Sand Control

Gravel Pack Design

Manuel Bramao
PE-SC-0006
Learning Objectives

 Main tests for a sand control design

 Gravel size
 Slot size for Gravel Pack
 Slot size for Natural Sand Pack or SAS (Stand Alone Screen)
 Fluid selection

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Information necessary for Sand Control

Partic • Dry sieve analysis

• Mineralogy le
Forma • Laser particle size
tion • Shale stability Size analysis
analys Distri
is butio
n
• Oil or water based • Theoretically Saucier etc.
Compl • Required additives for Grav • Verified with sand
etion el
fluid stability retention test
selecti Sizin
on g

• Open hole or cased • Wire wrap slot size

Gravel hole. Scre • Premium screen pore size
pack • 𝞪𝞫 or Alternate Path en
metho
d? sizing

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Information necessary for Sand Control

 Completion method based on the formation information

– Shale stability
– Bottom Hole Temperature (BHT)
– Bottom Hole Pressure (BHP)
– Formation Heterogeneity
– Formation Height
– Deviation
– Acid Solubility
– Reservoir Drive Type (water, gas, compaction, etc.)
 Completion fluid selection and compatibility

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Sand Control Completion will depend on:

 Type of drilling/drill-in fluids

 Casing setting depth
 Displacement procedures and well conditioning
 Completion equipment
 Perforation Strategy
 Fluid loss control
 Completion procedures
 How the well is brought on production
 How the well is produced
 Required producing life for the completion
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Formation sampling

 Per layer
– critical for gravel size determination
 Full core samples are best
 Sidewall cores are the next best
– frequent sampling
– heterogeneous formation - 1 ft
– uniform formations - 5, 10, 20 ft spacing
 Bailed samples are not representative because of loss of smaller particles which are
usually carried out with the hydrocarbon
 Sand separator samples are usually not representative because the larger particles may
have been left in the well and the very fine particles may pass though the separator.
 shale-shaker
– Is not acceptable. It is often mixed with the mud so the mineralogy and size distribution are suspect.

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Testing

 First step
– Determine the formation particle size distribution (PSD) or granulometry.
 Second step
– Determine the screen size (slot, gauge) and the gravel size using specific rules
– Or, perform lab test with formation sand and different screens
 Third step
– Select the different completion fluids
– Determine the packing mechanism you plan to use.
– If required, select the gravel packing fluid.
 Polymer and breaker to transport gravel
– Kill pill formulation
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Particle Size Distribution

 Two methods used in the industry

– Dry Sieve analyses
 Requires larger samples
 Simpler and cheaper equipment
 Can only measure down to about 45 microns

– Laser Particle Size Analysis

 More expensive equipment
 Smaller sample sizes
 Quicker to run multiple samples

 Data presented in cumulative weight % vs size

 Large particles contribute more to the results than smaller particles. There are far
more smaller particles in a given sand than the sieve analysis would indicate
– This error may lead to wrong gravel and screen selection
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Sieve analysis

 Formation Sand
– Sample is run through a series of sieves
– Only measure down to 45 µm
– Time consuming
– Results depend on lab procedure (crushing and
cleaning)
– Amount remaining on each sieve is plotted as a
function of cumulative weight % versus grain
diameter

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US Mesh Sizes

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 Laser particle size analysis
 Laser particle analysis
– Sample is dispersed in water* or alcohol. When the laser beam hits a particle,
the beam diffracts around, through and scatters from the particle.
– Measure down to 0.4 µm
– Very quick lab test
– Two theories for analysis
 MIE – Most accurate especially when
small prticles are present
 Fraunhofer – Technique in older units.

* The dispersing media is very important especially if

clays are present. Using distilled water could
disperse clays which would generate many more
finer particles
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Sieve analysis Results

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Example of granulometry (PSD)

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 Sieve Analysis Plot

 Various points are determined

– d10 is representative of the biggest particles 100

– d40 90

Poorly Sorted Sand

Cumulative Weight (%)

80
Well Sorted Sand

– d50 average size 70

60

– d90 is representative of the smallest particles 50

40

– d95 is representative of the smallest particles 30

– Sub 45 micron is considered to be fines

20

10

 Uniformity coefficient, UC = d40 / d90 0

0.1000 0.0100 0.0010 0.0001

Grain Diameter (inches)

Fines
 Sorting coefficient, SC = d10/d95
 These points and the UC are used to
determine the required size for gravel
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 First pass recommendations for screen and gravel

d50<75𝞵, use gravel pack

d50>75 𝞵 Tiffin Criteria (SPE 39437)
–D10/D95<10, D40/D90<3, sub 325 mesh <2%, OH SAS
–D10/D95<10, D40/D90<5, sub 325 mesh <5%, OH SAS Premium Screen
–D10/D95<20, D40/D90<5, sub 325 mesh <5%, Gravel Pack (GP)
–D10/D95<20, D40/D90<5, sub 325 mesh <10%,GP Screen sized for fines
–D10/D95>20, D40/D90>5, sub 325 mesh >10%,GP Horizontal

SPE 39437, Tiffin & al Criteria

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 Recommendations continued

 If SAS completion
– WWS use sand advisor or if that is not available start at slot size of d10
– For premium mesh screens us sand advisor or if that is not available
 For d50 > 200 micron , use 250 micron mesh screen
 For 200 micron > d50 > 140 micron , use 175 m mesh screen
 For 140 micron > d50 > 120 micron , use 115 m mesh screen
 For 120 micron > d50 > 65 micron , use 60 m mesh screen
 If Gravel Pack completion
– For gravel sizing uses Saucier’s criteria (D50 = 6 x d50)
– For screen sizing, w = 0.5 x D90
 For 40/60 gravel, use 8 gauge screen slot
 For 20/40 gravel, use 12 gauge screen slot
 For 16/30 gravel, use 18 gauge screen slot
 For 12/20 gravel, use 25 gauge screen slot
 Verify all final designs with simulation and retention testing
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Uniformity coefficient (UC)

UC = D40 / D90

100

90

Poorly Sorted Sand

80
Cumulative Weight (%)

Well Sorted Sand

70

60

50

40

30

20

10

0
0.1000 0.0100 0.0010 0.0001

Grain Diameter (inches)

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Heterogeneous formation with high % of fines

Hungo-2 Cummulative Grain Size

100.0

90.0

80.0

70.0

Cu mla tive (%)

60.0

50.0

40.0

30.0

20.0

10.0

0.0
10000 1000 100 10 1
44 mm
Grain size (m)

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18
Exercise - Granulometry

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Gravel Pack design : gravel size
 Gravel Pack design

 To better understand the gravel pack process we need to look at

several phenomena:

– Arching effect
– Matrix and Gravel damage
– Fines migration

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Comparison Permeability to Pore Size

Critical Plugging
Permeability Pore Size Range
(*Millidarcies) (Microns) 1/3 to 1/7
(Microns)
1 1 0.3 to 0.14
5 2.2 0.75 to 0.32
10 3.2 1.05 to 0.45
50 7.1 2.36 to 1.01
100 10.0 3.33 to 1.43
250 15.8 5.27 to 2.26
500 22.4 7.45 to 3.19
750 27.4 9.13 to 3.91
1000 31.6 10.54 to 4.52
1500 38.7 12.91 to 5.53
2000 44.7 14.91 to 6.39

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Arching Assists in Restricting Sand Production

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 Why Arches Do Not Remain Stable

 Changing Stress State

– Pore Pressure Reduction
 Changing Drag Forces
 Changes in Flow Velocity
 Changing Water Saturations
– Reduction of Capillary Pressure Forces
– Relative Permeability Effects
– Solubility of Cementing Material

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Gravel Sizing
Saucier (1974)
(SPE 4030)
 Gravel sizing criteria for GP application from sieve analysis
 Based on experiments with severe flow disturbances (flow rate changes,
pressure surges, and gas evolution), suggested a ratio of pack median grain
size (D50) to formation median grain size (d50 of the finest segment of
producing formation) to be between 5 and 6 for effective bridging without the
loss of pack permeability, i.e.,
 For ratios between 6 and 10.5, formation sand enters the pack and reduces
the effective pack permeability
 For ratios greater than 10.5, the formation sand is not adequately constrained

D50 ~ 5  6d 50

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 Saucier experiment

Gravel Pack Sand Formation Sand

Fluid Flow

 Establish initial flow rate (qi) and stabilized pressure drop, calculate initial permeability
(ki)
 Increase flow rate and establish new stabilized pressure drop
 Reduce flow rate to initial rate (qi) and establish stabilized pressure drop, calculate
final permeability (kf)
 Optimum sand control occurs when kf = ki
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 Gravel / Sand Ratio < 6

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 Gravel / Sand Ratio 6 - 10

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 Gravel / Sand Ratio > 10

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 Gravel Pack Size Selection
Sand Gravel

100 -

Gravel Pack Retained K %

0-
1 6 14
D50 / d50 Ratio

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 Gravel Pack Sizing

 Gravel size(D50) vs Sand size(d50)

Sand Gravel

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 Gravel Sizing

 Gravel Pack case

– Saucier rule for Gravel pack 5-6 x d50
 Frac Pack
– rule 7-10 x d50
– One size larger than Saucier/Schwartz’s Criteria

UC Saucier Schwartz
<5 uniform 5 to 6 d50 6xd10
5 to 10 Not very uniform 5 to 6 d50 6xd40
> 10 Not at all uniform 5 to 6 d50 6xd70
Sampling not very
representative 5 x d50 Cannot be used

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 Exercise – Gravel Pack

 a)

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 Gravel and Proppants

 Lots of options
 Quartz sand (API-RP-58)
 Man-made Proppants
– Carbolite / Econoprop
– Light Weight Proppants
– High Temperature Gravels
– High Density Proppant
 Generally speaking
Ex of Gravel perm @4000 psi
– The higher the permeability, the better. K20/40 = 480 Darcy
K16/20
– Typically ceramics are used more often than quartz = 830today.
sand Darcy
K12/18 = 1100 Darcy

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API RP58 (Gravel testing)

Sizing Crush Resistance

- 96 % in the sieve range - Maximum % of fines under
- Less 2 % through smallest 2,000 psi :
sieve - 8/16 = 8%
Roundness and Sphericity - 12/20 = 4 %
- Both superior to 0.6 in the - Smaller = 2 %
Krumbein Chart
Acid Solubility
- Not exceed 1% in (HCl-HF)

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 Gravel selection optimization

 Synthetic gravel
– Better sorting & less fines during handling / placement
– More uniform pore size distribution
– Narrower size ranges
– Optimize range (e.g. 20/25, 30/35…mesh) at minimal cost
 Saucier is still commonly used.
 Some indications that it may be overly conservative but…
– Some Gulf of Mexico (USA) experience may indicate that we have gotten
overly aggressive thus the increased market for fines control chemistry.
 When in doubt, go to the lab and test your sand with the gravel of
choice.
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Screen opening design
Gravel Pack case – Wire Wrapped situation

 In the 30’s Coberly : gravel can retain sand if d 50gravel >2.5

slot size

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

smallest gravel diameter
- For 20/40 sand the smallest gravel is 40 mesh (D50 = 0.0165”)
- 0.0165” x 70% = 0.01155” or 0.012” opening (12 gauge)

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Gravel and screen slot design

US f f f median f median Porosity k Screen slot

mesh (inch) (mm) (inch) (mm) (%) (D) gauges
Mesh   moyen moyen Porosité K Slot des
US (inch) (mm) (inch) (mm) (%) (D) crépines
3-4 0.265-0.187 6.73-4.75 0.226 5.74 8100 100
4-6 0.187-0.132 4.75-3.35 0.160 4.06 3700 90
6-8 0.132-0.094 3.35-2.39 0.113 2.87 2900 60
6 - 10 0.132-0.079 3.35-2.01 0.106 2.68 42 2703 50
8 - 10 0.094-0.079 2.39-2.01 0.0865 2.197 50
8 - 12 0.094-0.066 2.39-1.68 0.080 2.035 41.5 1970 30
10 - 14 0.079-0.056 2.01-1.42 0.0675 1.71 800 30
10 - 16 0.079-0.047 2.01-1.19 0.063 1.60 20
10 - 20 0.079-0.033 2.01-0.838 0.056 1.42 40.5 650 20
10 - 30 0.079-0.023 2.01-0.589 0.051 1.299 15
12 - 18 0.066-0.039 1.68-0.99 0.053 1.335 20
12 - 20 0.066-0.033 1.68-0.84 0.050 1.26 510 20
16 - 20 0.047-0.033 1.19-0.84 0.04 1.015 330 20
16 - 30 0.047-0.023 1.19-0.589 0.035 0.889 270 15
20 - 40 0.033-0.0165 0.84-0.419 0.025 0.629 40.9 170 12
30 - 40 0.023-0.0165 0.584-0.419 0.01975 0.502 110 12
40 - 50 0.0165-0.0117 0.419-0.297 0.014 0.358 8
40 -60 0.0165-0.0098 0.419-0.249 0.013 0.334 39.8 70 8
50 - 60 0.0117-0.0098 0.297-0.249 0.01075 0.273 40 6
40 - 70 0.0165-0.0083 0.419-0.210 0.013 0.314 6
40 - 100 0.0165-0.006 0.419-0.149 0.011 0.284
60 - 70 0.098-0.0083 0.249-0.210 0.053 0.230

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 Stand alone screen SAS

 Slotted Liner
– Slotted Liner Opening is approximately equal to d10
 Wire Wrapped Screen
– Slot width = d10
 Mesh Screen
– Nominal pore size = d10
 Lab test
– Slurry or pack test depending on which failure mechanism you envision.

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SAS WWS – slot design

Designing the adequate sand screen

for a typical turbiditic sand granulometry

Cumulative proportion (%)

100

75

50

25
d10
0
1000 Slot or pore = 300 micron100 10
approx. 12 gauge screen
Particle size (microns)

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Screen OD Sizing Guidelines

 Clearance: minimum 3" in OH and 2" in Case Hole

Casing Screens
5" and 5 1/2" 2 3/8"
7" 3 1/2" or 4"
7 5/8" 4" or 4 1/2"
9 5/8" 5" or 5 1/2"

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 Screen, blank pipe & wash pipe

 Screen length: 5 ft above and 5 ft below perforations

 Screen OD: gap of 1-in per side
 Wash pipe OD: very close to screen ID screen minimum gapwash-pipe

 Blank pipe OD: slightly less than screen ³ 1-in

 Blank pipe ID: same as screen

blank pipe

screen

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 Completion Skin

rw

s  s p  sd  sdp
kdp
rdp
rp

kR

Lp

 h  rdp  k R k R 
sdp   ln   
kd  L p n  rp  k dp k d 
   
rd
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After McLeod, JPT (Jan. 1983) p. 32.

 Gravel Pack Skin

Cement

k R hLg
s gp  2
2nk gp rp

Lg

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Exercise – Gravel Pack

b)

c)

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 Any Questions?

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