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Mahdi Mahmoudi and Vahidoddin Fattahpour, RGL Reservoir Management; Arian Velayati, University of
Alberta; Morteza Roostaei and Mohammad Kyanpour, RGL Reservoir Management; Ahmad Alkouh, College of
Technological Studies; Colby Sutton and Brent Fermaniuk, RGL Reservoir Management; Alireza Nouri, University
of Alberta
This paper was prepared for presentation at the SPE International Heavy Oil Conference and Exhibition held in Kuwait City, Kuwait, 10-12 December 2018.
This paper was selected for presentation by an SPE program committee following review of information contained in an abstract submitted by the author(s). Contents
of the paper have not been reviewed by the Society of Petroleum Engineers and are subject to correction by the author(s). The material does not necessarily reflect
any position of the Society of Petroleum Engineers, its officers, or members. Electronic reproduction, distribution, or storage of any part of this paper without the written
consent of the Society of Petroleum Engineers is prohibited. Permission to reproduce in print is restricted to an abstract of not more than 300 words; illustrations may
not be copied. The abstract must contain conspicuous acknowledgment of SPE copyright.
Abstract
Sand control and sand management require a rigorous assessment of several contributing factors including
the sand facies variation, fluid composition, near-wellbore velocities, interaction of the sand control with
other completion tools and operational practices. A multivariate approach or risk analysis is required to
consider the relative role of each parameter in the overall design for reliable and robust sand control. This
paper introduces a qualitative risk factor model for this purpose.
In this research, a series of Sand Retention Tests (SRT) was conducted, and results were used to formulate
a set of design criteria for slotted liners. The proposed criteria specify both the slot width and density for
different operational conditions and different classes of Particle Size Distribution (PSD) for the McMurray
oil sands. The goal is to provide a qualitative rationale for choosing the best liner design that keeps the
produced sand and skin within an acceptable level. The test is performed at several flow rates to account for
different operational conditions for Steam Assisted Gravity Drainage (SAGD) and Cyclic Steam Stimulation
(CSS) wells. A Traffic Light System (TLS) is adopted for presenting the design criteria in which the red
and green colors are used to indicate, respectively, unacceptable and acceptable design concerning sanding
and plugging. Yellow color in the TLS is also used to indicate marginal design.
Testing results indicate the liner performance is affected by the near-wellbore flow velocities,
geochemical composition of the produced water, PSD of the formation sand and fines content, and
composition of formation clays. For low near-wellbore velocities and typical produced water composition,
conservatively designed narrow slots show a similar performance compared to somewhat wider slots.
However, high fluid flow velocities or unfavorable water composition results in excessive plugging of the
pore space near the screen leading to significant pressure drops for narrow slots. The new design criteria
suggest at low flow rates, slot widths up to three and half times of the mean grain size will result in minimal
sand production. At elevated flow rates, however, this range shrinks to somewhere between one and a half
to three times the mean grain size.
2 SPE-193697-MS
This paper presents novel design criteria for slotted liners using the results of multi-slot coupons in SRT
testing, which is deemed to be more realistic compared to the single-slot coupon experiments in the previous
tests. The new design criteria consider not only certain points on the PSD curve (e.g., D50 or D70) but also
the shape of the PSD curve, water cut, and gas oil ratio and other parameters.
Keywords: Screen aperture size, Skin Factor, Open area to flow, Plugging tendency, Slotted liner design
criteria
Introduction
Sand control is a major concern in reservoirs, which contain unconsolidated sands. Slotted liners have been
the completion method of choice in many cases due to their low cost, ease of use, and excellent performance
(Fattahpour et al., 2016a&b)
Sand control selection, design, and evaluation are at the heart of completion design for wellbores in
unconsolidated and weakly consolidated sand reservoirs. Mahmoudi et al. (2016a; 2018a,b,c) discussed
two completion design approaches for sanding: (1) sand control where the well completion is designed to
avoid sand production; and (2) sand management a finite amount of sand production is allowed or even
encouraged but is now allowed to exceed levels that go beyond the tolerance of the wellbore and surface
facilities to continuous sand production.
Sand management has emerged as completion and operating strategy to overcome the deficiencies of
conventional sand control measures relying on sand exclusion (Mathis, 2003; McKay et al., 2008; Tronvoll
et al., 2001). There are several fields/wells where the sand exclusion cannot be applied or is very expensive
to execute (Gonzalez et al., 2014; Hussain and Gruening, 2008; Tugimin et al., 2018). In this approach,
detailed monitoring of the sand influx, fluid rate, and phase ratios along with reliable analytical and physical
models are used to manage the consequence of sand production (Rawlins, 2013; Tronvoll et al., 2001).
Over the last decade, sand management methodologies have been developed and successfully applied in
the field, which proves they are practical and economical approaches (Rawlins, 2013). Sand management
mitigates the formation damage and enhances wellbore productivity. The enhancement is attributed to the
self-cleanup associated with the episodic sand spurts that remove the sand within the damaged zone around
the wellbore and enhances near-wellbore permeability (Vaziri et al., 2000). Several researchers discussed
that the removal of the damaged zone in the near-wellbore region and the ensuing higher permeability is
the primary contributor to the higher productivity indices.
A good sand management must include the following components: (1) Prediction of the sanding initiation
to describe the conditions associated with the sanding onset; (2) quantitative sand rate modeling in relation
to fluid flow rates, downhole GOR, and water cut; (3) a good estimation of the sand transport from
the production point to the surface facility, sand accumulation and potential of wellbore fill up or other
completion component clogging by sand; (4) the sanding-induced erosion risk in the downhole completions
components, tubular, wellhead and surface facilities; and (5) a surface facility that can handle the volume
of the produced sand to separate the sand/silt particles from produced fluids by using hydrocyclone de-
sander, settlement tank in their production separator, or filters for solid separation. The surface facility must
allow the separated solids to be removed from the production facility safely and be removed from process
pressure and flow through the use of hydrocyclone accumulator, vessel drain, or sump tank. Once the sand
is removed, the adsorbed hydrocarbon and formation fluids are removed from the collected sand before the
sand is hauled away from the facility (Rawlins et al., 2000; Rawlins, 2013; Wilson, 2013).
A proper sand management approach requires the consideration of the components above in the overall
design of the well completion, wellhead, and production facility. One element of the sand management
framework is risk analysis. The next section discusses the application of risk assessment models and
introduces the risk modeling in the design of sand control screens as a part of the sand management system.
SPE-193697-MS 3
Methodology
This paper focuses on determining slot aperture and density for slotted liners to illustrate the proposed design
framework. The criteria are developed based on a series of sand retention tests (SRT) tests with different
PSD's in the McMurray Formation. The testing program used slotted liner coupons with different slot widths
and slot densities (Mahmoudi et al., 2016a,2016b, 2016c, 2017a, 2017b). The Traffic Light System (TLS)
is utilized as a quantitative risk indicator to determine the acceptable, marginal or unacceptable design.
consider 0.12-0.15(lb)ft2 for the produced sand as the maximum allowed (Hodge et al. 2002; Chanpura et
al. 2011).
In the TLS system, the green color signifies acceptable sanding when sanding is below 1% of the liner
volume for transient sanding. For continuous sanding, a limit of 5 gr/bbl has been suggested (2850 ppm, 11
lb per thousand bbl), although this seems to be inapplicable to SAGD wells due to inadequate sand transport
(Mahmoudi et al., 2016d).
The red color in the TLS signifies unacceptable sand production as it excesses 1% of the liner volume. The
red color is also assigned to continuous sand production in SAGD. The red color indicates an extreme risk
due to sand production as it can fill the liner and hampers productivity and can also damage the artificial lift
system. Table 1 recaps the TLS color coding with respect to sanding for defining the safe slot width window.
Table 1—TLS color code definition for sand production and flow performance
Maximum Acceptable Plugging. Conventional sand control installations result in higher pressure drops
than the open hole. The selection of the sand control requires the consideration of the best sand control
6 SPE-193697-MS
product that not only reduces the solid production but has the least flow impairments (pressure drop). The
flow impairment is related to the flow convergence, and near-wellbore velocities. The flow convergence
and the complex flow dynamics near the wellbore could lead to near-wellbore plugging or the corrosion/
fouling which in turn leads to the screen/liner aperture plugging.
Furui et al. (2007) described the near-wellbore area skin consists of a flow-dependent term and a flow-
independent term. The flow dependent term is caused by flow convergence which changes the near-wellbore
flow velocity and geometry while the flow-independent part is caused by pore plugging, sand retention on
the screen, and the additional pressure drop within the slots/screen aperture.
Commonly for open slots, the pressure drop inside unplugged slots is negligible while the pressure drop
of partially or fully plugged slot may be significant. This high-pressure drop is partly caused by the high
convergence velocity, and mainly because of the restriction imposed on the flow as a consequence of the
low permeability. The pressure drop in the plugged slot will increase the overall pressure drop due to flow
across the sand control product.
Retained permeability (Markestad et al., 1996; Ballard et al., 1999) has been commonly used to describe
the additional pressure drop caused by the sand control device. Retained permeability is the ratio of
the screen permeability to the formation permeability. Ideally, screen permeability should be similar to
the formation permeability which indicates the installation of the screen has no effect on the wellbore
productivity. Previous researchers assigned 50% retained permeability as the lowest acceptable permeability
(Markestad et al., 1996).
The TLS system assigns the green color for flow performance for retained permeability above 75%,
yellow color for retained permeability between 50 and 75%, and red color for less than 50% retained
permeability.
Figure 2—Linear axis illustration of the PSD and slot sizes in SRT tests, (a) DC-II (b) DC-III
SPE-193697-MS 7
Figures 3a and 3b show the color-coded design window for the slot density of 30 SPC on a 7" pipe for
DC-II. Figure 3a presents the sanding performance in the upper axis section and the flow performance in
the axis lower section. Figure 3b combines the two previous windows to present the combined slot window.
Likewise, the sanding and flow performance for two more SPC values (42 and 54) are presented in Figs.
4a through 5b for DC-II, and Figs. 6a through 8b for DC-III.
Figure 3a—Sanding performance (top section) and flow performance (bottom section) for DC-II, SPC=30
Figure 4a—Sanding performance (top section) and flow performance (bottom section) for DC-II, SPC=42
Figure 5a—Sanding performance (top section) and flow performance (bottom section) for DC-II, SPC=54
Figure 6a—Sanding performance (top section) and flow performance (bottom section) for DC-III, SPC=30
Figure 7a—Sanding performance (top section) and flow performance (bottom section) for DC-III, SPC=42
Figure 8a—Sanding performance (top section) and flow performance (bottom section) for DC-III, SPC=54
It is obvious from the overall performance slot window for the two PSDs (DCII and DCIII) that increasing
the slot density leads to a wider safe slot selection. This illustrates the shortcoming in the existing evaluation
and design protocols that are independent of the slot density.
Conclusions
This paper presents a risk model for the selection of optimal sand control. A set of new design criteria
are introduced for the selection of slot width and density for slotted liners. This new approach combines
multiple variables such as sand facies variation, slot density, slot width, flow rate, and sanding mode. The
TLS design approach was applied to the results of SRT physical testing on different types of sand facies.
The design criteria provide slot window which is bounded by a higher limit decided by sand production.
In other words, increasing the slot width beyond the upper bound results in unacceptable levels of sand
production. The lower bound is related to the flow performance. Any further reduction of the slot width
below the lower bound results in significant pressure drops and higher than acceptable skin build-up.
Physical testing and field results show that wider slots- within the slot window- and higher slot densities
result in superior liner performance. Further, the slot window is vastly sensitive to operational variables such
as flow rate. It is found that the slot window becomes narrower as the flow rate increases. The model could
be further expanded by formulating a more complex DRA and including the field monitoring of the pressure
and sanding rate in the model and incorporating the historical data from nearby fields in the assessment.
Acknowledgement
The authors would like to acknowledge the funding by NSERC through their CRD program and RGL
Reservoir Management for their financial and technical support and permission to publish the paper.
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