Sand Control.pdf
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Sand Prediction and Sa Sand Control Giuseppe Ripa
Junior Production Engineering/Sand Control
Map of Sand Producing Areas
Usually associated with younger Tertiary formations such as the Miocene or Pliocene Age Sands Approximately 70% of the world’s oil and gas reserves are contained in poorly consolidated reservoirs where solids production is likely to become a problem during the life of the field. [JPT October 1998, Page 80 ]
Junior Production Engineering/Sand Control
Map of Sand Producing Areas
Usually associated with younger Tertiary formations such as the Miocene or Pliocene Age Sands Approximately 70% of the world’s oil and gas reserves are contained in poorly consolidated reservoirs where solids production is likely to become a problem during the life of the field. [JPT October 1998, Page 80 ]
Junior Production Engineering/Sand Control
Sand Problems in ENI-E&P and Sand Completions
West Africa & GOM
On & Off-Shore Italy
On-Shore Italy
Sand
Thin Sand-Shale Sand-Shale Interbeds
Sand-Shale Sand-Shale Int erbeds
500-4800 m
600-3500 m
1200-1700 m
30-350 µm
20-150 µm
50-150 µm
200-8000 200-8000 mD mD
20-500 mD
200-2000 200-2000 mD mD Completion per year
Over 50% of the total production (~1700 BOED) is coming from reservoir requiring sand control
Cumulative Completions
120
1800
100
1500
80
1200
60
900
40
600
20
300
0
0 1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004
Year Junior Production Engineering/Sand Control
Consequences of sand production • Wellbore fill • Equipment problems due to sand fill • Sand erosion of downhole and surface equipments • Sand accumulation on surface and Sand Disposal •
• Production Loss • Casing / Liner Collapse
Junior Production Engineering/Sand Control
Forces Aiding in Resisting Sand Production
• Intergranular frictional forces and bonding (cementation) help resist grain movement • Capillary Pressure adds further grain-to-grain bonding Water-Wet Grains Oil Flow
Junior Production Engineering/Sand Control
Forces Contributing to Sand Production
• Pore pressure relieves frictional forces • Production of wetting phase reduces capillary pressure forces
Oil and Water Flow
Junior Production Engineering/Sand Control
What causes sand production? •
Totally or weakly unconsolidated formations
•
Changing stresses in the near wellbore area
•
Water Production
•Overburden •Cementing •Capillary •Drag
Junior Production Engineering/Sand Control
Sand Production Mechanism
•
Primer:
– Rock shear collapse owing to in situ stress forming “shear band”
•
Sand Production:
– Erosion of perforation tunnel around “shear band” by the produced fluids
Junior Production Engineering/Sand Control
Detecting sand production • Erosion of Equipment • Acoustic Detectors • Sand Traps/Desanders
Fluenta Acoustic Sand Detector
Sand Probe Junior Production Engineering/Sand Control
Predicting sand production
• • • • • • •
Experience in the area Offset well production data Drilling data Core sample evaluation Sand Flow Test Logs Computer modeling
Junior Production Engineering/Sand Control
Predicting Sanding Potential SAND FLOW TEST RESULTS ) 220 2 m c / g 200 k ( E R U S S E R P E L O H M O T T O B
PERFS CLEAN-UP D50=40- 60 µm
180
FINES REMOVAL D50=3 - 7 µm
CONTINUOUS SAND INFLUX D50=18 µm
2/16"
160
3/16"
140
9/16"
6/16"
4/16"
S =
5/16" 10/16"
120 100
11/16" 12/16"
8/16"
CHOKE SIZE
S = 8 0
- 1 7
S = 0
80 0
50
100
150
200
250
300
GAS FLOW RATE (ksm3/d)
FORMATION SAND : D50 = 22 - 44 µ m Junior Production Engineering/Sand Control
What can be done about sand production? • Rate Exclusion
– Drawdown Control – Selective Perforations • Mechanical Methods – “ Downhole Filter”
– Slotted Liner and Screens – Gravel Pack • Chemical Methods
– Consolidation of the formation – Resin-Coated Sand
Junior Production Engineering/Sand Control
Drawdown control
• Reduction in production rate will reduce drag forces and drawdown to provide reduced risk of sand production • Procedure: – Slowly increase rate until sand production begins to increase – Sequentially reduce flow rate until the sand production declines to an acceptable level • Attempting to establish maximum flow rate in conjunction with stable arch
Junior Production Engineering/Sand Control
Selective Perforating Practices Once formation characteristics are known, perforating strategies can be evaluated.
If possible, only high strength intervals can be perforated.
Low Strength
For high rate wells this will require a high shot density to prevent additional pressure drop and associated sand production. However, high shot density lead to perforation interaction which also promotes sand production.
Sand
Higher Strength Sand
The appropriate compromise is key to success . Junior Production Engineering/Sand Control
Slotted Liner and Screens
Slotted Liner (3-6%)
Wire Wrap Screen (6-12%)
Dual Screen Prepack (3-6%)
Slim-Pak Screen (3-6%)
Wire Mesh Screen (15-30%)
Expandabl e Screen (15-30%) Junior Production Engineering/Sand Control
Gravel Pack Consists of sized particles
Gravel Pack Sand
Formation Sand
placed in the annular space between an unconsolidated formation and a centralized screen. Open or cased hole. Screen Junior Production Engineering/Sand Control
Chemical Methods
Consolidation of the Formation
Resin-Coated Sand Junior Production Engineering/Sand Control
Information for designing a sand control FORMATION CHARACTERISTICS
Types of Clays, Mineralogy & water-sensitivity Permeability, Heterogeneity, Height, SBHT & SBHP FORMATION GRAIN SIZING
Sieve Analysis for gravel size selection SLOT SIZING
Gravel Pack vs. FracPack Slotted Liners, Screen only (wire wrapped, prepacked, etc.) TYPE OF WELL
Producer, Injector Deviation & Size Off-shore, On-shore, sub-see
Junior Production Engineering/Sand Control
Sieve Analysis Indicates Uniform and Non-Uniform Formations 100 90
) % ( t h g i e W e v i t a l u m u C
80
Poorly Sorted Sand We ll Sorted Sand
70 60 50 40 30 20 10 0 0.1000
0.0100
0.0010
0.0001
G r a i n D i a m e t er ( in c h e s )
Uniformity coefficient:
C= D40/D90
Poorly Sorted Sand:
C> 5 Junior Production Engineering/Sand Control
Gravel Pack Impairment: Saucier’s Results 1. 2
o t i y ) t i k l i / f b ( k a t e i l i m r b e a P e l m a r n e i F P f l a o i t o i i n t I a R
1. 0
0. 8
0. 6
0. 4
0. 2
0. 0 0
2
4
6
8
10
12
14
16
Ratio of Median Gravel Pack Sand Diam eter to M e d i a n F o r m a t i o n S a n d D i a m e t e r (D 50 / d 50 )
GRAVEL PACK
Saucier 5-6 x D50
18
20
• D50 /d50 ≤ 6, good sand control, no formation sand invasion of gravel pack sand • 6 < D50 /d50 ≤ 13, good sand control, but restricted flow due to formation sand invasion of gravel pack sand • D50 /d50 > 13, no sand control, formation sand passes through gravel pack sand
FRACPACK One size larger than Saucier’s Criteria Junior Production Engineering/Sand Control
Commonly Available Gravel Sizes U.S. Mesh Size Range
Grain Diameter Range (inches)
Median Median Grain Diameter Grain Diameter (inches) (microns)
Permeability (darcies)
6-10
.1320 - .0787
.1054
2677
2703
8-12*
.0937 -.0661
.0799
2029
1969
10-20
.0787 - .0331
.0559
1420
652
12-20*
.0661 - .0331
.0496
1260
518
16-25
.0469 - .0280
.0388
986
391
16-30* 20-40*
.0469 - .0232 .0331 - .0165
.0351 .0248
892 630
398 136
30-40
.0232 - .0165
.0199
505
138
30-50
.0232 - .0117
.0175
445
100
40-60*
.0165 - .0098
.0132
335
61
50-70
.0117 - .0083
.0100
254
32
1
* stocked size
Mesh refers to the number of openings per linear inch Junior Production Engineering/Sand Control
Screen Selection Gravel pack and Prepack Screen
– The screen opening is typically between 50-70% of the smallest gravel diameter For 20/40 mesh sand the smallest gravel is the 40 mesh which has a D50 of 0.0165” 0.0165” x 70% = 0.01155” or 0.012” opening (12 gauge) Screen Only and Slotted Liner
– Screen Opening is approximately equal to the D10 Screen Diameter
– Fishing (7” csg: IDmax= 4” screen; 9 5/8” csg: IDmax= 6” screen ...) – ID for logging and or selective equipment
Junior Production Engineering/Sand Control
Screen Length - Centralizers • Length normally 5’ above and below the perfs • Length needs to be considered for shipments (rig basket @ 30’, airplane @ 20’)
• Centralizer spacing to avoid any casing contact Open hole, Bow-Spring type Cased hole Weld-on Lug type
• Recommended centralizer OD clearance from casing ID to be 1/8” to 1/4”
Junior Production Engineering/Sand Control
Gravel and Screen Summary • Representative formation samples are required for gravel pack sand size design • Gravel pack sand is typically designed to be six times larger than the formation sand at the median grain size • Only gravel pack sand meeting API RP58 specifications should be used • Gravel pack sand substitutes are available for special applications • In a gravel pack the screen serves only to retain the gravel pack sand • Prepack screens offer “second line of defense”
Junior Production Engineering/Sand Control
Cased Hole Gravel Pack 1
Slurry is injected down the workstring
2
The slurry crosses over to the annulus below the packer, depositing sand adjacent to the screen
3
The carrier fluid leaks off through the screen and is carried back to the surface via the washpipe and crossover tool, crossing back over to the casingworkstring annulus just above the packer
MULTI-POSITION SERVICE TOOL GRAVEL PACK PACKER FLOW SUB OR CLOSING SLEEVE
BLA NK PIPE
SCREENS
O-RING SUB TELLTAL E SCREEN
SUMP PACKER
Junior Production Engineering/Sand Control
Quantum Packer Assembly Service Tool Quantum Packer Circulating Ports G.P. Extension Ball Seat Crossover Ports
Closing Sleeve Lower Seal Bore
Check Valve Indicating Collet Wash Pipe
Indicating Collar
Safety Shear Sub Blank Pipe
Perforations
Screen PBR
Sump Packer
Seal Assembly
Junior Production Engineering/Sand Control
Setting the Quantum Packer Service Tool 1. Packer at Set Depth - Drop Ball - Apply Pressure, set begins at 1,000 - 1,200 psi - Pressure Test Annulus and pull test to test set. 2. Release Service Tool - Apply 2,200 - 2,400 psi - Slack off 15K down - Pick up 3. Ball Seat Sti ll i n Place
Quantum Packer Set Position
Ball Seated on Ball Seat “Fluted” Crossover Sub
Junior Production Engineering/Sand Control
Service Tool Operations Blowing the Ball Seat (Openin g Crossover Port s) Pick up to t he reverse-out posit ion - Pressure Drill Pipe to 3,750 - 4,000 psi - Ball seat shifts and pressure is vented to the annulus. Formation is isolated from pressure spike.
Ball Seat is Shifted Open
- Fluids are spotted in this position. Collet Indicates at Upper Packer Seal Bore Shoulder Collet Drags the Port Closure Sleeve Into Closed Position
Junior Production Engineering/Sand Control
Service Tool Operations Circulating Position
To Reach Circul ating Posit ion - Pick up 18 inches at the tool or until collet indicator causes 15K increase in hook load
Circulating Ports are Open
- Circulating ports are now above packer bore. - All circulating fluids must flow through the screen, upwrd through the wash pipe and exit to the annulus.
Check Valve Allows Only Upward Flow
Junior Production Engineering/Sand Control
Service Tool Operations Reversing Out To Reverse Out: - Apply enough annular pressure to overcome hydrostatic in the pipe. Typically 500 psi. - Pick up service tool until pressure falls off. This occurs when crossover port clears the top of the upper packer bore. - Continue pumping
Check Valve Closed
- Check valve prevents slurry from entering the inside of the washpipe. - If annular fluid density is greater than the D.P. fluid density, 500 psi back pressure must be trapped on the tubing side to keep check valve closed.
Lower Set of Seals Still in Packer Bore Port Closure Sleeve Is Closed
Junior Production Engineering/Sand Control
ICGP – General Procedure
• • • • • • • • • •
Well site preparation Casing clean-up Fluid filtration Casing perforation Killing and fluid loss control Buttomhole clean-up Running and setting GP assembly Gravel placement Running and setting completion string Well clean-up
Junior Production Engineering/Sand Control
Casing Cleaning
• Prior to gravel packing the casing should be thoroughly cleaned with a bit and a scraper to remove any dirt or scale • Circulation of completion fluid, mud solvents, scouring material, acid, and caustic solutions may be required to fully remove these material • The casing should also be pressure tested for leaks on older wells
Brine Fresh or Seawater Gel pill Chemical Fresh or Seawater Caustic Fresh or Seawater Gel pill Drilling Mud
Junior Production Engineering/Sand Control
Casing Cleaning – when to stop?
well returns
U T N
irreducible minimum Injection fluid
Time (hrs)
• The irreducible minimum of solids is taken as the cleanliness value such that the level of cleanliness can only be increased marginally over lengthy circulating times Junior Production Engineering/Sand Control
Fluid Filtration • Clean completion, workover, injection, and treatment fluids are imperative to avoid formation damage and gravel’s permeability reduction. • Ideally, all solids larger than 1/6 of the average pore size of the productive formation should be removed from fluids.
•
Methods of determination
– – – •
From Kozeny: Dpore = √k From Coberly: Dpore = D50/6.5 SEM measurements of pore throat diameters from closely spaced core samples
Particle size and damage potential
– – –
Dpart > 0.33 Dpore 0.1 Dpore < Dpart < 0.33 Dpore Dpart < 0.1 Dpore
instant bridging of core invasion of core and deposition unrestricted passage
Junior Production Engineering/Sand Control
Filtration Systems
Maintaining the clarity of the completion fluid can be very expensive and time consuming. Diatomaceous earth filter in series with a downstream absolute rated filter have proved to be an effective and economical fluid cleaning system.
Junior Production Engineering/Sand Control
System Layout
Junior Production Engineering/Sand Control
Perforating • Each shaped shaped charge charge exer exerts ts up up to 4 milli million on psi psi on on the the reserv reservoir oir.. • This This force force crush crushes es and and compac compacts ts the the reserv reservoir oir rock rock and and perfo perforat rating ing debris can plug perforating tunnels.
Result:
Limited leakoff and poor injectivity
Junior Production Engineering/Sand Control
Clean Perforations Limit damage both within and surrounding perforations
Low debris/carrot free charge
Underbalanced perforating
Crushed zone removal
Limit use of fluid-loss control material in empty perforations
Damage Prevention is Also Critical
Junior Production Engineering/Sand Control
Perforation Cleaning • Underbalanced Pr Pressure – sele selected cted on form formatio ation n perme permeabi ability lity and Oil Wells Gas Wells
• Backflow – When perfo perforati rating ng is is perform performed ed overb overbalan alanced ced a period of backflow is sometimes used to clean up the perforations with a dedicated string
Junior Production Engineering/Sand Control
Perforating for Gravel Packs & Frac-Packs •
Numbe Numberr of perfo perforat ration ions s shou should ld be be suffi sufficie cient nt to to allow allow unimpa unimpaire ired d (flow (flow maximi maximize ze infl inflow ow area)
•
Larg Large e diam diamet eter er cha charg rges es rec recom omme mend nded ed whe when n grav gravel el pla place ced d in tun tunne nels ls
– Enha Enhanc nce e gra grave vell pla place ceme ment nt in tu tunn nnel elss – Enh nhan ance ce fl flow ow of pr prod oduc uced ed fl flui uids ds
Depth of pe p ene netration tration not cri critic tica al Various studies (SPE 71458, SPE 38633, SPE 68932) indicate that cavity is often not formed when perforating in unconsolidated un consolidated formations. “Disturbed” zone is filled with dilated formation material. Need to concentrate on tunnel through casing and cement
Junior Production Engineering/Sand Control
Perforating for Gravel Packing •
Entry holes less than 0.6 inches result in high pressure drops.
•
Benefits associated with maximized inflow area leads to need for high shot density.
•
Perforations must be fully packed to prevent excessive pressure drop, and screen plugging and/or erosion.
2
Linear Flow
20
Perfs diameter (in.)
1.6
r e t e m 1.2 a i D s 0.8 f r e P
Radial Flow
16
Effective shots per foot
12
8
0.4
f p s e v i t c e f f E
4
0
0 0
1
2
3
4
5
6
7
8
SKIN
9
10
11
12
13
14
15
Cement Casing Gravel Pack Sand Screen
Junior Production Engineering/Sand Control
High productivity requires: complete packing, large entry holes Pressure Drop (psi) Pack
Permeability
Flow Rate
3/8” Diameter
1/2” Diameter
3/4” Diameter
Material
(mD)
(bpd/perf)
Perforation
Perforation
Perforation
Formation
1,000
1
450
190
64
10
27,760
9,280
2,091
1
2
1
0.4
10
55
21
6
Sand 20/40 Mesh Gravel
119,000
0.888 L µ Q Q⎤ ⎡ 13 ∆P = + 9.1× 10 β L ρ ⎢ ⎥ KA ⎣ A ⎦
2
A= Perforation Cross-Sectional Area (ft 2) β= Inertia Coefficient (ft-1) ∆P= Differential Pressure (psi) K= Permeability (Darcies) L= Length Of Perforation (ft) µ= Viscosity (cp) Q= Flow Rate (bpd) ρ= Density Of Fluid (lb/ft3)
Junior Production Engineering/Sand Control
Use of Fluid Loss Control Material in Empty Perforations •
This should be avoided whenever possible.
Casing
•
Increased viscosity will decrease leakoff rate without halting it.
•
If leakoff completely stopped, perforations will not be able to be packed and it will be difficult to remove FLCM prior to prepacking.
•
Filtercake
Spearheading acid in front of prepack treatment may help re-establish initial leakoff rates.
Formation Cement
Junior Production Engineering/Sand Control
ICGP critical issue Ideal Wellbore
• Cased-Hole Gravel Packs still exhibit high skins • Improved Cased-Hole Gravel Packing methods have helped but have not solved problem • Implication is that perforations may not be completely filled with gravel and may not bypass the damaged zone
Damaged Zone
Actual Wellbore
Pumping Pressure < Fracture Pressure With Leakoff
Without Leakoff
Junior Production Engineering/Sand Control
Open Hole Gravel Pack – Slurry is injected down the workstring – The slurry crosses over to the annulus below the packer, depositing sand adjacent to the screen – The carrier fluid leaks off through the screen and is carried back to the surface via the washpipe and crossover tool, crossing back over to the casing-workstring annulus just above the packer
Junior Production Engineering/Sand Control
OHGP – General Procedure
• • • • • • • • •
Underreaming of the borehole Well site preparation Fluid filtration Killing and fluid loss control Bottomhole clean-up Running and setting GP assembly Gravel placement Running and setting completion string Well clean-up
Junior Production Engineering/Sand Control
Mechanism of Bore Hole Collapse Clay
Fluid Loss
Filter Cake
Pov
Sand Uncontroll ed Fluid Loss if BRINE or HEC (linear pol ymer) are used
Coll apse due to aqueous fluid - clay interactions
Controlled Fluid L oss improves Bore Hole stability
Modi fications of Rock Mechanical Prop erti es and Stress in-situ Equi lib riu m are responsib le for Bore Hole Collapse. Swelling alone does not explain the behavior of this kind of rock. Junior Production Engineering/Sand Control
OHGP vs. ICGP •
Due to its large flow area the OHGP has a better inflow performance than ICGP
•
The difference between the OHGP and the ICGP deliverability can be negligible at low rates but it becomes more marked at high rates
•
The difference between OHGP and ICGP deliverability increases as kh increases
•
The high deliverability of the OHGP can be wasted due to completion constraints (small tbg ID, high FTHP…): in this case ICGP can be more convenient
•
Pressure losses due to incomplete filling of perfs are negligible for high permeability formations whereas they are extremely high in low permeability formations
Junior Production Engineering/Sand Control
Important Factors for Gravel Placement • Washpipe size – Must keep area outside the screen larger than area inside the screen; especially in deviated wells where is much easier to create sand bridge • Return Flow Rate – Sufficient to keep an annular velocity of at least 1 ft/sec at end of screen (turbulence helps to suspend sand particles, annular velocity must kept less than 2.77 ft/sec to minimize turbulent effects) • Low-viscosity carrier fluids result in high-quality gravel pack in nearly all situations • For cased-hole completions, high fluid loss rates and prepacking both have positive effect
Junior Production Engineering/Sand Control
Gravel Pack Techniques
(I)
• Slurry Pack
– Cased or open hole completions – Typically used in very high permeability formations – The carrier fluid is viscosifed – Sand concentrations can range from 3 to 15 ppg • Water Pack – Cased or open hole completions, horizontal wells – Typically used in low permeability formations – Brine or slightly viscosifed brine – 2 bpm of Returns required – Lower sand concentrations required – Very good annular packing technique
Junior Production Engineering/Sand Control
Gravel Pack Techniques
(II)
• High Rate Water Pack
– Water or slightly viscosifed water – Higher rates required to fill perforations and create numerous mini-fracs into the formation in high permeability wells • Typically 5-10 bpm or 1 bpm per 10 ft of perforations – Sand concentrations 0.5-4 ppg – Additional Surface Equipment is required
Junior Production Engineering/Sand Control
Gravel Pack Techniques
(III)
Frac-Packing is a general term applied to the process of combining a hydraulic fracture with a gravel pack.
STANDARD
FRAC-PACK
GRAVEL PLACEMENT PPfrac
The main purpose is to provide the optimum combination of productivity improvement through damage bypass, and well life improvement through effective sand control
Kf
Junior Production Engineering/Sand Control
FracPack Technique – Used to bypass damage in the near wellbore area – Mini-Frac used to gather data about the formation to fine-tune the Frac design – Short (10 < L < 100 ft), Wide Fracs – Tip Screen-out designed to widen the frac and allow a high sand concentration at the wellbore
The process of injecting a slurry of gravel (proppant) and a fluid into the formation, faster than the formation can accept it.
Junior Production Engineering/Sand Control
FracPack: Step Rate Test •
Preliminary Test: – Step Rate Test (generally with brine) • Fracturing pressure • Propagation pressure • Closure pressure
SRT
BHP
Frac Extended Frac Matrix Injection Rate
P
Break Down
P Ppropag
Frictions
PNET
ISIP
PBreakDown = 2 ( /(1- ))( o- p) + PBreakDown = 2 ( o- p) + p PClosure = ( /(1- ))( o- p) + p
Pclosure
p
values:
[ mud ] [ brine]
0.28 (average)
theoretical: from the lab: Adriatic Sea:
Time
o
0-0.5 0.22-0.33 0.25-0.35
= sigma overburden = sigma pore = Poisson’s coefficient
p
Junior Production Engineering/Sand Control
FracPack: PClosure e Leak Off •
Preliminary Test: – Injection Test (with carrier fluid) • leak off coefficient (from fall-off)
Junior Production Engineering/Sand Control
Tip Screen Out Hydraulic Fracturing
An advanced hydraulic fracturing process designed to intentionally deplete the pad and have the slurry bridge on the perimeter of the fracture, locking the fracture length and height.
Slurry injection is continued to balloon the fracture creating a very wide, (1”) highly conductive fracture to by-pass near wellbore damage in high permeability formations. Junior Production Engineering/Sand Control
FracPack Final Design and Execution • Frac model calibration by measured data from Step Rate Test and Injection Test (P frac, Pc, Ct) • Main Treatment: – Pumping of designed treatment • Changing of the pumping parameters if TSO is not achieved (pump rate reduction, open return flow) • Fall off to close the fracture • POOH workstring and RIH completion tubing string • Clean up
Junior Production Engineering/Sand Control
Barbara C 24 Liv ello Q HRWP Tbg Pressure
Annulus Pressure
Mix Ratio
Flow in
Return
2200
11
2000
10
1800
9
1600
8
1400
7
) i s p 1200 ( e n o i s s 1000 e r P
6 5
80 0
4
60 0
3
40 0
2
20 0
1 0
0 14.52.48
15.07.12
15.21.36
15.36.00
15.50.24
16.04.48
16.19.12
Time (hh:mm:ss)
Junior Production Engineering/Sand Control
16.33.36
ENI - DIVISIONE AGIP, Adriatic sea, Barbara C - Well 24 - level O-O1 Frac Pack
1200
12
1000
10
800
8
) i s p ( e n 600 o i s s e r P
6
400
4
200
2
0
0 1 4 : 1 2 : 7 0
9 0 : 3 2 : 7 0
7 3 : 4 2 : 7 0
5 0 : 6 2 : 7 0
3 3 : 7 2 : 7 0
1 0 : 9 2 : 7 0
9 2 : 0 3 : 7 0
7 5 : 1 3 : 7 0
5 2 : 3 3 : 7 0
3 5 : 4 3 : 7 0
1 2 : 6 3 : 7 0
9 4 : 7 3 : 7 0
7 1 : 9 3 : 7 0
5 4 : 0 4 : 7 0
3 1 : 2 4 : 7 0
1 4 : 3 4 : 7 0
9 0 : 5 4 : 7 0
7 3 : 6 4 : 7 0
5 0 : 8 4 : 7 0
3 3 : 9 4 : 7 0
1 0 : 1 5 : 7 0
9 2 : 2 5 : 7 0
7 5 : 3 5 : 7 0
5 2 : 5 5 : 7 0
3 5 : 6 5 : 7 0
1 2 : 8 5 : 7 0
9 4 : 9 5 : 7 0
7 1 : 1 0 : 8 0
5 4 : 2 0 : 8 0
3 1 : 4 0 : 8 0
1 4 : 5 0 : 8 0
9 0 : 7 0 : 8 0
7 3 : 8 0 : 8 0
5 0 : 0 1 : 8 0
3 3 : 1 1 : 8 0
1 0 : 3 1 : 8 0
9 2 : 4 1 : 8 0
7 5 : 5 1 : 8 0
5 2 : 7 1 : 8 0
3 5 : 8 1 : 8 0
1 2 : 0 2 : 8 0
9 4 : 1 2 : 8 0
7 1 : 3 2 : 8 0
5 4 : 4 2 : 8 0
3 1 : 6 2 : 8 0
1 4 : 7 2 : 8 0
Time (hh:mm:ss) Tbg pressure
Annulus pressure
Rate
Mix ratio
Junior Production Engineering/Sand Control
9 0 : 9 2 : 8 0
) a p p ( o i t a R x i M ; ) m p b ( e t a R
Points to Consider When Designing a Fracture Treatment • The purpose of a hydraulic fracture is different in hard, low-permeability formations than in soft high-permeability formations
– Low-perm formations require long fractures for stimulation – High-perm formations require short fractures for damage bypass • The goal of the fracture treatment must be considered early in the design • Fluid selection should match application
Junior Production Engineering/Sand Control
FLOW EFFICIENCY 100
Total 26
Total 25
Range
Range
80 % E60 F e g a r 40 e v A 20
70-114
Total 22
80-97
Range
20-90
0 FRAC-PACK
ICGP
OHGP Junior Production Engineering/Sand Control
Clean Times & Performances 1.2
CF 100%
ICGP FracPack 1.0
y a p t e n / I P o d u e s P
TCP
OHGP
0.8
CF=85-100% 0.6
ICGP 0.4
CF=30-50% 0.2
0.0 0
100
200
300
400
500
600
700
800
900
1000
1100
Flow period (dd) Junior Production Engineering/Sand Control
GRAVEL PACKING: Possible Alternatives •ICGP (Saucier’s Criteria for gravel size, better if even smaller) – suitable for high perm, homogenous sands – no damage inside tunnels and into formation sand
•OHGP
(Saucier’s Criteria)
– recommended for: • high productivity wells • laminated reservoir – requires DIF for drilling and underreaming (no damage) – requires stable boreholes
•ICGP-F&P (TSO, gravel selection with bigger sizes) – recommended for laminated reservoirs – suitable for deep damage by-pass – TSO recommended for maximum productivity, and LONGEVITY
Junior Production Engineering/Sand Control
Gravel Pack Techniques
(IV)
• Horizontal Gravel Packing
– – – – – – – – –
Pump Rate and Fluid Velocity (2-4 bpm, 1-3 ft/sec) Alpha and Beta Wave Progression Through Pack Sand Concentration (0.5 - 2 ppg) Placement Procedure and Tool Configurations Liner / Tailpipe Ratio (> 0.80 ratio) Screen / Casing Clearance Screen / Open Hole Clearance Perforation Phasing Shunt tube technique
Junior Production Engineering/Sand Control
Horizontal Gravel Packing
Typically open hole
Must maintain adequate filter cake
Must have ability to remove filter cake after gravel placement
• • •
Dune Height /Hole ID = .65 - .85 Washpipe OD / Screen ID = .8 Superficial Velocity 1 ft/sec - Return Rate
Junior Production Engineering/Sand Control
Typical Well GP Configuration S. V. S. V.
S. V.
CSG size 7”
CSG size 9" 5/8
NO SAND CONTROL SHORT SELECTIVE STRING
ICGP
ICGP
ICGP
F V.C
SHORT STRING
ICGP CASING SHOE
OHGP
LONG SELECTIVE STRING
LONG STRING
ICGP
OHGP
CASING SHOE
Junior Production Engineering/Sand Control
Gravel Pack Stacked Completions RIH GUNS
PERFORATING
SCRAPER /
RIH AND SET "D" PKR
LAYER "A"
TAPER MILL
WITH TUBING / E-LINE
Junior Production Engineering/Sand Control
Gravel Pack Stacked Completions RIH GP ASSEMBLY
PERFORM HRWP
(cont)
RIH PKR PLUG
LEVEL "A"
Junior Production Engineering/Sand Control
Gravel Pack Stacked Completions SET PKR PLUG & PERFORM SAND PLUG
RIH GUNS
(cont)
PERFORATE LEVEL “B"
Junior Production Engineering/Sand Control
Gravel Pack Stacked Completions
(cont)
RIH RET.PKR PLUG and
RIH GP ASSY
SET PKR PLUG &
RETRIEVE IT
w PROD TBG FOR LEVEL A
PERFORM HRWP
Junior Production Engineering/Sand Control
Unconsolidated Sands Completion Criteria NEW WELLS SAND CONTROL DECISION TREE
YES
MULTI-ZONE COMPLETION NO
NO LOWEST ZONE COMPLETION
YES
YES
D50 FORMATION SIZE < 55 µm
NO
YES
YES RES. FLUID CONTACTS DEFINED
NO GEO-SECT. DEFINED
NO
FINES MIGRATION?
YES
NO
YES MULTYLAYERED NO NO
YES
ACTIVE SHALES
SHALES CAN BE ISOLATED OR STABILIZED
NO
YES NO PAY-ZONE > 25 ft vert YES
OPEN HOLE COMPLETION
CASED HOLE COMPLETION
Junior Production Engineering/Sand Control
Open Hole Sand Control Completion YES
YES
GAUGED HOLE
FORMATION GRAIN SIZE - D10> 150 microns
NO
NO
MAXIMISE
NO
COMPLETION ID
YES
ZONAL ISOLATION REQUIRED
NO
YES
YES NO
OPERATING WINDOW BETWEEN PORE PRESSURE AND Pfrac > 600 psi
CASING SHOE APPROPRIATELY SET
Available: •No damaging DIF •Effective matrix stimulation (back-up)
NO
YES
REMEDIAL J OB
EXPANDABLE SYSTEM
OPEN HOLE GRAVEL PACK
Junior Production Engineering/Sand Control
Cased Hole Sand Control Completion
Junior Production Engineering/Sand Control
Through Tubing Gravel Packs or Fracs Sanded up completion
Sand wash
Run Screen on Coil
Junior Production Engineering/Sand Control
Through Tubing Gravel Packs or Fracs (cont.) Release Screen from Coil
Fracture or GP Treatment
Sand wash
Junior Production Engineering/Sand Control
Through Tubing Gravel Packs or Fracs (cont.) Produce Well
>50’
Junior Production Engineering/Sand Control
Typical Screen Dimensions For 2 7/8” Tubing
For 2 3/8” Tubing
0.957” I.D. x 1.63” O.D. 1.38” I.D. x 2.16” O.D.
Junior Production Engineering/Sand Control
Flow Profiles Q
P
V
Rate (Q) BOPD
P Through Blank PSI 0.84
Velocity Through Pack Ft/Min 0.0016
144 288
2.83
V
Fluid
0.0055
P 432
5.80
0.0111
576
9.68
0.0185
720
14.4
0.0277
1440
49.8
0.0924
2160
103.4
0.196
For sand production, upward annular velocity must overcome sand settling velocity. Maximum upward velocity never exceeds 5% of this value in this case.
Q
40/60
µ = 1 cp
100’
Settling Velocity Ft / Min 20/40
12.6
40/60
4.0
7 5/8” Csg. Junior Production Engineering/Sand Control
Definition of Sand Consolidation •
Plastic Consolidation - is a method of stopping sand
production
by
artificially
bonding
the
formation sand grains into a consolidated mass. A liquid resin is pumped through the perforations and into the pore spaces of the formation sand. Excess resin is removed either by overflushing the resin or by phase separation. The resin coats the sand grains and then hardens to hold the sand in place. •
Typically utilized in wells that have not previously produced sand.
Junior Production Engineering/Sand Control
Conditions favoring consolidation • Short Interval • Lack of previous sand production • Upper zone of multiple completion • Limited sand production tendency • High reservoir pressure • Good sand quality with vertical permeability
Junior Production Engineering/Sand Control
Unconsolidated zone to be treated
Junior Production Engineering/Sand Control
Preflush Stage Preflush fluid is applied to condition the formation to accept resin .
Junior Production Engineering/Sand Control
Resin Stage Low viscosity resin with an affinity for silica surfaces coats each individual grain of sand.
Junior Production Engineering/Sand Control
Spacer / Overflush Stage A spacer fluid is pumped down to remove excess resin from sand, dilute the resin, and carry it into the formation.
Junior Production Engineering/Sand Control
Catalyst Stage
The hardening catalyst is pumped through the matrix of resin-wet sand, instantly beginning the hardening process.
Junior Production Engineering/Sand Control
Resin Coated Sand
• Single stage mechanical filter technique • Thermoset resin • Uses API specification gravel pack sand consolidated with resins • Filters out the formation sand in the perforation tunnels and behind casing
Junior Production Engineering/Sand Control
Application of Resin-Coated Sand Slurry Cement Sheath
Formation
Casing
Liquid Resin-Coated Proppant Entering Perforation and Filling Casing
Liquid Resin-Coated Proppant During Placement Junior Production Engineering/Sand Control
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