Sand Control
Sand Control
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Sand control
WELLS&COMPLETION (/WIKI/CATEGORY:WELLS%26COMPLETION)
| PRODUCTION ENGINEERING (/WIKI/CATEGORY:PRODUCTION_ENGINEERING)
Contents
1 Introduction
2 Reasons for sand production
3 Problems with sand ow
4 Predicting sanding potential
4.1 Field observations
4.1.1 Formation Strength
Log
(/wiki/File:Gravel_pack_sand_control.jpg)
4.1.2 Sonic Log
Sand control refers to managing/minimizing sand and ne production
4.1.3 Formation
during petroleum production. An illustration of sand control by screen
Properties Log with gravel pack[1].
4.2 Laboratory Experiments
4.3 Theoretical models
5 Control methods
5.1 Resin Injection
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Introduction
For normal ow of oil, formation should be porous, permeable and well cemented together, so that the large
volumes of hydrocarbons (/wiki/Hydrocarbon) can ow easily through the formations and into production wells.
There are few situations arises where these produced uids may carry entrained there in sand. Unconsolidated
sandstone reservoirs with permeability (/wiki/Permeability_(earth_sciences)) of 0.5 to 8 Darcie’s are most
susceptible to sand production. This may start during rst ow or later when reservoir pressure has fallen or water
breaks through. Sand production strikes with varying degrees of severity, not all of which require action. The rate of
sand production may decline with time at constant production conditions and is frequently associated with
cleanup after stimulation.
Sometimes, even continuous sand production is tolerated. But this option may lead to a well becoming seriously
damaged, production being killed or surface equipment being disabled. What constitutes an acceptable level of
sand production depends on operational constraints like resistance to erosion, separator capacity, ease of sand
disposal and the capability of arti cial lift equipment to remove sand laden uid from the well.
Sand entering production wells is one of the oldest problems faced by oil companies and one of the toughest to
solve. Production of sand during oil production causes severe operational problem for oil producers. Every year the
petroleum industry spends millions of dollars in sand cleaning, repair problems related to sand production and lost
problems related to sand production and lost revenues due to restricted production rates.
Consequently, sand control has been a research topic for over ve decades. The purpose of this document is to
help in understanding the causes of sanding, and how it can be predicted and controlled. It will examine the main
methods of sand control.
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The following list summarizes many of the factors that in uence the tendency of a well to produce sand:
Degree of consolidation: A mechanical characteristic of rock that is related to the degree of consolidation is
called “compressive strength”. This shows how strong the individual sand grains are bound together. The
cementation is typically a secondary geological process for consolidation. Poorly consolidated sandstone
(/wi/index.php?title=Sandstone&action=edit&redlink=1) formations usually have a compressive strength
that is less than 1,000 pounds per square inch. This indicates that sand production is normally a problem
when producing from poorly consolidated sandstone.
Production rate: The production of reservoir uids creates pressure differential and frictional drag forces
that can combine to exceed the formation compressive strength. This indicates that there is a critical ow
rate for most wells below which pressure differential and frictional drag forces are not great enough to
exceed the formation compressive strength and cause sand production. The critical ow rate of a well may
be determined by slowly increasing the production rate until sand production is detected. One technique
used to minimize the production of sand is to choke the ow rate down to the critical ow rate where sand
production does not occur or has an acceptable level.
Drawdown: An arch is a hemispherical cap of interlocking sand grains (below gure show the arch) like the
stones in an arched doorway that is stable at constant drawdown (/wiki/Drawdown) and ow rate,
preventing sand movement. Changes in ow rate or production shut-in may result in collapse of the arch,
causing sand to be produced until a new arch forms.
Reservoir Fluid Viscosity: The frictional drag force exerted on the formation sand grains is created by the
ow of reservoir uid. This frictional drag force is directly related to the velocity of uid ow and the
viscosity of the reservoir uid being produced. High reservoir uid viscosity will apply a greater frictional
drag force to the formation sand grains than will a reservoir uid with a low viscosity. The in uence of
viscous drag causes sand to be produced from heavy oil (/wi/index.php?
title=Heavy_oil&action=edit&redlink=1) reservoirs, which contain low gravity, high viscosity oils even at low
ow velocities.
Increasing Water Production: Sand production may increase or begin as water begins to be produced or as
water cut (/wi/index.php?title=Water_cut&action=edit&redlink=1) increases. Two possibilities may explain
many of these occurrences. First, for a typical water-wet sandstone formation, some grain-to-grain
cohesiveness is provided by the surface tension of the connate water (/wi/index.php?
title=Connate_water&action=edit&redlink=1) surrounding each sand grain. At the onset of water production,
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These results in an increasing pressure differential being required to produce oil at the same rate. An increase in
pressure differential near the wellbore creates a greater shear force across the formation sand grains. Once again,
the higher stresses can lead to instability of the sand arch around each perforation and subsequent sand
production
Accumulation in Surface Equipment: If the production velocity is great enough to carry sand up the tubing,
the sand may become trapped in the separator, HE, or production pipeline. If a large enough volume of sand
becomes trapped in one of these areas, cleaning will be required to allow for ef cient production of the well.
To restore production, the well must be shut-in, the surface equipment opened, and the sand manually
removed. In addition to the clean out cost, the cost of the deferred production must be considered.
Accumulation Down hole: If the production velocity is not great enough to carry sand to the surface, the
sand may bridge off in the tubing or fall and begin to ll the inside of the casing. Eventually, the producing
interval may be completely covered with sand. In either case, the production rate will decline until the well
becomes "sanded up" and production ceases. In situations like this, remedial operations are required to
clean-out the well and restore production.
One clean-out technique is to run a "bailer" on the end of slick line to remove the sand from the production tubing
(/wiki/Production_tubing) or casing. Since the bailer removes only a small volume of sand at a time, multiple slick
line runs are necessary to clean out the well. Another clean-out operation involves running a smaller diameter
tubing string or coiled tubing down into the production tubing to agitate the sand and lift it out of the well by
circulating uid.
Erosion of Down hole and Surface Equipment: In highly productive wells, uids owing at high velocity and
carrying sand can produce excessive erosion (/wiki/Erosion) of both down hole and surface equipment
leading to frequent maintenance to replace the damaged equipment. If the erosion is severe or occurs over
a suf cient length of time, complete failure of surface and/or down hole equipment may occur, resulting in
critical safety and environmental problems[2].
Collapse of the Formation: Large volumes of sand may be carried out of the formation with produced uid.
If the rate of sand production is great enough and continues for a suf cient period of time, an empty area or
void will develop behind the casing that will continue to grow larger as more sand is produced. When the
void becomes large enough, the overlying shale (/wi/index.php?title=Shale&action=edit&redlink=1) or
formation sand above the void may collapse into the void due to a lack of material to provide support.
When this collapse occurs, the sand grains rearrange themselves to create a lower permeability (/wi/index.php?
title=Permeability&action=edit&redlink=1) than originally existed. This will be especially true for formation sand
with a high clay content (/wi/index.php?title=Clay_content&action=edit&redlink=1) or wide range of grain sizes. For
formation sand with a narrow grain size distribution and/or very little clay, the rearrangement of formation sand
will cause a change in permeability that may be less obvious. In the case of overlying shale collapsing, complete
loss of productivity is probable. In most cases, continued long term production of formation sand will usually
decrease the well’s productivity and ultimate recovery.
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Predicting sanding
potential
Methods for predicting sanding rates include
eld observations, laboratory experiments,
and theoretical models (correlations). (/wiki/File:Sand3.jpg)
The picture shows Sand choking in separator, Pipe line failure, Erosion
The completion engineer needs to know the conditions under which a well will produce sand. This is not always a
straightforward task. At its simplest, sand prediction involves observing the performance of nearby offset wells.
In exploratory wells, a sand ow test (/wi/index.php?title=Sand_ ow_test&action=edit&redlink=1) is often used to
assess the formation stability. A sand ow test involves sand production being detected and measured on surface
during a drill stem test (/wi/index.php?title=Drill_stem_test&action=edit&redlink=1) (DST). Quantitative information
may be acquired by gradually increasing ow rate until sand is produced, the anticipated ow capacity of the
completion is reached or the maximum drawdown is achieved.
Field techniques like micro fracturing allow measurement of some far- eld earth stresses (see “Cracking Rock:
Progress in Fracture Treatment Design). Down-hole wire-line log measurements provide continuous pro les of
data. However, no logging tool yields a direct measurement of rock strength or in-situ stress.
Sonic Log
The sonic log (/wi/index.php?title=Sonic_log&action=edit&redlink=1) can be used as a way of addressing the sand
production potential of wells. The sonic log records the time required for sound waves to travel through the
formation in microseconds. The porosity is related to the sonic travel time. Short travel times, (for example, 50
microseconds) are indicative of low porosity and hard, dense rock; while long travel times (for example, 95
microseconds or higher) are associated with softer, lower density, higher porosity rock. A common technique used
for determining if sand control is required in a given geologic area is to correlate incidences of sand production
with the sonic log readings. This establishes a quick and basic approach to the need for sand control, but the
technique can be unreliable and is not strictly applicable in geologic areas other than the one in which it was
developed.
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Laboratory Experiments
Experiments on recovered cores may be used to gather rock strength (/wi/index.php?
title=Rock_strength&action=edit&redlink=1) data. This information may then be used to predict the drawdown
pressure that will induce sanding zones of some of the wells.
Theoretical models
A correlation may then be established between sand production, well data, and eld and operational parameters.
Accurately predicting sand production potential requires detailed knowledge of the formation’s mechanical
strength, the in-situ earth stresses and the way the rock will fail.
Finite Element Analysis Model: Probably the most sophisticated approach to predicting sand production is the use
of geo mechanical numerical models developed to analyze uid ow through the reservoir in relation to the
formation strength. The effects of formation stress associated with uid ow in the immediate region around the
wellbore are simultaneously computed with nite element analysis.
While this approach is by far the most rigorous, it requires an accurate knowledge of the formation’s strength both
in the elastic and plastic regions where the formation begins to fail. Both of these input data are dif cult to
determine with a high degree of accuracy under actual downhole conditions and that is the major dif culty with
this approach. The nite element analysis method is good from the viewpoint of comparing one interval with
another; however, the absolute values calculated may not represent actual formation behavior. Recently developed
models “IMPACT”-Integrated Mechanical Properties Analysis & Characterization of Near Wellbore Heterogeneity,
developed by Schlumberger and "Geo Mechanical International (GMI)" by Baker Hughes are mostly helpful for
superior and production predictions. (Website list provided in reference for model predictions)
(/wiki/Sand_control#References).
Control methods
Sand control methods may be classi ed as mechanical and chemical. Mechanical methods of sand control
prevent sand production by stopping the formation with liners, screens or gravel packs. Larger formation sand
grains are stopped, and they in turn stop smaller formation sand grains. Chemical control methods involve in
injecting consolidating materials like resins into the formation to cement the sand grains. Here we are discussing
the most important control measures which are in practice.
Resin Injection
This is simply considered as arti cial consolidation of sand. Which Involves injection of plastic resins, which are
attracted to the formation sand grains. The resin hardens and forms a consolidated mass, binding the sand grains
together at their contact points. If successful, the increase in formation compressive strength will be suf cient to
withstand the drag forces while producing at the desired rates. Three types of resins (/wi/index.php?
title=Resins&action=edit&redlink=1) are commercially available: epoxies, furans (including furan/phenolic blends),
and pure phenolic (/wi/index.php?title=Phenolic&action=edit&redlink=1). The resins are in a liquid form when they
enter the formation and a catalyst or curing agent is required for hardening. Some systems use “internal” catalysts
that are mixed into the resin solution at the surface and require time and/or temperature to harden the resin.
Properties of resins:
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Pre ush diesel oil which creates wettability and remove undesired material in the zone
Placement of resin by isolating the interval
Over ush of high concentrated resin injected to control the permeability and compressive strength
Advantages:
Disadvantages:
Sometimes dif cult to exclude undesirable uids such as water and/or gas
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Sieve analysis is the typical laboratory routine
performed on a formation sand sample for the
selection of the proper size gravel pack sand.
Sieve analysis consists of placing a formation
sample at the top of a series of screens which
have progressively smaller mesh sizes. The
sand grains in the original well sample will fall
through the screens until encountering a
screen through which that grains size cannot
pass because the openings in the screen are
too small. By weighing the screens before and
after sieving, the weight of formation sample
retained by each size screen can be
determined.
Gravel Pack Sand Sizing
There have been several published techniques
for selecting a gravel pack sand size to control
the production of formation sand. The
technique most widely used today was
developed by Saucier[4]. The basic premise of
Saucier’s work is that optimum sand control is
achieved when the median grain size of the (/wiki/File:Sand8.jpg)
gravel pack sand is no more than six times Gravelpacking in open and cased holes (3)
larger than the median grain size of the
formation sand. Saucier determined this
relationship in a series of core ow experiments where half the core consisted of gravel pack sand and the other
half was formation sand as illustrated in Figure
Gravel Pack Sand
Gravel pack well productivity is sensitive to the
permeability of the gravel pack sand. To
ensure maximum well productivity only high
quality gravel pack sand should be used. The
API RP582 establishes rigid speci cations for (/wiki/File:Sand9.jpg)
acceptable properties of sands used for gravel
packing. These speci cations focus on Gravel Pack Sand Diagram.
ensuring the maximum permeability and
longevity of the sand under typical well production and treatment conditions.
Although naturally occurring quartz sand is the most common gravel pack material used, a number of alternative
materials for gravel pack applications exist. These alternative materials include resin coated sand, garnet, glass
beads, and aluminum oxides. Each of these materials offers speci c properties that are bene cial for given
applications and well conditions. The cost of the materials will range from 2 to 3 times the price of common
quartz sand.
The speci cations de ne minimum acceptable standards for the size and shape of the grains, the amount of nes
and impurities, acid solubility, and crush resistance. Only a few naturally occurring sands are capable of meeting
the API speci cations without excessive processing. These sands are characterized by their high quartz content
and consistency in grain size.
Advantages
Disadvantages
While initial installation is economical, a remedial treatment to replace a failed screen may involve an
expensive shing job
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Comparison of technologies
Criteria Gravel pack Resin coated gravel without screens Resin injection
Pressure >1000 Psi 2500-3300 Psi Up to 3300 Psi
Temperature >150 oF <250 oF <250 oF
% of sand control 75% 5% 10%
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Recommendation
We must adopt new production practices for managing sand. These involved maintaining hydrocarbons
production at a level that is set over the long term to avoid reservoir damage, rather than pushing the wells to the
point where sanding occurred followed by a break in production. As a result of adopting these recommendations,
oil production has improved and sand production has been greatly reduced. More improved sand control
techniques are being researched and developed for new and more challenging environments.
References
1. ↑ Stephen P. Mathis, "Sand Management: A Review of Approaches and Concerns", SPE European Formation
Damage Conference, 13-14 May 2003, The Hague, Netherlands
2. ↑ George E. King, Pat J. Wildt, Eamonn O'Connell, BP America Inc., "Sand Control Completion Reliability and
Failure Rate Comparison With a Multi-Thousand Well Database", SPE Annual Technical Conference and
Exhibition, 5-8 October 2003, Denver, Colorado
3. ↑ Leone, J.A., ARCO Oil and Gas Co.; Mana, M.L., Consultant; Parmley, J.B., ARCO Oil and Gas Co., "Gravel-
Sizing Criteria for Sand Control and Productivity Optimization", SPE California Regional Meeting, 4-6 April
1990, Ventura, California
4. ↑ Wentao Xiang, Pingshuang Wang, China National Offshore Oil Corporation, " Application of Bridging theory
on Saucier gravel to examine the sand control effect", SPE Asia Paci c Oil and Gas Conference and
Exhibition, 9-11 September 2003, Jakarta, Indonesia
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