Weatherford Screens Catalogue

Sand Screen SelectorOpen Hole Evaluation Completion Sand control Conventional well screen Production Expandable sand control Gravel pack Inflow control Reservoir isolation Specialty screen Expert guidance on sand control technology selection and application for openhole completions. Solving your sand control challenges. Intervention May 2009 SAND REtENtION EROSION SOLIDS AND FLuIDS CONtROL SPE 64398 “Screen Selection for Sand Control Based on Laboratory Tests.” 2006 © 2010 Weatherford. C.. can have a far-reaching effect on the productivity and efficiency of a producing well. Sizing that is too large can lead to unacceptable production of sand.” 2006 SPE 107437 “Development. The choice of well screen.” 2000 SPE 82244 “Media Sizing for Premium Sand Screens: Dutch Twill Weaves.” 2007 122269 “Sand Control Screen Erosion – When are you at Risk?” 2009 SPE 68933 “Evaluation of Filter Cake Flowback in Sand Control Completions.” Jones. Simulia Customer Conference.” 2003 SPE 98308 – MS “Sand Retention Testing: The More You Do. All rights reserved. K...” Watson. The Worse It Gets. analysis. you can learn more about our applied technology through Weatherford’s technical papers. however.” 2001 SPE 98287 – MS “Expandable Sand Screens and Drilling Fluids: Laboratory Testing for Successful Field Application. particle size distribution (PSD) and particle size uniformity—is central to the design of sand-control completions. Sizing that is too small can lead to total or partial plugging. Verification and Application of a Screen Erosion Model. forcing hydrocarbon production through nonplugged sections. Excessive sand production rates can result in loss of the well. causing major problems with flowlines and surface production equipment. Why is selecting the right well screen so important? Oil and gas reservoirs exist in all types of sand. We will work with you to refine the completion design before detailed operational planning and wellsite execution. which in turn can lead to erosion of sand screens and surface equipment.. and Jones.” which can lead to screen erosion. & Watson. …selecting the appropriate screen… Weatherford’s Sand Screen Selector is a planning tool that guides you through the process of choosing the most effective sand-control method for your wellbore completion. … and applying the technology. C. . and the well screen to meet your reservoir sand-control challenges. Weatherford combines sandcontrol technology and expertise to provide you with a detailed engineering evaluation. but formation sand particles in a well stream can hinder production. FEA MODELING “FEA Modelling of Expandable Sand Screens.It’s all about the sand. K. This situation causes what is known as “hot spotting. based on the reservoir PSD and other considerations. Knowledge of reservoir sand properties―such as particle size. 2008 Abaqus Users Conference “FEA Modelling of Expandable Sand Screens Interactions with Rock Formations. We have made every endeavor to include all applicable information. 01 152.340 2.3 9.7 19.00 5.56 7.01 101.5 11.38 111.25 5.65 67.63 117.37 6. For gravel-pack operations.7 26.50 190. the wire wrap should be sized to retain the gravel placed between the screen and formation while minimizing any production restriction.90 149.4 29.501 472.45 4.276 159.130 783 182.000 101.) (lb/ft) (in. Maximum bend angle for screen (° per 100 ft.450 1.210 810.15 7.408 111.0 18./mm) (lb/ft) (lbf/kN) Angle (in.0 18.1 11. Wire-wrap screens are the appropriate choice for coarse.30 5.30 5.2 9.130 783.63 143.90 124.13 130.1 513.340 2.9 15.450 1.450 1.2 14.1 337. Alternatively.7 28.65 7.38 136.01 127.00 3.00 127. Wire-Wrap Metal-Mesh Openhole GP ESS Wire-Wrap Screens Wire-wrap screens consist of a shaped wire wound around perforated liner and are used alone or to support a gravel pack.440 1.25 184.60 5.15 5. All rights reserved.6 6.60 4.76 4.31 3.00 177.690 394.4 19.892 124.101 513.4 27.35 7.88 149.51 190. high-strength design and offers three direct-wrap options: Dura-Grip® ultra-Grip™ and Ultra-Grip HD screens.283.920 150.323.95 5.65 5.340 2./mm) (in.4 N/A N/A 176.1 176.340 2. © 2010 Weatherford.5 86° 75° 67° 60° 54° 45° 43° 4.1 337.009.38 187./mm) (lb/ft) (lbf/kN) Angle (in.340 2. including ESS® expandable sand screens.12 4.548 90.0 17.5 120° 105° 86° 75° 67° 60° 54° 45° 43° 4.61 3. called Super-Weld® screen. jacket-type design.4 9. or 30.1 513.77 146.980 1.80 7.00 6.4 19.86 7.Sand-control portfolio We offer all types of well screens.210 811 226.3 17.5 123.78 70.992 76.28 83.283 86° 75° 67° 60° 54° 45° 43° Screen tensile strength is based on entire screen assembly and L80 base pipe. Our technologies are designed to minimize sand production and maximize ultimate production. is available for less challenging applications.03 178.90 99.440 1.5 m) may exceed allowable bend angle for some threads.6 12.26 5. Weatherford originated the wrap-on-pipe.31 3. Base Pipe Dura-Grip Wire-Wrap Screens Ultra-Grip Wire-Wrap Screens Ultra-Grip HD Wire-Wrap Screens End Ring Screen tensile Maximum End Ring Screen tensile Maximum End Ring Screen tensile Maximum Size Weight ID OD OD Weight Strength1 Bend OD OD Weight Strength1 Bend OD OD Weight Strength1 Bend 2 2 (in.220 548.55 6.50 N/A N/A 12.70 6. and gravel packs.90 175.46 5.980 1.980 1.9 15.501.16 5.101.323 337.27 133.0 472.009.501.340 2.7 297.96 4.995 50.51 139.5 226.25 4.55 5.00 2.90 4.0 26.80 4.50 114.323.77 95.26 7.00 101.85 5. stand-alone screens.6 15.7 297.41 2.13 104.101.75 4.06 4.40 137.210 810.27 184.50 139.13 155.88 123.6 12./mm) (in.00 152.70 7./mm) (in.5 182.130 783. .85 4.65 7.283.55 4./mm) (lb/ft) (lbf/kN) Angle2 2-3/8 2-7/8 3-1/2 4 4-1/2 5 5-1/2 6-5/8 7 1 2 4.40 111.0 24.0 472.010 297.7 88. Maximum DLS (dogleg severity) is 50% of maximum bend angle.51 114./mm) (in.60 4.01 3.75 3.0 1.77 121.95 6.12 180.9 12.63 193.4 176.10 7.40 187.84 7. See thread manufacturer’s specifications.441 62.27 108.40 7.96 2.5 226. well-sorted sands.67 2.88 98.440 1.4 29.45 12.5 182.4 27. a slip-on.15 80.13 181. 450 1.440 1./mm) 3.96 4./mm) 1.690 394.995 50.992 76.ESS® Expandable Sand Screens A woven metal mesh is adhered to a slotted liner and protected by a perforated outer cover.210 810.5 226.0 17.980 1. The screen is mechanically enlarged downhole to expand compliantly against the wellbore.440 1.9 20.8 23. 2 Maximum bend angle for screen (° per 100 ft.60 4.11 104. which is slipped over a perforated liner/base pipe.2 31.63 143.5 14./mm) 6.24 158.27 184.22 107. providing borehole support.38 187.95 ESS Expandable Sand Screens Dutch twill Weave Petroweave 120 Petroweave 150 Petroweave 230 Petroweave 270 Petroweave 400 Weave Aperture (µm) 120 150 230 270 360 Metal-Mesh Screens A woven single-layer or a woven—sometimes sintered—multilayer metal mesh is shaped and combined with a protective.1 Maximum Bend Angle2 N/A N/A 86° 75° 67° 60° 54° 45° Shroud OD (in.02 Open Hole Size (in. Weatherford’s ESS systems provide retention of the widest range of sand types without the need for gravelpacking.6 15.10 154.70 7.12 130.94 7.37 Shroud OD (in. The screen opening stops some of the produced sand until larger grains “bridge” on the screen surface.2 13. These industry-leading.1 Maximum Bend Angle2 120° 105° 86° 75° 67° 60° 54° 45° All values are based on 316L screen jackets and L80 base pipe.210 810.68 4.1 176.501.50 7.92 6.130 783.4 16.78 6.5 182.47 113.0 472.0 ID (in. and removing the need to place gravel for filtration of formation sand.9 10.05 5. .101.74 145.5 14.89 5./mm) 4. Base Pipe Size (in.00 3.5 123.54 5. ESS Expandable Sand Screens Size (in.101. compliant systems provide high productivity and good reservoir management capability.340 2.009.06 153.23 3. perforated outer covering in a cartridge.450 1.8 23.000 101.5 182.323.5 m) may exceed allowable bend angle for some threads. or jacket.408 111. Maximum DLS (dogleg severity) is 50% of maximum bend angle.66 Excelflo Metal-Mesh Screens Weight (lb/ft) 7.323. Metalmesh screens reduce the risk of plugging at the screen face.7 297.45 Maxflo Metal-Mesh Screens Weight (lb/ft) N/A N/A 13.26 5.220 548.441 62.61 117.40 4.548 90.13 155. The sizing criteria recommended is that a weave will adequately retain sand with a D5 equivalent to the weave aperture./mm) N/A N/A 4.1 337.0 24.980 1.80 6. eliminating the annular space.6 6.9 20.23 132.00 6.07 128. horizontal wells and stand-alone applications.1 337.2 9.25 234.4 9.892 124. Weatherford’s Excelflo® and Maxflo® screens provide reliable sand control ideal for short-radius.88 174.7 297.00 2.920 150.2 31.) 2-3/8 2-7/8 3-1/2 4 4-1/2 5 5-1/2 6-5/8 Weight (lb/ft) 4.340 2.08 78.28 9.4 16. They are operationally efficient and compatible with many openhole zonal-isolation techniques. The sizing criteria recommended is that a weave will adequately retain sand with a D5 minimum to D10 maximum equivalent to the weave aperture.0 472.56 192.130 783.) 4 4-1/2 5-1/2 7 Running OD (in.5 226.57 90.12 4.19 4.83 224.72 119.75 8.09 5. or 30.67 2.501.84 5.1 tensile Strength1 (lbf/kN) 88.1 tensile Strength1 (lbf/kN) N/A N/A 176. 1 Screen tensile strength is based on entire screen assembly.009.5 11.) 5-7/8 6 6 6-1/8 6-1/2 8-1/2 8-1/2 Maximum Compliant Range (in. See thread manufacturer’s specifications. 44 138. This mass of gravel forms a depth filter and excludes sand from the wellbore./mm) ICD Base Material and Stress Intensity (ksi/MPa) Elastomer Material* Quantity 5 Material 10 .175 or 2.10 7.70 Tungsten carbide 13Cr L80 110 or 80 758 550 FKM95 Flow Ports Sizes (in. they enable predetermined setting of the designed pressure drop (heel-to-toe) along the production/screen section. keeps the load-bearing grains of sandstone reservoirs stationary.12 206.40 6.25 1/8 or 3/32 3.381 0.33 3.50 12. Weatherford’s WFX sand-control system simplifies gravel-packing operations by providing a reliable.18 6.00 127. The ICDs are fitted to the screen joints to balance the inflow profile from the production interval.00 152. fixed reference point that holds the right position and mode to avoid movement during critical phases of treatment. further mitigating sand production. preventing them from breaking away and being introduced into the wellbore with produced fluids.44 112. When ICDs are combined with either wire-wrap or metal-mesh screens. FloReg™ Inflow Control Devices Incorporation of inflow control devices (ICDs) in the screen design can extend the applicability for a wire-wrap or a metal-mesh screen.32 84.16 Suitable Screen Selection Overall Length (in.90 99./mm) OD (in. allowing the reservoir to drain more efficiently and thus maximizing production and ultimate recovery.50 165.78 5./mm) Length (in.06 4. openhole gravel packs placed around a wire-wrap or metal-mesh screen will stabilize the wellbore to a degree./mm) 3.33 8. Weatherford’s FloReg ICDs are designed to help distribute inflow evenly throughout a horizontal wellbore.) 2-3/8 2-7/8 3-1/2 4 4-1/2 5 5-1/2 6-5/8 7 *Alternative elastomer material is available.Sand Screen Selector Openhole Gravel Packs A gravel pack consists of a slotted or perforated liner placed in the well and surrounded by gravel.69 195. Installation of our Model 4P gravel-pack system. providing primary sand control. In addition.4 264. ICDs reduce the tendency of water or gas coning. Metal-mesh and wire-wrap screens 10. Openhole gravel packs are the appropriate choice for more poorly sorted sands and can be effective in long horizontal wellbores.00 5. using multiple open or closed flow ports. The gravel pack is sized to the formation sand. FloReg Inflow Control Devices ICD ICD Size (in. while the screen is sized to retain the gravel-pack sand. a well-established completion procedure that creates a reliable and durable downhole filter. crushed.0 100.25 0. sieve 7. single-layer or multilayer metal-mesh and protective perforated outer cover shaped over a perforated base pipe ESS ® Openhole GP A wire-wrap or metal-mesh screen is placed in the wellbore.0 Average screen approach velocity (ft/sec) 100. e. 6 Erosive wear (mg/g) 5 4 3 2 1 0 0 50 Actual erosive wear (mg/g) Predicted wear (Weatherford model) 100 150 Average particle size (µm) 200 250 Slurry Test Results: Well-Retained Sand Pressure across screen Sand passing screen 0.20 0. using a series of sieves with openings based on ASTM E1170. The screen is usualy sized to retain the gravel but can also be sized to retain the formation sand.00 250µm Dura-Grip 200µm Dura-Grip 175µm Dura-Grip 150µm Dura-Grip 0. 100 90 80 Cumulative (%) 70 60 50 40 30 20 10 d10 d40 d95 d90 Grain Size Distribution Analysis D95=15µm Fines content <45µm 12% 100 90 80 d95 d90 Uniformity Coefficient Examples The amount of sand passing the screen in slurry tests and sand-pack tests is recorded. Data after G P Tilly. the amount of sand passing through as well as the pressure drop.3 Sorting coefficient (SC) D10/D95=230/15=15.05 0. wire-wrap screens (WWS) or even slotted liners (SL) are suitable.00 4. uniform UC = 9.50 1.00 .1 1. 6911. for instance. During installation of the screens.10 0.045 0.025 0. The degree of conditioning required to prevent the drill-in fluid from plugging the screen during deployment is determined through laboratory tests. Influx 8 9 10 Heel Heel Heterogeneous reservoir Description of Filter Output from Inflow Performance Modeling Software Heel Influx 17 Influx Influx 15 Influx Influx Woven metal-mesh.15 0. Above 100 µm. the combined system has the required properties to withstand all depletion forces. Sand is placed directly onto the screen.0 Produced Sand versus Flow Rate 0. without ICD Gas Flux Reservoir with ICD Well length Influx Solving your sand control challenges. Another consideration—mud filter cake that is not properly cleaned up—can result in worm holes.50 1.25 Sand passing screen (ppb) 0. • Requires a sample size greater than 10g for a representative test • Measures down to 45 µm • Difficult to get good dispersion • Measures the second-smallest dimension 1/2-in. Analysis of produced sand usually indicates an exaggerated amount of fines present. Sand is suspended in a slurry and flowed downward onto the screen. well-sorted sands. developed by Weatherford. Typically.030 0. as flux is distributed through the screen. such as NACE MR0175 and ISO 15156. presence and severity of shales.2. • Requires much less sand than dry sieving • Measures down to 0. Sample Selection Sands should be representative of the proposed completion interval.50 2. Predicted Wear from Weatherford Screen Erosion Model Example plots B Highly uniform Assess Sand-Control Options Selection of the optimal method to control a given sand or group of sands is based on the measured PSD. pressure buildup is plotted.00 Slurry volume injected (liters) 2.UC = 4 Laser . and fluid type. acidizing). fixed guidelines for material selection. A more deviated or slanted plot indicates poor sorting of sand grains. Below 100 µm.10 0. 14 12 Pressure drop (psi) 10 8 6 4 2 0 0 50 100 150 200 250 Volume passing weave (mL) 300 350 400 200 mesh 75 µm 230 mesh 63 µm Unconditioned Effect of progressive conditioning on screen plugging Effect of Progressive Conditioning on Screen Plugging RESULTS Uniformity Coefficient (UC = D40/D90) Dry Sieve Uniform sands Non-uniform sands Highly non-uniform sands <5 5 to 10 >10 LPSA <10 >20 11 to 20 100 90 80 Cumulative (%) 70 60 50 40 30 20 10 0 1 Dry sieved . For ESS screens. extent and size of washouts. due to annular flow and hot-spotting. when expanded against the formation.50 1. one with the screen present and one without. • Uncertain source • Potentially incomplete distribution • Higher proportion of larger sand grains may distort the screen sizing process The Well Path Well conditions. this is usually an issue only in high-pressure. The test measures.00 25 20 15 10 5 0 0.00 1.0 Partial pressure of H2S (psi) Non-uniform Wire-Wrap A shaped wire wound around a base pipe. highly non-uniform 20 Particle Size to Erosive Wear Relationship Relationship of Particle Size to Erosive Wear Specific erosion (g/g) 1. Samples obtained with a sand bailer should be used with caution.E-08 0. As more sand accumulates on the screen. “A Two Stage Mechanism of Ductile Erosion”. which can cause focused flow into the screen. leading to erosive conditions. as the LDA unit is connected to a computer. protective perforated outer cover adhered to a slotted liner/base pipe Heterogeneous reservoir Balancing the inflow from the heel to the toe of the production interval can significantly delay potential water or gas breakthrough as well as increase total recovery. intervention work (for example.50 Sand reaching screen (g) 2. sieve Slurry Test Slurry tests simulate open-annulus/noncompliant borehole conditions. in these conditions metal mesh may be preferred to the wire-wrap design. little or no more sand will pass. The test measures the weight of solids produced through the screen and the rate of pressure buildup across the screen versus the amount of sand contacting the screen.4 µm • Sample dispersed ultrasonically in water • Measures the average diameter Weatherford’s proprietary EWBS modeling Wellbore diameter 500 psi overbalanced 20% deformation limit Screen yield Reservoir pressure FEA prediction Weatherford’s Proprietary EWBS Modeling RESULTS Piston Weave Pressure monitoring points Holder Retaining mesh O-ring Screw thread Pressure monitoring points Sand pack Weave sample No. The longer the time delay from the start of the test to the start of pressure buildup.00 Sand passing screen (ppb) Pressure drop (psi) Example plots D50=120µm Uniformity coefficient (UC) D40/D90=140/32=4.) LPSA This technique uses the concept that the diffraction angle of light striking a particle is inversely proportional to the particle size.E-07 ESS water Wire-wrap water Grain-size distribution is typically expressed in terms of uniformity coefficient and sorting coefficient.00 Slurry test results: poorly retained sand Pressure across screen Sand passing screen Slurry Test Results: Poorly Retained Sand 0.g. potential plugging may be identified by a steeper pressure rise.50 5.00 1. 0.50 1. the pressure increases. such as horizontal and extended-reach wells. If the return permeabilities are the same. L80. if good retention is achieved. Shattering of sand grains during coring can result in distorted grain-size distribution data.50 3. Finite element analysis (FEA) has been used to model ESS screens to better understand the interaction of the expanded screen with the rock formation. non-linear process. Sand/fluid inlet Sand Retention Testing Sand-Pack Test Sand-pack tests simulate compliant sand control or a collapsed borehole. 200 sieve Pan 2000 2500 Wellbore pressure (psi) 3000 3500 Dry-Sieve Process Laser Diffraction Process RESULTS Pressure-Buildup Data RESULTS Grain-Size Distribution For each sand sample tested. by weight. Detailed completion application engineering determines the most suitable of all possible sand-control options. Example plots Pressure Data from Four Dura-Grip® WWS for the Same Sand Sample 30 25 20 15 10 150 µm weave 175 µm weave 230 µm weave 270 µm weave Pressure Data from Four Slurry Tests There are two main concerns when considering drill-in fluid compatibility with sand screens: plugging the filter medium when running the screens in the hole. Detailed torque-and-drag (T&D) modeling is conducted during the completion design to ensure that the screens can be deployed safely and without damage. the sand passed initially increases slightly with flowrate. Well trajectory and the weight of the string are the critical factors in selection of the right work string.g. The aperture is created by the gap between the wire wraps Dura-Grip® Ultra-Grip™ Ultra-Grip HD Super-Weld® Metal-Mesh A woven. like this one. but if the flowrate is held constant.g. If these bridges are disrupted (for example by a flowrate change). which is especially important in more challenging trajectories. If the sand is poorly retained.50 ESS weaves tested for the same sand sample. the surrounding annulus is packed with gravel of a specific size to retain the formation sand Alternate path wire wrap or metal mesh or conventional wire wrap screen or metal mesh screen Gravel is sized from 5 to 6 times the formation sand D50.3.00 Pressure drop (psi) Cumulative (%) 70 UC = 1. are based on published literature and international documents and standards. build angle. 718 Uniform D Sorting coefficient (SC=D10/D95) Refine Sand-Control Selection Example plot Highly uniform Uniform 1.00 1.00 Fluids Program Drilling and completion fluids. non-uniform UC = 20.50 2.00 2. Core flood tests are conducted in pairs. and to extend their operational capability. the screen has no effect. wire-wrap or metal-mesh filters are tested with each sand. solids loading. 25 Slurry test results: well retained sand Erosion Potential Fluid type. Rig-site tests are also performed before screen deployment to ensure good conditioning and no plugging. as they cannot take into account all variations and permutations.45 Sand passing screen (g) 0. 718 1. 925. 25 20 Pressure drop (psi) Pressure drop (psi) 15 10 5 0 0. local well/field information. after which.00 3. but Weatherford can assess well-specific parameters and reference environmental diagrams to assist with the selection. FEA also allows the investigation of a wider range of configurations. Wear 23 (1973) 87-96. severely depleted reservoirs. the erosion rate depends on velocity through the screen to the power between 2 and 3. Erosion rate is higher with an open-annulus system. scale and plugging potential Influx Environmental diagrams.0 110ksi SMYS low-alloy steel SSC susceptible Standard sour-service low-alloy steel grades. For coarse. 925. and analysis software will record and plot the grain-size distribution. For every ESS application. This effect must be taken into account for the solids which typically cause erosion in screens. Slurry tests require time to build up the sand layer and bridges.E-07 316L 825 L80 S13Cr 22Cr 25Cr 1. Formation sand must be evaluated to determine the grain-size distribution. Results from the two techniques can vary and should be considered during screen selection. T Annu Non-uniform Annulus Weatherford Products Highly non-uniform Highly non-uniform 11 12 19 20 Excelflo® Maxflo® ESS ® Heterogeneous reservoir Heel Heterogeneous reservoir without ICD Gas Flux Reservoir with ICD Annulus without ICD Gas Flux Reservoir with ICD T Annu Well len Typical flow profile for an openhole completion with stand-alone screens. ensure the appropriate pressure drop along the production string to achieve maximum well Gas Flux Reservoir cleanup and reservoir drainage for ultimate recovery. they are quickly re-established and the produced sand returns to a low.00 2. • Uncertain source • Potentially incomplete distribution • Higher proportion of smaller sand grains/fines may distort the screen sizing process Bailed-Sand Samples Least preferred source. which more than compensates for the slightly higher specific erosion. combined with screens. It calculates the depth of a failed or yielded zone around a wellbore as a function of wellbore support from a mud overbalance or an expandable sand screen. In stand-alone screen completions with an open annulus. Fine sand mix (Group 1) Coarse sand mix (Group 2) Example Strain Harding Curves for Various Tubular Materials Martensities Duplex Example Strain Harding Curves for Various Tubular Materials Partial pressure of C02 (psi) 2 3 4 5 6 7 3 5 7 9 10 11 13 Solution-annealed 22Cr duplex Super 13Cr 95ksi SMYS S13Cr 110ksi SMYS 13Cr 80ksi SMYS 9Cr-1Mo and 13Cr 80ksi SMYS Solution-annealed and cold-worked 25Cr duplex Engineering stress (MPa) 3Mo nickelbase alloys 110ksi SMYS. formation of hot spots is possible and can lead to high flux rates and rapid.15 0. There are no absolute.30 0. In slurry tests sand passes the screen until a layer is formed over the screen surface. ESS technology removes the annulus and annular flow. A near vertical analysis plot represents a high degree of sorting or uniformity. Reservoir Management Flow rate/permeability profile. 8. The key to controlling this risk is an understanding of the erosion rate and how it affects the sand retention properties of the selected screen.E-06 Austenities Uniformity coefficient (UC=D40/D90) Once the optimal filter media is identified.40 0. This method is fully automated.00 Sorting Coefficient (SC = D10/D95) Dry Sieve Well-sorted sands Somewhat sorted sands Poorly sorted sands <10 11 to 20 >20 LPSA <20 21 to 40 >40 0. balances the inflow profile. The pressure buildup is initiated when a sand layer begins to form on the weave surface.2.00 6. such as the effect of an annulus or the interfaces between different formations. Sand/fluid inlet Tension Point/ Hook Load Effective Tension Reservoir Geomechanics Rock unconfined compressive strength (UCS).015 0.035 0.040 Produced sand (g) 0. The yielded zone grows as the mud support is removed and the well is drawn down and depleted. 0 100 200 300 Hook Load (kip) 400 500 600 Slide drilling Tripping out Tripping in Max weight yield (tripping out) Min wt. completion length Safe.50 0. the rate falls off quickly. providing excellent elongation. overall reservoir section net to gross (NTG) A geomechanical model (EWBS) has been developed to better understand the processes leading to excessive deformation and is used as a screening tool. Laboratory tests also evaluate the mud cake generated during the drill-in process as the mud passes through the screen on production startup. determining the size of individual particles.3 D10=230µm 60 50 40 30 20 10 0 d10 d40 15 10 5 0 0. The grain size and sorting of the finest sand likely to fail and produce solids can determine the appropriate type of screen. Integrated reservoir modeling tools are used Gas Flux Reservoir to establish optimal inflow performance.A Characterize the Reservoir Sand If mechanical means of controlling sand production are to be used. Produced-Sand Samples Rarely yields results representative of the in-situ grain size and grain-size distribution. The grain-size distribution analysis plot establishes the degree of sorting in a particular sample. as bailed samples will usually be skewed toward larger particles that have not been flowed to surface. and openhole gravel pack (OHGP) are more effective solutions.50 1. the D10 value is the grain-size diameter from the distribution scale where 10% by weight of the sand is of a larger size and 90% is of a smaller size. dried. the greater the amount of sand that has passed through the screen.45 0. All rights reserved.05 0.50 0.E-05 ESS® Openhole GP In general.00 5. hel. using both slurry and sand-pack test methods.35 0. flux rate. Key to selection of the most appropriate sand-control method is the ability to minimize sand production while limiting the impact on well productivity. 100 1000 Example plot Particle size (µm) RESULTS Sand Retention Data Mud residue after flowback tests on an ESS system. underlying level. solids loading and size distribution. erosion is less likely to be an issue. weighed and then sorted. there may be several viable sand-control options.50 Sand reaching screen (g) 4. configured specifically for each application.50 0.E-06 Metal-mesh water ESS gas – All mesh sizes 0 0.1 Engineering strain (%) 10. T95 Superaustenitics (alloy 28) and 3Mo nickel base alloys 110ksi SMYS. size and concentration of sand particles.00 4. whereas in pack tests the sand layer and bridges are already established when the tests start. reservoir thickness. 10 sieve No. Sand Screen Selector Open Hole E Consider Completion Design For any given reservoir. © 2010-2011 Weatherford. For compliant sand control. These tests measure the screen pressure drop caused by drill-in fluid subjected to progressively more stringent conditioning. erosion-related failures. mud solids control. the metallurgy of the production/injection tubing is the starting point for the screen-material selection process. Comparison of the return permeabilities from the two cases indicates whether the screen influences the mud-cake/filter-cake cleanup. 325 mesh (44 µm).50 Slurry volume injected (liters) 4.00 Comparison of Sand Produced for Slurry and Sand-Pack Test Slurry test Sand-pack test The graph shows the variation in erosion rate with particle size as measured in screen erosion testing. An erosion model. Cased Hole Completion Equipment at Specific Temperatures 1. metallurgy of production/injection tubing Material selection for well screens is based on corrosion potential over the planned completion service life. buckle (tripping in) Tension (kip) 700 800 900 1000 0 2000 Measured depth (ft) 4000 6000 8000 10000 12000 14000 16000 18000 Tension limit Helical buckling (non-rotating) Helical buckling (rotating) Sinusoidal buckling (all operations) Slide drilling Tripping out Tripping in Example plots A screen recommendation based on a sand’s PSD can be confirmed by sand retention testing. expected drawdown. Core samples or data from offset wells can be used if there is a high degree of certainty that they are representative of the sand to be retained.10 0. To determine the optimal filter media and aperture size. Sampling from sidewall cores usually provides a good compromise. 40 sieve Outlet (sample capture) Outlet (sample capture) 1500 No. and a wetting liquid is flowed through the sand-pack and screen. 50 75 Very fine sand 100 125 150 Fine sand 200 250 300 400 500 Sand Retention Guideline 1 × D25 1 × D10 1 × D5 / D10 Influx Influx Medium sand Influx Heel Homogeneous reservoir Toe Influx without ICD Grain size (µm) with ICD without ICD Heel Heterogeneous reservoir Annulus Toe with ICD Well len ICD technology.20 0.005 0 2 4 8 12 16 16 16 16 16 16 16 16 16 16 16 16 16 16 16 24 24 24 24 24 Flow rate (mL/min) 1. the pressure will be unstable and sand will continually pass through the screen. predicts probable time-to-screen-failure based on fluid type.50 2. Wire-Wrap Metal-Mesh Erosion in air/gas is an order of magnitude less than water.E-05 Specific Erosion SWRI Gas and Water Erosion Testsvs Fluid Approach Velocity Fluid Approach Velocity) (Specific Erosion versus SWRI Gas & Water Erosion Tests 1.50 6. For conventional well screens.020 0. such as ESS and openhole gravel-pack systems.8.35 0. dogleg severity. water/gas drive and location.010 0. metal-mesh screens (MMS). If the sand is tested on a different screen and/or screen aperture. The weight of sand retained by each successive sieve size is recorded down to No.0 10. e. Weatherford’s extensive mechanical testing has shown which materials provide the best expansion performance. mud filter cake Erosion is usually considered a major risk in cased-hole sand-control completions but can also be a risk in high-rate openhole and water-injection wells. Testing has also revealed that austenitic stainless and nickel-based alloys have a low work hardening rate.40 0. a specific sand-control method and screen selection can be refined. to enhance the performance of wire-wrap and metal-mesh screens. These diagrams are conservative. Run measured depth (ft) Whole-Core Samples The best source. The light diffraction caused by all particles is measured.00 1.30 0. downhole formation pressure. Corrosion Potential Well parameters from pressure/volume/temperature (PVT) analysis. 1. more sand is produced in slurry tests.00 7. The cumulative weight percent of each retained sample is then plotted as a comparison by the sieve aperture on semi-log coordinates to obtain a sand size distribution plot. Reading the graph at the 50% cumulative weight provides the median formation grain-size diameter. stable bridges form in the sand-pack. Note that the 175 µm weave has a steeper gradient. Example plots Sand-pack tests also record the change in sand passing through the screen with flowrate. cleanup method (including computational-flow-dynamics—CFD—modeling) FEA Modeling Percentile sand sizes can be obtained from the cumulative distribution where. Whole-Core Samples Sidewall-Core Samples Produced-Sand or Bailed-Sand Sample Expert guidance on sand control technology selection and application for openhole completions. highly uniform UC = 4.05 0.00 2.00 3. pore/fracture gradient. 4 sieve Example plot 3/8-in.50 3. Inflow control devices (ICDs).UC = 25 10 Dry Sieved versus Laser Diffraction 5 0 0. size distribution. and displacing the filter cake back through the screen when production is started.25 0. • Represents all sands present • Rock fabric undamaged • Can select appropriate samples Sidewall-Core Samples Acceptable source. such as MMS and WWS. the same model assists monitoring of T&D. flux rate.1 1 Example plots 10 Diameter (µm) 100 1000 1 10 Diameter (µm) 100 1000 0.00 3. damage-free deployment of sand screens is essential in any application. e. The sample is placed into the laser diffraction analysis (LDA) unit. If the sand is well retained. Representative samples from whole core yield the most accurate information about in-situ grain size and grain-size distribution. In this complicated.50 ESS ID (in. and the passed sand decreases. • Discrete locations • Mud contamination • Crushed grains C Specify Filter Media 0 2000 4000 6000 8000 10000 12000 14000 16000 18000 -1800 -1600 -1400 -1200 -1000 -800 -600 -400 -200 0 200 400 600 800 1000 Particle Size Analysis There are two common methods of particle size and particle size distribution (PSD) measurement: dry sieving and laser particle size analysis (LPSA).50 1000 No. Dry Sieving The sample is cleaned. alloy 825. the rate is constant. alloy 825.E-08 0.00 5. expandable sand screens (ESS®). the first step is determining the size of the formation sand so that the filter mechanism can be properly sized. As the sands become more poorly sorted and/or the fines content increases. a detailed analysis should be conducted to ensure that. Volume changes in the yielded zone compress the ESS system.15 0.20 0. com. available on request or at weatherford. Weatherford sells its products and services in accordance with the terms and conditions set forth in the applicable contract between Weatherford and the client. or visit weatherford. 6911.com. trademarks and service marks herein are the property of Weatherford. weatherford. Turn to Weatherford for the optimal balance between sand-control investment and return. All rights reserved. For more information contact an authorized Weatherford representative. .Sand Screen Selector Solving your sand control challenges. Unless noted otherwise. Specifications are subject to change without notice. Contact your authorized Weatherford representative.00 Weatherford products and services are subject to the Company’s standard terms and conditions.com © 2010-2011 Weatherford.