A set of graphical design criteria for slotted liners in steam assisted gravity drainage production wells

Authors: Chenxi Wang, Yu Pang, Mahdi Mahmoudi, Mohammad Haftani, Mahmoud Salimi, Vahidoddin Fattahpour, Alireza Nouri

Slotted liners have been widely used in steam-assisted gravity drainage (SAGD) wells owing to their low cost and superior mechanical integrity. Multiple factors affect the performance of slotted liners, such as particle size distribution (PSD) of formation sands, aperture size, slot density, fluid flow rate, and wellbore operational conditions. Currently, most of the existing design criteria formulate the lower and upper bounds of the aperture based on one or several points on the particle size distribution curve of oil sands. Most of these design criteria neglect the slot density, wellbore operational conditions, and shape of PSD curve.

This study carries out a series of large-scale pre-pack sand retention tests (SRT) in step rates. The aim is to investigate the impacts of aperture size, slot density, and fluid flow rate on the slotted liner performance. Comprehensive design criteria for determining the safe aperture window are presented to maintain the sanding and the wellbore plugging of the zone near the slotted liners within an acceptable level. Sand production governs the upper bound of the aperture size, and flow performance guides the lower bound of the aperture size. The new criteria are presented graphically to illustrate the optimal slot window as a function of the sand PSD, slot density, and fluid flow rate. The results of separate tests are used to demonstrate the performance of the new design criteria. The optimal slot window obtained via the new design criteria guides the slot liner selection in the SAGD process.

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A Concise Review of Experimental Works on Proppant Transport and Slurry Flow

Authors: Morteza Roostaei (RGL Reservoir Management Inc.) | Alireza Nouri (University of Alberta) | Seyed Abolhassan Hosseini (RGL Reservoir Management Inc., University of Alberta) | Mohammad Soroush (RGL Reservoir Management Inc., University of Alberta) | Arian Velayati (University of Alberta) | Mahdi Mahmoudi (RGL Reservoir Management Inc.) | Ali Ghalambor (Oil Center Research International) | Vahidoddin Fattahpour (RGL Reservoir Management Inc.)

Final proppant distribution inside hydraulic fractures which depends on particle properties, movement and deposition highly impact wellbore productivity and consequently is crucial in modeling and design of hydraulic fracturing. This paper presents a thorough review of laboratory scale tests performed on proppant transport related to hydraulic fracturing treatments and governing physics behind its mechanisms.

The interaction between fluid (gas and liquid) and solid particles has been investigated in applied mathematics and physics. In such phenomena, there is always a relative motion between particles and fluids. In this work this relative motion during proppant movement, sedimentation and fluidization in both small- and large-scale lab tests have been assessed in detail. Existing correlations which relate proppant particles settling velocity to concentration of proppant particles, fracture wall and inertia effect in Newtonian and non- Newtonian fluid are presented as well.

Lab tests show that various parameters determine the proppant particles distribution inside the fractures. Particle settling velocity, an influential parameter in this regard, is impacted by fracture walls, inertia and the presence of other particles. Inertia changes the relation of drag coefficient and Reynold number. Fracture wall and particles concentration decrease settling velocity as drag force increases. At a certain level, concentration reaches to its limit. Proppant concentration, in addition, increases the suspension viscosity, fracture width and net pressure. However, it deceases the fracture length as more pressure loss occurs along the fracture. As a result, well productivity is highly impacted by the proppant settling and distribution.

Many studies have been devoted to identifying different aspects of hydraulic fracturing and proppant transport mechanisms in porous media. This study highlights the key parameters and their effects, existing correlations and physics behind them for better understanding and management of this mechanism.

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Developing a methodology to characterize formation damage (pore plugging) due to fines migration in sand control tests

Authors: Chenxi Wang, Jesus D. Montero Pallares, Mohammad Haftani, Alireza Nouri

Stand-alone screens (SAS) have been widely used in steam assisted gravity drainage (SAGD) operations. Although many researchers investigated the flow performance of SAS through sand control tests, the formation damage (pore plugging) due to fines migration has not been characterized under multi-phase flow conditions. In this study, a methodology is developed to quantify and characterize the fines migration under multi-phase flow sand control testing conditions.

A large-scale sand retention test (SRT) facility is used to investigate the flow performance of SAS. Duplicated sand samples with similar particle size distribution (PSD), shape, and mineralogy properties to the McMurray Formation oil sands are obtained by mixing different types of commercial sands, silts, and clays. Oil and brine are simultaneously injected into the sand-pack at different water-cut levels and liquid rates to emulate the changing inflow conditions in SAGD operations. The saturation levels in each flow stage are measured to determine the relative permeability values. Next, the relative permeability curves of the duplicated sand-pack sample are measured following the steady-state method. Finally, the pressure data obtained from the SRT in each flow stage are coupled with the relative permeability values to calculate the retained permeability as the indicator of flow performance of SAS’.

Generally, testing results show that single-phase oil flow generates minor and negligible permeability impairments in the near-screen zone of the sand-pack. An evident permeability reduction is observed once the water breakthrough happens, indicating that the wetting-phase fluid significantly mobilizes fine particles and causes pore plugging. Also, with the increase of flow rate and water cut, a further reduction in permeability is found as a result of the higher drag force and greater exposure area of fines to brine.

The proposed methodology presented in this study allows quantitative characterization of the formation damage under multi-phase flow condition and provides a practical and straightforward method for the evaluation of the SAS’s flow performance.

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Numerical investigation of the hydraulic fracturing mechanisms in oil sands

Authors: Siavash Taghipoor, Morteza Roostaei, Arian Velayati, Atena Sharbatian, Dave Chan, Alireza Nouri

This paper presents a numerical investigation of hydraulic fracturing in oil sands during cold water injection by considering the aspects of both geomechanics and reservoir fluid flow. According to previous studies, the low shear strengths of unconsolidated or weakly consolidated sandstone reservoirs significantly influence the hydraulic fracturing process. Therefore, classical hydraulic fracture models cannot simulate the fracturing process in weak sandstone reservoirs. In the current numerical models, the direction of a tensile fracture is predetermined based on in situ stress conditions. Additionally, the potential transformation of a shear fracture into a tensile fracture and the potential reorientation of a tensile fracture owing to shear banding at the fracture tip have not yet been addressed in the literature. In this study, a smeared fracture technique is employed to simulate tensile and shear fractures in oil sands. The model used combines many important fracture features, which include the matrix flow, poroelasticity and plasticity modeling, saturation-dependent permeability, gradual degradation of the oil sands as a result of dilative shear deformation, and the tensile fracturing and shear failure that occur with the simultaneous enhancement of permeability. Furthermore, sensitivity analyses are also performed with respect to the reservoir and geomechanical parameters, including the apparent tensile strength and cohesion of the oil sands, magnitude of the minimum and maximum principal stress, absolute permeability and elastic modulus of the oil sands and ramp-up time. All these analyses are performed to clarify the influences of these parameters on the fracturing response of the oil sands.

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Protocol for sand control screen design of production wells for clayey silt hydrate reservoirs: A case study

Authors: Yanlong Li, Fulong Ning, Nengyou Wu, Qiang Chen, Alireza Nouri, Gaowei Hu, Jiaxin Sun, Zenggui Kuang, Qingguo Meng

The process of extracting natural gas from gas hydrate‐bearing sediments (GHBS) may yield significant sand influx due to the metastable nature of GHBS. Selecting appropriate sand control media is vital to addressing the challenges caused by excessive sand production. This study proposes a protocol called holding coarse expelling fine particles (HCEFP) for sand control design. The protocol aims to provide a new optimization method for screen mesh size selection for clayey silt hydrate reservoirs. Detailed optimizing procedures of proper candidate screen mesh sizes in hydrate exploitation well in clayey silt hydrate reservoirs are depicted based on the HCEFP. Then, the site W18, which is located in the Shenhu area of the northern South China Sea, is taken as an example to illustrate the optimization procedure for screen mesh size selection. The results reveal that complete solid retention via a standalone screen is rarely beneficial as high clay contents can adversely affect wellbore productivity due to excessive plugging. Screen aperture size selection for clayey silt hydrate wells should strike a balance between retaining coarser particles and avoiding screen blockage by the relatively fine particles. Furthermore, longitudinal heterogeneity of the PSDs also increases the difficulties associated with sand control design. Multistage sand control optimization is necessary in hydrate production wells. For Site W18, we recommend that the entire production interval can be divided into two subintervals for multistage sand control operations.

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A Novel sand control testing facility to evaluate the impact of radial flow regime on screen performance and its verification

Authors: M. Haftani, O. Kotb, P. H. Nguyen, Chenxi Wang, Mahmood Salimi, Alireza Nouri

Optimum design of the sand control devices in oil sand reservoirs plays a vital role in minimizing the sand production and increasing the reservoir productivity in Steam-Assisted Gravity Drainage (SAGD) operations. Various sand control testing facilities have been developed to evaluate the performance of sand control screens, such as the pre-packed Sand Retention Test (SRT). Current testing apparatuses are based on the linear flow regime. However, fluid flow around SAGD production wells is radial flow, not linear. This study introduces a Full-scale Completion Test (FCT) facility to emulate the radial-flow condition in SAGD wells. Instead of using a disk-shaped screen coupon, this facility utilizes a cylindrical-shaped screen. A couple of tests were carried out to determine the flow uniformity inside the cell and identify the test repeatability. Test results show that flow is distributed uniformly inside the cell, and experiments are repeatable in terms of differential pressures, fines production, and sanding levels. Therefore, this innovative FCT experimental setup and procedure allows a more realistic evaluation of the liner performance by emulating the real SAGD flow regime around the liner. Testing results obtained from the FCT can be used to complement and validate the current testing procedures. These tools can be adopted for an objective custom-design and selection of standalone screens in SAGD.

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Comparison of Various Particle Size Distribution Measurement Methods: Role of Particle Shape Descriptors. In SPE International Conference and Exhibition on Formation Damage Control

Authors: Morteza Roostaei (RGL Reservoir Management Inc.) | Mohammad Soroush (RGL Reservoir Management Inc., University of Alberta) | Seyed Abolhassan Hosseini (RGL Reservoir Management Inc., University of Alberta) | Arian Velayati (University of Alberta) | Ahmad Alkouh (College of Technical Studies) | Mahdi Mahmoudi (RGL Reservoir Management Inc.) | Ali Ghalambor (Oil Center Research International) | Vahidoddin Fattahpour (RGL Reservoir Management Inc.)

Sieve analysis, sedimentation and laser diffraction have been the methods of choice in determining particle size distribution (PSD) for sand control design. However, these methods do not provide any information regarding the particle shape. In this study, we introduce the application of Dynamic Image Analysis (DIA) to characterize particle sizes and shape descriptors of sand bearing formations.

Dynamic Image Analysis, an advanced method of particle size and shape characterization, along with other PSD measurement methods, including sieving combined with sedimentation, and laser diffraction, was utilized to study size and shape variations of 372 unconsolidated formation sand samples from North America, Latin America, and the Middle East. Different methods were compared for the estimation of PSD and fines content, which is important for sand control design.

Through minimizing the sampling and measurement errors, the deviation between different PSD measurement techniques was attributed solely to the shape of the particles and the amount of fine fraction. For fines content measurement, the values obtained through Feret Min. parameter values (the minimum size of a particle along all directions) calculated by DIA and sieving measurement are comparable within a 5% confidence band. The deviation between the results of different methods becomes more significant by increasing fines content. Moreover, this deviation increases for less isodiametric grains. The fines and clay content show higher values when measured by any wet analysis. Laser diffraction also tends to overestimate the fines fraction and underestimate silt/sand fraction compared to other dry techniques. By comparing the deviation of the DIA and sieving at standard mesh sizes, an algorithm has been developed which chooses the equivalent sphere sizes of DIA with minimum deviation from sieving.

This study performs several measurements on formation sands to illustrate the real advantage of the new methods over traditional measurement techniques. Furthermore, particle shape descriptors were used to explain the deviation between the results of different PSD measurement methods.

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Full-Scale Physical Modeling of Stand-Alone Screens for Thermal Projects. SPE International Conference and Exhibition on Formation Damage Control

Authors: Vahidoddin Fattahpour (RGL Reservoir Management Inc.) | Morteza Roostaei (RGL Reservoir Management Inc.) | Mohammad Soroush (RGL Reservoir Management Inc., University of Alberta) | Seyed Abolhassan Hosseini (RGL Reservoir Management Inc., University of Alberta) | Kelly Berner (RGL Reservoir Management Inc.) | Mahdi Mahmoudi (RGL Reservoir Management Inc.) | Ahmed Al-hadhrami (Occidental Petroleum Oman) | Ali Ghalambor (Oil Center Research International)

Standalone screens (SAS) have been widely employed as the main sand control solution in thermal projects in Western Canada. Most of the test protocols developed to evaluate screen designs were based on the scaled screen coupons. There have been discussions regarding the reliability of such tests on scaled coupons. This paper presents the results of the tests on full-scale wire-wrapped screen (WWS) and slotted liner coupons for typical McMurray Formation sands.

A large-scale sand control evaluation apparatus has been designed and built to accommodate all common SAS with 3 1/2″ in diameter and 12″ in height. The set-up provides the capability to have the radial measurement of the pressure across the sand pack and liner, for three-phase flow. We outline certain challenges in conducting full-scale testing such as establishing uniform radial flow and measuring the differential pressure. Produced sand is also measured during the test. The main outputs of the test are to assess the sand control performance and the mode of sanding in different flow direction, flow rates and flow regimes.

We were able to establish uniform radial flow in both high and low permeability sand packs. However, the establishment of the radial flow in sand packs with very high permeability was extremely challenging. The pressure measurement in different points in radial direction around the liner indicated a uniform radial flow. Results of the tests on a representative PSD from McMurray Formation on the WWS and slotted liner coupons with commonly used specs in the industry have shown similar sanding and flow performances. We also included aperture sizes smaller and larger than the common practice. Similar to the previous large-scale tests, narrower apertures are proven to be less resistant to plugging than wider slots for both WWS and slotted liner. Accumulation of the fines close to screen causes significant pore plugging, when conservative aperture sizes were used for both WWS and slotted liner. On the other hand, using the coupon with larger aperture size than the industry practice, resulted in excessive sanding. The experiments under linear flow seems more conservative as their results show higher produced sand and lower retained permeability, in comparison to the full scaled testing under radial flow.

This work discusses the significance, procedure, challenges and early results of full-scale physical modeling of SAS in thermal operation. It also provides an insight into the fluid flow, fines migration, clogging and bridging in the vicinity of sand screens.

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Challenges and Potentials for Sand Control Design and Management in Oil Reservoirs of Kazakhstan

Authors: Mohammad Soroush (University of Alberta) | Seyed Abolhassan Hosseini (University of Alberta) | Morteza Roostaei (RGL Reservoir Management Inc) | Peyman Pourafshary (Nazarbayev University) | Mahdi Mahmoudi (RGL Reservoir Management Inc) | Ali Ghalambor (Oil Center Research International) | Vahidoddin Fattahpour (RGL Reservoir Management Inc)

Kazakhstan owns one of the largest global oil reserves (~3%). This paper aims at investigating the challenges and potentials for production from weakly-consolidated and unconsolidated oil sandstone reserves in Kazakhstan.

We used the published information in the literature, especially those including comparative studies between Kazakhstan and North America. Weakly consolidated and unconsolidated oil reserves, in Kazakhstan, were studied in terms of the depth, pay-zone thickness, viscosity, particle size distribution, clay content, porosity, permeability, gas cap, bottom water, mineralogy, solution gas, oil saturation, and homogeneity of the pay zone. The previous and current experiences in developing these reserves were outlined. The stress condition was also discussed. Furthermore, geological condition, including the existing structures, layers and formations were addressed for different reserves.

Weakly consolidated heavy oil reserves in shallow depths (less than 500 m) with oil viscosity around 500 cP and thin pay zones (less than 10 m) have been successfully produced using cold methods, however, thicker zones could be produced using thermal options. Sand management is the main challenge in cold operations, while sand control is the main challenge in thermal operations. Tectonic history is more critical in comparison to the similar cases in North America. The complicated tectonic history, necessitates the geomechanical models to strategize the sand control especially in cased and perforated completion. These models are usually avoided in North America due to the less problematic conditions. Further investigation has shown that Inflow Control Devices (ICDs) could be utilized to limit the water breakthrough, as water coning is a common problem, which initiates and intensifies the sanding.

This paper provides a review on challenges and potentials for sand control and sand management in heavy oil reserves of Kazakhstan, which could be used as a guideline for service companies and operators. This paper could be also used as an initial step for further investigations regarding the sand control and sand management in Kazakhstan.

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Comparison of Various Particle-Size Distribution-Measurement Methods

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