Sand Control

Quartz School for Well Site Supervisors
Module – 12
Well Completions
Schlumberger Private
Section – 3
Sand Control Completions
Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions
1/71
Outline
y Sand Control Market
y What is Sand Production
y Problems with Sand Production
y Sand Production Mechanism
y Factors Affecting Sand Production
y Sand Production Prediction
y Sand Control Methods
2/71
What is Sand Production?
y Sand Production refers to the Production of solid particles
which support the overburden
y The Rock needs to fail for Solids to be produced
y Fines Particles are NOT sand production
y not considered part of the mechanical structure of the
formation
y Once the destabilizing forces overcome the formation

strength, the rock will fail.
y Sand production will follow if sand can be transported.
Solid production in excess of 0.1% by Volume is considered

excessive and should be controlled
3/71
Favorable Conditions
y Young and Shallow Reservoir Rock
y Unconsolidated with Compressive Strength < 1000 psi
y Permeability
y 0.5 to 8 darcies
4/71
Sand Problems
y Sand Disposal
y Casing / Liner Failure
y Sand Erosion
y Sand Bridges
5/71
Sand Disposal
y Even wells with successful sand control measures will
produce small quantities of sand. In offshore installations,
where several wells produce into a common platform, this
may be critical.
y Sand must be first separated from the produced fluids and
all oil removed prior to disposal.
y Sand Separation
y Disposal
y Can not be dumped overboard
y Must be trucked away
y Classified as NORM (Natural Occurring Radioactive Material)
6/71
Casing / Liner Collapse
Failure may occur due to :
y Non uniform lateral loading
as rock is produced.
y Cavities or voids behind
casing are formed
y High axial compressive
load due to slumping of the
overlying casing-bearing
formation.
7/71
Sand Erosion
Sand production can cause erosion in both surface and
downhole equipment such as :
Downhole Surface
Blast Joints Chokes
Gas lift Equipment Elbows / Tees
Standing Valves Swages
Pumps Valves
Safety Valves Metering Devices
Circulating sleeves Flanges
Nipples Wellhead
Tubulars
8/71
Sand Erosion Cont’d
9/71
Sand Bridges
y Bridges may form in casing
or tubing and obstruct well
flow.
y Causes
y Sand fall back over time
y Increase in water
production
y Fluid Velocity too low
y They must be removed by
bailing or washing with
Coiled Tubing
y If bridging is severe sand
control will be required.
10/71
Sanding Mechanisms
Sand Structure
Failure Mechanism
Sand Transportation
11/71
Sanding Mechanism
In weak but consolidated formations:
Stage 1 Stage 2
Failure Transportation
Failure of reservoir
rock due to shear Transportation of
stresses (failure of failed material due
bonds between to flow
grains)
If we can predict and prevent Stage 1, we do not need to worry about Stage 2!
12/71
Consolidation
Same problem, different mechanism Ædifferent solutions
Unconsolidated Consolidated
Zero strength Very very weak Very weak Consolidated
Dry sand Damp sand Weakly-cemented Stronger cement
high Φ lower Φ
13/71
Sand Structure Cementation
Overburden
Pore
Pressure
• Structure of Sand Grains
• Packed together by Overburden
Stress
• Additional support from Pore
Pressure
• Sand Grains kept in place by
cementing material
14/71
Conditions for Rock Failure
Forces holding the Rock Forces trying to fail the Rock
Structure together Structure
y Intergranular bonds y Differential Pressure
(cementation) between Reservoir and
y Pore Pressure Wellbore
y intergranular friction y Drag forces related to Fluid
y Gravity Viscosity
y capillary forces y Drag forces related to Fluid
Velocity
15/71
Sand Transportation
y In most sand formations, fines particles are water-
wet and move with the water phase.
y No water production – No, or little sand Production
16/71
Triggering Sand Production
y Sand Production is very much
related to fluid production
y Even better consolidated
formations can produce sand
y Production Rate Fluctuations
y Drawdown changes
y Onset of water production
y Change in Oil/Water ratio
17/71
Time Dependence
Reservoir Depletion
y Reduction in Pore Pressure
Increase in Water Production
y Dissolve natural cementing material and weaken bonds
y Change capillary pressures
Formation Permeability Reduction

y Fines migration
y Paraffin and asphaltenes deposits
y Increase in Drag Forces
18/71
Sand Production Prediction
19/71
Sand Production Prediction
y Experience
y Special Well Test
y Core Inspection and Testing
y X-Ray, SEM
y Flow Tests
y Uniaxial and Triaxial Compressive Strength Measurements
y Log Interpretation
y No direct measurements of Rock Strength. Calculations from
Sonic, Density and Neutron Logs
y IMPACT
y Simulator which uses data from DST, Well Tests, Core Analysis
and Logs
20/71
Flow Tests
POverburden
P2 P1
21/71
Conventional Sand Strength Analysis Rock Mechanics
Poisson’s Ratio (PR) was

calibrated to validated core
data
Young’s Modulus (YME) was
calibrated to validated core
data
Uniaxial Compressive Strengt
(UCS) was calibrated to
validated core data
Minimum Horizontal Stress
was calibrated to mini frac
closure gradient
Tensile and Shear failure

prediction
Sanding Tendency is
higher if both failures
are close to each
other
22/71
Formation Stress Logging
“New Direction in Sonic Logging”, Oilfield Review, Spring 1998 p40
SWA
23/71
Rock Classification
Term BHN Remarks
Unconsolidated <2 No cementing material
Partially 2-5 Crushed with fingers
Friable 5 - 10 Crushed when rubbed
Consolidate 10 - 30 Crushed with force
Hard > 30 Can not be broken with force
Medium Hard 30 - 50
Hard 50 - 125
Very Hard > 125
(BNH - Brinell Hardness Number)
24/71
Sand Control
Although some fines are probably always produced in any
well, in sand control we mean control of the
LOAD BEARING SOLIDS
25/71
Completion Options
y No Shocks to the System
y Keep System as stable as possible
y Restrictive Production Rate
y Limit drawdown
y Selective and Oriented Perforating

y Selective perforations placed in the strongest
formation (based on logs)
y Perforate in direction of maximum stress
y Implications to Production
26/71
Sand Control Methods
In Situ Consolidation
y Resin Injection into the formation
Resin Coated Gravel
y Placement of a “Filter” in the wellbore without the use of
screens
Screens - Natural Sand Packing
y Placement of Screens in the wellbore without the use of Gravel
Gravel Pack
y Placement of Screens and Gravel
27/71
In Situ Consolidation
y Resin material is pumped
into the formation.
y Most common resins are
Phenolic, Furan or Epoxy
y Resin is followed by a
Catalyst
y Resin “glues” formation
grain-grain into a
consolidated structure
y Compressive strength
>1,000 psi with 60-75%
retained permeability.
y Acid treatment prior to
treatment
28/71
Resin Coated Gravel
y Proppant ( Gravel ) is Resin
precoated with resin material.
y Particles are mixed with
viscous gel and squeezed into
the formation.
y A resin coated gravel plug is Gravel
left in the wellbore
y Particles are contacted grain-
to-grain.
y Temperature + H2O fuses the
particles together into a Formation
consolidated permeable, (Unconsolidated)
drillable network
y Low Cost, onshore
29/71
Resin Coated Gravel
y Resin coated particles are placed in the perforations and
wellbore.
y When cured a strong permeable synthetic sandstone
network is formed.
y
Drillable.
y Diversion to be considered.
y Main Well Services System : SANDLOCK V*
30/71
Slotted Liners & Prepacked Screens
y Sized to stop largest 10% of sand
y Friable formations only (BHN
from 5-10) with > 1 Darcy Perm.
y Unconsolidated formations will
cause liner or PP Screens to
quickly plug with fines
y Only 5 % of all Sand Control
completions
y Simpler to install
y Cheaper
y Larger effective inside diameter
compared to normal GP
31/71
Learning Points
y What is Sand Production
y Problems with Sand Production
y Sand Production Mechanism
y Structure
y Failure Mechanism
y Sand Transportation
y Sand Production Prediction
y Sand Control Methods
32/71
Gravel Packing
Completions with Gravel Packing
33/71
Overview
y Gravel Pack Principle
y Completion Types
y Gravel Pack Tools
y Systems
y Types of Deployment
y Placement of the Pack
y Job Design
y Schlumberger Products
and Services
34/71
Gravel Packing Principle
y Objective is to trap the Sand
Particles in the formation
y Leaving a Permeable Pack
allowing Fluid to enter the
wellbore
y
A sand screen is placed in front
of the producing interval
y The screen will stop particles
of a certain size
y Gravel is pumped in the annular
space and the perforation tunnel
y Gravel can not enter the
screen
y Larger sand grains will pack off
against the gravel
35/71
Which Size
Requirements for Long Term
Productivity
y Clean
y Tightly Packed
y No damage to Formation
y Minimize pressure drop in
perforations
Therefore
y Gravel as large as possible
y Filter out fines as small as
possible
36/71
The System
SG: Gravel: 6x-9x of Mean

Gravel / Proppant formation size.
100-500 Darcys
0.5 TO 0.75 D
Screen Gravel Casing Cement Reservoir
37/71
Completion Types
Natural Sand Pack
Open Hole Gravel Pack
Cased Gravel Pack
Expandable Screens
38/71
Completion Types
y Natural Sand Pack
y OH Gravel Pack
y Cased Hole Gravel Pack
y Expandable Screens
39/71
Natural Sand Pack
y screen is designed to contain
formation sand
y annular may be filled up with low
permeability sand pack,
reducing production
y
sand may cause screen erosion
or plugging
y not viable for cased hole
40/71
Natural Sand Pack Considerations
y NSP Erosion
y Formation particle flow velocity through the screen may cause
erosion
y Consequences are more severe in gas wells
y Increased formation particle flow velocity will occur due to
partial screen plugging
y NSP Plugging
y If not eroded, in a sand producing environment in which
particles are allowed to flow, the screen openings tend to plug
y Screens should be sized to allow the fines to produce
41/71
y Gravel pack will stabilize formation
y Screen will be protected from formation sand plugging and
erosion
y Annular will be packed with very high permeability particles
43/71
y Gravel is selected to contain the formation sand
y Size Screen to stop gravel or formation sand?
y Considerations based on NSP
y Gravel placement technique to be considered
y Water Pack versus Alternate Path
44/71
Open-Hole GP Considerations
y Can be under-reamed, increasing wellbore area.

y No damage due to poor perforation pack efficiency.
y Hole stability is a concern while drilling and completion.
y Horizontal completions
y Water production control may become impractical.
45/71
Cased Gravel Pack
y Ease to complete as selective
y Expensive perforation
y Difficult lower perforations cleaning.
y Difficult upper perforations packing
y Screen only have high failure rate
y 25% of GOM wells with stand-alone screens failed
46/71
Cased-hole GP Considerations
y Isolate production from undesirable zones.
y Reliable drilling and completion methodologies.
y Requires efficient perforation system.
y Poor perforation pack may lead to low productivity.
y Easier workover compared to EGP.
47/71
GP Tools
Sump Packer
Screens
Service Tools
GP Packer
49/71
Gravel Pack Packer
Remains in hole (QUANTUM*)
after Gravel Pack
operation Gravel Pack Extension
Large Bore Flapper Valve
Safety Shear Joint
Blank Pipe
Screen
Sump Packer
50/71
Sand Control Schematic
1. Wellbore Clean up
2. Install Sump Packer
51/71
3. TCP Perforation
52/71
4. RIH Screens and G.P.
Assembly
5. Gravel Pack Pumping
53/71
Service Tool and
Wash Pipe
Workstring
Service Tool
Wash Pipe
54/71
Circulating Position
y Service Tool is in Circulating Position
y Slurry pumped in Screen/Casing Annulus
y Washpipe pulled out of Seal Sub leaving leak-off path up the
screen
y Fluid leaks-off to formation or into screen
y Fill annulus and cover perforations
55/71
Service Tool Operations – Circ Position
QUANTUM Drill Pipe

Service Tool
QUANTUM
Packer
Slurry from Drill Pipe to
Service Tool, and out to
annulus
Clean Fluid (without gravel) flows
through Screen, Service Tool and
returns to Annulus and back to Surface
56/71
Squeeze Position
y Move down with Service Tool
y Service Tool in Squeeze Position
y Leak-off path back in screen is closed off
y Fluid can only leak-off to formation
y Gravel is squeezed in perforations
57/71
Service Tool Operations - Squeeze Position
58/71
Reverse Circulation
y Service Tool is set in Reverse Circulating position
y Fluid pumped down the Drillpipe/Casing Annulus
y Fluid Cross-Over and circulated back up the Drillpipe
59/71
Pull out of hole
after Gravel Pack
operation Workstring
Service Tool
Wash Pipe
60/71
Screens
61/71
6. Install Production Seals,
Tubing, GLM, and SCSSV
7. Install Well Head
62/71
GP Deployment
Rig
Coiled Tubing
Wireline
63/71
Gravel Pack Installation
y Hardware is installed with :
y Rig (most common)
y Coiled Tubing (Snub-in)
y Wireline
y Gravel is transported by fluid in slurry form.
64/71
Placing the Pack
Objectives
Methods
Well Trajectory
65/71
Objective
y To achieve maximum long-term productivity in cased hole,
gravel-packed completions, gravel must be tightly packed in
the perforation tunnels and in the screen - casing annulus.
y In open hole, the open hole-screen annulus must be packed
efficiently.
66/71
Gravel Placement Methods
y Gravel Pack
y 1-5 BPM – pumping gel + proppant at high concentration.
Typically (10-15 PPA)
y HRWP - High Rate Water Pack
y 5 to 15 BPM - pumping completion fluid with low concentration
gravel. Typically (1 to 2 PPA)
y Frac Pack
y 5 to 40 BPM - pumping gel with “ramped” concentration
gravel. Typically (.5 - 15 PPA)
y High Rates -----Æ Erosion, Burst , Collapse ( Stronger
Equipment Required)
67/71
Well Trajectory and Placement
Vertical Wells Deviated Wells

8
60 ° 7
6
5
4
3
21
Horizontal Wells
68/71
Products and Services
All Pack
PerfPAC
69/71
Advanced Technology in Schlumberger
y Alternate Path Service (APS)
y AllPAC* - for Gravel Packing
y AllFRAC* for “Frac & Pac”
y PERFRAC*
y Perforation and Gravel Packing in one trip
70/71
Alternate Path Shunt Design
y Small or large tubes depending
on flow rates and treating
lengths
y Eccentric or concentric design
y Stainless Steel construction
y Tungsten Carbide nozzle inserts
y
*Service Mark of Mobil Oil Corporation
* Service Mark of Mobil Oil Corporation
Transport-Packing tube
arrangement
AllPack Animation
71/71

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Quartz School for Well Site Supervisors

y Once the destabilizing forces overcome the formation

Solid production in excess of 0.1% by Volume is considered

In weak but consolidated formations:

y Intergranular bonds y Differential Pressure

Increase in Water Production

Formation Permeability Reduction

Poisson’s Ratio (PR) was

Tensile and Shear failure

“New Direction in Sonic Logging”, Oilfield Review, Spring 1998 p40

(BNH - Brinell Hardness Number)

y Restrictive Production Rate

y Selective and Oriented Perforating

SG: Gravel: 6x-9x of Mean

Screen Gravel Casing Cement Reservoir

y Natural Sand Pack

y Can be under-reamed, increasing wellbore area.

Large Bore Flapper Valve

QUANTUM Drill Pipe

Vertical Wells Deviated Wells

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