicals

• Leaves wellbore open• Hard to evenly apply• Length of effective life questioning

Industry results with resins have been mixed and the jobs maybe short-lived

Many new products available

The gravel is placed in the perforations and also fills thewellbore

Gravel is pre-coated with resin

Also used for other purposes, such as screenless frac packs

After allowing the resin to set, drill out the wellbore, leavingthe perforations filled with the consolidated gravel

Resin-Coated Gravel



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Mechanical Sand Control Methods

Basic Problem• Control sand without reducing productivity

Design Parameters• Optimum gravel-sand size ratio• Optimum slot width to retain gravel or sand• Effective placement technique

Screen Alone – or – Screen with Gravel

Learning Objectives

Identify both non-mechanical and mechanical methods of sandcontrol

Recognize that rate restriction is a valid practice to manage sandproduction

Recognize that minor sand volume produced may be tolerated




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Non-Gravel Pack Completions, Options, and Design Alternatives

Sand Control Core

Learning Objectives


Identify various screen types for sand control

Outline aspects of pre-packed screens for sand control



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Wire-Wrapped Screen

Consists of base pipe with drilledholes and wire-wrapped screenjacket

Jacket is welded or mechanicallyattached to base pipe

Rod-based screen without innerpipe is also available

The gauge of the screens issized based on the formationsand size distribution

Views of Sand Screen and Mesh

Construction



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Ported base pipeMesh

Support screen

Woven Wrap Mesh

Premium Screen

Base Pipe

Bakerweld Inner Jacket

Vector WeaveMembrane

Vector Shroud



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Note resin-coated sand between outer and inner wraps

This type of screen offers improved abrasion control

This type of screen plugs easily

Pre-Packed Screen

Pre-Packed Screen



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Examples

Slotted liners and screens in a non-gravel pack are

Except For Expandable Screens

Non-Gravel Pack Horizontal Well Completions

Open Hole With Slotted Liner

FILTRATION DEVICES

Open Hole With

Screen or Prepacked Screen



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Learning Objectives

Identify various screen types for sand control

Outline aspects of pre-packed screens for sand control




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Gravel Pack Completions, Options, and Design Alternatives

Sand Control Core

Learning Objectives


Describe the principles of sand control screen and gravelcompletions

Identify the three steps comprising a gravel pack completiondesign

Describe various fluid options for pumping gravel slurry into agravel pack completion

Outline the function of a gravel pack “crossover tool”

Outline the function of a gravel pack “shunt tube”



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Consolidation:Resin

Sand Control Principles: 3 Ways

Filtration:Stand-Alone

Screen

Bridging:Gravel Pack

Sand Control Principles

Screen

Gravel Pack

Perforation

Formation Sand

PerforationTunnelCement

Casing

Internal gravel pack

recommended thickness of pack

or pre-pack is 0.75 in. to 1.25 in.

(19 mm to 31.8 mm)



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Gravel Pack Design Principles

• Establish a highlypermeablepathway betweenformation andwellbore thatformation sandcannot penetrate

• Gravel retainsthe formationsand in place

• Screen holds thegravel in place

Gra

vel

Pac

k D

esig

n

Pri

nci

ple

#2

Gra

vel

Pac

k D

esig

n

Pri

nci

ple

#2

Gra

vel

Pac

k D

esig

n

Pri

nci

ple

#1

Gra

vel

Pac

k D

esig

n

Pri

nci

ple

#1

• Gravel is placed between the screen and the formation

Open Hole2

• Gravel is placed between screen and casing, andinside perforations

Cased Hole1

Cased Hole vs. Open Hole Gravel Packs

The trend is toward more open hole gravel packs beingplaced in horizontal wells



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Gravel Pack Completion Sand Control

Works as a two-part retainer:

Step 1: Gravel is sized to retain formation sand

Step 2: Screen sized to retain gravel in place

“Bridging” occurs at this interface

Importance of Good Bridging in a Gravel Pack Design


GOOD BRIDGING

Formation Sand is Restrained By Gravel Pack Gravel in a Good Design

POOR BRIDGING

Formation Sand Invades Gravel Pack



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Gravel Pack Design Principles – 3 Steps

Obtain a good description of the formation sand grainsize distribution1

Select gravel size based on the formation sandgrain size distribution2

Select screen based on smallest gravel range3

• 50% cumulative grain size x 6 for gravel pack• 50% cumulative grain size x 8 for frac pack

• 50% to 75% of smallest gravel range size

Formation Sampling for Sieve Analysis

Conventional Cores

Sidewall Cores

Produced Samples

• Avoid Composite Samples, whenever possible

Bailed Samples



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Conducting a Sieve Analysis in the Lab

Core sample is frozenand then thawed

During thaw, it breaks upinto smaller components

Sample is placed on thetop tray

Screens of different sizesfilter sand formationsample into a range ofdifferent sizes




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Sieve analysis resultsmeasure weight percentsample retained on eachsieve size screen opening

The following series of slides illustrate gravel

pack design

1. Determine Gravel Size for Gravel Pack



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2. Determine Range of Gravel Size Using Median

mesh inch mm microns18 0.0394 1 100020 0.0331 0.84 84025 0.0278 0.71 71030 0.0234 0.59 59035 0.0197 0.5 50040 0.0165 0.42 42045 0.0139 0.35 35050 0.0117 0.3 30060 0.0098 0.25 25070 0.0083 0.21 21080 0.007 0.177 177

100 0.0059 0.149 149120 0.0049 0.125 125140 0.0041 0.105 105170 0.0035 0.088 88200 0.0029 0.074 74

Gravel PackChoose 20/40

Frac Pack

Choose 16/30

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100 0.0059 0.149 149120 0.0049 0.125 125140 0.0041 0.105 105170 0.0035 0.088 88200 0.0029 0.074 74

2. Max/Min Mesh Size For Gravel Pack Example: 20/40

Median gravel size for gravel pack example: 570 microns

Median gravel size for gravel pack example: 570 microns

(0.57 mm)Gravel Packchoose 20/40based upon Uniformity Coefficient

Median Gravel size for gravel pack example: 570 microns (0.57 mm)

[95 x 6]



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Blend gravel size range as follows:• Gravel sizing specifications are per ASTM E-11 and API RP 58• Gravel size distribution is a bell shaped curve by weight• A 20/40 distribution mean % retained on sieves is approximately

• Also, < 2% undersized gravel is allowed(i.e., gravel may not be smaller than 40 mesh for 20/40 gravel)

Max / Min Range

Gravel sizing is a function of the

Uniformity Coefficient of the

grain size distribution plot

2. Determine Range of Gravel Size Using Median

Sieve Size %

20 mesh 0.4

25 mesh 14.1

30 mesh 29.3

35 mesh 47.3

40 mesh 8.1

45 mesh 0.8

3. Determine Screen Slot Cut Spec as 75% of Min Gravel Size


100 0.0059 0.149 149120 0.0049 0.125 125140 0.0041 0.105 105170 0.0035 0.088 88200 0.0029 0.074 74

Median Gravel size for gravel pack example: 570 microns

(0.57 mm)Gravel Packchoose 20/40

Frac Pack

choose 16/30

Therefore: screen slot spec is 75% x 0.0165 in. (0.42 mm) = 0.0124 in. (0.32 mm)

Illustratessize conversion

Minimum Gravel Size Range (D98)



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Sieve Analysis Indicates Whether Formation has Uniform or Non-Uniform Grain Size Distribution

Non-uniformNon-uniform

UniformUniform

Poorly Sorted Sand

Well Sorted Sand

(2.54 mm) (.254 mm) (.0254 mm) (.00254 mm)

Selecting Gravel Based Upon Sand Grain Size

Lower case “d“ designates formation sand median diameter

Upper case “D” is the selected gravel median diameter

Definitions to Assist Sand Control Design (SPE 37437)

Uniformity Coefficient40

90

d=

dCu

Sorting Coefficient10

95

d=

dC s

Saucier50

50

Gravel

Formation sand

D=

d6

1

2

3



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15© 2010 PetroSkills, LLC. All rights reserved. 15

Uniformity Coefficient

Cu = Uniformity Coefficient

d40 = Grain Diameter at 40% Cumulative Weight

d90 = Grain Diameter at 90% Cumulative Weight

Cu = d40 / d90

if Cu < 3

if 3 < Cu < 7

if Cu > 7

Sorting Coefficient is defined as Cs = d10 / d95

Uniform Sand Distribution=

Non-Uniform Sand Distribution=

Highly Non-Uniform Sand Dist.=

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Various Grain Size Distribution Design Points

Design Point = d40

Design Point = d90

Design Point = d70

Design Point = d50

Design Point = d10

x 6

(2.54 mm) (0.254 mm) (0.0254 mm) (0.00254 mm)



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1717

Design Point Selection for Gravel Pack

Coberly and Wagner – D10 10(d10)

Saucier – D50 6(d50)

Stein – D85 4(d15)

Schwartz – D10 6(d10) for Cu < 5

D40 6(d40) for 5 < Cu < 10

D70 6(d70) for Cu > 10

Lower case “d“ designates formation sand median diameter

Upper case “D” is the selected gravel median diameter

Saucier Method:The most common gravel pack design

method

Saucier Method:The most common gravel pack design

method

Gravel to Sand Size Ratio (Saucier Method)

Gravel‐pack perm

eab

ility ratio

(Eff. vs Initial)

Gravel‐pack perm

eab

ility ratio

(Eff. vs Initial)

Gravel‐sand size ratio

(D50 Gravel vs D50 Formation)

Gravel‐sand size ratio

(D50 Gravel vs D50 Formation)



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Another Example: Grain Size Distribution Sieve Analysis

Sieve Size Opening – inches (mm)

U.S. Sieve Number

.08(2.54) (2.03) (1.52) (1.02) (0.51) (0.25) (0.203) (0.152) (0.102) (0.051) (0.025)

U.S. Sieve Number

Other Examples: Grain Size Distribution Sieve Analyses

Bailed Sample

Core Barrel Sample

Produced Sample

(2.54 mm) (0.254 mm) (0.0254 mm)



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Grain Size Comparison Analyses at Various Depths –Same Well

Grain Diameter (mm)

Grain Diameter US Mesh Size

Obtain a good description of the formation sand grain sizedistribution

Select gravel size based on the formation sand grain sizedistribution

Select screen based on smallest gravel range

Summary Review: Gravel Pack Design – 3 Steps

• 50% cumulative grain size x 6 for gravel pack• 50% cumulative grain size x 8 for frac pack

• Design screen opening as:− 75% of the diameter of the smallest gravel range size

− This size retains gravel in place behind screen

1

2

3



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Gravel Pack Rules of Thumb

Gravel to Sand Size Ratio• Use a gravel size as large as possible; the sand must be retained

at the outer edge of the pack• The size of the gravel is usually 6 times the size of the formation

sand at D50 or D40 (many other sizing techniques have beenreported in the literature)

• For frac packs, multiply the median by 8 instead of 6• Pay more attention to smaller sand grain sizes with:

– Non-uniform sands

– Higher flow velocity– Fluctuating flow rates

– High gas oil ratios

Again – Sorting Coefficient Defined as

Cs = d10 / d95

24© 2010 PetroSkills, LLC. All rights reserved. 24

Other Relevant Reservoir Criteria

How Does Degree of Sorting Affect Gravel Sizing?

May Require Smaller Gravel Size if Highly Non-Uniform

Fines % of particles smaller than 44 μm (0.00173 in.)



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Gravel Placement Fluid

Gravel can be placed with brines or polymer fluids

Super-clean fluid essential (especially for brines)• No solids• Most open hole pack failures result from surface solids (dirty fluid /

brine / polymer tanks)

Properly hydrate the polymer fluid• Shear properly; permit no “fisheyes”

Problems• Viscosity and fluid loss control• Density

Key is achieving a tight pack

How is the gravel actually placed in the well?How is the gravel actually placed in the well?

Polymers as Carrying Fluid

Three different polymer concentrations providing a wide range ofviscosities



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Polymer (HEC) Mixing Procedure (per bbl fluid)

Use fresh water or 2-5% KCl or NH4Cl in water

Lower the pH to 3-5 with citric acid [0.25 - 0.33 lbs (0.11 - 0.15 kg)]

Disperse 1.5 - 2.0 lbs (0.68 - 0.91 kg) polymer in agitated tank

Raise pH to 6-8 with caustic or soda ash

Mix at high shear rate, but avoid over-shearing• Monitor viscosity with Brookfield viscometer• And run sand suspension test• Monitor filterability – 1 quart (946 cm3) in 1-2 minutes

Filter to remove any unhydrated solids

Pre-hydrated polymers are also available

Well Site Gravel Pack Pre-Job Preparation

Onsite Gravel Pack Operations



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Polymer (HEC) Carrier Fluid Being Mixed at the Well Site

Prior to Job

Gravel Pack Pumping Equipment

Baker Hughes Sand Control Skid Mounted Frac Pack and Gravel Pack

Pumping Equipment Package

Large volume operations

Horizontal well applications

Modular for offshore or onshore jobs

Superior Energy Services Sand Control Barge Mounted Gravel Pack Pumping

Equipment Package

Rated for inland waters

Pumps: 2 x 2000 hydraulic HP / 1 x 600 HP

Sand storage / mixing tanks / sand screw feeder

Wet chemical storage / delivery

Related sand control support equipment systems



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Stimulation Vessel

Equipment SchematicCrew’s

Quarters and Wheelhouse

Downhole Pumps –High Pressure








Proportioning Blender

Observation Deck and

Control Room

Platform Rig Up

Offshore Stimulation

Vessel

High-Pressure Discharge Line to Platform

High-Pressure Discharge Line to Offshore Vessel

Hydraulic Quick

Disconnect

High-Pressure Discharge Line to Tubing Rig

Pump

Check Valve

Radioactive Densometer

Flow Meter

Electronic Pressure

Transducers

Rig manifold to casing

Blender bypass

High-Pressure Regulating Pop-Off Valve

High-Pressure Discharge Line to annulus High-Pressure

Regulating Pop-Off ValveHalliburton

Lo TorcValve

Gel feed line from below dock storage

Gel feed line from below dock storage

Sand Tank

3 ½ in IF tubing with full-opening TTW valve

Dow

nhol

e P

ump

Suc

tion

and

Dis

char

ge M

anifo

ldin

g

The layout of the stimulation equipment on vessels and platforms for offshore frac pack and gravel-pack treatments is critical.

On vessels especially,horizontal and vertical weightdistribution affects the centerof gravity.

Equipment placement onplatforms is crucial forpersonnel safety and efficientworking conditions.



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Gravel Packing Position

.

.

Multi-Function Gravel Pack Packer

Crossover Tool

Packer shifted to crossoverposition

Carrier fluid and gravel arepumped down tubing andthrough tool to be placed inthe screen / perforatedcasing annulus atperforations

By job end, packer is shiftedback to producing position

Gravel Pack Equipment – Packer

Crossover open

Crossover open

Wire wrapped screen

Wire wrapped screen

GravelGravel

Port Collar, Open

Wash Pipe(Tail Pipe)

Cased Hole

Note that gravel also fills perfs



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Horizontal Well Gravel Pack Completions

Horizontal well pack gravel pack completions are quite common

Certain mechanical methods should be used for an extendedlength horizontal gravel pack

Horizontal wells allow significantly more reservoir accesscompared to vertical wells

More access results in significantly higher well productivity

Sand production is normally decreased because of lower fluidflux rates

However, sand control if often required in horizontal wells

Horizontal Well Gravel Packing

Long horizontal wells can be successfully gravel packed using:• Brine carrier fluids• Gel carrier fluids (with alternate path technology)• In cased hole mode• In open hole mode

Frac packs can also be successfully placed

Expandable Sand Screens (ESS) have been used to controlsand production

Stand-Alone Screens (SAS) can be used (no gravel pack) butonly in uniform sands



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Can completion and tight packing of the whole section be achieved in long extended length holes?

With proper design and equipment, the answer is… Yes.

Gravel Placement in Horizontal Wells with Brine

gk14.ppt

Shunt Tube Tool• Alternate slurry path• Ports every 3 ft (0.9 m)

Alternate Path Shunt Tube Configuration



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Halliburton “PetroGuard” Shunt Tube System

Use of a shunt tube in a gravel pack completion is referred to as alternate path technology to mitigate incomplete annulus gravel packing

Two transport shunt tubes deliver slurry along the well and shunttube path

Two packing shunt tubes are separately connected from tubingjoint to tubing joint

Along the shunt tubes are exit ports for fluid slurry to leave theshunt tubes

Gravel Exit Port

Packing Shunt Tubes Transport Shunt Tubes

Horizontal Well and Multi-Zone Gravel Pack

Alternate path technologies allow gravelpacking of horizontal wells using gelcarrier fluids

Zonal packing is also aided by shunt tubes

from: Schlumberger

Gravel Pack Equipment Tool String



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Sources of Gravel Packing Problems

Formation sand mixed withshale layers

Damage from drilling fluidinvasion

Dirty gravel placement fluids

Improper gravel size

(1) Case Study: An engineer’s first gravel pack with complete responsibility for the job resulted in a total failure requiring pulling all G.P. equipment out of the hole, a cleaning out of the well, and the re-running of the entire completion. The failure was due to dirty tanks (even though a rigorous Clean Tanks spec was included in the gravel pack completion program) which picked up huge amounts of trash. The rig tried to pump it all downhole. This has not happened to the engineer ever since. All tanks are inspected!!

Insufficiently packed perforationsplugged by formation particles

Gravel crushed or mixed with formationsand

Dirty brine(1)

Solids InvasionSolids Invasion

Filtrate invasionFiltrate invasion

Improper perforation packing

Improper perforation packing

Crushed zoneCrushed zone

Importance of Clean Tubulars and GP Equipment

Clean tubing before setting packer (pickle tubing)

Apply pipe dope moderately on pin only

Check that equipment is free of rust, mill scale, acidizingand cementing materials

Check that gravel pack completion equipment is not painted

Check that fluids storage containment is thoroughly cleanedbefore mixing completion fluids

• Acid• Solvent



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API RP 58 Gravel Quality Specifications

Sieve analysis• Less than 0.1% oversized and less than 2% undersized

Sphericity and Roundness• Average sphericity and roundness of 0.6

Acid solubility• Less than 1% soluble in 12/3 HCl-HF mud acid

Silt and Clay Content• Turbidity NTU reading lower than 250

Crush resistance• Less than 2% fines created by 2,000 psi (13,790 kPa) confining stress

Gravel Pack Quality Control



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Learning Objectives


Describe the principles of sand control screen and gravelcompletions

Identify the three steps comprising a gravel pack completiondesign

Describe various fluid options for pumping gravel slurry into agravel pack completion

Outline the function of a gravel pack “crossover tool”

Outline the function of a gravel pack “shunt tube”



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Frac Pack for Sand Control

Sand Control Core

Learning Objectives


Describe the function of a frac pack completion

Outline the frac pack completion well performance results



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Frac Pack Completions

Gravel pack screencompletion equipment inplace

Gravel / proppant pumpedto fill fracture created

Completion properties are:• Enhanced rate and sand

protection control

Fracture completion andgravel pack completioncombined

Highest end completionthat can be designedallowing for both fractureproductivity and protectionagainst sand production asa gravel pack

Frac Pack – Sand Control with Well Stimulation

Conventional cased hole gravel packs often result in low well productivity, i.e., a high skin.

A technique was developed to place short, wide fractures A technique was developed to place short, wide fractures in cased holes, followed by a gravel pack in the annular space.

Typical frac wing lengths are from 30 - 150 ft (9 – 46 m).

Typical fracture widths at the wellbore are 2 - 3 in (51-76 mm).



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Well drainage radius

Frac pack half length

Frac Pack for Sand Control

Top view of a well with a frac pack placed through the damaged zone

Wellbore damaged zone

Fracture has proppant with designed conductivity

Frac Pack Results

Typical skin value for fracpacked well: -2 to -3

Frac packs often result in 3 to 5 times more productioncompared to a conventional cased hole gravel pack

Longevity / gravel pack well life often very good

Fines migration is often completely eliminated



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Frac Pack of Horizontal Wells

Many operators are placing frac packs in highly deviatedand horizontal wells

Multiple frac packs may be placed in horizontal wells

Screenless Frac Pack

Wells can also be fracpacked without screens

Usually resin-coated proppant will be used to hold the proppantinside the fracture (to prevent proppant flowback)

Alternatively, resin can be pumped into the proppant at the endof the job

Some early failures have occurred with screenless frac packs,while other operators have had good successes

One major advantage is that the wellbore is left fully open for alarger flowpath

Not as common as standard frac pack completions



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With multiple frac packs, well productivities are very high

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Learning Objectives

Describe the function of a frac pack completion

Outline frac pack completion well performance results




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Expandable Sand Screens

Sand Control Core

Learning Objectives


Outline the function of an expandable sand screen completion

Identify the components of an expandable screen and possiblebenefits resulting from the use of expandables



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ESS – Expandable Sand Screens

ESS joint and “roller” typeexpanding tool

An ESS joint consists of:• A slotted steel tube with

overlapping layers of Petroweavefilter membrane attached

• An outer layer of pre-slotted steelplate which holds and shields themembrane

Connections function well afterrecent design improvements

From: Weatherford



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ESS – Expandable Sand Screens

Remedial Sand Controlcapability – reducedworkover costs

Optimized O.D. / I.D. ratios– maximized flow conduit,minimized well costs

Reduced erosion potential

Reduced P – optimizedproductivity

Borehole stabilization

Sand Control for slimhole /slender wells

From: Weatherford

Example shown:6" (15 cm) O.D. Pre-expanded8-½" (21.6 cm) O.D. Post Expansion

Learning Objectives

Outline the function of an expandable sand screen completion

Identify the components of an expandable screen and possiblebenefits resulting from the use of expandables




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PetroAcademyTM Production Operations

Production Principles Core Well Performance and Nodal Analysis Fundamentals Onshore Conventional Well Completion Core Onshore Unconventional Well Completion Core Primary and Remedial Cementing Core Perforating Core Rod, PCP, Jet Pump and Plunger Lift Core Reciprocating Rod Pump Fundamentals Gas Lift and ESP Pump Core Gas Lift Fundamentals ESP Fundamentals Formation Damage and Matrix Stimulation Core Formation Damage and Matrix Acidizing Fundamentals Flow Assurance and Production Chemistry Core Sand Control Core Sand Control Fundamentals Hydraulic Fracturing Core Production Problem Diagnosis Core Production Logging Core Production Logging Fundamentals



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Documents

COPYRIGHTcloud1.activelearner.com/contentcloud/portals/...Sand Control Completion Options and Design Sand Control Core Learning Objectives Identify both non-mechanical and mechanical