You are on page 1of 88

G

Sand Prediction and Sand Control


Giuseppe Ripa

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 1 of 88

Map of Sand Producing Areas

Usually associated with younger Tertiary formations such as the Miocene or Pliocene Age Sands
Approximately 70% of the worlds 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 ]

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 2 of 88

Sand Problems in ENI-E&P and Sand Completions


OIL FIELD

GAS FIELD

GAS STORAGE FIELD

West Africa & GOM

On & Off-Shore Italy

On-Shore Italy

Sand

Thin Sand-Shale
Interbeds

Sand-Shale Interbeds

Reservoir Depth

500-4800 m

600-3500 m

1200-1700 m

Formation Sand
Size

30-350 m

20-150 m

50-150 m

200-8000 mD

20-500 mD

200-2000 mD

Lithology

Permeability

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
1976 1978 1980 1982 1984 1986 1988 1990 1992 1994 1996 1998 2000 2002 2004

Year

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 3 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 4 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 5 of 88

Forces Contributing to Sand Production

Pore pressure relieves frictional forces


Production of wetting phase reduces
capillary pressure forces

Oil and
Water Flow

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 6 of 88

What causes sand production?

Totally or weakly unconsolidated formations

Changing stresses in the near wellbore area

Water Production

Overburden
Cementing
Capillary
Drag

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 7 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 8 of 88

Detecting sand production


Erosion of Equipment
Acoustic Detectors
Sand Traps/Desanders

Fluenta Acoustic Sand Detector

Sand Probe

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 9 of 88

Predicting sand production

Experience in the area


Offset well production data
Drilling data
Core sample evaluation
Sand Flow Test
Logs
Computer modeling

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 10 of 88

Predicting Sanding Potential


220

PERFS CLEAN-UP
D50=40- 60 m

200
180

FINES REMOVAL
D50=3 - 7 m

CONTINUOUS
SAND
INFLUX
D50=18 m

2/16"

160

3/16"

140

9/16"

6/16"

4/16"

S=

5/16"

-17

10/16" 11/16"
120

12/16"

8/16"

CHOKE SIZE

=0

80

100

S=

BOTTOM HOLE PRESSURE (kg/cm2)

SAND FLOW TEST RESULTS

80
0

50

100

150

200

250

300

GAS FLOW RATE (ksm3/d)

FORMATION SAND : D50 = 22 - 44 m

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 11 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 12 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 13 of 88

Selective Perforating Practices


Once formation characteristics are known, perforating strategies
can be evaluated.

If possible, only high strength intervals can


be perforated.
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.

Low Strength
Sand

Higher Strength
Sand

The appropriate compromise is key to success.


Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 14 of 88

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%)

Expandable Screen
(15-30%)

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 15 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 16 of 88

Chemical Methods

Consolidation of the Formation

Eni Corporate University Eni E&P Division

Resin-Coated Sand
Junior Production Engineering/Sand Control
Rev. 00 - Jan. 05/EP
Page 17 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 18 of 88

Sieve Analysis Indicates


Uniform and Non-Uniform Formations
100

Cumulative Weight (%)

90
80

P o o rly S o rte d S a n d
W e ll S o rte d S a n d

70
60
50
40
30
20
10
0
0 .1 0 0 0

0 .0 1 0 0

0 .0 0 1 0

0 .0 0 0 1

G r a in D ia m e te r (in c h e s )

Uniformity coefficient:

C= D40/D90

Poorly Sorted Sand:

C> 5

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 19 of 88

Gravel Pack Impairment: Sauciers Results


1 .0

Initial Permeabilit (kf / ki)

Ratio of Final Permeability to

1 .2

0 .8

0 .6

0 .4

0 .2

0 .0
0

10

12

14

16

R a tio o f M e d ia n G ra v e l P a c k S a n d D ia m e te r to
M e d ia n F o rm a tio n S a n d D ia m e te r (D 5 0 / d 5 0 )

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 Sauciers Criteria

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 20 of 88

Commonly Available Gravel Sizes


U.S. Mesh
Size Range
6-10
8-12*
10-20
12-20*
16-25
16-30*
20-40*
30-40
30-50
40-60*
50-70
* stocked size

Grain
Diameter Range
(inches)
.1320 - .0787
.0937 -.0661
.0787 - .0331
.0661 - .0331
.0469 - .0280
.0469 - .0232
.0331 - .0165
.0232 - .0165
.0232 - .0117
.0165 - .0098
.0117 - .0083

Median
Median
Grain Diameter Grain Diameter
(inches)
(microns)
.1054
2677
.0799
2029
.0559
1420
.0496
1260
.0388
986
.0351
892
.0248
630
.0199
505
.0175
445
.0132
335
.0100
254

Permeability
(darcies)

2703
1969
652
518
391
398
136
138
100
61
32

z1

Mesh refers to the


number of openings
per linear inch

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 21 of 88

Screen Selection
Gravel pack and Prepack Screen

The screen opening is typically between 50-70% of the


smallest gravel diameter
z

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 22 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 23 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 24 of 88

Cased Hole Gravel Pack


1

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 casingworkstring annulus just above the
packer

MULTI-POSITION SERVICE
TOOL
GRAVEL PACK
PACKER
FLOW SUB OR CLOSING
SLEEVE

BLANK PIPE

SCREENS

O-RING SUB
TELLTALE SCREEN

SUMP PACKER

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 25 of 88

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

Eni Corporate University Eni E&P Division

Seal Assembly

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 26 of 88

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.

Quantum Packer
Set Position

2. Release Service Tool


- Apply 2,200 - 2,400 psi
- Slack off 15K down
- Pick up

3. Ball Seat Still in Place

Eni Corporate University Eni E&P Division

Ball Seated
on Ball Seat
Fluted Crossover
Sub

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 27 of 88

Service Tool Operations


Blowing the Ball Seat (Opening Crossover Ports)
Pick up to the
reverse-out position
- 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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 28 of 88

Service Tool Operations


Circulating Position

To Reach Circulating Position


- 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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 29 of 88

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 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.

Eni Corporate University Eni E&P Division

Check Valve Closed

Lower Set of Seals


Still in Packer Bore
Port Closure Sleeve
Is Closed

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 30 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 31 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 32 of 88

Casing Cleaning when to stop?

NTU

well returns

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 33 of 88

Fluid Filtration
Clean completion, workover, injection, and treatment fluids are
imperative to avoid formation damage and gravels 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
= k
From Kozeny:
Dpore
From Coberly:
Dpore
= D50/6.5
SEM measurements of pore throat diameters from closely spaced core samples

Particle size and damage potential


instant bridging of core
Dpart > 0.33 Dpore
0.1 Dpore < Dpart < 0.33 Dpore
invasion of core and deposition
Dpart < 0.1 Dpore
unrestricted passage

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 34 of 88

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.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 35 of 88

System Layout

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 36 of 88

Perforating
Each shaped charge exerts up to 4 million psi on the reservoir.
This force crushes and compacts the reservoir rock and perforating
debris can plug perforating tunnels.

Result:
Limited leakoff and
poor injectivity

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 37 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 38 of 88

Perforation Cleaning
Underbalanced Pressure
selected on formation permeability and
Oil Wells
Gas Wells

Backflow
When perforating is performed overbalanced a
period of backflow is sometimes used to clean
up the perforations with a dedicated string

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 39 of 88

Perforating for Gravel Packs & Frac-Packs

Number of perforations should be sufficient to allow unimpaired (flow maximize inflow


area)
Large diameter charges recommended when gravel placed in tunnels
Enhance gravel placement in tunnels
Enhance flow of produced fluids

y Depth of penetration not critical


Various studies (SPE 71458, SPE 38633, SPE 68932) indicate that
cavity is often not formed when perforating in unconsolidated
formations.
Disturbed zone is filled with dilated formation
material.
Need to concentrate on tunnel through casing and cement

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 40 of 88

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
Perfs diameter (in.)

1.6

Perfs Diameter

Linear
Flow

20

Effective shots per foot

16

1.2

12

0.8

0.4

0
0

Radial
Flow

Effective spf

10 11 12 13 14 15

SKIN

Eni Corporate University Eni E&P Division

Cement
Casing
Gravel Pack Sand
Screen

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 41 of 88

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

450

190

64

10

27,760

9,280

2,091

0.4

10

55

21

Sand
20/40 Mesh
Gravel

P =

119,000

0.888 L Q
Q
+ 9.1 10 13 L
KA
A

Eni Corporate University Eni E&P Division

A= Perforation Cross-Sectional Area (ft2)


= Inertia Coefficient (ft-1)
P= Differential Pressure (psi)
K= Permeability (Darcies)
L= Length Of Perforation (ft)
= Viscosity (cp)
Q= Flow Rate (bpd)
= Density Of Fluid (lb/ft3)

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 42 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 43 of 88

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

Damaged Zone

Implication is that
perforations may not be
completely filled with gravel
and may not bypass the
damaged zone

Actual Wellbore

Pumping Pressure < Fracture Pressure


With Leakoff

Without Leakoff

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 44 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 45 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 46 of 88

Mechanism of Bore Hole Collapse


Clay

Fluid Loss

Filter
Cake

Pov

Sand
Uncontrolled Fluid Loss
if BRINE or HEC (linear
polymer) are used

Collapse due to
aqueous fluid - clay
interactions

Controlled Fluid Loss


improves
Bore Hole stability

Modifications of Rock Mechanical Properties and Stress in-situ Equilibrium are


responsible for Bore Hole Collapse.
Swelling alone does not explain the behavior of this kind of rock.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 47 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 48 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 49 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 50 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 51 of 88

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
P<Pfrac

Kd

GRAVEL PLACEMENT
P>Pfrac

The main purpose is to provide


the optimum combination of
productivity improvement
through damage bypass,
and well life improvement
through effective sand
control

Kf

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 52 of 88

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.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 53 of 88

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

Break
Down

P
Ppropag

Frictions

PNET

ISIP

PBreakDown = 2 (/(1-))(o-p) + p
PBreakDown = 2 (o-p) + p
PClosure
= (/(1-))(o-p) + p

Pclosure

[mud]
[brine]

values: 0.28 (average)


theoretical:
from the lab:
Adriatic Sea:

Time

Eni Corporate University Eni E&P Division

0-0.5
0.22-0.33
0.25-0.35

o = sigma overburden
p = sigma pore
= Poissons coefficient

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 54 of 88

FracPack: PClosure e Leak Off

Preliminary Test:
Injection Test (with carrier fluid)
leak off coefficient (from fall-off)

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 55 of 88

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.
Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 56 of 88

FracPack
Final Design and Execution
Frac model calibration by measured data from Step Rate Test
and Injection Test (Pfrac, 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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 57 of 88

Barbara C 24 Livello Q
HRWP

Pressione (psi)

Tbg Pressure

Annulus Pressure

Mix Ratio

Flow in

Return

2200

11

2000

10

1800

1600

1400

1200

1000

800

600

400

200

0
14.52.48

0
15.07.12

15.21.36

15.36.00

15.50.24

16.04.48

16.19.12

Time (hh:mm:ss)

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 58 of 88

16.33.36

Tbg pressure
Annulus pressure

Eni Corporate University Eni E&P Division


Rate

Time (hh:mm:ss)

Mix ratio

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 59 of 88

08:29:09

08:27:41

08:26:13

08:24:45

08:23:17

08:21:49

08:20:21

08:18:53

08:17:25

08:15:57

08:14:29

08:13:01

08:11:33

08:10:05

08:08:37

08:07:09

08:05:41

08:04:13

08:02:45

08:01:17

07:59:49

07:58:21

07:56:53

07:55:25

07:53:57

07:52:29

07:51:01

07:49:33

07:48:05

07:46:37

07:45:09

07:43:41

07:42:13

07:40:45

07:39:17

07:37:49

07:36:21

07:34:53

07:33:25

07:31:57

07:30:29

07:29:01

07:27:33

07:26:05

07:24:37

07:23:09

07:21:41

Pressione (psi)
1200
12

1000
10

800
8

600
6

400
4

200
2

0
0

Rate (bpm); Mix Ratio (ppa)

ENI - DIVISIONE AGIP, Adriatic sea,


Barbara C - W ell 24 - level O-O1
Frac Pack

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 60 of 88

FLOW EFFICIENCY
100

Total
26

Total
25

Range

Range

Average FE %

80
60

70-114

40

Total
22

80-97

Range

20-90

20
0
FRAC-PACK

ICGP

Eni Corporate University Eni E&P Division

OHGP
Junior Production Engineering/Sand Control
Rev. 00 - Jan. 05/EP
Page 61 of 88

Clean Times & Performances


1.2

CF100%

ICGP FracPack

Pseudo-PI /net pay

1.0

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)

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 62 of 88

GRAVEL PACKING: Possible Alternatives


ICGP (Sauciers Criteria for gravel size, better if even smaller)
suitable for high perm, homogenous sands
no damage inside tunnels and into formation sand

OHGP

(Sauciers 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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 63 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 64 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 65 of 88

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

Eni Corporate University Eni E&P Division

ICGP

OHGP

CASING
SHOE

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 66 of 88

Gravel Pack Stacked Completions


RIH GUNS

PERFORATING
LAYER "A"

SCRAPER /
TAPER MILL

Eni Corporate University Eni E&P Division

RIH AND SET "D" PKR


WITH TUBING / E-LINE

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 67 of 88

Gravel Pack Stacked Completions (cont)


RIH GP ASSEMBLY

PERFORM HRWP
LEVEL "A"

Eni Corporate University Eni E&P Division

RIH PKR PLUG

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 68 of 88

Gravel Pack Stacked Completions (cont)


SET PKR PLUG &
PERFORM SAND PLUG

RIH GUNS

Eni Corporate University Eni E&P Division

PERFORATE
LEVEL B"

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 69 of 88

Gravel Pack Stacked Completions (cont)


RIH RET.PKR PLUG and
RETRIEVE IT

RIH GP ASSY
w PROD TBG FOR LEVEL A

Eni Corporate University Eni E&P Division

SET PKR PLUG &


PERFORM HRWP

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 70 of 88

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 m

NO

YES

YES
RES. FLUID
CONTACTS
DEFINED

NO FINES MIGRATION?

YES

GEO-SECT. DEFINED

NO

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

Eni Corporate University Eni E&P Division

CASED HOLE
COMPLETION

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 71 of 88

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 JOB

EXPANDABLE
SYSTEM

OPEN HOLE
GRAVEL PACK

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 72 of 88

Cased Hole Sand Control Completion

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 73 of 88

Through Tubing Gravel Packs or Fracs


Sanded up completion

Sand wash

Eni Corporate University Eni E&P Division

Run Screen on Coil

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 74 of 88

Through Tubing Gravel Packs or Fracs (cont.)


Release Screen from Coil

Fracture or GP Treatment

Eni Corporate University Eni E&P Division

Sand wash

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 75 of 88

Through Tubing Gravel Packs or Fracs (cont.)


Produce Well

>50

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 76 of 88

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.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 77 of 88

Flow Profiles
Q

Rate (Q)
BOPD
144

P Through
Blank
PSI
0.84

Velocity Through
Pack
Ft/Min
0.0016

288

2.83

0.0055

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
Fluid = 1 cp

40/60

100

Settling Velocity
Ft / Min
20/40

12.6

40/60

4.0

7 5/8
Csg.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 78 of 88

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.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 79 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 80 of 88

Unconsolidated zone to be treated

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 81 of 88

Preflush Stage
Preflush fluid is applied to condition the formation to accept resin.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 82 of 88

Resin Stage
Low viscosity resin with an affinity for silica surfaces coats each individual grain of
sand.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 83 of 88

Spacer / Overflush Stage


A spacer fluid is pumped down to remove excess resin from sand, dilute the
resin, and carry it into the formation.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 84 of 88

Catalyst Stage

The hardening catalyst is pumped through the matrix of resin-wet sand,


instantly beginning the hardening process.

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 85 of 88

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

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 86 of 88

Application of Resin-Coated Sand Slurry


Cement Sheath

Formation

Liquid Resin-Coated
Proppant Entering Perforation
and Filling Casing

Casing

Liquid Resin-Coated
Proppant During Placement

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 87 of 88

Sand Grains Locked Together Sand in Casing Then Drilled Out


Drillstring
Cement

Clean Wellbore, Excess


Resin-Coated Proppant Removed

Hardened Resin-Coated
Proppant

Eni Corporate University Eni E&P Division

Junior Production Engineering/Sand Control


Rev. 00 - Jan. 05/EP
Page 88 of 88

You might also like