5 - GP Completions

GP Completions
Copyright 2007,
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Sand Control Completion
Cased Gravel Pack
OH Natural Sand Pack (NSP)
OH Gravel Pack
Copyright 2007,
Cased Gravel Pack

Ease to complete as selective
Expensive perforation
Difficult lower perforations cleaning.
Difficult upper perforations packing
Copyright 2007,
Natural Sand Pack

Introduced in the early 90
Hole could be safely drilled
Slotted Liners and Pre-Pack Screen used initially
Premium Screen were developed
Copyright 2007,
Pre-Pack Screens
Copyright 2007,
Premium Screens
Halliburton Sinterpac
Pall Stratapac
Halliburton (Purolator) Poroplus
Baker Excluder
USF Superflo
USF Excel
Schlumberger (Secure) MeshRITE*
Copyright 2007,
Natural Sand Pack (NSP)

To get sand from well to the screens:
the sand must be separated from the rock (failure)
the sand must be transported
Stress, controlled by drawdown, does the first
Flow rate, controlled by drawdown, does the second

If the rock doesnt fail, no sand production, at any flow rate.
If the sand isnt transported, no sand production, at any stress
(But well fills with sand)
Copyright 2007,
NSP Erosion
Formation particle flow velocity through the screen will cause
erosion.
Consequences are more severe in gas wells.
Increased formation particle flow velocity will occur due partial
screen plugging.
Copyright 2007,
NSP Screen Plugging

If not eroded, in a sand producing environment in which
particles are allowed to flow, the screen openings tend to plug.
Copyright 2007,
NSP Considerations
Uniformity of the sand
For uniform sand (C<3), consider WWS / SL, (Economic decision).
For non uniform sand (C>3), consider PP or Premium.
Hole collapse
If instantaneous and uniform hole collapse is expected, consider WWS
/ SL (Economic decision).
If initially stable hole, the decision will be dictated by production rate.
In high rate environment PP or Premium are recommended.
Even in low rate environment consider tolerance to fines production SPE
39437 SPE 31087
Copyright 2007,
NSP Opening Sizing

Coberly (1937): Slot size = 2 * D10 (California)
Rogers (1971): Slot size = D10
Rogaland Research (1996): SPE 31087
Copyright 2007,
EXCEL SINTERED LAMINATE FORMATION SAND RANGE
NON UNIFORM - 112 TO 550 MICRON
EX250
UNIFORM 200 TO 450 MICRON
NON UNIFORM 90 TO 440 MICRON
EX200
UNIFORM 120 TO 360 MICRON
NON UNIFORM 45 TO 220M
EX100
UNIFORM 60 TO 180M
NON UNIFORM 27 TO
132 MICRON
EX60
UNIFORM 36 TO
108 MICRON
50
100
Very Fine Sand

(50 to 125M)
150
200
Fine Sand
(125 to 250M)
250
300
350
400
Medium Sand
250 to 500M
FORMATION SAND D50 SIZE
Copyright 2007,
450
500
550
1000
Coarse Sand
(500 to 1000M)
Gravel Pack - No Gravel Pack

Uniformity of sand : The more non uniform the sand, the more
GP is to be considered.
Hole stability: If an instantaneous hole collapse is not likely to
occur, consider GP.
Drawdown: Higher the drawndown (or higher the Q/L), the more
GP is to be considered.
Copyright 2007,
SELECTION GUIDE FOR OPEN HOLE COMPLETIONS

SCREEN TECHNOLOGY FOR SAND RETENTION
Medium Sands (d50 > 150 m)
(Sand Uniformity d40/d90)
Gravel Pack*
6
5
High Flow
WW
Premium
4
3
2
Prepack
WWS
25%
50%
100%
Reservoir Heterogeneity (d50 variations)

Copyright 2007,

Fine Sands (75 m < d50 < 150 m)
(Sand Uniformity (d40/d90)
Gravel Pack*
6
5
4
Premium
High Flow
WW
3
2
Prepack
WWS
25%
50%
100%
Copyright 2007,

Very Fine Sands (d50 < 75 m)
(Sand Uniformity (d40/d90)
Gravel Pack*
6
5
4
3
2
Premium
High Flow
WW
25%
50%
100%
Copyright 2007,
Gravel Pack
Introduction in the middle 90
Water Pack
AllPAC
Copyright 2007,
Water Pack
Relies on circulation.
Circulation can be achieved by a combination of filter cake
efficiency, downhole string configuration, pump schedule and
reservoir condition.
Mechanical back up (Premium Screens) normally used.
Job can be simulated using SandCADE* software.
Copyright 2007,
Effect of Formation Permeability
Perm = 500 mD
Perm = 3000 mD
Copyright 2007,
Effect of Skin
Skin = 10
Skin = 100
Copyright 2007,
Effect of Wash-pipe OD/ Screen
OD / ID = 0.8
OD / ID = 0.3
Copyright 2007,
AllPAC Technology
Does not rely on circulation. Gravel Pack is achieved even with
100% losses.
Comparable or reduced total system cost.
Continuos system support and development.
History
1st Design 1996
Manifold 1998
Eccentric Design 1999
Copyright 2007,
Horizontal AllPAC 1st Design
Copyright 2007,
Horizontal AllPAC Manifold
Copyright 2007,
Copyright 2007,
Stab in Coupling Assembly
7" 20# Liner (Shroud)
Stab in Box
Stab in Pin
7" Coupling with Nozzle Insert
TUBE #4
"B" RING NOT
WELDED TO SCREEN
TUBE #1
TUBE #3
TUBE #2
SECTION A-A
Copyright 2007,
SECTION B-B
SECTION C-C
SECTION D-D
Horizontal Eccentric AllPAC

2x2 Packing Tubes Eccentric Design on 4-1/2 12.6# Base Pipe.
* To reduce the screen weight for easy installation, 26# per foot.
* To increase the ID of the screen base pipe, 3.958 (can use 5 base pipe)
Copyright 2007,

Slurry can be seen travelling down the transport tubes. Once friction pressure is great enough,
the screen will be packed of via the packing shunt tube. Slurry in transport tube may be quite a
long distance down the well prior to achieving a tight pack in a section of screen further back
towards the heel of the well.
Transport tube
Gravel
slurry
3/8 ID
nozzles
4 Base pipe
Packing tube
Top manifold
ring
Copyright 2007,
Bottom
manifold ring
Single wire
wrap screen
Bottom ring
Standardized Shunt Tube
1. Seamless Carbon Steel (5000 psi)

2. The tungsten carbide insert eliminated erosion
3. Exit port hole size increased to 1/4 inch and is angled. This combination results
in minimal separation of the liquid from slurry
4. The length of the insert provides a linear flow cell which minimizes
leak off after the port is packed
5. Two sizes of shunt tubes 0.5 to 2 bbl/min or 4 to 6 bbl/min
6. Nozzles every 6 feet.
Copyright 2007,
Copyright 2007,
3,000 Horizontal Eccentric

Client: Texaco North Buzachi Inc.
Oil Field: Nort Buzachi
Well No. NB4Z
Job date: 27 July, 1999
NB4Z Gravel Pack Pumping Chart

5000
Reduce rate
to keep up
w ith slurry
mixing
Slurry at
crossover
3000
48 bbls in the w ell

Annular Bridge Forms Packing
through shunts
2000
Tubing Pressure
Pumping Rate (bpm)
1000
0
Copyright 2007,
60
Time (min)
120
180
Rate (bpm)
Pressures (psi)
4000
Final Screenout
33% Excess
Gravel Placed
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Reliability Considerations
How to Complete a Horizontal Well in the Gulf of Mexico:
Operators Shares Experiences
Harts Petroleum Engineer International, Nov 97
Schlumberger experience.
Copyright 2007,
How to Complete a Horizontal Well in the Gulf of Mexico
What was the actual failure rate in unconsolidated horizontal

completions as per early 1996 with screen only completion?
The results were overwhelming. The failure rate was about 20% at
that time, with failure defined as well sanded up or production sanded up.
From 123 wells 27 failed.
Copyright 2007,
Schlumberger Experience
Screen Only Completion.
Total: 90
Failure: 12-15
Mean Time: 3 years
Water Pack
Total: 49 ( 14 packages, 35 pumping)
Failure: Not available
AllPAC
Total: 14
Failure: None in 4 years since its introduction
Copyright 2007,
Completion Installation
Rotation
Wash Down Feature
Copyright 2007,
Mechanical Zone Isolation

External Casing Packers (ECP) are used to isolate zones.
ECP may be used with Stage Collar to cement build up zone.
Copyright 2007,
Chemical Zone Isolation

In Re-entry completions, the gas cap may be isolated by a
special system as MaraSeal*.
Copyright 2007,

5 - GP Completions

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5 - GP Completions

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GP Completions

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Sand Control Completion

Cased Gravel Pack

OH Natural Sand Pack (NSP)

, All rights reserved

Cased Gravel Pack

, All rights reserved

Natural Sand Pack

, All rights reserved

, All rights reserved

, All rights reserved

Natural Sand Pack (NSP)

the sand must be separated from the rock (failure)

the sand must be transported

Stress, controlled by drawdown, does the first

Flow rate, controlled by drawdown, does the second

, All rights reserved

, All rights reserved

NSP Screen Plugging

, All rights reserved

, All rights reserved

NSP Opening Sizing

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EXCEL SINTERED LAMINATE FORMATION SAND RANGE

NON UNIFORM - 112 TO 550 MICRON

UNIFORM 200 TO 450 MICRON

NON UNIFORM 90 TO 440 MICRON

NON UNIFORM 45 TO 220M

Very Fine Sand

, All rights reserved

Gravel Pack - No Gravel Pack

, All rights reserved

SELECTION GUIDE FOR OPEN HOLE COMPLETIONS

(Sand Uniformity d40/d90)

Reservoir Heterogeneity (d50 variations)

, All rights reserved

SELECTION GUIDE FOR OPEN HOLE COMPLETIONS

(Sand Uniformity (d40/d90)

Reservoir Heterogeneity (d50 variations)

, All rights reserved

SELECTION GUIDE FOR OPEN HOLE COMPLETIONS

(Sand Uniformity (d40/d90)

Reservoir Heterogeneity (d50 variations)

, All rights reserved

, All rights reserved

, All rights reserved

Effect of Formation Permeability

, All rights reserved

, All rights reserved

Effect of Wash-pipe OD/ Screen

, All rights reserved

, All rights reserved

Horizontal AllPAC 1st Design

, All rights reserved

Horizontal AllPAC Manifold

, All rights reserved

Horizontal AllPAC Manifold

, All rights reserved

Horizontal AllPAC Manifold

Stab in Coupling Assembly

7" 20# Liner (Shroud)

7" Coupling with Nozzle Insert