SPE-4030-PA Consideration On Gravel Packing
SPE-4030-PA Consideration On Gravel Packing
SPE-4030-PA Consideration On Gravel Packing
Introduction
Gravel packs have been used extensively along the
Louisiana Gulf Coast in an effort to reduce or avoid
sand production from unconsolidated formations.
Statistics show,l however, that through 1966, gravel
packs were only about 70 percent successful. *
The early literature on gravel pack design is based
primarily on the work of Coberly and Wagner2 and
of Hill. 3 Coberly's work in essence suggested that a
gravel pack having granular particles of diameter 10
times the formation grain size at the IO-percentcqarse point on a cumulative sieve analysis would
provide effective sand control. Numerous failures of
this criterion were noted, especially in the Gulf Coast
sands. Hill suggested that the ratio of lObe reduced
to 8. Failures were still noted in many applications.
At least one writer suggested concentrating on the
"fines" end of a cumulative sieve analysis. Winterbum4 states that "actual experience in the field has
shown that sand entry can virtually be eliminated by
the use of gravel which is approximately 10 times
the grain size of the 10 percentile of the finest sand
to be screened." Clearly a finer gravel will be more
effective in screening formation particles. However,
it must be evaluated in the light of how the finer
gravel affects permeability and reduces production.
Depending upon the writer, recommended ratios
of gravel to the IO-percent-coarse point may range
from 4 to 13. Other suggestions appear in the litera'Some liberty is taken with Mantooth's statistics; nevertheless,
the value is indicative of the problem.
Tests with physical models have shown that sand production and pack impairment are
minimized when the ratio of pack median grain size to formation median grain size is
between 5 and 6. In a study of the inertia and viscosity effects of flow in gravel packed
wells it was found that increasing the size and the density of the perforations should
increase productivity.
FEBRUARY, 1974
205
(1)
dt =
dp =
C, or pack pres-
DAMPER
INTENSIFIER
T
6"'
~
7"'
CASING
ELEVATION
'"'"'--+-_+,-F""OR.:..::M ATI ON
PLAN
206
85
90
FEBRUARY, 1974
Ratio of Pack
10% Coarse
Point to
Formation
10% Coarse
Point
14.3
7.4
5.7
5.7
4.5
3.2
Results of Test
Failed to constrain
formation
Failed to constrain
formation
10.7
Retained formation
Retained formation
pack length or thickness from 1 to 3 in. had a negligible effect on sand retention; (2) slight increases in
effective stress simulated by mechanical loading on
the sands during tests caused slight decreases in sand
production; (3) high starting rates caused higher initial
quantities of sand production and greater pack
impairment.
600~
3 0 0 r ; j - - - - - - - -_ _ _ _ _ _ _ _ _ _ _---,
~306
\o~
--------."
250
200
~'"
Fpf =6.7
o~
33
O~o~--033
6---0
IOO~06
r-
Fpf =94
p - o _ o _ o _ o _ /0_0_""'0206
-/o-o__o__ O~\
27
'-- 0 - 0
50
___ -027
10
15
20
25
30
35
Fpf =94
F f=94
p
.1
.1
40 45
50
t, MINUTES
55
60
65
70
75
80
85
90
207
-"
o~L-~L-T-L-T-L-T-L-~,o-L~-L-+,-L-+,~-+,~~
'pI
140
(2)
130
120
.......
110
>-
100
:0
:x;
90
a = ke/kf =
,;'
60
o
o
~
(a1>f-
fp)
(Z:), . (3)
70
~
u
13l
80
:i
(~;r e
50 -
40
20
___ a-f=O.Z
Well Productivity
10
12
13
fpf
The nature of the flow through gravel packed perforation tunnels (casing and cement thickness) is of
primary importance in the performance of gravel
packed wells. The pressure drop through gravel
packed perforations may often be considerably
greater than that predicted by Darcy's law.
The limit of applicability of Darcy's law is for
Reynolds number (N Re = ud p/ f-t) less than or equal
to 10.** For N Re > 10, inertia effects as well as viscous effects of flow must be accounted for. For one
dimensional flow, Greenberg et al. l2 suggest the following relationship between pressure gradient and
volumetric flow rate:
- dp/dx = Sf-t(q/ A)
(viscous)
+ (3p(q/ A)"
(4)
(inertia)
20-40
o ..
o ..
x TEST
us
tlPpf
MESH SAND
"
OTTAWA FUNT
"
GLASS SPHERES
k (dorcies)
208
with coefficients calculated from the previously discussed test data. The multicycle extrapolation is sufficient cause for the lack of complete agreement.
Fig. 8 is a graphical display of Eq. 5 for typical
values of perforation size. The significant difference
between Darcy's law and actual perforation pressure
drop is evident. Fig. 8 also illustrates how great the
pressure drop can be across formation-filled perforations; this emphasizes the necessity of placing gravel
in the perforations.
From the foregoing, the productivity from gravel
packed wells compared with that from open holes
may now be calculated. For unconsolidated sands,
the perforation depth into the formation is assumed
to be negligibly small. If we further assume that the
pressure drops in a gravel packed well are due only
to the packed perforations (~Ppf) and the formation
(~Pfm)' * then the productivity ratio is
1 /l 0
factual
~Pfm
lopen hole -
UP!m
Ap
U
pf
~Pfm
= ~,
up""
(6)
where
~Ppf
Perforation
Pressure
Flow Rate
Drop,
cc/sec B/D/perforation t.p p , (psi)
15.5
8.2
16
27.0
14.0
30
15.6
8.2
16
Fp ,
Test
Fine Pack
k i :::::; 150 darcies
6.0
Fine Pack
(Repeat)
6.0
15.5
26.6
15.5
8.2
13.8
8.2
20
39
18
Intermediate Pack
k i :::::; 270 darcies
8.5
14.8
25.
14.8
7.7
l3.
7.7
54
180
94
Coarse Pack
k, :::::; 700 darcies
12.8
15.7
21.6
15.5
8.3
11.2
8.2
160
397
270
900,--------------------,
PERFORATION FILLED
WITH 0 5 DARCY
LENGTH
OF
pf = 2"
FORMATION SAND
i
800i
3/8
f'-
=1 Cp
0.8
t3 ~ 2 3
10 4
_ q,u In(re/re)
Pfm 7.08 k f h
Fig. 9 shows 1 / 10 vs p"" for typical production interval data and various perforation sizes and densities. It is evident that increases in perforation size or
density should result in substantial increases in productivity. From Fig. 9 for the conditions assumed we
see that for a drawdown of 500 psi and four % -in.diameter perforations per foot only 46 percent of
open-hole productivity is available. Increasing the
perforation size to lh-in. diameter provides 63 percent of open-hole well productivity, and increasing it
to % -in. diameter provides 86 percent. Assuming no
casing or cement damage would result, 95 percent of
open-hole productivity could be obtained with eight
%-in.-diameter perforations per foot.
A previous evaluation by Muskat14 has indicated
that the flow resistance through perforated casing is
greater than the flow resistance of an open-hole completion. Thus, if in addition to ~Ppf and ~Pfm we
assume the perforated casing resistance of Muskat,
then Fig. 10 may be generated. It must be pointed
out that Muskat's relation for perforated casing is a
function of the perforation radius, whereas our analysis includes radius to the second power (area) hence
it is not completely consistent to combine the two.
However, it illustrates possibly the relative influence
of gravel packs on well productivity, assuming there
is some reduction due to perforated casing.
In the preceding examples, typical values were
used. It should be pointed out that for increasing
formation permeability (i.e., permeability greater than
the 0.5 darcies used) the curves of 1/ fo indicate a
lower percentage of open-hole productivity available.
Nevertheless, this still may be overcome to a large
degree by increasing perforation size and density, and
<l 400
I
i
300
3/4
200
,
100
I
______ -.L__
__
50
75
q[bpd/pf)
~~
100
125
PRODUCING
INTERVAL' 20'
k,'05dorc'.$
ki ,180 dore,n
,6.23.10
(I
=1
t:. (joB
PERFORATIONS FILLED WITH fORMATION SAN?
O~~1~OO--~2~OO~~m~~'~OO~~~=6~OO~~~~~~~~_~~,=
"From the tests, pressure drops through the gravel annulus and
the screen are indeed negligibly small. The effects of per
forated casing alone on well productivity is discussed in the
followi ng pa ragra phs.
FEBRUARY, 1974
1 0 , - - - - - - - - - - - - - - - - - - -_ _-,
3/ .... ,ppf
------__
.----____.
PRODUCING
INTERVAl' 20'
-'--'-'-----112".ppl
3/8"4> pi
---'-.:....~-
kl .05 do",.,
ki =180 do,,;n
IJ =23"
lOA
-------
Cj '4
900
1000
b,PCJgI
A FAIRLY ROUNDED
~
<120
40
~I
<120
15
10
q pf ( BPD)
1.0
r-------------------~
.9
.8
-:i .7
~ .6
~ .5
o .4
UNCORRKTED SW CORES
o CORRECTED SW CORES
:::;
~ .3
'"
o
Field Results
~ .2
_'______'____L_L___'____'____.J
11
12
13
14
15
16
17
40
also were installed improperly (that is, they were circulated in place instead of being squeezed into the
interval).
Fig. 12 shows the probability of failure vs mediangrain-size ratio based upon the uncorrected sidewall
cores and also after an empirically defined correction
was applied. No failures occurred for Fpf less than 6,
with the probability of failure increasing with increasing Fpf These data support the laboratory findings
that the median-grain-size ratio should be less than 6
to prevent gravel pack failure.
It has also been noted that the productivity indices
of more recent wells are greater than those of wells
completed with the older conventional techniques.
However, gravel pack productivity still needs to be
improved, and increased perforation size and density
as well as improved gravel placement techniques are
being used toward that end.
Conclusions
From the preceding, we conclude the following:
1. To minimize sand prosuction, the ratio of pack
median grain size to formation median grain size
should be between 5 and 6 where there is severe
flow disturbance.
2. Bridging, though satisfactory for uniform undisturbed flow, is unsatisfactory for severe (but realistic) flow conditions.
3. Pack permeability impairment is minimized and
hence production is maximized if the median-grainsize ratio is 6 under severe flow conditions and with
given perforations.
4. Rounded grains appear to be better than angular grains for gravel packing.
5. Well productivity may be increased with increased perforation size or density.
6. Perforation tunnels must be tightly packed with
gravel to minimize impairment; therefore, squeeze
packing must be employed.
7. Before packing, perforation debris must be removed by backsurging or some equivalent method.
8. It is mandatory that completions be clean and
that packing fluids be compatible with the formation.
9. Crossover tools should be used in gravel placement.
Nomenclature
A = cross-sectional area of a perforation
C = function of particle shape, packing and
skewed ness
C j = concentration of jets per foot
C = average sand concentration in gravel
pack effluent in time increment t1t
Cmax = maximum C value during test period
dp f dx = pressure gradient
d = mean particle diameter (general)
df = median formation grain size
dp = median pack grain size
FgL = gas-liquid ratio
F pf ~-= ratio f'f rnpd;afJ err;:,;" ,,;71' nf Dack to
median grain size of formation
h = net pertoratlon helgat
FEBRUARY, 1974
Acknowledgment
I express my appreciation to Shell Oil Co. and Shell
Development Co. for granting permission to prepare
and publish this paper. I also acknowledge the subsequent work by R. S. Torrest on flow through gravel
packed perforations, which expanded this initial effort.
References
1. Mantooth, M. A.: "Statistical Analysis of Recent Sand
Control Work," API Paper 926-13-G, API Committee
on Sand Control (1968).
2. Coberly, C. J., and Wagner, E. M.: "Some Considerations in the Selection and Installation of Gravel Packs
for Oil Wells," Pet. Tech. (Aug. 1938) 1-20.
3. Hill, K. E.: "Factors Affecting the Use of Gravel in
Oil Wells," Oil Weekly (May 26, 1941) 13-20.
211
212