Gravel pack system

design

Dickson Omonze

Introduction to gravelpacking
• Two stage filter system
• Formation sand will bridge
on the gravel/proppant
• Gravel will bridge on
Formation
sand
screen
• Hydrocarbon will flow Gravel

through the pack, into

screen and up the tubing
Screen

2
Introduction to gravelpacking
• Ensuresa “sand-free” production
• Provides highest assurance of:
ɆSand control
ɆWell longevity & productivity
•2 types of gravelpacks:
ɆInternalgravelpacks
ɆExternal gravelpacks

Introduction to gravelpacking
• Internal gravelpacking:
Ɇ Cased hole operation
Ɇ Isolation of undesirable zones
Ɇ Requires efficient perforation system
Ɇ Annular & perforation packing Perforated
casing
operation
Ɇ Poor perforation packing leads to
low productivity
Ɇ Easier workover and remedial
operations if required

4
Introduction to gravelpacking
‡ External gravelpacking:
± Open hole operations
± Can be under-reamed, increasing
wellbore area
± No damage due to poor perforation
pack efficiency
Open hole
± Hole stability considerations section

± Requires effective filter cake stability

± Common applications in horizontal
completions
± Water production control is complicated

Gravelpacking equipment
• Surface equipment:
ɆPumps, blenders, tanks etc…
• Downhole tools:
ɆService tools, packers, Isolation valves
etc..
• Screens:
ɆSlotted liners, wire wrapped, etc…

6
 Surface equipment
• Pumps:
Ɇ HP Pump
Ɇ Pumping slurry into
the well
Ɇ E.g CatFRAC

Surface equipment
• Pump:
Ɇ LPCentrifugal pumps
Ɇ Used for fluid transfer

8
 Surface equipment
• Blenders:
Ɇ Mixing of gravelpack
slurry
Ɇ Can be mixed “on
the fly” or batch mix
system

Dual “tub” batch blender

Surface equipment
• POD blender
Ɇ Automatic gravel
concentration
control
Ɇ “On the fly” mixing
Ɇ Densitometer controls
gate position

POD (Proportional Optimized Density) blender

10
 Surface equipment
• Sand silos and feeder:
Ɇ Storage of sand & transfer
into mixing system
• Fluid storage tanks:
Ɇ Completion fluids, gelling
systems etc…
• Electronic systems:
Ɇ Data acquisition systems,
software etc…
Ɇ Flow meters
Ɇ Densitometers

11

Downhole tools
‡ Internal assembly:
± Service tools
± Wash pipes & accessories
‡ External assembly:
± Gravelpack packer
± Circulating housing
± Mechanical fluid loss control device
± Tension shear subs
± Blank pipes
± Screens
± O-ring seal subs and washdown shoes

12
Service tool
• Service tool provides means of:
ɆSetting of the gravelpack packer
ɆConduit for placement of gravelpack
slurry
ɆFlow configuration for “squeeze”,
“circulating” or “reversing” of fluids during
gravelpacks
• Also called the “crossover tool”

13

Service tool
• Modular seal assembly configuration:
Ɇ Packer setting module
Ɇ Crossover sub module
Ɇ Isolation valve module
Ɇ Position indicating module
• Configurations based on applications e.g.
washdown capabilities, high rate jobs etc…

Packer setting module Crossover sub Isolation valve Indicating module

14
Service tool flow path
Slurry path Clean fluid return path

‡ Fluid travels through the service tool to reach the crossover

sub
‡ Fluid exits service tool through the flow ports of the crossover
sub
‡ Return fluid travel up through the isolation valve to the base of
the crossover sub
‡ Return fluid then diverts through the “gun drilled” ports of the
crossover sub
‡ Flow continues through the concentric annulus
‡ Clean fluids exits at the circulating ported sub

15

Washpipe and accessories

• Washpipes:
ɆFlow tube system (flush or integral joint
tubing) connected to base of service tool
ɆLocates in the ID of screen & blank pipe
assembly
ɆCritical return flow path for clean fluids
ɆWashpipe OD to screen ID ratio impacts
flow frictional pressures & placement of
gravelpack

16
Washpipe and accessories
• Accessories:
ɆWashpipe gauge carrier/gauges:
• Records bottomhole pressures &
temperatures for gravelpack operational
analysis
ɆGravelpack logging tools:
• Evaluation of pack efficiency

17

Gravelpack packer
• Retrievable seal bore packer
• Provides zonal isolation &
support for gravelpack
assembly
• Also utilized as “sump packer”
in cased hole applications
• Typically utilized as
completion packer for sand
control completions
18
Circulating housing
‡ Connects to the bottom of the GP
packer
‡ Communication ports for slurry flow
‡ “Closure sleeve” to prevent backflow of
slurry
‡ Incorporated profiles for service tool
location

Ported housing Seal bore extension Indicating collar

19

Fluid loss control devices

• Installed in gravelpack assembly:
ɆMitigate/eliminate need for pumping
damaging fluid loss pills
• Common types include:
ɆFlapper valves
ɆIsolation ball valves

20
Fluid loss control devices
• Flapper valves:
ɆHeld open with washpipe
during gravelpack operations
ɆIsolation provided only from
the top
ɆApplications limited by
differential ratings-reservoir
Frangible
flapper
pressure
ɆFragile- flapper material easily
broken

21

Fluid loss control devices

• Isolation ball valves:
ɆIsolates wells from to & bottom
ɆIsolation not affected by reservoir
pressures
ɆOperated with intervention with use of a
shifting tool or remote actuation
ɆCommon types include; FIVs* MFIV*,
RBIV** etc…

22
Fluid loss control devices
• Formation Isolation Valve (FIV)
ɆProvides 2-way barrier system
ɆNon-intervention one-time opening cycle
ɆUnlimited mechanical cycling

Shifting tool

23

Tension shear-off subs

• Safety shear subs:
ɆConnects housing
extensions to blank pipe/
screen assembly Shear
screws
ɆEmergency release point if
screens are Stuck
ɆOnce actuated, designed
fishing profile is exposed

24
Blank pipes and screens
• Blank pipes:
ɆTubing assembly run above the screen
assembly
ɆTypically same OD size as screen base
pipe
ɆProvide means of spacing out GP packer
at desired depths
ɆProvides reservoir area for settled gravel
after gravelpack operations

25

Blank pipe and screens

• Screens:
ɆDownhole mechanical sand filters
ɆApplicable as standalone or in
gravelpacking operations
ɆVarious types including slotted liners, wire-
wrapped etc…

26
O-ring seal sub & washdown shoes
• O-ring seal sub:
Ɇ Provide sealing area of polish
stinger
• Dual poppet washdown shoe
Ɇ Connected to the bottom of
screens
Ɇ Allows for washing down the
assembly through the openhole
Ɇ Flow only in one direction

DPWS

27

Gravelpack tool system configuration

Position indicating module
Internal isolation module

Washpipe & accessories

Ported Seal Sub

Crossover sub

Service tool

Packer Circulating Housing Extension Fluid loss Shear-off Blank pipe Screens
device sub

28
Gravelpack tool system configuration

29

Questions

30
 Sand Control Systems

Sand control screens

Sand control screens

‡ Downhole mechanical filters
‡ Used standalone:
± Isolate formation sand
‡ Gravelpack applications:
± Filter accurately sized gravel
‡ Types:
± Slottedliner screens
± Wire wrapped screens
± Pre-packed screens
± Premium mesh screens

32
Wire wrapped screens
Base pipe
• Single wire wrapped around a
perforated base pipe
• Wire is wrapped & welded
around support rods before
Wire
installation across the base
pipe
• More inlet area compared to
Support rods
slotted liners

33

Wire wrapped screens

• Spacing designed
to isolate formation
sand or sized gravel
• Wire design:
ɆKeystone shaped
ɆHouse shaped

Keystone shaped House shaped

34
Wire wrapped screens
Erosion area Erosion area

d1

d1

d2
d1

d2 > d1

House shaped Keystone shaped

35

Direct wrap screens

• Screens is “shrink fitted” to grip base
pipe at all points
• No welding required
• Results in a more “rugged” WW- screen
• Greatly improved torque, tensile and
collapse strength
ɆAdvantage for openhole applications
ɆMore expensive than conventional WW
screens
36
Prepacked screens
• Utilizes a specifically sized
gravel (resin coated) held in
between 2 layers of WW
screens
• Lower inflow area compared
to slotted liner & conventional
WW screens Resin coated gravel

• Easily plugged by formation

fines, mud or dirty fluids

37

Prepacked screens
‡ Sometimes utilized in place of
gravelpack operations
‡ Higher collapse resistance than
conventional WW screens
‡ Detailed evaluation required for specific
determined value:
± Complex gravelpack
± Expensive sand control
± Formation sand & fines analysis
± Life of well expectations

38
Premium mesh screens
‡ Woven filter media (“net”)
‡ Layers of filter media wrapped
around the perforated base Base pipe

pipe Drainage

‡ Screen protected by a shroud layer

‡ Offers more sand retention-in Filter

layer
heterogeneous formation Outer

‡ High inflow areas- dependent shroud

on weave design

39

Alternate path systems

‡ Screen design to mitigate risk of premature
bridging in highly deviated or horizontal wells
‡ Bypass channel design incorporated around
the base screen
‡ Channel allows for alternate flow path past
sand bridges resulting
‡ Placement at ~3-6bpm and 6-8ppa gel slurry
‡ Common industry systems:
± SLB Shunt tube (AllPAC/AllFRAC), HAL Concentric
Annular Pack (CAPS), BOT-DirectPAK

40
Alternate path systems

HAL CAPS system

BOT DirectPAK System SLB Shunt tube system- AllPAC & AllFRAC

41

Alternate path systems

SLB Shunt tube assembled configuration

Slurry bypassing bridge

42
Screen design and selection
• Sand screen design objective are:
Ɇ Retention of load bearing sand particles
Ɇ Avoid screen plugging
Ɇ Optimize well productivity
• Design requires understanding of:
Ɇ Bridging theory principles
Ɇ Reservoir completion conditions
• Wellbore fluids (Drilling Mud, Drill-In-Fluids, Completion
fluids etc…, Openhole cases)
Ɇ Operational deliverability

43

Screen design and selection

• Bridging theory through filter Invasion
media:
Ɇ Pore space Ȃ = ¥K
•Ȃ = microns & K = permeability (mD)
Ɇ Particle size behavior: Bridging

• Invasion: Particle size < 1/6 pore space

diameter- flow through- no damage
• Bridging: Particle size between 1/6 & ½
pore space diameter, can results in
permanent damage
Plugging
• Plugging: Particle size larger > ½ pore
space diameter: Reduces flow through
filter media
Screen

44
Screen design and selection
• Particle size obtained from
concise sand particle size
distribution analysis (PSD):
• Laser
• Optical
• Dry Sand Sieve analysis

45

Screen design and selection

D90

D50

D40

D10

PSD Sieve analysis of a typical formation sand

46
Screen design and selection
‡ Screen design (type of screen, slot/pore
spacing) choice determined on grain size
uniformity coefficient C= D40/ D90:
± C<3: Highly uniform sand
± 3<C<5 uniform sand
± 5<C<10 moderate/poorly sorted sands
± C>10 Highly non-uniform sand
‡ Use guideline relationships for screen selection
‡ It is crucial to ensure wellbore fluids (drilling
mud, LCM) and debris DO NOT plug screens

47

Screen design and selection

• Plugging in one of the biggest risks to a
screen type completions
• The screens can be plugged with drill solids
and/or hole debris during installation
• Major resulting impacts are:
Ɇ Production impairment
Ɇ Creation of areas of high local velocity (hot spots),
erosion & premature failure
Ɇ Impact on successful gravelpacks & well longevity
Ɇ Costly remedial operations for screen cleanout

48
Screen design and selection
• “Plugging” is linked to screen
opening/pore space by the 1/7th rule:
ɆA DIF containing D50 solids particles >1/7th
of spacing will plug the screen (Lau &
Davies. SPE38638)
• Pre-packed wire-wrap & premium
mesh screens are more prone to
plugging by DIF than single wire wrap
screens

49

Screen design and selection

• Plugging of premium
mesh screen
• Occurred during
circulation in openhole
application
• Recommended practice
to install screens in brine
or non-solid laden fluids

Mud particle plugging failure

50
Screen design and selection
• Mitigating screen plugging risks:
ɆInstall
screens in clear, solids-free fluids or only
conditioned drilling mud that will sized
particles flow freely through screens
• Utilize
appropriate surface shakers sizes based on
plugging theory relationships
ɆAvoid circulating mud through the sand
screen
ɆAlways perform a sand screen plugging
testing

51

Screen design and selection

• Openhole horizontal well considerations:
ɆPotential scraping during installation of
filter-cake
• Shrouded screens applications
• Solid centralizers
ɆNon-uniform low-pressure drawdown
during production
ɆDifficult stimulation treatments across
entire length

52
Screen design and selection
Sand screen Filter cake

Sand screen as installed in openhole horizontal well

Sand screen in post acid treated openhole horizontal well

Poor filter cake clean up leads to non-uniform production and “hot spots”:
Potential “coning” problems and screen damage

53

Screen design and selection

• Screen diameters:
ɆInflow area
ɆPack thickness (desired radial clearance)
ɆInternal diameter for intervention
ɆFishing requirements
• Length:
ɆOperational ease, centralization,
transportation, etc…
ɆCommon lengths – 5ft, 10ft, 20ft, 30ft & 40ft

54
Screen design and selection
• Material type:
ɆCorrosive environments:
• Corrosion resistant alloys (CRA) or carbon
steel
ɆMechanical limitations:
• Compressive loads
• Tensile strength
• Torque limits

55

Sand control systems

Gravelpack design &

execution
Gravelpack design and execution
• Gravel & fluid selection:
Ɇ Gravel sizes, fluid type properties etc…
• Gravelpack calculations:
Ɇ Volumes, densities, etc…
• Gravelpack pumping:
Ɇ Pumping modes, placement techniques, cased
hole, open hole considerations
• Field operations:
Ɇ Typical operational procedure

57

Gravel selection
• Gravel size:
Ɇbased on formation sand PSD
ɆTwo common selection methods based
on gravel (Dg) & formation sand (Ds)
diameters
• Saucier:Dg50 = 6x Ds50
• Schwartz: based on Uniformity coefficient C
D10g = 6 x D10s for C < 5 uniform sand
D40g = 6 x D40s for C > 5 moderate uniform sand
D70g = 6 x D70s for C > 10 non-uniform sand

58
Gravel selection
‡ Gravel density:
± Specific gravity between 1.5 – 3.5
± Affects gravel settling velocities & transportation
during gravelpacking
± “Matched density” concept applications-(Particle
density (Dp) /Carrier fluid Density (Dc) ratio)
± Test show best perforation packing with 1.0” Dp/Dc ”
1.8
± Common density value for gravelpack sands:
‡ Light-sands: 1.55 SG or 12.9ppg
‡ Regular sand: 2.65 SG or 22.1ppg
‡ Bauxite: 3.6 SG or 30.00ppg

59

Gravel selection
• Content solubility:
ɆPresence of HCl or HF
ɆIndustry limits < 1% in HCl-HF
• Sphericity & Roundness:
ɆCoarse particles can provide more
effective sand control
ɆBetter sphericity & roundness however
provides better permeability

60
Gravel selection
• Bottom hole temperatures:
ɆDissolution
of certain materials at high
temperatures e.g. steam wells
• Gravel classification:
ɆRegular sands - PACSAN*
ɆLight weight sands- (ISOPAC*), Liteprop*
ɆHeavy sands - Bauxite

61

Fluids selection
• Fluid density:
Ɇ Completion fluid requirement, well Control etc…
• Carrying capacity:
Ɇ Rheological
properties, shear behavior,
temperature impact, etc…
• Chemical & physical stability:
Ɇ Temperature, precipitation etc…
• Compatibility:
Ɇ Formationclay, shale reactivity
Ɇ Produced fluids – hydrocarbons, formation water

62
 Fluids selection
• Solids contents:
ɆCleanliness (filtration), plugging risks,
formation damage
• Fluid types:
ɆCompletion fluids- sea water, brines
ɆWater based gels
ɆOil base gels

63

Visco-Elastic Surfactants (VES)

• Polymer free fracturing fluid
• Chemistry of surfactant with
water based system
• Simplified field mixing
• Reduced friction Brine

• Enhances permeability Oil or

produced fluids
• Breaks on contact with:
Ɇ Produced liquid hydrocarbon
Ɇ Dilution with formation water

64
Gravelpack calculations
• Gravel volumes:
ɆBlank pipe/casing annular volume (V1)
ɆScreen/casing annular volume (V2)
ɆScreen/openhole annular volume (V3)
ɆPerforation tunnel volume (V4)
ɆTotal volume:
• VT = V1 + V2 + V4 (Cased hole)
• VT = V1 + V3 (Open hole)

65

Gravelpack calculations

Blank pipe/casing
annulus (V1)

Screen/casing annulus Screen/open hole annulus

(V2) (V3)

Perforation tunnel
(V4)

Cased hole Open hole

66
Gravelpack calculations
Ɇ VT = Total gravel volume
• V1 = ʌ/4 * (Dc2 –db2)/144 *Lblank required (ft3)
(ft3) Ɇ Dc = casing ID (inches)
• V2 = ʌ/4* (Dc2 –ds2)/144 * Lscreen Ɇ Do = openhole diameter
(ft3) (inches)
• V3 = ʌ/4* (Do2 –ds2)/144* Lscreen Ɇ db = blank pipe OD (inches)
Ɇ ds = screen OD (inches)
(ft3) Ɇ Cp = perforation tunnel pack
• V4 = Cp x Lperforations (ft3) factor (ft3)/ft
• Weight of gravel required : • 0.25 -1.5 (ft3)/ft based on
Ɇ Wg = VT*ȡbulk (lbs) tunnel conditions &
experience
Ɇ L = length (ft)
Ɇ ʌ = 3.142
Ɇ ȡbulk = bulk density

67

Gravelpack calculations
• Carrier fluid volume required (Vcf):
ɆDependent on desired gravel (proppant)
loading
ɆGravel loading unit = PPA
• Pounds of proppant added in 1 gallon of
carrier fluid
Ɇ(Vcf) = Wg/PPA (gals)

68
Gravelpack calculations
‡ Slurry volume (Vsl):
± Sum of equivalent proppant volume and
carrier fluid volume
± Proppant volume equivalent determined by
yield factor:
‡ Yield factor = 1 + PPA/(ȡabs)
± (Vsl)= (Vcf)*Yield factor
‡ Effective slurry density:
± Slurry density = ((ȡcf + PPA)/Yield) (ppg)
‡ ȡcf = Carrier fluid density

69

Gravelpack calculations
• Maximum wellhead pressure limits
ɆPwh = BHP – Ph + Pf
• Cased hole:
Ɇ Bottomhole equipment limits
• Openhole:
Ɇ Bottomhole equipment limits
Ɇ Fracturing pressure limitations

70
 Gravelpack calculations
• Maximum applied Pt
annulus pressure
ɆLimited by differential
pressure across the
packer system
ɆPacker pressure testing
ɆSlurry reverse-out
operations
Pr

71

Gravelpack calculations
‡ A gravelpack operation is required in vertical well with a 9 5/8” 53.5ppf casing. The
perforation interval is 300ft and 320ft of 5 ½” 20ppf wire-wrapped screen (6.5” OD) is
installed with a 100ft 5 ½” blank pipe assembly. The packer setting depth is at 10,000ftmd.
Completion fluid density is 9.6ppg and “regular” gravel is to be used and the job will be
executed at 2PPA concentration. Assuming a 0.25cuft/ft perforation packing factor, and a
25% blank volume sand coverage; Calculate the following:
± Total gravel volume required
± Weight of gravel required: assuming bulk density factor of 1cuft = 100lbs
± Carrier fluid volume required
± Effective slurry volume to be pumped
± Slurry density
± Estimated required minimum annular pressure to reverse out a full pipe column of
slurry once screenout is achieved

72
Gravelpack calculations
‡ Casing ID= 8.535”
‡ Screen OD = 6.50”
‡ Screen length = 320ft
‡ Blank pipe OD = 5.00”
‡ Blank pipe length = 100ft
‡ Perforation factor = 0.25cuft/ft
‡ Perforation length = 300ft
‡ Completion fluid density = 9.6ppg
‡ Gravel density = 22.1ppg (regular sand)
‡ Gravel concentration = 2PPA
‡ Gravel bulk density = 100lbs/cuft
‡ Packer depth = 10,000ft TVD

73

Gravelpack calculations
‡ Casing/Blank annulus volume:
± (ʌ/4*(8.5352 – 5.52)/144)*100 =23Cuft
± 25% Blank Volume = 0.25*23= 5.75Cuft
‡ Casing/Screen annulus volume:
± (ʌ/4*(8.5352 – 6.52)/144)*320 =53.4Cuft
‡ Perforation pack volume:
± (Cp x Lperforations)
± 0.25 x 300 = 75Cuft
‡ Total gravel volume required:
± 5.75+53.4+75 = 134.15Cuft
‡ Weight of gravel to be pumped:
± Wg=VT*ȡbulk (lbs)
± 134.15 * 100 = 13,415lbs of Gravel required

74
Gravelpack calculations
‡ Carrier fluid volume required
± (Vcf) = Wg/PPA (gals)
± 13415lbs/2PPA =6707.5 gals (160bbls)
‡ Slurry volume:
± (Vsl)= (Vcf)*Yield
± Yield factor = 1 + PPA/(ȡabs)= (1 + 2/22.1)= 1.09
± Slurry Volume = 6707.5*1.09 =7311.2 gals
‡ Slurry density:
± ((ȡcf + PPA)/Yield)
± (9.6 +2)/1.09 = 10.64ppg
‡ Required minimum reverse-out pressure:
± Minimum differential pressure created at screenout:
± Hydrostatic pressure = Density *depth(TVD)*0.052 (psi)
± (Tubing pressure – Annulus pressure)
± (10.64*10000*0.052)- (9.6*10000*0.052)= 540.8psi

75

Gravelpack placement
‡ Operational and design objectives:
± Obtaintotal annular pack around screens
± Complete perforation tunnel packing
‡ Poor tunnel pack efficiency leads to screen failure
± Sufficient blank volume reserves
‡ Key considerations:
± Flow position (Squeeze, circulating and reverse)
± Slurry system
± Placement rates
± Well trajectory effect

76
Squeeze position
‡ Ported seal sub is embedded in
the polish ID of the packer
‡ Closed system position
‡ No fluid returns allowed
‡ Slurry dehydration resulting from
leak-off into perforations
‡ Gravel is packed in perforation
tunnels and screen/casing
annulus

77

Circulating position
‡ Fluid returns through:
‡ The screens
‡ Up the washpipe and
‡ bypass in the service tool into the
annulus
‡ Slurry dehydration results from leak-off
into perforations and screen inflow
‡ Return rates function of fluid loss rates
‡ Return rates = Pump rates – fluid
loss rates
‡ Gravel is packed in perforation
tunnels and screen/casing annulus

78
Reversing position
• Service tool “ported sub” above
packer ID
• Direct communication between
workstring & casing annulus
• Pump pressures isolated from the
reservoir
• Position for:
Ɇ Reversing out excess slurry
Ɇ Pipe pickling operations

79

Slurry systems
• Low density system:
ɆGravelconcentration 0.5 – 2PPA
ɆNormally Newtonian carrier fluid
Ɇ“Conventional/waterpack”
• High density system:
ɆGravel concentrations up to 15PPA
ɆNormally viscous fluid carrier fluid (water or oil
based)
Ɇ“Gel pack”

80
Placement techniques
• Low rate gravelpack:
ɆTreatment rate up to 6bpm
ɆTreatment pressure below fracture
pressure
• High rate gravel pack:
ɆTreatment rate above 6bpm
ɆTreatment pressure may reach fracture
pressure in lower permeability or highly
damaged wells

81

Placement techniques
• “Frac and Pack”:
ɆCombined fracturing & gravelpack
• Increased perforation tunnel packing
• By-pass formation damage
• Restore formation stress
• Reduce matrix flow velocity- reduced
drawdown pressures
• Connect reservoir layers
ɆCased hole & openhole applications

82
Trajectory effects: Vertical wells
• Gravity assisted gravel
transportation
• Screen coverage of the
from bottom to top
• Low risk of sand bridge
formation
• Focus required on
perforation tunnel packing
83

Trajectory effects: Deviated wells

‡ Gravel settle on the low side causing
dune formation (alpha waves)
‡ Usually are evident at deviations >60
degrees
‡ More pronounced when using low
viscosity carrier fluids
‡ Dune formation can lead to bridging
and early screen-out
‡ Bridging risk minimized with
adequate washpipe OD to screen ID
ratio (§0.7-0.8) & pump rates

84
Trajectory effects: Horizontal wells
‡ Openhole sandface applications
‡ Technique using full circulation (rate
in = rate out)
‡ Fluid loss can be detrimental to
successful placement:
± Premature bridging & early screenout
± Competent filter cake critical

Heel Filter cake Toe

85

Trajectory effects: Horizontal wells

• Gravel deposits to the low side of
the hole forming a propagating
“alpha” wave from “heel-to-toe
• The faster the pump rate, the
lower the alpha wave height
Ɇ Low dune height ratio

Alpha wave Dune height

Heel Filter cake Toe

86
Trajectory effects: Horizontal wells
‡ Once alpha wave dune reaches
toe, a “beta” wave starts to form
‡ The “beta” wave back-fills the
open annulus from “toe-to-heel”
‡ Placement pressure increases as
“beta” wave continues

Beta wave

Heel Toe
Filter cake

87

Trajectory effects: Horizontal wells

• Packing process continues
until screen-out is achieved:
Ɇ Always extend screen length into
casing:
• Eliminates
screen-out shock on the
openhole section

Beta wave

Heel Filter cake Toe

88
System field operations
• BHA placement
• Packer setting
• Service tool release
• Pipe pickling
• Pack placement
• Reverse-out operation
• Service tool retrieval
• Particle management

89

Field operations
‡ Make up and RIH with BHA to depth
‡ Drop setting ball and set packer:
± Apply ~1600psi tubing pressure
± Bleed of pressure, pressure test annulus
packer sealing
± Perform pull test to confirm packer
anchoring
‡ Release service tool from packer:
± Apply ~ 2200psi tubing pressure
± Bleed of pressure
± Pick up service tool to confirm release Run in hole

90
Field operations
‡ Shift ball seat:
‡ Pick up service tool to reverse
position
‡ Apply ~ 3100psi tubing pressure
‡ Confirm ball shift with instant loss
of tubing pressure
‡ Perform pickle treatment in reverse
position

Pickling in reverse position

91

Field operations
‡ Perform gravelpack operation
‡ Return service tool to placement
position:
‡ Squeeze or circulating
‡ Pump gravelpack slurry
‡ Achieve screen-out
‡ Bleed off tubing pressures

Squeeze Circulating

92
Field operations
‡ Reverse out excess slurry:
‡ Apply required annulus pressure
‡ Move service tool to reverse-
position
‡ Reverse out excess slurry from
string
‡ Pull out of hole service tool

93

Particle management
• Drilling & completion fluids:
ɆCarrier fluid chemistry & compatibility
ɆSelection & PSD of weighting agent
ɆScreen plugging issues
ɆFilter cake removal etc…
ɆCompletion brine cleanliness
ɆStimulation operations

94
Particle management
• Surface solids handling:
ɆFluidsconditioning- shaker screens
ɆCentrifuges, surface lines
• Wellbore cleanout practices:
ɆStuck or failed packers
ɆTool failures- service tool plugging etc…
ɆFormation damage

95

GP design: Step-by-step guide

• Establish the need for sand control
Ɇ Cores
Ɇ Drill Stem testing
Ɇ Formation Strength logs
Ɇ Field Experience
• Perform formation analysis
Ɇ Properly size the gravel
• PSD analysis
Ɇ Determine formation compatibility with completions
fluid
• Clay, shale analysis
Ɇ Determine type of stimulation requirements
• Acid solubility etc…

96
GP design: Step-by-step guide
• Select type of completion
ɆBased on log data:
• Single
or Multizone cased hole
• Openhole completion
• Confirm effective zonal isolation
• Select gravel type and size
• Select screen
ɆSlot size/pore space
ɆScreen diameter
ɆScreen Material

97

GP design: Step-by-step guide

• Select Completion Fluids
ɆWellbore and carrier fluids
• Perform inflow performance analysis
• Design Casing and wellbore clean up
• Determine Screen interval length and
overlap
• Determine Centralizer spacing
• Determine slurry treatment technique
• Determine Workstring and Washpipe size

98
GP design: Step-by-step guide
• Determine blank length requirements
• Identify packer setting depth
• Perform gravelpack calculation
ɆGravel volume
ɆCarrier fluid volume
ɆDetermine pre-pad and pad volumes
• Perform placement analysis
• Plan pre and post job stimulation
requirements
99

GP design: Step-by-step guide

• Determine surface equipment
requirement
• Perform all displacement calculations
• Calculate all pressure requirement
ɆMax allowable surface pressure
ɆReverse out pressures
• Plan all contingency procedures etc..
• Establish Gravelpack evaluation
method
100
Questions

101