03 Sand Control Completions.pdf

Quartz School for Well Site Supervisors Module – 12 Well Completions

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Section – 3 Sand Control Completions

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Outline Sand Control Market What is Sand Production Problems with Sand Production Sand Production Mechanism Factors Affecting Sand Production Sand Production Prediction Sand Control Methods

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y y y

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What is Sand Production? y Sand Production refers to the Production of solid particles y y

which support the overburden The Rock needs to fail for Solids to be produced Fines Particles are NOT sand production formation

y Once the destabilizing forces overcome the formation y

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y not considered part of the mechanical structure of the

strength, the rock will fail. 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

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Favorable Conditions y Young and Shallow Reservoir Rock y Unconsolidated with Compressive Strength < 1000 psi

y Permeability y 0.5 to 8 darcies Schlumberger Private

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Sand Problems Sand Disposal Casing / Liner Failure Sand Erosion Sand Bridges

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y

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Sand Disposal y Even wells with successful sand control measures will

y Sand Separation y Disposal

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y

produce small quantities of sand. In offshore installations, where several wells produce into a common platform, this may be critical. Sand must be first separated from the produced fluids and all oil removed prior to disposal.

y Can not be dumped overboard y Must be trucked away y Classified as NORM (Natural Occurring Radioactive Material)

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Casing / Liner Collapse

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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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.

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Sand Erosion

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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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

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Sand Erosion Cont’d

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Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Sand Bridges y Bridges may form in casing y

y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

or tubing and obstruct well flow. Causes y Sand fall back over time y Increase in water production y Fluid Velocity too low They must be removed by bailing or washing with Coiled Tubing If bridging is severe sand control will be required.

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Sanding Mechanisms

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Sand Structure Failure Mechanism Sand Transportation

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Sanding Mechanism

In weak but consolidated formations: Stage 2 Transportation

Failure of reservoir rock due to shear stresses (failure of bonds between grains)

Transportation of failed material due to flow

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Stage 1 Failure

If we can predict and prevent Stage 1, we do not need to worry about Stage 2!

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Consolidation Same problem, different mechanism Ædifferent solutions Unconsolidated

Consolidated Schlumberger Private

Zero strength

Very very weak

Very weak

Consolidated

Dry sand

Damp sand

Weakly-cemented

Stronger cement

high Φ

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

lower Φ

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Sand Structure

Cementation

Overburden

• Structure of Sand Grains

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Pore Pressure

• Packed together by Overburden Stress • Additional support from Pore Pressure • Sand Grains kept in place by cementing material Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Conditions for Rock Failure Forces holding the Rock Structure together

Forces trying to fail the Rock Structure

y Intergranular bonds

y Differential Pressure y y

between Reservoir and Wellbore Drag forces related to Fluid Viscosity Drag forces related to Fluid Velocity

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y

(cementation) Pore Pressure intergranular friction Gravity capillary forces

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Sand Transportation y In most sand formations, fines particles are waterwet and move with the water phase. y No water production – No, or little sand Production Schlumberger Private

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Triggering Sand Production y Sand Production is very much

y y y y

Production Rate Fluctuations Drawdown changes Onset of water production Change in Oil/Water ratio

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

related to fluid production Even better consolidated formations can produce sand

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Time Dependence Reservoir Depletion

y Reduction in Pore Pressure Increase in Water Production Schlumberger Private

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

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Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Sand Production Prediction

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Sand Production Prediction y Experience y Special Well Test y Core Inspection and Testing

y Log Interpretation y No direct measurements of Rock Strength. Calculations from

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y X-Ray, SEM y Flow Tests y Uniaxial and Triaxial Compressive Strength Measurements

Sonic, Density and Neutron Logs

y IMPACT y Simulator which uses data from DST, Well Tests, Core Analysis and Logs

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Flow Tests

POverburden P1

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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P2

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Conventional Sand Strength Analysis

Rock Mechanics Poisson’s Ratio (PR) was calibrated to validated core data

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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 Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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

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SWA

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Rock Classification BHN

Remarks

Unconsolidated Partially Friable Consolidate Hard

<2 2-5 5 - 10 10 - 30 > 30

No cementing material Crushed with fingers Crushed when rubbed Crushed with force Can not be broken with force

Medium Hard Hard Very Hard

30 - 50 50 - 125 > 125

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Term

(BNH - Brinell Hardness Number)

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Sand Control Although some fines are probably always produced in any well, in sand control we mean control of the

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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LOAD BEARING SOLIDS

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Completion Options y No Shocks to the System y Keep System as stable as possible

y Restrictive Production Rate y Selective and Oriented Perforating y Selective perforations placed in the strongest y

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y Limit drawdown

formation (based on logs) Perforate in direction of maximum stress

y Implications to Production Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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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 - Natural Sand Packing

y Placement of Screens in the wellbore without the use of Gravel

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screens

Gravel Pack

y Placement of Screens and Gravel

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In Situ Consolidation y Resin material is pumped y

y y y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

into the formation. Most common resins are Phenolic, Furan or Epoxy Resin is followed by a Catalyst Resin “glues” formation grain-grain into a consolidated structure Compressive strength >1,000 psi with 60-75% retained permeability. Acid treatment prior to treatment

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Resin Coated Gravel y Proppant ( Gravel ) is y

y y

y

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y

precoated with resin material. Particles are mixed with viscous gel and squeezed into the formation. A resin coated gravel plug is left in the wellbore Particles are contacted grainto-grain. Temperature + H2O fuses the particles together into a consolidated permeable, drillable network Low Cost, onshore

Resin

Gravel

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

Formation (Unconsolidated)

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Resin Coated Gravel y Resin coated particles are placed in the perforations and y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y

wellbore. When cured a strong permeable synthetic sandstone network is formed. Drillable. Diversion to be considered. Main Well Services System : SANDLOCK V*

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Slotted Liners & Prepacked Screens y Sized to stop largest 10% of sand y Friable formations only (BHN y

y y y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

from 5-10) with > 1 Darcy Perm. Unconsolidated formations will cause liner or PP Screens to quickly plug with fines Only 5 % of all Sand Control completions Simpler to install Cheaper Larger effective inside diameter compared to normal GP

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Learning Points y What is Sand Production y Problems with Sand Production y Sand Production Mechanism

y Sand Production Prediction y Sand Control Methods

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y Structure y Failure Mechanism y Sand Transportation

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Completions with Gravel Packing

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Gravel Packing

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Overview Gravel Pack Principle Completion Types Gravel Pack Tools Systems Types of Deployment Placement of the Pack Job Design Schlumberger Products and Services

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y y y y

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Gravel Packing Principle y Objective is to trap the Sand y

y

y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

Particles in the formation Leaving a Permeable Pack allowing Fluid to enter the wellbore A sand screen is placed in front of the producing interval y The screen will stop particles of a certain size Gravel is pumped in the annular space and the perforation tunnel y Gravel can not enter the screen Larger sand grains will pack off against the gravel

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Which Size

Therefore y Gravel as large as possible y Filter out fines as small as possible

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Requirements for Long Term Productivity y Clean y Tightly Packed y No damage to Formation y Minimize pressure drop in perforations

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The System SG: Gravel: 6x-9x of Mean formation size.

Gravel / Proppant 100-500 Darcys

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0.5 TO 0.75 D

Screen

Gravel

Casing

Cement

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

Reservoir

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Completion Types

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Natural Sand Pack Open Hole Gravel Pack Cased Gravel Pack Expandable Screens

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Completion Types y Natural Sand Pack

y Cased Hole Gravel Pack

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y OH Gravel Pack

y Expandable Screens

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Natural Sand Pack y screen is designed to contain y

y

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y

formation sand annular may be filled up with low permeability sand pack, reducing production sand may cause screen erosion or plugging not viable for cased hole

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Natural Sand Pack Considerations y NSP Erosion y Formation particle flow velocity through the screen may cause

y NSP Plugging y If not eroded, in a sand producing environment in which

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erosion y Consequences are more severe in gas wells y Increased formation particle flow velocity will occur due to partial screen plugging

particles are allowed to flow, the screen openings tend to plug y Screens should be sized to allow the fines to produce

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Open Hole Gravel Pack 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 Schlumberger Private

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Open Hole Gravel Pack y Gravel is selected to contain the formation sand y Size Screen to stop gravel or formation sand? y Considerations based on NSP y Water Pack versus Alternate Path

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y Gravel placement technique to be considered

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Open-Hole GP Considerations Can be under-reamed, increasing wellbore area. No damage due to poor perforation pack efficiency. Hole stability is a concern while drilling and completion. Horizontal completions Water production control may become impractical.

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y

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Cased Gravel Pack Ease to complete as selective Expensive perforation Difficult lower perforations cleaning. Difficult upper perforations packing Screen only have high failure rate y 25% of GOM wells with stand-alone screens failed

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y

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Cased-hole GP Considerations Isolate production from undesirable zones. Reliable drilling and completion methodologies. Requires efficient perforation system. Poor perforation pack may lead to low productivity. Easier workover compared to EGP.

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y

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GP Tools

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Sump Packer Screens Service Tools GP Packer

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Remains in hole after Gravel Pack operation

Gravel Pack Packer (QUANTUM*) Gravel Pack Extension

Safety Shear Joint Blank Pipe

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Large Bore Flapper Valve

Screen

Sump Packer

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Sand Control Schematic 1. Wellbore Clean up 2. Install Sump Packer Schlumberger Private

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Sand Control Schematic 3. TCP Perforation

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Sand Control Schematic 4. RIH Screens and G.P. Assembly 5. Gravel Pack Pumping Schlumberger Private

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Service Tool and Wash Pipe Workstring

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Service Tool

Wash Pipe

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Circulating Position

y y

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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 Fluid leaks-off to formation or into screen Fill annulus and cover perforations

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Service Tool Operations – Circ Position QUANTUM Service Tool

Drill Pipe

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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

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Squeeze Position

Move down with Service Tool Service Tool in Squeeze Position Leak-off path back in screen is closed off Fluid can only leak-off to formation Gravel is squeezed in perforations

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y y y y y

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Service Tool Operations - Squeeze Position

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Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Reverse Circulation

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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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

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Pull out of hole after Gravel Pack operation

Workstring

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Service Tool

Wash Pipe

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Screens

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Sand Control Schematic 6. Install Production Seals, Tubing, GLM, and SCSSV 7. Install Well Head Schlumberger Private

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GP Deployment

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Rig Coiled Tubing Wireline

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Gravel Pack Installation

y Hardware is installed with :

y Gravel is transported by fluid in slurry form.

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y Rig (most common) y Coiled Tubing (Snub-in) y Wireline

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Placing the Pack

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Objectives Methods Well Trajectory

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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.

efficiently.

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y In open hole, the open hole-screen annulus must be packed

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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 gravel. Typically (1 to 2 PPA)

y Frac Pack y 5 to 40 BPM - pumping gel with “ramped” concentration

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y 5 to 15 BPM - pumping completion fluid with low concentration

gravel. Typically (.5 - 15 PPA) y High Rates -----Æ Erosion, Burst , Collapse ( Stronger Equipment Required)

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Well Trajectory and Placement Vertical Wells

Deviated Wells 7

6 5 4

3 21

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°

60

8

Horizontal Wells Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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Products and Services

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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All Pack PerfPAC

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Advanced Technology in Schlumberger y Alternate Path Service (APS) y AllPAC* - for Gravel Packing y AllFRAC* for “Frac & Pac”

y Perforation and Gravel Packing in one trip

Quartz School. Module 12: Well Completions / Section 3: Sand Control Completions

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y PERFRAC*

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Alternate Path Shunt Design y Small or large tubes depending

*Service Mark of Mobil Oil Corporation

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y y y y

on flow rates and treating lengths Eccentric or concentric design Stainless Steel construction Tungsten Carbide nozzle inserts Transport-Packing tube arrangement

* Service Mark of Mobil Oil Corporation

AllPack Animation

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