Sand Control Techniques & Challenges
Sand Control Techniques & Challenges
Sand Control
Sand production is usually associated with wells which are completed at shallow depths
of tertiary age. It can also be associated with unconsolidated formations encountered in
depths of 16,000 feet or deeper. The appropriate selection of well completion practices is
critical in formations that have a tendency towards sand production. Very often problems
of sand production are created due to inadequate completion practices.
According to Allen and Roberts, 1989 and DePriester, 1972 producing sands are solids
that form part of a mechanical structure in formations. Loosely attached fines on the pore
surface are always produced and are beneficial because the more they are free to move,
the less likely they are to plug the pore by forming bridges across the pore channels. Most
sandstone reservoirs can be described as:
Solids smaller than 90 percentile are interstitial fines and are produced when
production is initiated.
Solids between 90 and 75 percentile range bear the smallest formation load and
are likely to be produced.
Solids larger than 75 percentile are load bearing solids. If a significant part of
solids are produced (50-75 percentile) they will certainly present production
problems.
From past experience industry has developed a basic strategy for controlling sand
production. For example, for oil wells in the Gulf Coast, the limit of sand production is
considered to be 0.1 percent or 900 lbs/1000 bbl (28gm/m3). In wells with high GOR
(>10,000 scf/bbl) the limit is set at around 10lbs/100bbl (28gm/m 3). In areas where costs
of well operation is high, such as the North Sea, this limit is set at as low as 5 lbs/1000
bbl (14 gm/m3). There has been no norm for gas wells as it has been difficult to estimate a
sand production limit. Historically, the limit for gas wells was determined based on the
erosion in chokes, probes etc in flow lines.
Production interruptions are caused by sand plugging of casing, tubing, flow lines
or separator. This involves additional expenses with “clean out” workovers to
return wells to production.
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Collapse of casing due to changes in overburden stresses within the formation.
Casing may buckle due to void space created by the sand production (unsupported
casing). Also, casing or liner is subjected to an additional compressive loading as
subsidence occurs, which may lead to casing buckling or collapse
Downhole and surface equipment can be damaged due to erosion, thus costing
time and money for equipment replacements, spills, clean ups or even a dangerous
uncontrolled blow-out.
Sand accumulation in surface lines and equipment leading to abrasive wear on
surface controls, valves and pipes.
Sand production causes very serious problems with subsurface safety valves by
eroding or jamming them. Operating subsurface safety valves are mandatory
under government regulations.
Lost revenue due to restricted or shut-in production.
Disposal of produced sand is costly.
In this chapter first the causes of sand production and different techniques used to reduce
and or prevent sand production are discussed. Finally, design and implementation of
gravel pack technique with Chapter objectives are as follows:
2
7.1 Causes of Sand Production
Sands and formations fines are produced with formation fluids (oil/water/gas) due to the
lack of grain bonding or consolidation. Miocene (tertiary or 5-23 million years before the
present) and later sands lack consolidation due to young age. Due to the young age and
shallow deposition these sands are prone to movement when disturbed by the produced
fluids. Thus, loosely consolidated or unconsolidated sands move when subjected to
stresses caused by:
When the net effect of the above conditions exceeds the formation restraining forces,
sand grains and formations fines may be produced.
Laboratory studies and field experience suggest that sand production may take place by
one or more combination of the following mechanisms:
The simplest mechanism is the grain by grain movement away from the formation
face at low fluid viscosities under low pressure.
At high fluid flow rates small masses of sand break away leading to rapid failure of
the formation.
In cases, where high overburden stress combined with high fluid flow rates exist
formation become fluidised, resulting in the gross flow of sands with the produced
fluid.
Semi-competent formations can initially produce fines followed by sands that are
loosely bonded. The cause of this sand production is primarily due to fluid friction
(drag force). As the reservoir pressure declines the individual sand grains carry more
and more over burden stress which eventually causes the bonding (cementing
between the sand grains) to fail, leading to sand production.
Changes in fluid phases, such as oil to water and/or gas result in the reduction of
intergrain cementing /bonding due to change in interfacial tension. Water has the highest
interfacial tension (72 dyne/cm). This phenomenon of sand production (water wet
situation) has been observed frequently when the well starts to produce water.
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Among the factors discussed previously fluid velocity plays a critical role in sand
production problem as this causes a drag force where separated grains are transported
with the flowing fluid.
Particle fluid drag force is a function of:
The two equations most commonly used to determine the critical flow at which sands of a
given geometry and diameter begins to move with the producing fluid are the:
critical transport velocity for oil/water wells and
critical transport velocity for gas wells.
In gas producing wells, the appropriate equation to predict critical velocity of formation
sand that can be carried up the production string is:
d (165.36 f )
V 2.052
f
These equations help predict whether formation sands will be lifted through the
production string or the sands will be accumulated at the bottom of the borehole.
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7.2 Characteristics of Formation Sand
In order to control the sand production successfully one need to look at the background of
the sand production problem so that potential solutions can be found. Formation sand
characteristics which impact sand production include depositional environment, physical
and chemical properties.
CEMENTATION
Sand can be defined in the geological sense as a granular material with particle size
ranging from 2 to 0.625 mm in diameter. The primary composition of sand is silicon
dioxide (SiO2) although other material is present. The strength of sandstone is given by a
process called oregenesis where after deposition sand grains undergo compaction by the
overburden pressure of subsequent layers. This process also includes cementation
between grains which leads to natural consolidation. The most common cementing
material is calcite calcium (carbonate), dolomite (magnesium carbonate) and clays. Some
sandstone formations are formed in environments where cementing materials are not
available which cause the sand to remain unconsolidated.
Most sandstone formations contain some clays and detrital fines. They can be attached to
the sand grains or interbedded within the formation or placed interstitially. If sandstones
are consolidated by clays as the cementing agent this will results in a very weak
formation.
Porosity is a measure of void space while permeability is the fluid’s ability to flow in the
rock. Porosity and permeability of rocks generally decreases with poorer sorting, tighter
packing, more cementing and smaller grains. There are two types of packing: tight
packing and loose packing as described in Fig.7.1.
5
d d
D D
D/d=6.5 D/d=2.4
Tight pack Loose pack
Fig. 7.1: Idealised comparison of tight pack vs. loose pack.
Relative permeability is a measure of the effective permeability of one phase (oil) in the
presence of another phase (water) and a function of relative saturation of individual
phases. Most sandstone formations are naturally water wet and the individual grains are
surrounded by a thin film of water resulting in about 10% to 30% water saturation. In
water drive reservoirs water saturation increases as the production continues. In water
drive reservoirs, when water saturation increases sand production also increases.
There are three general categories of sands which are related to sands strength:
quick sand,
partially unconsolidated sand and
friable sand.
Quick Sands:
Quick sands usually refer to completely unconsolidated formations. Sands of this type
have no effective cementing capabilities and are only held together by small cohesive
force and compaction. Quick sands occur all over the world, including California, Libya,
Venezuela and Nigeria where tons of sands are produced from wells each year. This type
of formation usually produces sands of constant concentration. Special gravel packs with
screen liners could be used to control sand production (to be discussed later).
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control measures, shale beds in close proximity may collapse to form a mixture of clay
and sand which is harder to control and thus reduces near well bore permeability (as
discussed in chapter 1).
Friable Sands:
Friable sands or fragile sands are semi-competent and susceptible to movement. Core
analysis from this type of formation appears to be consolidated enough not to produce
sand; however, when fluids are produced the face of the formation will produce sand.
Usually sand types are identified by core sampling. Types of sand also can be identified
by monitoring the concentration of sand produced and logs which measure the relative
strength of rocks. The following guide can be used to identify sand types:
Figure 7.2 describes the relation between sand production and stress.
Friable
sand Controllable
No sand
sand
production
Intermittant
sand production
Uncontrollable sand
production
Quick sand
Increasing Stress
regional geology,
statigraphy and
hydrodynamics.
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Other sources with respect to formation evaluation include:
The most essential design parameter for sand control, however, is the determination of
formation sand size and their distribution. This information is used to decide which sand
control measure is most suitable. Formation sand size and the respective distribution can
be best obtained by:
To acquire a representative formation sand sample entire interval through the field must
be considered as the formations are heterogenous in nature. Samples are usually obtained
through:
Sidewall cores:
Sidewall coring can be carried out where there are no full size cores available. Due to
their small sample size these samples are less representative than full cores.
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Bailings:
Where there are no cores (full cores or sidewall cores) available, produced sands or
bailings can be used in order to characterise sand size and size distribution. Because of
intermixing and tendency for larger grains to settle at the bottom (including the rat hole)
these samples cannot be related to any statiography or depth. Sometimes it is better to
have some form of information than no data.
SIEVE ANALYSIS
Sieve analysis involves sorting of sand grains of similar sizes using a series of sieves.
Prior to conducting sieve analysis, it is important to clean and dry the sample (core or
bailings). It is also important that the samples do not break during preparation. Then the
weighted sample is placed on the top sieve of a series of sieves (see Fig. 7.3) which are
shaken either mechanically or sonically. The screens are arranged progressively finer
mash as the sample moves downward by combination of gravity and shaking. Materials
(grains) retained in each sieve are weighed and plotted in a cumulative weight vs.
diameter graph.
Screens
Becoming
Finer
Common measuring scales for mesh are the opening sizes of the screens as presented in
Table 7.1 whose typical ranges for sands, silts and clays are given in inches and
millimetres. For example, mesh 8 corresponds to 8 openings for every linear inch as
shown in Fig. 7.4 and has the opening diameter of 0.094 inch (2.380 mm).
9
Fig. 7.4: Sieve opening and its relation with US mesh.
Interpretation of grain size and grain size distribution:
A typical grain size distribution is presented in Fig 7.5. Where d10 represents sand in the
10 percentile on the distribution scale and is described as the point on the distribution
scale where 10% of the sand size (by weight) is of a larger grain size. Where d 90
represents sand in the 90 percentile on the distribution scale and is described as the point
where 90% of the sand (by weight) is of a larger grain size and 10% of smaller grain
size.
D100
100
Cumulative weight percentages
D40
D10
0
1.0 0.5 0.1 0.05 0.005 0.01
Grain size, inches
Fig. 7.5: Graph for grain diameter vrs. cumulative weight percentage.
Sand size distribution varies greatly from formation location to formation location. An
example is shown in Fig. 7.6 where the left-hand graphs show a wider grain size
distribution (non-uniform grain size distribution) whereas right hand curves show grain
size distribution in a narrow band (uniform grain size distribution).
10
100
Non Uniform
Uniform
Distribution
Fig. 7.6: Cumulative sand size distribution for different sand sorting.
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Table 7.1: Sand sieve sizes
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7.3 Sand Control Methods
Reducing drag force on sand grains by production fluid makes sand grains less prone to
movement and hence is a more effective method of avoiding sand production problems.
Drag force can be reduced by:
When flow area increases, the velocity of the produced fluid decreases. This can be
achieved through a number of ways:
Good Engineering practises use perforation charges that produce large diameter long
holes and less debris which is an effective method to controlling sand production.
Reducing production rate is, will in essence, reduce the drag force on the sand grain by
the producing fluid velocity. According to Allen and Roberts, 1982 it is possible to
control sand production by carefully observing sand production rate with fluid production
rate which is known as the “Bean-up” technique.
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7.3.2 Mechanical Method of Control
Mechanical sand control provides a physical barrier to sand movement while allowing
fluid to flow across passages. In the rock, physical barrier is provided either by
a screen,
a combination of a screen and gravel pack
The flow passages through screen or gravel or gravel pack and screen must be small
enough to stop the formation sand but large enough to achieve adequate well
productivity. The flow passages are reduced with time due to plugging by clays,
asphaltenes, wax and scales.
Choice of sand control method depends on specific well characteristics which include:
SCREENS
Screens are effective in controlling sand production from formations which are composed
of clean large grained sands with very narrow grain size distribution. These are primarily
water wells. Oil and gas wells are much deeper and formation sands are smaller grained,
poorly sorted and often contain clay sized particles. This type of sand plugs the screens.
Use of screens as a sand control technique has a number of inherent problems. They
include:
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DESIGN CONSIDERATION OF SCREEN/LINER
The screen/liner must be designed to effectively trap formation sand while retaining
maximum productivity. This is achieved by selecting appropriate size (slot width),
geometry and density of slots to trap the larger grains which inturn stop smaller grains.
Smaller grains are trapped in the interstices of larger grains.
Hence, important design considerations for screens are as follows:
Screen
/Liner
Small grains
bridging at
openings
Fig 7.7: Parallel face screen slot opening and sand bridging across the slot opening.
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Screen
/Liner Production
Fluids
Large grains
bridging at
the face of
the openings
Fig 7.8: V-shaped screen slot opening and sand bridging at the face of the slot opening.
The above correlation is based on the understanding that the sand grains form stable
bridges on slots that are twice the size of 10 percentile of formation sand. Following
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Coberly’s work Wilson derived a correlation for the Gulf Coast where the sand grains
tends to be more uniform as:
W=2d10
This means that the width of the screen should be selected based on 10 percentile of the
formation sand. Gill, 1937 suggested a more conservative correlation to select slot width
as:
W= d 10
A general rule was provided by DePriester,1972 in relation to selecting slot size for
formation for which very little information is available. To avoid plugging the minimum
slot width should be 0.05 inch. If the 20 percentile of sand is less than 0.05 inch then an
alternative approach should be adopted.
0.05inch w d 20
Wire wrapped screens are manufactured in many forms which include ripped welded,
grooved and wrapped on pipe. They are made as continuous slot on outside of the pipe
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that has already milled or machined holes or slots. The wrapping wire is usually made of
403 stainless steel and the core pipe is usually grade S or K. The typical screen sizes used
by the industry are presented in Table 7.2.
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Table 7.2: Typical dimensions of slots for slotted and wire wrapped screens (dimensions
vary with different manufacturer)
GRAVEL PACKS
Gravel Pack refers to uniform graded commercial sand placed between the wellbore and
slotted screen to retain formation sands from movement. Figure 7.11 describes a typical
gravel pack. The main advantages and disadvantages of a gravel pack are described in
Table 7.3.
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Oil flow up
FORMATION
SAND GRAVEL
Advantages Disadvantages
1. Effective control of formation sand as sands 1. Effective flow diameter of the
are stopped in pores formed by gravel wellbore is reduced
2. High production is achieved because the near 2. Zone isolation is not feasible
wellbore permeability remained mostly 3. Screens are susceptible to erosion
undamaged due to grain intermixing
3. Screen is subject to less erosion
4. No chemical reaction involved
5. Regulating acid wash is feasible
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Selection of Gravel Size:
Selection of gravel is important as the gravels must form interstices which can effectively
trap formation sands and prevent sand movement. Similar to selection of screen slots
gravel size is determined based on well established correlations. These correlations are
summarised in Table 7.4.
From the table, it is apparent that the diameter of the gravel sands is selected by matching
the diameter of certain percentile formation sand. Rules for selection of gravel sands are
based on the correlation present in Table 7.4 which varies significantly and that the
distribution of sand size is described by a particular percentile on the distribution curve.
To overcome the above anomaly of the selection process, Schwartz,1969 came up with a
unique uniformly coefficient, C. The uniformly coefficient is determined by comparing
40 percentile formation sand (d40) with 90 percentile formation sand (d90) as:
d
C 40
d 90
C<3, sand is considered to be uniform
C>5, sand is non-uniform
C>10, Sand is very non-uniform.
For the above uniformity coefficient Schwartz gave the following correlations:
for uniform sand(C<5), D50 6d10
fro a non-uniform sand (C>5), D40 6d 40
The flow velocity for all the range of C should not exceed a critical value and be
calculated as:
Flow velocity = production rate (ft3/sec)/ 50% of the open area of slots, ft2.
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Gravel Thickness:
Gravel thickness is also an important factor which affects productivity of the well.
Through laboratory experiments, Allen and Roberts, 1989 have shown that the gravel
pack thickness of 3 to 4 grain diameter should be sufficient in order to stop sand
movement. In practice, however, a thicker gravel pack is needed for effective sand
control. Sage and Lacey, 1942, based on their work, provided a rule for gravel thickness.
Based on their work it is clear that 3 inch or greater gravel pack thickness is required to
effectively control sand production.
roundness or sphericity,
grain strength,
acid solubility,
uniformity,
presence of clay and clay size materials and
wetness.
Gravels should have a uniform geometry with roundness or sphericity 0.6 in Krumbein
scale or better. Flat or angular geometry reduces the porosity and hence reduces trap
capacity of gravels. Gravels should have strength greater than 2000 psi so that they do not
breakdown on formation stress and produce clay size particles. Presence of clay size
materials reduces gravel pack permeability. Usually turbidity is used to determine the
presence of clay and the turbidity should be less than 1. Gravel should have a Uniformity
Coefficient, C=1.5. Materials finer than 1.5 (C=1.5) would have little effect on the
control of sand movement.
Gravel should also be resistant to acid as often acid treatments are employed to clean up
of sand pack to remove pore blockage (formation damage).
Finally, gravel should be water wet to increase the effective permeability. It has been
shown that when water wetness increases relative permeability to oil increases greatly
(Williams et al, 1972).
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PLACEMENT OF GRAVEL PACK
SCREEN
CASING
PERFORATIONS
GRAVEL
23
PERFORATIONS
SCREEN
CASING
GRAVEL
The combination pack provides an effective sand control and is widely used in the
industry.
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SCREEN
CASING
PERFORATIONS
25
SCREEN
UNDERREAMED
CASING
AREA
GRAVEL
26
Washing Behind the Casing:
In order to provide thick gravel pack, perforations are required to be washed. A typical
washing technique (after Tausch and Corley, 1958) or a cup type (after Allen and
Roberts, 1989) can be employed to wash behind casing and perforation tunnel (see
Fig.7.17a)
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Fig.7.17b: Cup type perforations.
According to Tausch and Corley, 1958 a wash pipe is run with a packer which is set at
the half way through the perforation interval. Brine is pumped through the annulus into
the perforation and back to the surface through the wash pipe as shown in Fig.7.17a. In a
cup type washing technique, a ball is dropped before circulation commences. A Selective
selective circulating sleeve is used to direct brine to the perforation tunnel via wash pipe.
Brine and sand mixtures are recovered back to the surface via the annular gap (casing and
wash pipe, see Fig.7.17b).
Telltale:
Telltale is a device to indicate the position that can not be easily seen, in this case a short
section of the screen/liner located below the screen. A seal sub is installed between the
telltale and the screen to seal the wash pipe therefore ensuring that the return is from the
telltale only. The objective is to direct the gravel to the bottom of the screen to achieve a
tight pack.
Crossover Tool:
Crossover tool is used to divert down flowing slurry (mixture of sands and fluids) to the
outside of the liner and flowing fluid into the annulus to return to surface. The slurry is
pumped down the tubing, as shown in Fig.7.18, through the crossover tool into the
casing-screen annulus. This prevents the gravel to travel back to surface.
28
Fluid returns up casing
annulus
Crossover
Fig. 7.19: Gravel blending unit (Courtesy of Solum Oil Tool Corporation).
29
SLURRY CIRCULATION TECHNIQUE
Each technique is unique for certain bottomhole conditions and has associated advantages
and disadvantages. Selection of appropriate circulation technique is important for
effective sand control.
Gravity Circulation:
In gravity circulation the slurry is dumped down the casing and allowed to settle (see
Fig.7.20). To allow the gravel to settle, low viscous brine is used as a carrier fluid. This
technique results in a poor gravel pack as the different gravel size travel down the well at
different velocities leading to segregation of gravel. This results in poor compaction of
the gravel and hence is primarily used in shallow water wells. Gravity circulation would
be used as a cost effective solution for water wells.
Gravel dumped
downhole
Linear
perforations
Gravel
segregation
30
Fig 7.20: Gravitate placement technique.
Normal Circulation:
In a normal circulation, the slurry is pumped down the working string via a crossover tool
and the carrier fluid is returned through the annulus as shown Fig.7.21.
SLURRY DOWN
WORKSTRING
CARRIER FLUID
RETURN UP
PACKER AND
CROSSOVER
ANNULUS
DEHYDRATED
GRAVEL
It is primarily used for the inside casing gravel pack. Due to the injection pressure, the
same gravel may flow through the perforation tunnel. In order to achieve a gravel pack a
two step procedure is used: Outside pack and inside pack. The circulation is described in
the following steps:
1. Gravel is pumped down the tubing and forced into the perforation as shown in
Fig.7.22. The carrier fluid passes through the liner and up the wash pipe leaving
the gravel behind.
2. The tubing and wash pipe are then pulled up to some distance and step1 is
repeated again allowing more gravel to settle (see Fig.7.23).
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3. Figure 7.24 shows the final outcome of repeating stage one. Gravel is tightly
packed behind the casing and inside the casing.
4. The second stage is a wash down procedure. It consists of pumping fluid down
the wash pipe to displace the gravel, thus allowing the screen to be placed down
hole. This procedure is demonstrated in Fig.7.25.
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Fig. 7.24: Gravel packed inside and out casing.
Fig. 7.25: The Wash pipe is pushed down with the screen to remove gravel from inside.
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Wash Down Procedure:
The wash down procedure, described in Fig.7.25, is also used inside the gravel pack. In
the wash down method, the gravel is injected into the perforations before the screen is
placed. Then the screen is run into the hole. The assembly is then “washed down” into its
final position by circulating brine through the wash pipe and shoe. When the shoe reaches
the bottom,circulation is stopped and the gravel is allowed to settle around the screen and
liner (see Fig.7.26).
Washpipe
Liner Screen
Sealing Mechanism
Reverse Circulation:
In reverse circulation a conventional water/gravel mixture is circulated down the casing-
tubing annulus allowing the fluid to return up the tubing (see Fig.7.27). The slurry flows
down the annulus and the gravel is retained on the outside of the screen. The carrier fluid
flows through the screen and up to the surface through the tubing.
Assemblies for reverse circulation usually involves running in the hole, down hole
functional check, packing of gravel to a selected point in the casing, pack off after
packing and disengagement. A production packer with an overshot assembly is then run
over the polished bore nipple. A prepack should be used as discussed earlier in case of
outside casing gravel pack.
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WATER/GRAVEL
DOWN ANNULUS
TELL TALE
SCREEN
GRAVEL PACK
35
SLURRY DOWN
WORSTRING
PACKER AND
CROSSOVER
DEHYDRATED GRAVEL
SCREEN
CARRIER FLUID
LOST TO
FORMATION
In order to obtain a successful gravel pack it is important to select fluids with the
appropriate properties for effective transportation. Essential characteristics of gravel
transport include:
Viscosity,
fluid leak off control and
density.
Viscosity:
Brine has been the common fluid used for transportation of gravel as it readily leaks off
into the formation, thus providing a tighter gravel pack. It must be a clean and contain
minimum amounts of any clay-like solids (clear fluid) and its water wettability should not
be impaired. Low viscosity has limited transport capability to 0.5-1 lbs gravel/ gallons of
fluid with a pump rate of 5 bbls/min.
High viscous fluid is needed to increase the carrying capacity characteristic of the fluid.
This is achieved by adding gelling agent such as the hydroxyethyl cellulose (HEC) or x-
tham gum polymers. For 8 to 9 lbs of HEC in 100 gallons of brine can yield a viscosity of
100-200 mPaS at 100 S-1 and can transport upto 15 lbs of gravel /gallon of brine. By
36
adding beaker fluids this viscosity can be easily broken and recovered by producing
fluids (oil and gas) without much formation damage.
Ground calcium carbonate provides good fluid leak off by plugging pores of formation
sands. Calcium carbonate is also acid degradable such that with acid (HCl) treatment
carbonate particles can be removed. Finely graded oil soluble particles are used to control
leak off.
Fluid Density:
Densities of up to 10 lbs/gallon can be achieved in common brines which are adequate to
control formation pressure in shallow and low pressure reservoirs. In deeper and high
pressure wells brine densities are often required to increase densities up to 19 lbs/gallon.
Using calcium chloride, brine density can be increased to 11.4 lb/gal. Calcium and zinc
bromide can provide densities between 12 and 19.2 lbs/gal. These brines are expensive
and corrosive. In most cases, ground calcium carbonate is added to the common brine in
order to increase density between 12 and 14 lbs/gallon and polymers to suspend both
gravel and carbonate particles, leading to a cost effective solution,
When the inclination angle exceeds 60 degrees from the vertical, significant changes
must take place in the dynamics of gravel transportation. This can be illustrated by
calculating the fall of gravel. For example, 15 lbs/gallon slurry has a fall velocity of
approximately 500 ft/min in a vertical wellbore. The slurry fall rate in a horizontal well
will become zero. And any angle between 90 degrees and 0 will depends on the cosine of
the angle. For a 60 degree inclination angle, in a high angle well slurry flows along the
low side of the well forming dunes of gravel as shown in Fig.7.29.
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DUNE
FORMATION
o SCREEN (with
0
>6 washpipe)
Laboratory studies by Maby et al, 1974 using 1/10th scale model showed that the packing
efficiency decreases rapidly as the hole angle reaches 60 degrees and more (see Fig.7.30).
Similar results were also observed by Gruesbeck et al., 1977.
100
Unipack
80 tool
60
Packing Efficiency
[% of full pack]
40
Conventional tools
20
30 60 90 120
0
Hole Angle
[Degrees from vertical]
Fig 7.30: Effect hole angle on gravel packing efficiency(After Maly et al).
Various laboratory and field experience have shown that the transport efficiency of grave
can be significantly improved by:
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Use of flexible baffles in the wash pipe/screen (Unocal).
Selection of outer diameter of the casing 0.8 (or more) times greater than the inner
diameter of the screen (Chevron, Halliburton, Dowell and Marathon).
Vibration of the liner during gravel packing operation (Solum oil Tool
Corporation).
Selection of transport fluid with high viscosity and low fluid leak off.
Circulating the slurry using reverse flow.
These measures have been successful in improving transport efficiency however they
cannot solve every problem. For example, high viscous fluids can improve suspending
gravel, but do not allow the slurry to fully dehydrate when the gravel reaches the
perforation interval. Also, the use of reverse flow has the potential to mix formation sand
with gravel sand resulting in a looser gravel pack.
In this method, sand grains are consolidated by plastic resin. In general, with the use of
plastic resin, strengths between 1000psi and 3500psi of the consolidated sand can be
achieved. Measured limits plastic consolidations are:
Consolidation by plastic resin involves injection of liquid plastic resin into the formation
following a preflush. Then an after-flush is carried out to displace the resin from the pore
space and distribute it around the grain surface. Certain resin treatments have an inherent
self-activation and others are activated during the afterflush. Thus the procedure for
chemical consolidation is as follows:
1. Preflush
2. Resin injection
3. Afterflush
Consolidation of formation sand by plastic resin is dependent on a) the type of resin used
b) the activation mechanism and c) formation temperature.
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Type of Plastic Resin:
Commonly resins used in industry are furan, phenolic and epoxy. Furan and phenolic
deteriorate over time due to their inherent imperfection (chemical makeup). This can
result in stress concentrations leading to premature failure when subject to production
related stress (hydrodynamic stress).
Expoxy resins on the other hand, deposit around sand grains and spread out to coat the
surface and create strong bonding between grains. After consolidation it produces little
shrinkage, no harmful polymerisation as a by product and also crosslinks to produce a
strong inert plastic.
Activation Mechanism:
Activation is the reaction process by which liquid resin turns into a solid resin, which
provides a physical strength to bond individual grains. A catalyst is used to activate the
reaction that causes the resin to cure with time and temperature.
internal and
external
In an interval activation system the resin contains a catalyst which activates the curing
with time or temperature. Once the resin reaches a certain time or temperature the curing
begins. The drawback of this system is that it can put a constraint to the operation. The
resin could set prior to proper placement of around the sand grain and therefore can plug
the entire interval.
In an externally activated system catalyst is pumped with the afterflush. This system has
no time or temperature constraints. It is, however, possible that the activator may not
contact the resin leaving behind an uncured resin.
40
Resin Characteristics:
A number of chemical and physical properties of resin must be considered in the sign.
They include:
viscosity,
adhesion,
strength,
storage,
chemical resistance,
formation compatibility and
safety.
Resin must remain pumpable during the execution of the job. To achieve this, the
viscosity of the resin must not be high. Also high viscosity prevents the resin to be placed
deeper into the formation and remain trapped in the formation pores. It should be wet to
the sand grain so that it can easily coat the grain to provide a strong bond. It is important
that the resin, after forming a coating around the grain, develop a strong tensile strength
which can resist formation forces. During the life of the well the resin must be resistant to
any chemical deterioration and remain compatible with formation fluid. Its operational
safety must meet the HSE guide lines and have a reasonable storage life.
Pay Thickness:
Pay thickness is an important consideration as the resin consolidation is limited to a short
interval. If possible, long intervals should be treated at different stages for quality
assurance.
Formation Characteristics:
Operational characteristics that are essential include:
heterogeneity,
clay content,
formation fluid compatibility andand
temperature
There is a potential for the plastic to bypass sections with low porosity and permeability
when intervals with high heterogeneity (porosity and permeability varies varing vertically
or horizontally or both) exist. To ensure good zone coverage it is important to select
small section (preferably 30 feet or less) with uniform porosity and permeability for the
treatment.
Formations with high clay content in the pore space are susceptible for fines
mobilisations, resulting in formation damage. To avoid this damage, the formation must
41
be treated (acidised) before the consolidation treatment commences. The general rule of
them is to avoid consolidation treatment if the formation contains clay in excess of 10%.
Formation fluids (water, oil, gas) may contain chemicals that may reduce the
effectiveness of the resin. To overcome this problem a preflush must be designed to
separate the formation fluid coming into contact with the resin. This will keep the resin
free from contamination by formation fluids.
Operational Requirements:
Operational requirements that must be taken into considerations include:
storage and handling facilities at the rig,
surface facilities such as pumps and
rig time.
Rig should have sufficient quality storage facilities so that the resin does not degrade
overtime. Appropriate handling facilities are required in order to prevent physical contact
with handling crews. Surface facilities should have excess pumping capacity as viscous
fluids require high injection pressure in order to be injected into low to average formation
permeability. It is also important to consider mixing the resin offsite to reduce rig time
which can significantly reduce job cost and prevent contamination at the rig site.
Depth of Treatment:
Most plastic treatments use 200-300 gallons per foot to allow sufficient penetration depth
better distribution of the resin and allow well compacted sand matrix with a high strength
bonding of grains.
42
SAND GRAINS
i) Oil and Brine before
consolidation
BRINE
PREFLUSH
ii) Preflush miscibly displaces
Oil and brine
RESIN SOLUTION
OIL
v)Well ready for production
PLASTIC
Preflush:
Preflush is designed to separate resin from the formation fluids and clean sand grains for
good bondage. For phenolic and furan resins, diesel oil is used to drive the water and
prevent water dilution or acids that may accelerate the settings process. Similarly, for an
epoxy resin, all free water must be removed and a large volume of oil and alcohol is used.
A typical preflush is presented in the Fig.7.32.
43
Tubing
Casing
Cement
44
Tubing
Casing
Cement
Afterflush:
The final step of this process is to distribute the resin around the grain forming a coating
deep into the formation. This is achieved by an afterflush of a non-contaminant and an
immiscible fluid usually hydrocarbon (see Fig.7.34). The viscosity and density is about
the same as the resin to have a uniform displacement. For external afterflush an activator
is mixed with afterflush. The amount of afterflush determines the thickness of the resin
coating and hence the porosity and strength of the bonding.
45
Tubing
Casing
Cement
Diesel
Resin + Activator
Rock Matrix
46
7.4 Exercises
Example 7.1
For a formation with the following sand distribution, plot a relationship to determine liner
slot size:
Solution
C = d40/d90 = 0.007/.0035 = 2
3. Determine the liner slot width for fifty percentile (D 50) and ten percentile (d10) rule
as:
4. Plot liner slot distribution line on same curve (see Fig. 7.36).
47
Fig.7.36: Sand size distribution plot as function of diameter.
Selection of a screen or slotted liner, once the slot size has been determined, depends on
well conditions. Sawcut slots are cheaper. Wire-wrapped screen permits use of harder,
48
more corrosion-resistant metal. Screens set inside casing usually reduce productivity
since fine sand moving through the perforations fills the annulus between the screen and
casing. Use of largest diameter screen possible is good practice.
REVIEW QUESTIONS
3. How large should the screen slot size (i.e. slot width) be? What is the minimum thickness of a
gravel pack?
4. In planning/designing a gravel-packing job, what are the two key aspects that you should
normally consider?
5. Describe the major parameters which are normally considered in selecting a gravel pack
fluid?
6. What are the advantages and disadvantages of sand control by plastic resin?
49
References
1. Allen T.O and Roberts AP, Production Operations - well completion,
Workover and stimulation, 3rd Edition, 1989, Oil and Gas Consultants International
Inc., pp 37-59.
8. Hill, KE, Factors Affecting the use of gravel in Oil and Gas Wells,
Drilling and Production Practices,1941, pp 134-143.
10. Smith, HF, Gravel Packing Water wells, Water Well Journal, Jan-Feb 1954.
12. Schwartz, RH, Successful Sand Control Design for High Rate Oil and Gas Wells,
Journal of Petroleum Technology, Sept 1969, pp 1193-1198.
13. Sage BH and Lacy, WN, Effectiveness of Gravel Screens, Transactions, AMIE
1941, pp 89-107.
14. Sparlin DD and Copeland CT, Pressure Packing with Concentrated Gravel Slurry,
SPE 2649, 1972.
50
15. Williams BB, Elliott, LS and Weaver R.H, Productivity of Inside Casing Gravel
Pack Completion, Journal of Petroleum Technology, April,1972, pp 419-425.
16. Tausch, GH and Corley CB, Sand Exclusion in Oil and Gas Wells, Drilling and
Production Practices, 1958, pp 66-81.
17. Maly, GP, Robinson, JP And Laurie, AM, New Gravel Pack Tool for Improving
Pack Placement, Journal of Petroleum Technology, Jan 1974 pp 19.
18. Gruesbeck, C, Salathiel WM and Echols, DE, Design of Gravel Packs in Deviated
Wells, 10 October 1977, SPE 6805.
51