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Summary
Sand-control problems in existing wells typically result from improper completion techniques or changes in reservoir properties. While recompletion of many of these wells with conventional sand-control
methods and workover rigs is economically unfeasible, enhancements to gravel-pack fluid systems, downhole equipment, and service
capabilities have increased success and reduced costs in through-tubing recompletions, providing new options to the operator for successful sand control in existing wells.
Introduction
As is often the case before any decision is made on remedial maintenance to put the well back on production, the tubing has already
sanded up and the well has been shut in for some time. Once the decision has been made to clean up the well and perform through-tubing sand control, the job method and design will depend on the mechanical configuration of the well bore. Factors to consider are tubCopyright 1994 Society of Petroleum Engineers
Original SPE manuscript received for review Feb. 11, 1992. Revised manuscript received
April 12. 1994. Paper accepted for publication June 1.1994. Paper (SPE 23130) first pre
sented at the 1991 SPE Offshore Europe Conference held in Aberdeen, Sept. 3-6.
236
ing and casing sizes, minimum restriction in the wellbore, type and
locations of landing nipples, packer-setting depth, tail pipe below
the packer, length of interval to be recompleted, location of interval
in relation to production tubing, length of rat hole below interval,
formation type, and type of well production (oil or gas). In some
cases, through-tubing sand-control techniques are used to "repair"
an existing, but damaged, gravel-pack screen.
Mechanical Methods
PRODUCTION
TUBING
PACK OFF
ANCHOR STOP
HYDRAULIC
DISCONNECT
PRODUCTION
TUBING
PRODUCTION
TUBING
CENTRMJZED
SEAL
RECEPTICAL
PRODUCTION
PACKER
PRODUCTION
PACKER
WASH PIPE
RUNNING
NECK/PLUG
Fig. 1-Mechanical methods: (a) packoff, (b) dual-screen, and (c) wash-down.
Tubing Size
WeighV
00
Length
(in.)
(Ibm/tt)
2.375 4.6 to 4.7
2.875 6.4 to 6.5
3.5
9.3 to 10.3
Standard
Nipples
Packing
Bore 10
(in.)
1.875
2.313
2.813 to
2.750
4.0 10.9 to 11.0
3.313
4.5
3.813
12.75
5.0
13.00
4.313
5.5 15.50 to 17.00 4.562
1.791
2.205
2.635 to
2.635
3.135
3.725
4.455
1.735
2.100
2.550
1.750 1.049
2.100 1.380
2.630 1.751
1.460
1.750
2.550
1.995
2.441
2.992
2.992
2.970
3.480
2.970
3.480
4.130
4.130
4.130
1.660
1.900
2.375
0.720
0.720
0.824
1.049
1.610
1.995
237
OVERSHOT
TYPE
RUNNING
TOOL
SHEAR PIN
RETRIEVABLE
RECEPTACLE
PLUG
CENTRALIZED
SEAL
RECEPTACLE
SUB
Attached to
"G" packott
assembly
0>
8Z
U'-..J.._/
(c)
o
o
SINTERED
SCREEN
o
o
(a)
Z
u'--__
'--_...J...J
(b)
Fig. 2-Through-tubing gravel-pack tool: (a) centralized seal receptacle sub, (b) overshot-type running tool, and (c) retrievable
receptacle plug.
(Fig. la). Blank pipe lengths of > 100 ft can create excessive pressure loss through the small diameter and are difficult to deploy.
BHA's can be run into the wellbore by several methods. Most assemblies consist of a bull plug, screen, blank pipe, centralizers, and
some type of combination running/releasing tool. The combination
tool is designed to run the BHA by means of wireline or coiled tubing. Either method has its pros and cons, but wireline would be recommended in most cases because of its capability to jar and shear
off the assembly being placed on bottom. Generally, if the total BHA
weight is < 400 pounds, 0.092-in. wire can be used. If the BHA is
heavier, 0.108-in. or 3/ w in. braided line is recommended.
The standard through-tubing gravel-pack tool, which allows the
screen to be run and set in the hole, consists of several parts. A
centralized seal receptacle (Fig. 2a) is made up on the top section
of blank pipe and is carried into the hole by an overshot-type running
tool (Fig. 2b). The seal receptacle also houses a retrievable bull plug
with a fishing neck. The bull plug (Fig. 2c) keeps the slurry from entering the screen and liner during the pumping operation.
The seal receptacle, running tool, and receptacle plug are all
pinned together and connected to the blank pipe and screen. The
BHA is then run into the wellbore to bottom (Fig. 3a). The running
tool is released while the receptacle plug is left pinned in the seal receptacle in preparation for the slurry pack. The coiled tubing is
rigged up and run to 30 ft above the screen assembly. The injection
rate is established; then, the sand slurry is pumped at a concentration
of 0.5 to I Ibm/gal. Case histories have recorded 4- to 7-lbm/gal sand
concentrations being pumped through I-in. coiled tubing. When
screenout occurs, the excess sand is circulated out. On completion
of the pumping phase, the slurry is given a predetermined time to
settle out around the screen and liner; then, any sand left above the
receptacle plug is circulated out of the hole with coiled tubing. The
receptacle plug is then pulled with wireline and replaced with a
small O-ring stinger run below a packoff-element assembly (Fig.
3b). Coiled tubing can now be used to jet the well onto production.
Not all through-tubing gravel packs are set on bottom. Today,
more operators are asking for prepack screens to be run without
(a)
o
o
o
Z
()==-...:w
(b)
<.)
IM---+t--
I~,_c
I.
ANCHOR
II
,,~PACKOFF
'~
=
IIO-I+--+f--~
c- -
STINGER SEAL
FLUTED RECEPTACLE
UPPER NIPPLE
ANCHOR
REELED
TUBING
PACK OFF
RECEPTACLE
PLUG
PORTED PUP
JOINT
NIPPLE
LOCATOR IN
LOWER NIPPLE
SHORT SPACER
j---- PORTED PUP
PORTED PUP
JOINT
LOWER NIPPLE
JOINT
II\;~::;;:_=:-:::/~tt--
LOWER NIPPLE
Fig. S-Completions: (a) tail-pipe through-tubing, (b) tail-pipe through-tubing with packoff, and
(c) new non-gravel-pack.
SLIDING SLEEVE
LOCKING MANDREL
EQUALIZING SUB
OPEN PORTS
PREPACK SCREEN
BULL PLUG
nels on an inner retention screen, which allows maximum flow potential. The design accommodates the maximum ID and the screen OD is
the same as that of the standard all-welded design with a thin wall of
gravel pack available between the screen jackets for added sand control. It is available in sizes as small as 1.3IS-in.-OD base pipe.
Screen advantages are a large flow area and the same OD and ID
as regularnonprepack screens. Its disadvantages are that it has minimal prepack gravel and is recommended only for wells that will be
gravel packed.
Sintered-Metal Screen. The sintered-metal screen (Fig. Se) embodies a technology proved in the industrial filtration markets. Sintered stainless steel (or other applicable high-nickel alloys) is bonded
under extreme temperature and pressure and shaped into a cylindrical body (tube), producing a porous metal filter medium whose performance compares favorably with that of such devices as prepack
well screens. This cylindrical body provides a porous medium capable of = 100-,um absolute filtration. This tolerance can be adjusted
downward by reducing the individual sintered-metal diameters.
The advantages are that one size sintered-screen design fits most
gravel-pack sand sizes vs. requiring a specific wire-wrapped-screen
gauge size, the sintered screen design is tougher than the wirewrapped design, its wall thickness allows for a minimum OD with a
maximum ID, and it allows 100% inlet flow from any direction. In
addition, the sintered-metal screen has less flow restriction than current prepack screen designs; has more flexibility to pass short radial
bends compared with standard prepack-screen designs; is impervious
to acid, which will dissolve the sand in current prepack screens as well
as resin; and in some applications, will allow the sintered screen to be
run without the base pipe, lowering the cost and increasing the ID. Its
disadvantages are that the current maximum limit is 100-,um absolute
filtration and certain high-nickel alloys currently cannot be sintered.
SPE Drilling & Completion, December 1994
241
Resin Method. Water-compatible furan resins have been used effectively for near-wellbore sand consolidation. Resins have been
used to "repair" damaged gravel-pack screens in place. An average
wellbore radius of > 3 ft can be consolidated. 5
The process involves cleaning up the well bore and preparing the
treatment interval as discussed earlier, then pumping a leading load
of salt water into the formation to prepare the sand surfaces so that
they will provide a site for the chemical reaction needed for the resin
to absorb the sand. The resin is then pumped, followed by a saltwater
spacer to separate acid and resin, to remove excess resin from the
pore spaces, and to flush the resin further into the foundation. The
acid is then pumped to catalyze the resin. A final brine flush is injected to enhance displacement of the acid catalyst. Nitrogen is
often commingled with the injected fluids to act as a diverter and to
aid in uniform placement of the resins in the formation. Coiled tubing has proved beneficial in placing these chemicals uniformly over
long intervals by use of specially designed nozzles and by manipulating the tubing through the entire interval during treating. After the
resin hardens, a permeable, but solid, sand filter is formed. Typically, 85% to 90% of the original formation permeability will remain.
Resin-Coated-Sand Methods. For any type of sand control, having
sand packed very tightly behind every perforation to compress the
formation to its "natural" state is considered very desirable. Packing
presumably replaces formation sand in the perforations with higherpermeability pack sand. 5 Studies have shown that the resin-coated
sands can achieve very high compressive strengths and remain
highly permeable even after a flow of 30 million PV. 6
The procedure for resin-coated sand packs is very similar to the
resin procedures. Typically, resieved Ottawa 20/40- or 40/60-mesh
sand is used; this is batch-mixed with the resin and carrier fluids at
a ratio of 1 Ibm sand/gal carrier fluid and 1.5 gal resin/per sack sand.
The system can either be catalyzed internally or externally. Using
an externally catalyzed system will allow placement of the pack into
the perforations and formation, with any excess sand washed out of
the wellbore before the acid to set the resin is pumped.
An internally catalyzed system, which requires fewer steps for
pack placement because catalysts are mixed with the resin-coated
sand mixture before pumping, can be used. The treatment is pumped
until sandout occurs in the perforations, meaning that the resincoated sand will extend above the producing formation. This will
form a sand column that will have to be removed after the resin
cures. 6 Removal can be accomplished with mills and under-reamers
on concentric or coiled tubing.
Case Histories
Fig. 8-Screens and slotted liner: (a) all-welded screen, (b) dual
prepack screen, (c) perforated prepack screen, (d) special-clearance prepack screen, (e) sintered-metal screen, and (f) slotted
liner.
Case History I-PackoffMethod. An offshore U.S. Gulf of Me xico well was originally completed by the operator as a single gravelpack completion. This well was a leaseholder and was sanded up;
average production had been 160 BOPD, 55 BWPD, and 1.28
MMcflD gas. The last test yield showed 13 BOPD, 7 BWPD, and
935 McflD gas with a 1,624-psi flowing tubing pressure (FTP). The
original gravel pack consisted of 180 ft of 27/g-in. 0.006-gauge
screen set across the perforations at 11,164 to 11 ,346 ft. An "S-I"
nipple was 268 ft above the top perforations in the 27/g-in. tubing.
The average deviation through the completion interval was 40 . The
job was designed with a through-tubing prepacked screen assembly
run on 1.25-in. coiled tubing and located in the nipple profile.
Procedure. The following was the gravel-packing procedure.
1. Surface equipment was rigged up and tested.
2. The hole was entered and sand was washed to 11,350 ft with
8.6-lbm/gal salt water. Then, we checked for fill.
3. The well was killed with 13.2 Ibm/gal CaBr2, and we pulled out
of the hole.
4. Braided line was rigged up, and a gauge run was made.
5. Screen assembly was run into the hole on coiled tubing and located in S-I nipple. The screen assembly consisted of a bull plug,
198 ft of prepacked screen, 270 ft of centralized blank pipe, and an
S- I locator with upper seal receptacle and milled bypass.
6. With the end of the coiled tubing 5 ft above the locator assembly, the tubing was flushed with two tubing volumes of filtered fluid
and the following pack performed: (a) 6 bbl 10% HCl with 7 Ibm of
SPE Drilling & Completion, December 1994
citric acid and 0.2% organic inhibitor, (b) 3 bbl3% ammonium chloride water, (c) 3 bbl gel pad without gravel, (d) 5 bbl sand slurry containing 50nO-mesh resieved sand, (e) 3 bbl3% ammonium chloride
water, and (t) filtered 13.2-lbmlgal completion fluid .
7. Acid and slurry were squeezed into the formation until a
2,500-psi sandout was reached.
8. 13.2 Ibmlgal fluid was displaced with 8.6-lbmlgal seawater,
and we pulled out of the hole.
9. Braided line was used to pull the receptacle plug and install the
packoff. The well was placed back on production at 82 BOPO, 92
BWPO, and I MMcflD gas. The cost of a rig-type workover was
= $1.5 million, while the cost of the through-tubing gravel pack was
=$150,000.
Case History 2-Dual-Screen Method. The operator's well was
on inland water and completed as a single gas well with 23!s-in. tubing to 11,510 ft and 95!s-in. casing to a plugged-back TO of 11,683
ft. The average production was 2.8 McflD gas with 80 BWPO at a
2,400-psi FrP. The job was designed to run a dual screen through
the tubing, which had a 1.7I -in. no-go nipple, and set it in the casing.
Procedure. The procedure used follows.
1. I-in. coiled-tubing unit was rigged up and tested. Tubing was
pickled.
2. The wellbore was entered and foam washed to TO.
3. The injector rate was checked with filtered fluid.
4. Fill was checked for, and we pulled out of the wellbore.
5. Oual screen was run on wireline with ajar-down-release running tool consisting of a bull plug, centralizer, 16 ft of O.OOS-gauge
screen, centralizer, 132 ft of blank pipe, and 5 ftofupper screen with
a running-neck bull plug. This was set and released on bottom.
6. Coiled tubing was into the wellbore to the top of the liner at
11,495 ft, and the injection rate was established.
7. A preacid treatment was performed.
8. A gravel-pack slurry was pumped that consisted of (a) 3 bbl of
gel, (b) 5 of bbl gel containing 1,000 Ibm of 40/60-mesh gravel, and
(c) 3 bbl of gel.
9. The slurry was displaced into the formation until sandout occurred.
10. The slurry was washed down past the upper screen to a maximum of 11,593 ft.
11. The well was jetted in with nitrogen.
The well was placed back on production at 2.1 McflD gas and 70
BWPO with a 2,1 OO-psi FrP. Estimated cost of a rig-type workover
was $250,000, while the dual-screen sand-control job was performed for =$15,000.
Case History 3-Resin Method. This offshore U.S. Gulf of Mexico
well was originally completed as a single completion with a selective
alternative, or "stack pack," where two reservoirs were gravel packed
individually with the upper sand blanked off with an isolation string.
The lower zone watered out and was isolated with a tubing plug set
in a landing nipple. The upper zone was accessed through wireline
with a tubing punch to perforate the isolation string. Initial gas production was 14 MMcflD, but the well test indicated an I8-MMcflD
potential. An acid stimulation job was performed; however, the well
started to produce sand and flow rates had to be reduced to 2.5 MMcf/
O. A resin treatment was designed to consolidate the sand behind the
32 ft gravel-pack screen with nitrogen and a I-in. coiled-tubing unit.
Procedure. In this well, we used the following procedure.
1. Surface equipment was rigged up and tested.
2. Coiled tubing was pickled with acid, and the acid was displaced with neutralizer.
3. Sand was washed to 11,499 ft with 2% KCI water.
4. Coiled tubing was positioned across interval, spotted, and
squeezed with following treatment at V4 to V2 bbl/min: (a) 65 bbl
15% NaCI water with 0.25% surfactant and 600 scf/bbl nitrogen; (b)
25 bbl externally catalyzed furan resin with 600 scf/bbl nitrogen; (c)
24 bblI5% NaCl water with 0.25% surfactant and 600 scf/bbl nitrogen; and (d) 83 bbllO% HCI catalyst (mixed with NaCI water) with
0.25% surfactant, 0.3% acid inhibitor, and 600 scf/bbl nitrogen.
6. Coiled tubing was displaced with filtered 2% NaCl water.
7. The well was shut in for 8 to 12 hours while the resin cured.
SPE Drilling & Completion, December 1994
New downhole completion techniques that include a family of coiledtubing-conveyed through-tubing tools and fluid systems have been
developed to work with wireline and hydraulic workover services.
These fully coordinated methods reduce the exposure time when incompatible fluids are in contact with the formation, allowing a higher
percentage of regained permeability. These services have proved
their success as a means of well maintenance with the onset of sand
production, even in deviated wellbores. However, the considerable
reduction in well maintenance costs that these services can offer
compared with the cost of a workover rig is of special significance in
light of the prevailing climate of the oil and gas industry.
References
I. Fowler, S.H.: "A Reeled-Tubing Downhole-Jet Cleaning System," paper
SPE 21676 presented at the 1991 SPE Production Operations Symposium. Oklahoma City, April 7-9.
2. Shurtz, G.C., Breiner, WG .. and Comeaux, B.G.: "New Through-Tubing
Gravel-Pack Techniques," paper SPE 5660 presented at the 1975 SPE
Annual Technical Conference and Exhibition, Dallas, Sept. 28-Oct. I.
3. Otis Sand Control Customer Manual (1991) .
4. Caillier. M.: "Process for Washing Through Filter Media in a Production
Zone With a Pre-Packed Screen and Coiled Tubing," U.S. Patent No.
4,856,590 (Aug. 15 1989).
5. Murphey, J.R., Bila, V.J., and Totty, K. : "Sand Consolidation Systems
Placed With Water," paper SPE 5031 presented at the 1974 SPE Annual
Meeting, Dallas, Oct. 6-9.
6. Stutz, L., Cavender, T., and Murphy, J. : "Epoxy-Coated Sand Taps New
Gas in Old Wells," Oil & Gas J. (March 4, 1991) l.
Restarick
Fowler
243