Sand may be produced with fluid production because of lack of grain bonding or consolidation. Structural weakness causes sand grains to move when subjected to stresses caused by Fluid pressure drop from reservoir to wellbore Fluid friction Overburden stresses Other important factors : Critical Flow rate Formation strength vs Drag force CRITICAL FLOW RATE EFFECT Under normal producing conditions a well may produce some amount of sand or fines independent of production rate till a critical production rate is exceeded. Continued production above critical rate results in increased amount of sand. FORMATION STRENGTH VS. DRAG FORCES Sand grains are stabilized by 1.Compressive forces due to weight of overburden 2.Capillary forces 3.Cementation between sand grains. Causes of sand production : Drag forces of flowing fluid increase at high flow rate Higher fluid viscosity. Reduction in formation strength: Water production-due to loss of cementing material, Reduction in capillary forces with increasing water saturation. Reduced relative permeability to oil-due to increased saturation This leads to increased drawdown for a given oil production rate. Declining reservoir pressure-which increases compaction force and disturbs cementation between grains. CONSEQUENCES Production and Economic Losses Sanding-clean out cost-well, separators, treaters, tanks, etc. , production loss, formation damage. Wells operating at restricted rates to avoid or reduce sand production. Loss of well head or surface equipment by abrasive force of sand laden fluid which may lead to physical danger or disaster. Casing collapse, due to slumping of higher formations into zone weakened by sand production. Sand Control Three methods: Reducing Drag Forces - Cheapest and most effective. Should be considered along with any other method of control. Often due to proper well completion. Bridging Sand Mechanically - If properly done it has wide application. Difficult to apply in multiple zones or small diameter casing. Increasing Formation Strength - Sand consolidation Drag Force Reduction Most effective and simplest way of sand control. Production rate at which sanding starts should be considered as a rate-per-unit area of permeable formation open to wellbore. Can be done by: Increasing flow area Restricting production rate INCREASING FLOW AREA 1. Clean, large perforations. 2. Increasing perforation density. 3. Exposing increased length of section. 4. Create a conductive channel some distance into reservoir by a packed fracture Can be accomplished by good completion practices, use of clean fluids, proper selection of perforation charges and perforating conditions RESTRICTING PRODUCTION RATE :Important to know critical flow rate. Step wise increase in production rate leads to increase in sand production at each increase then gradually decreases to original rate .This is due to surge effect which breaks unstable bridge which is formed at a certain rate, these bridges are formed again at higher rate. When critical rate is reached, bridges do not reform. Strength of structure has been exceeded and sand production continues at higher rates. Production rate is reduced much below critical rate allowing bridges to reform. Once such a condition is reached then rate can be increased to a level which is below critical. produced sand concentration versus production rate Mechanical Methods of Sand Control Provides a physical barrier to sand movement. Holds sand in formation Screen to stop sand without gravel. Physical barrier : Screen, Gravel pack Combination of both Flow passages through gravel or screen are small enough to prevent sand production and large enough to allow good well productivity and minimize plugging by clays, asphaltenes, wax or scale. SCREEN TYPES Wire wrapped and slotted pipe screens are generally used Wire wrapped screens : Made by forming a nearly continuous slot on the outer side of pipe which has machined holes or large slots. Slot opening in wire wrapping is set by lugs formed on one side of wire. Wire has a trapezoidal cross-section to provide a vee-shaped slot narrow towards formation and wide in the direction of flow towards inside of liner to minimize particle bridging in slots. Slotted pipe Is milled in different patterns. Liner slots are machined to have an undercut vee-shape similar to wire-wrapped screen. Wire-wrapped screen has much larger slot area than slotted pipe, but slotted pipe is still preferred. PREPACK LINERS Two types of prepack liners are in use Gravel filled liner-is the earlier form. Gravel filled prepack failed in heavy oil completions, because liners plugged with mixture of asphaltenes and silt. Bonded sand prepack: Developed after dependable bonding resins became available. Used extensively in clean formations with medium to high gravity oil. Both forms of prepack are used if formation sand and fluid characteristics are satisfactory, and size distribution of prepack sand is selected appropriately Screen Liner Considerations Ribbed wire wrapped screens costs twice the slotted pipe. It provides eight to ten times the open area. for same slot width. All-weld screen provides twice the open area as the ribbed screen and costs twice as much. Wire-wrapped screens have the advantage of using erosion and corrosion resistant materials. Liner is centralized inside casing or in open hole. A liner packer is required to prevent flow of fluids and gravel upward around outer side of liner. PRE-PACKED LINERS GRAVEL PACK Advantages: High productivity due to less restriction of formation sand. Generally less overall cost Screens are subjected to lesser corrosion Effective in controlling long intervals Better at treating wells where sanding has already started Effective in controlling intervals with high heterogeneity. Disadvantages: Wellbore diameter is restricted due to gravel and screen Requires complete removal of pack and liner during workover Difficult to isolate undesirable zones like water, gas Design Criteria 1.Optimum gravel size in relation to formation sand size. 2. Optimum screen slot width to retain gravel or, formation sand if there is no gravel. 3. Effective placement is critical. FORMATION SAND SIZE ANALYSIS Getting representative samples. Sand-grain size distribution varies in any sand body and from one zone to other. To get a representative sample large number of samples are required. Full dia. cores Produced sand samples-back wash or sand bailed Perforation washing or backsurging Sieve analysis provides grain size distribution on percentile basis. Typical sand analysis distribution
Ten-percentile sand size is defined as the point on
distribution scale where 10% by weight of the sand is of larger size and 90% of smaller size. In tight pack sand grain is too large to move through pores of gravel pack. Sand is stopped at boundary. In loose pack sand grain can move through pores between gravel grains. SELECTION OF GRAVEL SIZE TO CONTROL FORMATION SAND Formation sand must be stopped at outer face of gravel pack. This allows maximum productivity. If sand bridging occurs within gravel pack itself permeability is reduced to a large extent. Gravel size determination - studies carried out by Coberly and Wagner(1938) Hill (1941) Gumpertz (1940) Saucier (1974) Schwartz (1968) Maly and Kreuger (1970) G-S ratio-gravel to sand size ratio Coberly and Wagner, Hill Gumpertz : Defined gravel size with respect to the sand size. Term "gravel-sand size ratio". Largest gravel size G-S ratio = 10 percentile sand size Saucier: 50 percentile gravel G-S ratio = 50 percentile sand size Schwarts 10 percentile gravel G-S ratio = 10 percentile sand size or 40 percentile gravel G-S ratio = 40 percentile sand size Mary and Kreuger Smallest gravel G-S ratio = 10 percentile sand size Uniformity coefficient Determined by comparing 40-percentile size (D40) with 90- percentile size (D90) (D40) C = 90 (D ) If C < 3 - sand is uniform and is described by the (D10) size If C > 5 - sand is non-uniform and is described by the (D40) size If C > 10 - sand is very non-uniform and is described by (D70) size Effect of G-S ratio on gravel pack permeability is shown by lab work by Saucier. It indicates ideal ratio in the range of 5 to 6. Schwartz method takes in to account the effect of flow velocity and recommended 1. Uniform sand (C less than 5) and with flow velocity less than 0.05 ft/sec: G-S ratio: D 10 gravel = 6 x D 10 sand 2. Uniform sand (C greater than 5) and with flow velocity greater than 0.05 ft/sec: G-S ratio: D 40 gravel = 6 x D 40 sand 3.Flow velocity is calculated production rate cubic feet per second Flow velocity= 50% of open area of slots sq.ft Generally gravel-sand size ratios is kept in the range of 5 to 6 Gravel size is generally based on recommendation of Schwartz or Saucier. Gravel Selection 1. Roundness and sphericity: Krumbein scale of 0.6 or better. Flat or angular grains are avoided. 2. Grain strength: depends on depth and formation stress level same as frac sand. In standard lab tests, fines generated by 2,000 psi stress should be less than 4%. 3. Acid solubility: acid solubility should be checked. Gravel should be greater than 98% pure silica. Feldspar content should be zero as feldspar is fully soluble in HF Glass beads are slowly soluble in HF . KRUMBEIN SPHERICITY AND ROUNDNESS 4. Uniformity: closer the limits on gravel grain size variation, greater will be the permeability. Schwartz suggests a uniformity coefficient less than 1.50. Material finer than the lower size limit is particularly bad. 5. Clay size material: Presence of clay or silt can be determined by adding clear water to a bottle partially full of gravel. After vigorous shaking turbidity indicates fines. Turbidity should be less than 1%. SAND - GRAVEL MIXING Mixing of high permeability gravel with formation sand, may occur during placement of gravel. This will reduce permeability. Fines in gravel will also decrease gravel pack permeability. General Rules followed in industry 1. Use as large a gravel as possible, and sand is stopped at outer boundary of gravel pack. 2. Gravel size at 40-percentile point should be 6 times 40-percentile point on sand analysis curve. For low velocities and uniform sands 3. Where sand grain analyses vary within formation, attention paid to smaller sand sizes, specially for wells with higher flow velocity, more non-uniform sand, fluctuating flow rate, and high gas-oil ratios. 4. Pack gravel tightly. G-S ratios are based on a tight pack. 5. Pack thickness should be at least 3 inches. Thicker packs permit higher flow velocity. 6. Don't mix gravel with formation sand in placement. Selection of gravel pack fluid : Low viscosity-Brine, oil, diesel, Viscosity and fluid loss control-Calcium carbonate,HEC ,oil soluble particulate matter like benzoic acid Fluid density-to hold formation pressure Viscous water fluid-for high concentration slurries Gravel Packing Fluid For transportation gravel to formation It is necessary to mix it with carrier fluid. After gravel is transported to formation fluid is either lost to formation or returns to surface through well. Two main methods: Conventional technique Slurry technique CONVENTIONAL GRAVEL PACKING In conventional method gravel is added to water or oil as it is being pumped down the hole. Minimum equipment is needed to do these treatments. Generally surface equipment: Injection pump Gravel packing pot. Gravel is packed into pot and it is picked up by flowing stream of liquid going through bottom of pot. Sand water blenders are used now which help in controlling gravel concentration Difficulties: Due to low viscosity of water, carrying capacity is limited (0.5-1 pound of gravel per gallon of fluid). Requires high pumping rate to avoid gravel settling. At fluid injection rates through perforations fluid travels at high velocity which may leave formation sandblasted. In cased hole completions, low viscosity is not efficient to transport gravel through perforations. Most of settles down due to gravity or inertia. SLURRY GRAVEL PACKING Gelled fluid like a gelled brine is used as fluid. Higher gravel concentration can be pumped (15 pound of gravel per gallon of fluid).Allows lower pumping rates. High gravel concentration reduces injection rates which minimize mixing of formation sand and gravel. System works like a cement slurry and pushes the formation back as a mass. Advantages: Less gravel/formation sand mixing Less fluid loss to formation Tighter pack Less chance of voids Better transport in deviated holes Disadvantages: Leak off to formation is slower (slower dehydration of gravel) Viscous fluid is difficult to clean up Gravel Placement Techniques To ensure a good gravel pack over entire productive interval, different placement techniques are used Normal circulation – using the crossover tool Reverse circulation Squeeze gravel packing Washdown gravel packing Normal Circulation Gravel Pack Circulation of gravel pack in conventional way using crossover tool. Gravel and water are pumped through tubing and through crossover tool in the screen/casing annulus. Crossover tool diverts sand and fluid which is flowing down to outside liner and upward flowing fluid to annulus for return to surface. Gravel is deposited across liner and water circulates through screen and flows through crossover tool into annulus above packer and returns to surface through annulus NORMAL CIRCULATION GRAVEL PACK REVERSE CIRCULATION Circulate conventional water/gravel mix through tubing-casing annulus which allows the fluid to return through tubing. Slurry flows through annulus and gravel is retained on the outside of screen. Carrier fluid flows through screen and moves up to surface through tubing REVERSE CIRCULATION SQUEEZE GRAVEL PACKING Generally used to pack intervals of 30 ft or less where chance of high permeability is less. These streaks may cause incomplete pack. Carrier fluid is lost to formation. Gravel pack assembly is positioned across completion interval, packer is set and crossover is opened. Viscous slurry with gravel carries gravel to its location by pumping slurry through tubing and through crossover tool. Then It passes into the screen- casing annulus and through perforations. Carrier fluid is squeezed out into formation to dehydrate slurry and form an effective pack . Pumping is continued till sand out occurs indicating no more gravel can be squeezed into the annulus. After gravel pack excess gravel above liner is reverse washed and workstring is pulled out. Carrier fluid should be compatible with formation matrix and formation fluids SQUEEZ GRAVEL PACK WASHDOWN TECHNIQUE Used in cased hole completions. Gravel is injected into perforations before placing screen. Then screen is run into well. Assembly is then washed down to final position by circulating brine through washpipe and shoe. When shoe reaches desired depth circulation is stopped and gravel is allowed to settle around screen and liner WASHDOWN TECHNIQUE CASED HOLE - PERFORATION GRAVEL PACK In cased hole gravel packs, gravel is placed within perforations. To do this the perforations should be: large enough to accept the gravel allow carrier fluid to penetrate easily (high injectivity) clean Gravel cannot be carried into a perforation that does not accept fluid readily. Perforations should be large diameter and clean . Even where clean perforating fluids are used, injectivity into a perforation is restricted by metallic particles from charges and crushed formation particles. Restriction is severe when overbalanced perforation is done. A cavity is created behind casing Perforation washing tools Surging FIRST STAGE
Gravel is pumped through tubing and
forced through perforations. Carrier fluid then passes through liner and moves up through washpipe and leaves gravel behind. SECOND STAGE
Tubing and washpipe are then pulled up
a little and stage 1 is repeated again which allows more gravel to settle Second stage is a washdown procedure. It consists of pumping fluid through washpipe to displace gravel, which allows screen to be placed downhole. FINAL STAGE THICKNESS OF GRAVEL PACK Thickness of the gravel pack is an important factor which affects well productivity. Lab studies and field tests have shown: In lab a gravel pack thickness of four or five gravel diameters controls sand effectively. Actually thicker packs are needed. 3-in. of gravel thickness is taken as minimum due to practical problems of gravel placement and fluctuating flow velocities Open hole is generally underreamed to give 3 in. on radius between screen and formation. In perforated casing, gravel is placed through perforation tunnel and outside casing.