SPE DISTINGUISHED LECTURER SERIESSPE DISTINGUISHED LECTURER SERIESis funded principally

through a grant of the

SPE FOUNDATIONTh S i t t f ll k l d thThe Society gratefully acknowledges those

companies that support the programby allowing their professionalsy g p

to participate as Lecturers.

Special thanks to The American Instit te of Mining Metall rgicalSpecial thanks to The American Institute of Mining, Metallurgical,and Petroleum Engineers (AIME) for their contribution to the program.

Selection and Design Criteria Selection and Design Criteria Selection and Design Criteria Selection and Design Criteria ggfor Sand Control Screensfor Sand Control Screens

ggfor Sand Control Screensfor Sand Control Screens

William K. Ott, P.E.,

Well Completion Technology H t T USAHouston, Texas, USA

Sand Control MethodsSand Control Methods

• No control• Slotted Liner / Punched Slot LinerSlotted Liner / Punched Slot Liner• Wire-Wrapped Screen• Pre-Packed ScreenPre Packed Screen• Shrouded Metal Mesh Screen• Expandable Screenp• In Situ Consolidation (Resin)• Oriented & Selective Perforating• OHGP & IGP• Frac Pack (Including Extension Pack or HRWP)

3• Screenless Frac Pack

Screen SelectionScreen SelectionScreen SelectionScreen Selection

Screens are an integral part of most do nholeScreens are an integral part of most downhole sand control strategies.

• Stand alone (open and cased hole)Common applications include:

Stand alone (open and cased hole)• Combined with gravel or frac packs, extension

packs and HRWPpacks and HRWP• Remedial or artificial lift protection

applications4

applications

Screen SelectionScreen Selection

Screen should be selected for maximum sand retention and minimum productivity impairmentretention and minimum productivity impairment

NOTE: potentially conflicting criteria

• Formation Particle Size Distribution (PSD)• C t l t i ti ( i i l• Correct slot or micron rating (empirical

methods)• S P bilit• Screen Permeability• SAND Software

5• Sand Retention Tests

Screen Selection Screen Selection Using Sieve Analysis TechniquesUsing Sieve Analysis TechniquesUsing Sieve Analysis TechniquesUsing Sieve Analysis Techniques• Formation Sand Sampling• Sieve Analysis Techniques

• Dry Sieving• Laser Light Scattering (LPSA)

• Particle Size Distribution (PSD)Laser Light Scattering (LPSA)

6

PSD Relationships with Slot Width PSD Relationships with Slot Width and Screen Micron Ratingand Screen Micron Ratingand Screen Micron Ratingand Screen Micron Rating

Screen opening (slot/micron rating) is dependent on particle size distribution (PSD)• Important parameters are:

d50, d10, d90, d95,, d40, d5 Sorting Coefficient (Sc) – d10/d95,

particle size distribution (PSD)

Uniformity Coefficient (Uc) – d40/d90

• Empirical selection criteria: COBERLY (ROGERS): 2 to 1 x d10 (largest 10%)COBERLY (ROGERS): 2 to 1 x d10 (largest 10%)SAUCIER: ~ 6.5 x d50

GILLESPI et al: Uc< 2 use d50, Uc~2 use d40, Uc> 2 use d30

SCHWARTZ: Uc < 3 use d10, Uc > 5 use d40, Uc > 10 use d70

BALLARD AND BEARE: d5 or d10 of finest sand that fails

7

• Semi-empirical method:SAND Software (developed by International Research Institute of Stavanger [IRIS])

Particle Size Distribution (PSD)Particle Size Distribution (PSD)

8

Comparison of Methods for Stand Alone Screen Selection

Screen PermeabilityScreen Permeability

• Any screen is permeable media through which flow penetrates under certain hydraulicflow penetrates under certain hydraulic conditions

• Major importance is to determine screenMajor importance is to determine screen permeability

True indicator of inflow capacityTrue indicator of inflow capacity Interface with formation, not open area, which is only part of the screen structurewhich is only part of the screen structure

• Permeability is 3D; open area 2D• Comparison criteria Screen permeability not

9

• Comparison criteria – Screen permeability, not % open area

SAND SoftwareSAND Software

Sieve Curves Sieve Analysis data from various measured depths

80

90

100(right) are input into Sand Software

Results presented in graph (below)

50

60

70

p g p ( )

Smallest slot opening where continuous sand production expected to occur

20

30

40expected to occur

Largest slot opening where sand production not expected to occur

0

10

20

1 10 100 1000

Smallest slot opening where no plugging is expected to occur

Largest slot opening where

“Safe” slot width range

10

G ra in S ize (mic rons)

g gsevere plugging is expected to be frequent

SPE 31087

Correct Slot Width or Micron RatingCorrect Slot Width or Micron Rating

Many operators do not use published empirical or semi-empirical selectionempirical or semi empirical selection methods• Coberly and Rogers - do not give reliable results

No accounting for sorting or uniformity of sandNo accounting for sorting or uniformity of sand• Gillespi et al, Schwartz and Ballard & Beare – better

•• Account for sand sorting and uniformityAccount for sand sorting and uniformity• SAND does not work with LPSA due to high

percentage of fines measuredpercentage of fines measuredStandard practice – perform sand retention tests with real or simulated formation sand

11

tests with real or simulated formation sand

Sand Retention Test MethodsSand Retention Test MethodsSLURRY TESTS

• Sand in slurry and flow SANDPACK TESTS

• Place sand directly on onto screen

• Weigh sand passing through

screen and flow through sand pack

• Weigh sand passing • Log pressure through

• Log pressure

Piston

Mediasample

Sandpack

Retaining meshPressure tappings

Test

12SPE 98308

mediadisc

Factors Affecting Sand Retention TestsFactors Affecting Sand Retention Tests

• Sand retention testing not easyg y• Tests do not relate to real world and

subject to experimental artefacts• View results with caution• Factors affecting test results:g

Wetting fluidFlow rateFlow rateChannelling

13

Correct Slot Width or Micron RatingCorrect Slot Width or Micron Rating

6

7 ScreenRetntn(@ P)

m2-1 12/20 prepack

Selection of test sandResults: Differential Pressure and % Sand Retention

80

90

100

c1

m3

4

5

6

12/20Prepack 40 %

230Excluder 70 %

m2 1 12/20 prepack

m2-6 12/20 prepack

m2-14 230 excluder

m2-37 250 excluder

ssur

e D

rop

(bar

)

60

70

80

%

c2

0

1

2

0 5 10 15 20 25 30 35 40

sand (g)

250Excluder 46 %

12/20Stratapac 70 %

Pre

s

30

40

50

volu

me

6

7

)

c2-1 12/20 prepack

ScreenRetntn(@ P)

12/20Prepack 94 %

(g) Stratapac

10

20

2

3

4

5

pres

sure

dro

p (b

ar)

c2-5 250 excluder

c2-4 12/20 stratapac

c2-3 12/20 stratapac

c2-2 300 wire wrap

250Excluder 94 %

12/20Stratapac 95 %

14

01 10 100 1000 10000

particle size (microns)0

1

0 5 10 15 20 25 30 35 40

sand (g)

Stratapac

300μmBaker sww 87 %

Sand Exclusion Devices (Filters)Sand Exclusion Devices (Filters)

• Based on SlotsSl tt d LiSlotted LinerPunched Slot Liner Wi W dWire-Wrapped Screen

• Based on PoresBased on PoresPre-Packed ScreenShrouded MetalShrouded Metal Mesh ScreenExpandable Screen

15

p• Other

Sand Exclusion Devices (Filters)Sand Exclusion Devices (Filters)

ISO Sand ControlISO Sand Control Screens Standard, ISO 17824

Scheduled to be sent to ballot in February 2008

16

ISO Sand Control Screens Standard, ISO 17824ISO Sand Control Screens Standard, ISO 17824

Scope: Sand Control Screens are

• Provide sand retention of the gravel pack and/or

mechanical filtration or retention devices to:

formation sand• Allow passage of fluids during well clean up,

production or any stimulation activitiesproduction or any stimulation activitiesProducts covered:• Wire wrap screensWire wrap screens• Pre-pack screens• Metal mesh screens

17

Slotted LinerSlotted Liner

Straight and Keystone Slots

18

Punched Slot LinerPunched Slot Liner

Stainless Steel Filt ti J k tFiltration Jacket

Support Ring

Base PipeBase Pipe

19

WireWire--Wrapped ScreenWrapped Screen• Came out in 1970s• Advantages

Keystone slotsHigh manufacturing efficiencyProfile materials can be stainlessProfile materials can be stainless steel

• DisadvantagesI t i i llInaccurate wire spacing can allow production of formation sand or pluggingCan be damaged when installed through doglegs, high angle and horizontal sections because of

20

horizontal sections because of vertical orientation between wrapped wires and support rods

WireWire--Wrapped ScreenWrapped Screen

Slip-on screen jacket constructionJacket toBase pipe

B Pi

Base pipeweld

Base PipeAll forces transferred through end connections

Tight Fit wrap-on-pipe construction

21

All forces are transferred to base pipe, and screen and base pipe behave as one unit

Rod Based Rod Based –– WireWire--Wrapped ScreenWrapped Screen

Wedge Wire(no base pipe)(no base pipe)

22

PrePre--Packed ScreensPacked Screens

D l Si l Sli P k23

Dual-screenprepack

Single-screenprepack

Slim-Pak

Metal MeshMetal Mesh• Stainless steel mesh developed in 1980s

Consists of base pipe, layered filtration j k t ( t t ) d tjacket (uneven pore structure) and outer shroudLess damage occurs during installation C i i t f t i l t lCorrosion resistance of stainless steel mesh

• Sintered (diffusion bonded) stainless steel mesh introduced in 1990s

Consists of base, multi-layer sintered metal mesh jacket (uniform pore

)structure) and outer shroudSimilar damage and corrosion resistance to non-sinteredHi h i 100

24

High pore size accuracy, even 100 μm diameter sand can be controlled

Metal MeshMetal Mesh

Layered with Non Uniform

PPores

SinteredSintered Laminate

with

Weave Patterns Uniform Pores

25

Shrouded Metal Mesh ScreensShrouded Metal Mesh Screens

Base Pipe

Base Pipe

26

Shrouded Metal Mesh Shrouded Metal Mesh –– Sintered ScreenSintered Screen

Base Pipe

Sintered LaminateFilter Media

Diffusion of Metal Molecules

27

Sintered Screen Filter MediaSintered Screen Filter Media

Technical Specification Summary

28

Shrouded Metal Mesh Shrouded Metal Mesh –– NonNon--Sintered ScreenSintered Screen

Protective Shroud

Micropore Weaves• Introduced in China

circa 2000• Uniform micropore

Weaves

Uniform micropore weave composite jacket on base pipe

Special welding technique eliminates costly sintering (diffusion bonding)Double-layer media and uniform pores improves

29

uniform pores improves performance Base Pipe

Shrouded Metal Mesh ScreenShrouded Metal Mesh Screen

Stainless Steel

Base

Wool ~ 600 Darcy

Pipe

Perforated Jacket

30

Expandable ScreensExpandable Screens

31

Next Generation SelfNext Generation Self--Expanding ScreenExpanding Screen

32

Guidelines for Screen SelectionGuidelines for Screen Selection

Select largest slot size or micron rating possible (under confines of required retentionpossible (under confines of required retention efficiency)Determine screen permeability if convenientDetermine screen permeability if convenientLarger open area of screen is betterScreen strength should be consideredScreen strength should be considered (protective shrouds, etc.)

33